GENERAL REQUIREMENTS AND TECHNICAL SPECIFICATIONS

GENERAL REQUIREMENTS AND

TECHNICAL SPECIFICATIONS

FOR

IAD HYDRANT FUEL LINE IMPROVEMENTS

AT

WASHINGTON DULLES INTERNATIONAL AIRPORT

IA1302

Prepared for:

METROPOLITAN WASHINGTON AIRPORTS AUTHORITY 1 AVIATION CIRCLE

WASHINGTON, DC 20001-6000

Prepared by:

MICHAEL BAKER JR. INC. 1304 CONCOURSE DRIVE, SUITE 200

LINTHICUM, MARYLAND 21090

February 24, 2014

.

WASHINGTON DULLES INTERNATIONAL AIRPORT IA1302 IAD HYDRANT FUEL LINE IMPROVEMENTS FEBRUARY 24, 2014

TABLE OF CONTENTS i

GENERAL REQUIREMENTS AND TECHNICAL SPECIFICATIONS

TABLE OF CONTENTS

Division 00 – Procurement and Contracting Requirements

Section 000107 Seals Page

Section 007300 Supplementary Conditions

Division 01 – General Requirements

Section 011000 Summary

Section 012100 Allowances

Section 012200 Unit Prices

Section 012210 Measurement and Payment

Section 012900 Application for Payment

Section 013100 Project Management and Coordination

Section 013200A Construction Progress Documentation

Section 013233 Photographic Documentation

Section 013300 Submittals

Section 014000 Quality Requirements

Section 014200 References

Section 015000 Temporary Facilities and Controls

Section 015516 Haul Roads and Staging Areas

Section 016000 Product Requirements

Section 017113 Mobilization/Demobilization

Section 017114 Airport Safety and Security

Section 017300 Execution

Section 017329 Cutting and Patching

Section 017700 Project Closeout

Section 017823 Operation and Maintenance Data

Section 017839 Project Record Documents

Division 02 – Existing Conditions

Section 026500.01 10 Fuel System Piping Abandonment and Removal


TABLE OF CONTENTS ii

Division 20 – FAA Specifications

Part 2 – Earthwork

Item P-152 Excavation and Embankment

Item P-153 Controlled Low-Strength Material (CLSM)

Part 3 – Flexible Base Courses

Item P-209 Crushed Aggregate Base Course

Section P-221 Choke Stone Interlayer

Part 4 – Rigid Base Courses

Section P-304 Cement-Treated Base Course

Part 5 – Flexible Surface Courses

Section P-405 Bituminous Concrete Pavement

Part 6 – Rigid Pavement

Section P-501 Portland Cement Concrete Pavement

Part 7 – Miscellaneous

Item P-603 Bituminous Tack Coat

Item P-605 Joint Sealing Filler

Item P-610 Structural Portland Cement Concrete

Item P-620 Runway and Taxiway Painting

Division 26 – Electrical

Electrical Service

Section 260519 Electrical Service, Low-Voltage Electrical Power Conductors and Cables

Section 260526 Electrical Service, Grounding and Bonding for Electrical Systems

Section 260543 Electrical Service, Underground Ducts and Raceways for Electrical Systems

Section 260553 Electrical Service, Identification for Electrical Systems

Section 262416 Electrical Service, Panelboards

Fuel System

Section 260500.10 10 Fuel System Electrical


TABLE OF CONTENTS iii

Section 260533.11 10 Fuel System Conduit

Section 260553.12.10 Fuel System Identification for Electrical Systems

Section 260900.10 10 Fuel System Instrumentation

Section 262913.11 10 Fuel System Motor Starters

Section 262921.13 10 Fuel System Disconnect Switches

Division 31 – Earthwork

Section 312319 Dewatering

Section 312323.13 10 Fuel System Excavation Bedding and Backfill

Section 312514 Storm Water Pollution Prevention Plan

Section 315000 Excavation Support and Protection

Division 32 – Exterior Improvements

Section 329200 Turf and Grasses

Division 33 – Utilities

Section 330850.10 10 Fuel System Inspection, Testing and Flushing

Section 330950.11.10 Fuel System Emergency Shutoff System

Section 335243.08 10 Fuel System Microtunneling, Boring & Utility Casings

Section 335243.10 10 Fuel System General Provisions

Section 335243.11 10 Fuel System Piping Specialties

Section 335243.13 10 Fuel System Pipe, Fittings and Installation

Section 335243.15 10 Fuel System General Valves

Section 335243.16 10 Fuel System Control Valves

Section 335243.17 10 Fuel System Metering Equipment

Section 335243.20 10 Fuel System Service Pits and Valve Vault Access Covers

Section 335243.23 10 Fuel System Pumps

Section 335280.10 10 Fuel System Coatings

Section 335343.91 10 Fuel System Cathodic Protection Systems

Section 335343.92 10 Fuel System Cathodic Protection System Testing

Section 335643.13 10 Fuel System Aboveground Horizontal Tanks

Section 335800.10 10 Fuel System Leak Detection

Section 335809.93 10 Fuel System Description of Operation

.


SEALS PAGE 000107 - 1

DOCUMENT 000107 - SEALS PAGE

1.1 DESIGN PROFESSIONALS OF RECORD

A. Civil Engineer:

1. Lordian P. Turner. 2. 017376. 3. Responsible for all specifications except where indicated as prepared by other design

professionals of record.

.

.

.

.



E. Cathodic Protection Specialist:

1. Thomas Mollica III 2. 5163 3. Responsible for:

335343.91 10 Fuel System Cathodic Protection System 335343.92 10 Fuel system Cathodic Protection System Testing

.



F. Electrical Engineer:

1. Gary Lott 2. 037458 3. Responsible for:

260519 Electrical Service Low-Voltage Electrical Power Conductors and Cables 260526 Electrical Service Grounding and Bonding for Electrical Systems 260543 Electrical Service Underground Ducts and Raceways for Electrical Systems 260553 Electrical Service Identification for Electrical Systems 262416 Electrical Service Panelboards

END OF DOCUMENT 000107

.


SUPPLEMENTARY CONDITIONS 007300 - 1

SECTION 007300 — SUPPLEMENTARY CONDITIONS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings, Contract Provisions, Special Provisions, and other Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. The articles and paragraphs of this Section represent supplements or additions to the Contract Provisions or the Special Provisions.

1.3 WORK UNDER OTHER CONTRACTS

A. During the period of this Project, the Authority anticipates that other construction contracts may be underway at or near the site of work of this Contract. A list of adjacent construction activities follows:

A380 Boarding Bridge Upgrades Gates B-42/B-44

Airfield Trench Drain Repairs

Glycol Runoff Enhancements

Taxilane C Reconstruction

Taxiway Y Reconstruction

Taxiway Z Reconstruction

1.4 PERMITTING

A. Comply with all requirements set forth in the Authority's “Building Codes Manual”. This manual describes Building Codes organization, Building Code inspection process, Certificate of Occupancy requirements, and information regarding elevators, escalators, and moving walks. The Authority will file for and provide the construction permit.

1.5 MAINTENANCE OF PEDESTRIAN AND VEHICULAR TRAFFIC

A. Maintain adequate pedestrian and vehicular traffic flow and safety along the service roads, sidewalks, parking lots and other roadways on Airport property. In addition, this requirement applies to crossroads, approaches, and entrances affected by or made necessary by the Work. Coordinate activities throughout the project in a manner that allows emergency access, without



delays to emergency response vehicles, to all areas of the Project that are occupied by employees.

B. Prior to starting construction operations affecting pedestrian, vehicular, or aircraft traffic movement, submit and obtain the COTR's written approval of a Traffic Maintenance Plan. Develop plan in accordance with the safety requirements of the FAA, Airport Operations, and the Commonwealth of Virginia Department of Transportation’s “Manual of Uniform Traffic Control Devices”. Utilize the form indicated in the latest edition of the Virginia Department of Transportation’s “Virginia Work Area Protection Manual – Standards and Guidelines”.

C. Provide and maintain temporary signage, "Jersey barriers," and such other traffic control devices or personnel as required complying with approved Traffic Maintenance Plan.

D. Maintain the construction operations affecting pedestrian, vehicular, or aircraft traffic movement from the beginning of construction operations until final acceptance of the project. The maintenance shall constitute continuous and effective work prosecuted day by day with adequate equipment and forces to the end of project to ensure that roadways and structures are maintained in satisfactory condition at all times, including barricades and warning signs as necessary for performance of the work.

E. Keep the portions of the project being used by public, pedestrian, aircraft, [mobile lounges] and vehicular traffic, whether it is through or local traffic, in such condition that traffic will be adequately accommodated. Remove snow and control all ice within the project boundaries. Removal of snow and ice for the benefit of the traveling public will be performed by the Authority. Bear all cost of maintenance work during construction and before the project receives a Certificate of Occupancy for constructing and maintaining approaches, crossings, intersections and other features as may be necessary.

F. Keep the portions of the road and aircraft pavement surfaces being used by the public free from irregularities, obstructions, mud, dirt, snow, ice, and any characteristic that might present a hazard or annoyance to traffic in such condition that traffic will be adequately accommodated. Maintain a vacuum/sweeper and flusher truck at the site at all times to clean roadway and aircraft surfaces affected by construction traffic at the request of Airport Operations or the COTR.

1.6 AIRFIELD AND TERMINAL BUILDING OPERATIONAL REQUIREMENTS

A. The Work, or a portion thereof, will be performed in proximity to the Air Operations Area (AOA), including, active runways, taxiways, and aprons. Normal airport operations will continue adjacent to the Work during all phases of the Project. These activities include:

1. Aircraft movement on runways, taxiways, aprons; aircraft landing and takeoff operations. 2. Aircraft parking, refueling and other aircraft servicing. 3. Baggage handling. 4.



B. The Work, or a portion thereof, will be performed nearby the public Terminal or Concourse buildings. Normal airport operations and public activities will continue adjacent to the Work during all phases of the Project. These include:

1. Passenger enplaning and deplaning. 2. Passenger baggage deposit/retrieval. 3. Ground transportation arrivals/departures.

C. Phase construction activities as necessary to accommodate all airport operations without

disruption. Adhere to all current Airport Orders and Instructions (O & Is), Airport Bulletins, and Airport Advisories. The Authority will provide relevant Orders and Instructions to Offerors in the Solicitation Package. Bulletins and Advisories will be provided to the offeror by the Authority as they are issued.

1.7 ENVIRONMENTAL PROTECTION

A. Comply with all Federal, state and local laws and regulations controlling pollution of the environment. Take necessary precautions to prevent pollution of streams, rivers, lakes, ponds, and reservoirs with fuels, oils, bitumens, chemicals, or other harmful materials and to prevent pollution of the atmosphere from particulate and gaseous matter.

B. Notify COTR immediately in the event that abnormalities, discolorations, odors, oil, or other signs of potential contamination by hazardous materials are encountered during excavation or other construction activities. Follow with written notice within 24 hours, indicating date, time, and location of potential contaminants encountered. The COTR will provide further direction to Contractor regarding disposition of materials encountered.

C. All painted surfaces are assumed to contain lead-based paint. The Contractor shall maintain the necessary health and safety requirements for all personnel in accordance with OSHA regulations to work in these conditions. The removal and disposal of lead-based paint is part of this contract.

D. Aircraft deicing fluids will be encountered in the water (including utility manholes) and in the soils. Concentrations of aircraft deicing fluids in water and soils will range from non-detect to saturation. Aircraft deicing fluids are propylene based Type I and Type IV fluids. The fluids emit an unpleasant odor when the breakdown (biodegradation) is occurring. Follow OSHA requirements while working in aircraft deicing impacted areas. Coordinate with the COTR for obtaining Material Safety Data Sheet (MSDS) for aircraft deicing fluids.

E. Petroleum Contaminated Soil – Soil that is that is excavated from this project and assumed to be petroleum contaminated by sensory observation shall be stockpiled at the Contractor’s staging area. Suspect petroleum contaminated soils shall be placed on two layers of 6 mil reinforced plastic and covered (securely) to prevent water infiltration. Silt fence and straw bales shall be placed around the soil stockpile. At the end of the soil excavation activities for all work areas, the Authority will characterize the soil for disposal. The Contractor is responsible for the initial excavation, stockpiling, hauling. The Contractor shall be responsible for re-loading the escorting disposal trucks on/off airport property and disposing of all confirmed petroleum contaminated excess material for quantities in excess of 100 cubic yards. The excess soil shall



be disposed of at a recycling facility capable of accepting and treating low level contaminated soil containing petroleum constituents. The recycling facility shall be approved by the Authority before the start of any land disturbing activities. Disposing of the soil at a landfill or reclamation site is prohibited. The Contractor shall not haul any soil off Airport property until the soil has been characterized by the Authority's Environmental Consultant. The Contractor shall allow three weeks for the Authority to sample and receive analytical results from the stockpiles. The disposal facility shall be approved by the Authority prior to the start of any excavation activities.

1.8 ARCHAEOLOGICAL AND HISTORICAL FINDINGS

A. Notify immediately, through the COTR, the PMC Archaeology/Historic Preservation Coordinator if subsurface structural features, concentrations of artifacts, rubble, bone/shell, or burnt material are uncovered or otherwise discovered. Prompt reporting will avoid potentially severe problems resulting from the destruction of significant resources and may limit the impact on construction operations and schedules.

1.9 DAMAGES AND PRE-EXISTING CONDITIONS

A. Be responsible for all damages caused by Contractor’s construction activities. Provide all labor, materials, etc. to return any damaged areas, systems or equipment to their original condition at no additional cost to the Authority.

B. Perform a survey of pre-existing conditions in the vicinity of Contractor’s construction activities, utilizing photographs and other means as necessary to document existing damage or conditions. Submit two copies of this survey to the Contracting Officer within 21 calendar days after Notice-to-Proceed. This survey will assist in resolving any damage claims against the Contractor during and after construction.

C. Preserve all roadways, pedestrian and directional signage. Deliver all signs removed and not required for reinstallation to the Authority as directed by the COTR.

D. Replace or repair lost or damaged signs at no cost to the Authority.

1.10 SECURITY DURING CONSTRUCTION

A. Maintain the integrity of the Airport Security fence. Maintain the integrity of doors and walls between public areas and Air Operations Area (AOA) at all times. Comply with Title 49 Code of Federal Regulations, Parts 1500, 1540, 1542 and 1544.

B. Possession of and display of a proper and current Airport Identification Badge, issued by Airport Operations is required for all Contractor personnel passing into the AOA. Refer to "Airport Orders and Instructions" attached as part of the Contract for specific requirements. Security requirements have increased significantly at Washington Dulles International Airport and Ronald Reagan Washington National Airport. Contractor can expect up to two hours waiting time to clear construction vehicles into the AOA. Offerors shall become intimately familiar with all TSA and Authority security requirements. No increase in contract price will be provided to the Contractor should the contractor not be aware of any security procedure in place



at time of submitting their offer that leads to increased time and inconvenience to accomplish the work.

C. Pay all fines levied by the Transportation Security Administration for penalties resulting from security infractions perpetrated by or caused by Contractor’s personnel or work forces of Contractor’s subcontractors or suppliers.

D. Establish and maintain the security of Contractor’s staging areas, equipment and materials.

E. Provide escort for delivery vehicles transporting materials and supplies to or from the Contractor's staging or work areas into the AOA, in accordance with requirements stated in "Airport Orders and Instructions" attached as part of the Contract.

F. Do not park within 300 feet of a terminal building unless specifically authorized by Airport Operations.

G. No firearms or weapons of any type are allowed on the airport.

H. No cartridge style nail guns, nor any tools that use a cartridge or any explosive charge, are allowed without prior written notification of COTR. Obtain written approval from the COTR before bringing such tools on the project.

I. Conform to all Orders and Instructions pertaining to vehicle inspection.

1.11 MATERIAL HAULING

A. Restrict deliveries and removal of bulk materials, supplies, waste soils and equipment to and from the Project site to the Authority-designated roads and haul routes indicated on the Drawings.

B. Access and egress to and from the Airport for hauling operations shall be through the entrances indicated. Conduct hauling operations as indicated on the Construction Phasing Plans.

C. The designated haul routes for hauling operations may require vehicles crossing and/or utilizing existing active taxilanes. All aircraft have the right-of-way at all times. Haul routes for this project are as indicated.

D. Schedule, phase, and sequence work operations to minimize the number and duration of taxiway and taxilane closures. Submit a detailed Work Plan for Contractor’s entire operations to the COTR for approval prior to commencing work. Obtain written approval from the COTR of the Work Plan. Identify clearly on Work Plan each operation requiring coordination with Airport Operations.

1. For taxiway closures of short duration, provide flagmen, with radio contact with the FAA Airport Traffic Control Tower and the Authority Ramp Control Tower, at taxiway crossing intersections. COTR will determine the number of flagmen required.

2. For long-term taxiway closures, clearly mark, light, and barricade the taxiway closures and haul routes in accordance with FAA and Airport Operations requirements.



E. Notify the COTR at least 72 hours in advance of his requirement for scheduled taxiway, taxi lane, fuel line, and hydrant cart test stand impacts and potential closures. Obtain the written approval of the Authority prior to closing, crossing, using, or modifying a taxiway, taxilane or roadway.

F. Bear all costs associated with establishing, maintaining, signing, lighting and marking haul routes and taxilane crossings. These costs are considered incidental to the pay items of this Contract.

G. Use load covers on all dump trucks. Load dump trucks so that no spillage occurs during transit on the State, municipal, or Airport roadways, taxilanes, and aprons. Clean wheels of trucks leaving the Project construction site of all soil and rocks. Provide a truck washing rack on the Project site to minimize the tracking of soil onto paved surfaces.

H. Be responsible for the cost of the immediate cleaning of earth tracking and spills on paved surfaces resulting from the Contractor's operations. Because of the potential for extreme damage to aircraft engines due to the ingestion of foreign objects, maintain on the project mechanical sweeper/vacuum (wet/dry) equipment with nylon brushes complete with operators. Maintain a water truck on site at all times in order to effectively control dust rising from construction activities.

I. Provide sweeper/vacuum equipment with a usable hopper capacity of 6 cubic yards and with a regenerative air capacity of 15,000 CFM. Provide equipment with gutter brooms of poly brush material so as not to damage airfield pavement markings; a dust control system that includes an external spray system with front mounted spray bar, nozzles located at each gutter broom; and an internal spray system with nozzles in the internal air stream. Maintain the equipment in good working order throughout the project and replace the brooms and or spray systems, as necessary, to ensure proper sweeping and vacuuming of paved surfaces.

1.12 PORTABLE LIGHTING

A. Portable lighting: If used for Contractor operations, aim and shield portable lighting at all times to eliminate glare that could impair runway, taxilane, apron, ground operations, and Airport Traffic Control Tower operations. Equip portable lighting with reflectors and glare shields to prevent spillover of light into operational areas.

1.13 SPECIAL AUTHORITY CONSULTANT

A. The Contractor is hereby advised of the involvement of the Authority’s Program Management Consultants (PMC) as Program Management Support Services Consultant to the Authority for the capital construction programs at Ronald Reagan Washington National Airport and Washington Dulles International Airport. PMC will have a continuing role in this project by assisting the Authority in specialized areas.

1. PMC will provide administrative support during design, solicitation, and construction. 2. PMC will coordinate Contractor requests for technical information and receive, review

and manage all Contractor submittals.



3. PMC has reviewed technical submittals during design, including drawings, specifications, cost estimates, construction phasing plans, and technical reports.

4. PMC will be responsible for review of technical submittals during construction, including selected shop drawings, certifications, test reports, calculations and samples.

5. PMC will conduct field inspections of the Work in progress and inspect for Substantial Completion and Final Acceptance. PMC inspection does not relieve Contractor of responsibilities of performing Contract required inspections as required by contract documents.

B. All other contract management is the sole responsibility of the Authority.

1.14 SAFETY

A. Comply with all requirements set forth in the most current edition of the Authority Construction Safety Manual”. Offerors are provided with the most recent addition when obtaining contract documents prior to proposal. Requirements included in this Section are in addition to the Authority’s Construction Safety Manual. Comply with all local, State and Federal requirements. Where conflicts or discrepancies exist between requirements, the more stringent requirement shall govern. For additional information see Division 01 Section “Quality Requirements”.

B. Contractor Safety Organization:

1. Safety Engineer.

a. Duties: Outlined in The Authority Construction Safety Manual. b. Qualifications: Outlined in The Authority Construction Safety Manual.

C. Submit the résumés of individuals proposed to serve in the role of Contractor’s Safety Engineer

to the COTR for approval in writing. In addition to indicating the qualifications in the Authority Construction Safety Manual résumés shall include but not be limited to such items as: work experience, education, safety and health training completed, memberships in professional associations, professional certifications, professional registrations and professional references confirming the qualifications and personal references of contacts for verification shall also be required.

D. Provide safe and healthful working conditions on each operation at all times during execution the work of this Contract. Conduct the various operations connected with the Work so that they will not be injurious to safety or health. Comply with all provisions, regulations and recommendations issued pursuant to the Occupational Safety and Health Act of 1970 and the Construction Safety Act of 1969, as well as amendments to these laws. Comply with laws, rules and regulations of other authorities having jurisdiction, with regard to all matters relating to the safety and health of workers and the general public. Compliance with government requirements is mandated by law and considered only a minimum level of safety performance. Perform all work in accordance with best safe work practices recognized by the construction industry. Stop work whenever a work procedure or a condition at a work site is deemed unsafe by the either of the following individuals: COTR, Program Safety Manager (PSM), the Contractor’s Project Manager, the Contractor’s Foreman, or the Contractor’s Safety Engineer(s).



E. The Safety Engineer shall be responsible for all safety and health requirements as included herein and as required by the Authority’s Construction Safety Manual.

F. The contractor shall submit the resumes of all proposed safety and health professionals who shall serve in the role of Contractor’s Safety Engineer(s) to the COTR for approval. The resumes shall include, but not be limited to such items as: work experience, education, safety and health training completed, memberships in professional associations, professional certifications, professional registrations, and professional references confirming the qualifications shall also be required. Documentation confirming the qualifications and personal references of contacts for verification shall also be required.

G. Comply with all requirements set forth in the Authority's "Construction Safety Manual." Provide during the Work the services of Safety Engineer(s) as outlined in the Authority’s “Construction Safety Manual” and in Division 01 Section “Quality Requirements”. The Safety Engineer shall undertake the duties and responsibilities as stated in the Authority's "Construction Safety Manual".

H. Prior to start of construction activities in the Air Operations Area (AOA), the Contractor's Safety Engineer(s) shall tour the AOA with the Authority Safety Program Manager.

I. Flagmen Training: The Authority will sponsor Flagman training sessions. Contractor's personnel who will be assigned flagmen duties on the Airport for this project shall attend training sessions.

J. Fire Safety: Conform to the following requirements:

1. Obtain a permit to perform any welding, cutting, or hot work from the Office of the Authority Fire Marshal.

2. Ensure adequate access to all construction areas for emergency response. 3. Obtain a permit from the Office of the Authority Fire Marshal to store, handle, or use any

hazardous material, including but not limited to fuels for equipment. Complete an application prior to issuance.

4. Remove combustible debris from the site daily. 5. Provide at least seven (7) days notice for any request for inspections, tests, permits, etc.,

required of personnel from the Office of the Authority Fire Marshal. 6. Provide to the Office of the Authority Fire Marshal a list of emergency contact numbers

for the COTR and the Contractor prior to the commencement of Work. K. Submit Site-Specific Safety and Health Plans to COTR within 15 calendar days of Notice to

Proceed and prior to the start of any construction activities. Prepare this plan using the Authority’s Guidelines as defined in the Authority’s “Construction Safety Manual” and as supplemented by these specifications for each and every work zone as shown on the drawings or as anticipated by the Contractor. COTR must approve the Site-Specific Safety Plan prior to the start of any work.

L. Be responsible for the safe operation of all job site motor vehicles. Provide a “spotter” or flagman for all backing operations of construction vehicles with restricted rear vision.

M. All motorized equipment and vehicles working on or entering MWAA construction project work areas shall be equipped with functional audible backup alarms.



N. Crane Operators. On Airports Authority projects, Crane Operators shall be certified to operate the equipment by an approved independent certifying agency.

O. For all airside projects attach a Safety Plan to the Safety Program. Include in the Safety Plan, to the extent applicable, provisions for the following:

1. Scope of work performed by Contractor, including proposed duration of work. 2. Possible safety problems (job hazard analysis program). 3. Work control measures. 4. Limitations on equipment height. 5. Location of airport operational areas. 6. Location of and access to stockpiled construction materials and equipment. 7. Inspection requirements. 8. Trenches and excavations, and cover requirements. 9. Threshold marking and lighting. 10. Closed runway marking. 11. Vehicle operation and pedestrian access in airport movement areas. 12. Construction site access and haul roads, includes maintenance of and keeping open ARFF

access routes. 13. Limitations on construction. 14. Radio communications. 15. Foreign object debris (FOD) control provisions. 16. Hazardous materials (HAZMAT) management. 17. Wildlife abatement. 18. NOTAM issuance. 19. Vehicle identification. 20. Vehicle parking. 21. Use of temporary visual aids. 22. Obstacle-free zones (OFZ). 23. Approach clearance to runways. 24. Runway and taxiway safety areas. 25. Procedures and equipment, such as barricades (identify type) for closing portions of the

movement area. 26. Required compliance of contractor personnel. 27. Procedures for notification of aircraft rescue firefighting (ARFF) if deactivating water

lines or fire hydrants, or if emergency access routes are rerouted or blocked. 28. Emergency notification for fire, medical, and police response. 29. Coordination of plan with an FAA airport certification safety inspector.

P. Comply with sample safety plan as designated in the MWAA Construction Safety Manual.

1.15 HEIGHT LIMITATION

A. For all demolition and construction within the Airport, limit the height of Contractor's equipment to a maximum height as indicated on the construction phasing plans.

B. Prior to beginning any work coordinate with the COTR the height of all cranes, boom trucks, scaffolds or similar vehicles of construction. Properly mark all construction equipment with safety flags and warning lights in accordance with current FAA and Airport Operations



requirements. Submit FAA Form 7460, provided by COTR, for all variations on approved crane heights.

1.16 EXAMINATION OF PLANS, SPECIFICATIONS AND SITE OF WORK

A. The offeror is expected to examine carefully the site of the proposed work, the proposal, plans, specifications, solicitation provisions, contract provisions, special provisions and contract forms before submitting a proposal. The submission of a proposal will be considered conclusive evidence that the offeror has made such examination and is satisfied as to the conditions to be encountered in performing the work as to the requirements of the Contract.

1.17 AIRPORT SECURITY/VEHICLE INSPECTION PROCEDURE

A. The number of vehicular access points into secure areas at IAD has been reduced to an operational minimum. Those gates that remain open are divided into two categories:

1. Vehicular gates for approved vehicles and individuals who hold appropriate and valid airport access media and do not require escorts.

2. Vehicular gates for those vehicles that have invalid or no airport access authorization and/or the vehicle operator and passenger(s) do not have valid access authorization media and require escorts.

B. The access points for vehicle operator and passenger(s) who have appropriate and valid airport access media are Gates 127 and 141. Vehicles that require escorts of any type are prohibited at those gates.

C. All vehicles and personnel that will require an escort shall enter the AOA via Gates 313. Gate 313 is designated as large equipment contractor/construction access point.

D. Other access gates through which the contractor may gain access to a specific project site are as indicated and must be approved by Airport Operations and the Transportation Security Agency.

E. The following procedures will be utilized for all escorted vehicles and AOA approved vehicles with non-badged passengers seeking entry to the AOA:

1. All vehicles are searched. 2. Coordinate all vehicle deliveries with the COTR in advance. Provide the vehicle license

plate number and expected delivery time for all vehicle deliveries. Contractor may compile the expected daily delivery schedule on one sheet for submission to the COTR.

3. The vehicle operator shall have in his or her possession a commercial manifest, which identifies the contents of the vehicle and/or trailer.

4. An escort from the company for whom the shipment is intended shall respond to the vehicle access gate and remain with the vehicle until the vehicle exits the secured area.

5. A vehicle search will be conducted and once cleared, vehicles will be permitted escorted access to their delivery point.

6. Contractors should expect delays up to 2 hours at Gate 313 as a result of these security provisions.



7. Priority consideration may be offered to concrete trucks with resulting delays estimated to be 20 minutes. To receive priority consideration, schedule concrete deliveries with Airport Operations and COTR at time of batching.

F. Prior approval from the Manager of Airport Operations or his/her designated representative is

required for any exceptions to the above procedures.

PART 2 - PRODUCTS (Not Used)

PART 3 - EXECUTION (Not Used)

END OF SECTION 007300

THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK


SUMMARY 011000 - 1

SECTION 011000 - SUMMARY

PART 1 - GENERAL


A. Drawings, Contract Provisions, Special Provisions, Supplementary Conditions, and other Division 01 Specification Sections apply to this Section.

1.2 SUMMARY

A. This Section includes the following:

1. Work covered by the Contract Documents.

2. Type of the Contract.

3. Work phases.

4. Work under other contracts.

5. Products ordered in advance.

6. Authority-furnished products.

7. Use of premises.

8. The Authority's occupancy requirements.

9. Work restrictions.

10. Specification formats and conventions.

B. Related Sections include the following:

1. Division 01 Section "Temporary Facilities and Controls" for limitations and procedures governing temporary use of the Authority's facilities.

1.3 WORK COVERED BY CONTRACT DOCUMENTS

A. Project Identification: Project consists of Hydrant Fuel Line Improvements.

1. Project Location: Washington Dulles International Airport.

B. Architect/Engineer Identification: The Contract Documents, dated February 24, 2014, were prepared for Project by Michael Baker Jr., Inc., 1304 Concourse Drive, Suite 200, Linthicum, MD 21090.

C. Construction Manager: Parsons Management Consultants has been engaged as Construction Manager for this Project to serve as an advisor to the Authority and to provide assistance in


SUMMARY 011000 - 2

administering the Contract for Construction between the Authority and Contractor, according to a separate contract between the Authority and Construction Manager.

1. For additional functions of Parsons Management Consultants, see "Supplementary Conditions."

D. The Work consists of improvements/modifications to the hydrant fueling system.

1. The Work includes new fuel lines, new fuel pits, changes to the emergency fuel shut-off (EFSO), hydrant cart test stand, and leak detection system along with ancillary work needed to support the fuel line work.

2. For additional requirements for the examination of plans, specifications, and Project site see Section "Supplementary Conditions."

1.4 TYPE OF CONTRACT

A. Project will be constructed under a general construction contract.

1.5 WORK AREAS AND RESTRICTIONS

A. Work is separated into eight (8) work areas.

Work Area General Work

Area A Disconnect existing laterals from main and fill existing decommis-

sioned lines with grout at Concourses C and D. Limited Pavement

Demolition and reconstruction. Plating excavations at gates during

non-working hours.

Area B Install new line and abandon existing line to Signature Flight Support.

Limited Pavement Demolition and reconstruction. Plating excavations

at gates during non-working hours.

Area C Modify and protect existing fuel line via pit installation and nitrogen

charging.

Area D Remove valve pits and replace with spool piping. Limited pavement

removal and reconstruction.

Area E Hydrant cart test stand construction.

Area G Reconfigure leak detection system.

Area H Protect existing waterline and natural gas line. Cathodic protection

installation.

Area I Connect new lines to Emergency Fuel Shut Off (EFSO) system via

new ductbank.


SUMMARY 011000 - 3

B. The general construction sequence envisioned during design was

1. Area D and E commence with start of construction 2. Area B commences upon completion of area D 3. Area A and C happen concurrently upon completion of Area B 4. Area G occurs as phasing dictates 5. Area H happens concurrently with Area B and/or C 6. Area I happens concurrently with Area B

C. The general construction sequence envisioned during design for the work in Area A was coordinated with United Airlines (UAL). The sequence for the work was D-5 area, then C-27 area, followed by C-3 and ending with C-26. The work at C-3 and C-26 is time critical based on the UAL operation. Performing D-5 and C-27 initially would provide the contractor with a thorough understanding of the system and requirements allowing a more efficient construction operation for the final two gates.

D. Work areas/sequence indicated above is not intended to restrict Contractor to this specific phasing. Contractor may submit its own phasing schedule to COTR for review and written approval.

E. Schedule the execution of the Work according to the phasing sequence indicated and to avoid interference with normal functions of the Airport.

F. Before commencing Work of each phase, submit a schedule to COTR showing the sequence, the commencement and completion dates, and the move-out and move-in dates of personnel for the various phases of the Work.

G. On completion, each phase of the Work shall be fully operational.

H. See 1.8.A “Contractor hours of operation” and contract drawings for additional project restrictions.

1.6 WORK UNDER OTHER CONTRACTS

A. General: Cooperate fully with separate contractors so work on those contracts may be carried out smoothly, without interfering with or delaying work under this Contract. Coordinate the Work of this Contract with work performed under separate contracts.

B. Concurrent Work: Authority will award separate contract(s) for the following construction operations at Project site. Those operations will be conducted simultaneously with work under this Contract.

1. A380 Boarding Bridge Upgrades Gates B-42/B-44 2. Airfield Trench Drain Repairs 3. Glycol Runoff Enhancements 4. Taxilane C Reconstruction 5. Taxiway Y Reconstruction 6. Taxiway Z Reconstruction


SUMMARY 011000 - 4

1.7 USE OF PREMISES

A. Use of Site: Limit use of premises to work in areas indicated. Do not disturb portions of site beyond areas in which the Work is indicated.

1. Limits: Confine constructions operations to eight (8) areas.

a. Area A – This area is at Concourses C and D at aircraft Gates, C-3, C-26, C-27, and D-5.

b. Area B – This area is between the apron on the north side of Concourse A to roadway Compass Court. It extends from the signature load rack to gate A1.

c. Area C – This area runs just south of Taxiway F to north of Taxiway J3.

d. Area D – This area is near RON positions R-15 and R-19 on R Ramp Tier 3 Apron.

e. Area E – hydrant cart stand location is near the Runway 30 apron.

f. Area G – reconfigure leak detection system location varies.

g. Area H – Cathodic protection is co-located with areas B and C.

h. Area I – EFSO connection runs from the Signature Load rack to adjacent manhole.

2. Concurrent Projects: There is a potential for several projects to be concurrent and in the same work area as listed in paragraph 1.6. Coordination with the COTR on integrating project schedules will be required prior to starting construction. The known projects as listed in paragraph 1.6 are indicated on the overall phasing plan, exact limits may vary. Standard coordination should be included in the appropriate unit cost item.

3. Authority Occupancy: Allow for Authority occupancy of site and day-to-day use by tenants, air carriers, and the public.

4. Contractor shall have full use of premises for construction operations within the Contract Limit Lines indicated during construction period, during the hours indicated, and as directed by COTR. Contractor's use of premises is limited only by the Authority's right to perform work or to retain other contractors on portions of Project.

5. Driveways and Entrances: Keep driveways and entrances serving premises clear and available to the Authority, the Authority's employees, tenants, air carriers, and emergency vehicles at all times. Do not use driveways and entrances for parking or storage of materials.

a. Schedule deliveries to minimize use of driveways and entrances.

b. Schedule deliveries to minimize space and time requirements for storage of materials and equipment on-site.

B. Utilize areas designated for Contractor staging, storage, and parking, as indicated. For additional requirements, see Section "Supplementary Conditions."


SUMMARY 011000 - 5

1.8 CONTRACTOR HOURS OF OPERATION

A. Contractor Working Hours: The Authority anticipates that the Contractor may be required to work multiple shifts to accomplish the work of this Contract within the established schedule. Work is subject to restrictions of the Airport operational requirements as outlined on the phasing plans. Notify the COTR 24-hours in advance of any change to the work schedule.

There are numerous work/time restrictions shown on the contract drawings and in Paragraph 1.5.A “Work Areas and Restrictions” of this Section. Some additional items of note are:

1. Active work shall remain clear of the operational Taxilane Object Free Area (TLOFA) or Taxiway Object Free Area (TOFA).

2. All work areas shall meet Group V taxiway safety area criteria (214 foot total width, 107 feet each side of taxiway/taxilane centerline) when contractor is not working.

3. All work affecting aircraft operations shall be coordinated through the COTR before commencing.

4. The Contractor shall develop and submit for review and approval their work plan describing the work at Pit D (Work Area B). At minimum, the work plan shall include the work activities, sequence of activities, temporary support of excavation, temporary support of utilities, and methods for restoring the area to Group V TSA requirements at the conclusion of each work shift.

1.9 SPECIFICATION FORMATS AND CONVENTIONS

A. Specification Format: With the exception of Federal Aviation Administration (FAA) standard specifications and Virginia Department of Transportation standard specifications the Specifications are organized into Divisions and Sections using the 33-Division format using the CSI/CSC's "MasterFormat 2004" numbering system.

1. Section Identification: The Specifications use Section titles to help with cross-referencing in the Contract Documents. Sections in the Project Manual are in numeric sequence; however, the sequence is incomplete as all available Sections and Section numbers are not used and the CSI numbering system is not sequentially complete. Consult the table of contents at the beginning of the Project Manual to determine numbers and names of sections in the Contract Documents.

B. Specification Content: The Specifications use certain conventions for the style of language and the intended meaning of certain terms, words, and phrases when used in particular situations. These conventions are as follows:

1. Abbreviated Language: Language used in the Specifications and other Contract Documents is abbreviated. Interpret words and meanings as appropriate. Infer words implied, but not stated, as the sense requires. Interpret singular words as plural, and plural words as singular where applicable as the context of the Contract Documents indicates.

2. Imperative mood and streamlined language are used in these Specifications. This imperative language is directed to the Contractor, unless specifically noted otherwise.


SUMMARY 011000 - 6

Requirements expressed in the imperative mood are to be performed by Contractor. Occasionally, the indicative or subjunctive mood may be used in the Section Text for clarity to describe responsibilities that must be fulfilled indirectly by Contractor or by others when so noted.

a. The words "shall," "shall be," or "shall comply with," depending on the context, are implied where a colon (:) is used within a sentence or phrase.

1.10 MARKING UTILITY SERVICES

A. Employ underground utilities location subcontractor to locate and mark the horizontal location of all utility lines that might be impacted by construction activities, including, but not limited to, the following:

1. Electric power lines.

2. Natural gas lines.

3. Sanitary Sewers.

4. Storm Sewers.

5. FAA communications, signal, and security lines.

6. Runway lighting lines

7. Water supply piping.

8. Fuel Lines.

9. Telephone lines.

10. Data lines.

11. Underground Storage Tanks.

12. High Temperature Hot Water (HTHW) and chilled water lines.

13. Dedicated Fire System (DFS) lines.

B. Contact the Airport Communications System (ACS) Help Desk at (703) 417-8300 a minimum of 72 hours prior to starting activities that include but are not limited to location and marking of horizontal locations of telephone and telecommunications lines belonging to the Authority as part of the Airport Communication System. Contact the Airport Communications System (ACS) Help Desk a minimum of 72 hours prior to beginning operations that include but are not limited to excavating, boring, digging or planting. Note the ACS does not locate utilities. Location is the responsibility of the Contractor’s underground utilities location subcontractor. The Airport Communications System (ACS) is merely notified as indicated previously.

C. The information in the Contract Documents concerning the type and location of underground utilities is neither guaranteed nor inclusive. The Contractor is responsible for determining the type and location of underground utilities, regardless of whether such utilities are indicated or not, so as to avoid damage thereto.

D. Check and verify the horizontal and vertical location (coordinates and elevation) of all utility lines that may exist within the limits of new work, regardless of whether such utilities are


SUMMARY 011000 - 7

indicated or not, by use of a Subsurface Utility Engineering company. Reconfirm such locations and verification of utilities discovered, regardless of whether such utilities are indicated or not, and submit to the COTR a dimensional survey with such notations.

E. Dig test pits by hand shovel in the vicinity of the discovered utilities. Excavate test holes utilizing a vacuum excavator.

F. Repair any damage to discovered utility lines due to construction operations at no expense to the Authority. The Authority will assist the Contractor by making available any known information.

G. Submit to the COTR, for written approval, the name of the independent subsurface utility engineering company to be used.

H. The individual who performs the utility detection and location work shall have as a minimum five (5) years of similar experience in the area of subsurface utility detection and location engineering.

I. Submit to COTR the following:

1. List of utility detection equipment along with product information and data sheets that will be used specifically for this contract.

2. List of employee qualifications and résumés of those individuals who will be assigned specifically to this contract.

3. Within 45 calendar days of Notice to Proceed, a survey of all subsurface utility engineering results indicating the horizontal and vertical location, coordinates and elevation of all utilities.

1.11 UTILITY OUTAGES

A. Prior to any utility outage/interruption, prepare a schedule of such outage. Include in outage schedule duration, identification of the service affected, temporary utility service to be provided, identification of available service alternative, and the action to be taken in any emergency. Apply for all outages of utility systems in writing. Fully coordinate outage requests with COTR. Obtain approval in writing by COTR. Schedule all outages at least three (3) weeks in advance with a 96-hour notification provided by the Contractor confirming date, time, and duration. Outages will normally be scheduled to occur between the hours of 11:00 pm and 5:30 am, Tuesday through Thursday.

B. Provide a suction/pump truck during all fueling line outages to support the required construction windows.






ALLOWANCES 012100 - 1

SECTION 012100 - ALLOWANCES

PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes administrative and procedural requirements governing allowances.

1. Certain materials and equipment are specified in the Contract Documents by allowances. In some cases, these allowances include installation. Allowances have been established in lieu of additional requirements and to defer selection of actual materials and equipment to a later date when additional information is available for evaluation. If necessary, additional requirements will be issued by Contract Modification.

B. Types of allowances include the following: 1. Unit-cost allowances. 2. Quantity allowances.

C. Related Sections include the following:

1. Division 01 Section "Unit Prices" for procedures for using unit prices.

2. Division 01 Section “Measurement and Payment.”

3. Division 01 Section “Application for Payment.” 4. Divisions 02 through 33 Sections for items of Work covered by allowances.

1.3 SELECTION AND PURCHASE

A. At the earliest practical date after award of the Contract, advise COTR of the date when final selection and purchase of each product or system described by an allowance must be completed to avoid delaying the Work.

B. At COTR's request, obtain proposals for each allowance for use in making final selections. Include recommendations that are relevant to performing the Work.

C. Purchase products and systems selected by COTR from the designated supplier.



1.4 SUBMITTALS

A. Submit proposals for purchase of products or systems included in allowances, in the form specified for Contract Modifications.

B. Submit invoices or delivery slips to show actual quantities of materials delivered to the site for use in fulfillment of each allowance.

C. Coordinate and process submittals for allowance items in same manner as for other portions of the Work.

1.5 COORDINATION

A. Coordinate allowance items with other portions of the Work. Furnish templates as required to coordinate installation.

1.6 UNIT-COST AND QUANTITY ALLOWANCES

A. Allowance shall include cost to Contractor of specific products and materials ordered by Owner under allowance and shall include taxes, freight, and delivery to Project site.

B. Contractor's costs for receiving and handling at Project site, labor, installation, overhead and profit, and similar costs related to products and materials ordered by Owner under allowance shall be included as part of the Contract Sum and not part of the allowance.

1.7 CONTINGENCY ALLOWANCES

A. Use the contingency allowance only as directed by COTR for Authority's purposes and only by Change Orders that indicate amounts to be charged to the allowance.

B. Contractor’s overhead, profit, and related costs for products and equipment ordered by the Authority under the contingency allowance are included in the allowance and are not part of the Contract Sum. These costs include delivery, installation, taxes, insurance, equipment rental, and similar costs.

C. Change Orders authorizing use of funds from the contingency allowance will include Contractor's related costs and reasonable overhead and profit margins.

D. At Project closeout, credit unused amounts remaining in the contingency allowance to the Authority by Change Order.




PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine products covered by an allowance promptly on delivery for damage or defects. Return damaged or defective products to manufacturer for replacement.

3.2 PREPARATION

A. Coordinate materials and their installation for each allowance with related materials and installations to ensure that each allowance item is completely integrated and interfaced with related work.

3.3 SCHEDULE OF ALLOWANCES

A. Allowance No. 1: Include a unit price based on the contingent quantity shown in Schedule III for removal of contaminated soils per cubic yard as specified in Division 20 Item P-152, “Unclassified Excavation.” Price should also include backfilling with in-situ material in accordance with Item P-152, “Unclassified Excavation.”

B. Allowance No. 2: Include a unit price based on the contingent quantity shown in Schedule III for striping of temporary pavement markings per square foot as specified in Division 20 Item P-620, “Runway and Taxiway Painting” and as shown on the drawings. Price shall also include the removal of the temporary pavement markings.




UNIT PRICES 012200 - 1

SECTION 012200 - UNIT PRICES

PART 1 - GENERAL



B. The Price Proposal Form can be found in Section III, "Schedule”.

1.2 SUMMARY

A. This Section includes administrative and procedural requirements for unit prices.


1. Division 01 Section "Allowances" for procedures for using unit prices to adjust quantity allowances.

2. Division 01 Section "Measurement and Payment" for procedures for measurement and payment for unit-price items.

1.3 DEFINITIONS

A. Unit price is an amount proposed by offerors, stated on the Schedule as a price per unit of measurement for materials or services added to or deducted from the Contract Price by appropriate modification according to the Contract Provision Payments. -Construction Contracts, Paragraph H, "Variation in Estimated Quantities," if estimated quantities of work required by the Contract Documents are increased or decreased.

1.4 PROCEDURES

A. Unit prices include all necessary material, plus cost for delivery, installation, insurance, applicable taxes, overhead, and profit. The sum of all extended unit prices in the Section III, "Schedule," shall be deemed to include all work described in the Contract Documents including Drawings and Specifications.

B. Measurement and Payment: Refer to Part 4 and Part 5 of this Specification Section for work that requires establishment of` unit prices. Methods of measurement and payment for unit prices are specified in those Parts and in Division 01 Section "Measurement and Payment."

C. The Authority reserves the right to reject Contractor's measurement of work-in-place that involves use of established unit prices and to have this work measured, at the Authority's expense, by an independent surveyor acceptable to Contractor.



D. List of Unit Prices: A list of unit prices is included in Section III “Schedule” of the Contract Documents. Specification Sections referenced in the Schedule contain requirements for materials described under each unit price.

1. The Price Proposal Form can be found in Section III, "Schedule," of the Contract Documents. If applicable, Specification Sections referenced in the Schedule contain requirements for materials and methods described under each unit price.



PART 4 - METHOD OF MEASUREMENT

4.1 12-inch Fuel Line Abandonment (Drain, Flush/Pig and Grout in Place) – Fuel line abandonment shall be paid or deducted on a linear foot basis.



PART 5 - BASIS OF PAYMENT

5.1 12-inch Fuel Line Abandonment (Drain, Flush/Pig and Grout in Place) –Payment will be made or deducted at the Contract Unit Price. Payment/Deducts will be full compensation for furnishing all labor, equipment, materials, tools, and incidentals necessary to abandon the fuel line in place as shown on the Contract Drawings. This includes, but is not limited to: permits/notifications, excavation, sheeting/shoring/bracing, cutting tools/equipment, vacuum and transport trucks, frac tanks, flushing/pigging materials and equipment, grout, disposal/recycling fees, pipe, fittings, backfill/compaction, dewatering, welding, testing, and surveys. Assumes all fuel meets spec (ASTM D1655) and is returned to the Authority.

5.2 6-inch Fuel Line Abandonment (Drain, Flush/Pig and Grout in Place) –Payment will be made or deducted at the Contract Unit Price. Payment/Deducts will be full compensation for furnishing all labor, equipment, materials, tools, and incidentals necessary to abandon the fuel line, hydrant pits, high points, and low points in place as shown on the Contract Drawings. This includes, but is not limited to: permits/notifications, excavation, sheeting/shoring/bracing, cutting tools/equipment, vacuum and transport trucks, frac tanks, flushing/pigging materials and equipment, grout, disposal/recycling fees, pipe, fittings, backfill/compaction, dewatering, welding, testing, and surveys. Assumes all fuel meets spec (ASTM D1655) and is returned to the Authority.



5.3 8-inch Fuel Line Abandonment (Drain, Flush/Pig and Grout in Place) –Payment will be made or deducted at the Contract Unit Price. Payment/Deducts will be full compensation for furnishing all labor, equipment, materials, tools, and incidentals necessary to abandon the fuel line, hydrant pits, high points, and low points in place as shown on the Contract Drawings. This includes, but is not limited to: permits/notifications, excavation, sheeting/shoring/bracing, cutting tools/equipment, vacuum and transport trucks, frac tanks, flushing/pigging materials and equipment, grout, disposal/recycling fees, pipe, fittings, backfill/compaction, dewatering, welding, testing, and surveys. Assumes all fuel meets spec (ASTM D1655) and is returned to the Authority.

Item 026500.01 10-6.1 12-inch Fuel Line Abandonment (Drain, Flush/Pig and Grout in Place) – Per Linear Foot






MEASUREMENT AND PAYMENT 012210 - 1

SECTION 012210 - MEASUREMENT AND PAYMENT

PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes administrative and procedural requirements governing methods of measurement and computations to be used in determination of quantities of material furnished and unit amount of Work performed under the Contract in order for Contractor to receive payment according to pre-established unit prices.

B. At the discretion of the COTR, payment may be reduced for any Work which is not in full compliance with the Contract Documents or which has been damaged or repaired by Contractor. Such action may be used when the end product may have a reduced service life or less than desirable aesthetic characteristics.

C. Descriptions of unit-price items are specified in Division 01 Section "Unit Prices."

1.3 MEASUREMENT OF QUANITITES

A. All volumes or quantities used to determine unit-price payment will be measured by COTR, or by COTR’s authorized representatives, using methods generally recognized as conforming to good engineering practice. Unless otherwise indicated, measurement shall be in U.S. Customary Units of Measurement.

B. Unless otherwise indicated, longitudinal measurements for area computations will be made horizontally, and no deductions will be made for individual fixtures (or leave-outs) having an area of 9 sq. ft. or less. Unless otherwise indicated, transverse measurements for area computations will be the neat dimensions shown on Drawings.

1. Structures will be measured according to neat lines shown on the plans or as altered to fit field conditions.

2. Measure all Contract items measured by the linear foot, such as electrical ducts, conduits, pipe culverts, under drains, and similar items, parallel to the base of foundation on which such items are placed, unless otherwise indicated.

3. In computing volumes of excavation, use the average end area method or other acceptable method.

C. The thickness of plates and galvanized sheet used in the manufacture of corrugated metal pipe, metal plate pipe culverts and arches, and metal cribbing will be specified and measured in decimal fraction of inches.



D. Haul materials, to be measured by volume in the hauling vehicle, in approved vehicles and measured therein at the point of delivery. Vehicles for this purpose may be of any size or type acceptable to and approved in advance by COTR, provided that the body is of such shape that the actual contents may be readily and accurately determined. Load all vehicles to at least their water-level capacity. Level loads when the vehicles arrive at the point of delivery.

1. When requested by Contractor and approved by COTR in writing, material specified to be measured by the cubic yard may be weighed, and such weights will be converted to cubic yards for payment purposes. Factors for conversion from weight measurement to volume measurement will be determined by COTR and agreed to by Contractor before such method of measurement of pay quantities is used.

2. The term "ton" will mean the short ton consisting of 2000-lb avoirdupois. Weigh all materials, which are measured or proportioned by weights, on accurate, approved scales by competent, qualified personnel at locations designated by COTR.

a. If material is shipped by rail, the car weight may be accepted, provided that only the actual weight of material will be paid for. However, car weights will not be acceptable for material to be passed through mixing plants.

b. Weigh trucks used to haul material being paid for by weight empty daily at such times as COTR directs. Each truck shall bear a plainly legible identification mark.

E. Measure bituminous materials by the gallon or ton. When measured by volume, measure such volumes at 60 deg F or measure corrected to the volume at 60 deg F, using ASTM D 1250 for asphalts or ASTM D 633 for tars.

1. Net certified scale weights or weights based on certified volumes in the case of rail shipments will be used as a basis of measurement, subject to correction when bituminous material has been lost from the car or the distributor, wasted, or otherwise not incorporated into the Work.

2. When bituminous materials are shipped by truck or transport, net certified weights by volume, subject to correction for loss or foaming, may be used for computing quantities.

F. Concrete will be measured by the cubic yard in place, unless otherwise indicated.

G. The term "each" when used as an item of payment shall mean complete payment for the work described in the Contract.

1. When a complete structure or structural unit is to be provided, and "each" is specified, as the unit of measurement, the unit will be construed to include all necessary fitting, accessories, and work incidental to the work item.

H. Rental of equipment will be measured by time in hours of actual working time and necessary traveling time of the equipment within the limits of the Work. Special equipment ordered by COTR in connection with "force account work" will be measured as agreed in Contract Modification authorizing such force account work as provided in the Contract Documents.

I. When standard manufactured items are specified such as fence, wire, plates, rolled shapes, pipe conduit, etc., and these items are identified by gage, unit weight, section dimensions, etc., such identification will be considered to be nominal weights or dimensions. Unless more stringently controlled by tolerances in cited Specifications, manufacturing tolerances established by the industries involved will be accepted.



J. When estimated quantities for a specific portion of the Work are designated as the pay quantities in the Contract, they shall be the final quantities for which payment for such specific portion of the Work will be made, unless the dimensions of said portions of the Work shown on Drawings are revised by Contract Modification signed by the Contracting Officer.

1. If revised dimensions result in an increase or decrease in quantities of such Work, final quantities for payment will be revised in the amount represented by the authorized changes in the dimensions.

1.4 SCALES

A. Scales for weighing materials, which are required to be proportioned or measured and paid for by weight, shall be furnished, erected, and maintained by Contractor or be certified permanently installed commercial scales.

B. Scales shall be accurate within one-half percent of the current weight throughout the range of use. Contractor shall have scales checked under the observation of the inspector before beginning Work and at such other times as requested. The intervals shall be uniform in spacing throughout the graduated or marked length of the beam or dial and shall not exceed one-tenth of 1 percent of the nominal rated capacity of the scale, but not less than 1 lb. The use of spring balances will not be permitted.

1. Beams, dials, platforms, and other scale equipment shall be so arranged that the operator and the inspector can safely and conveniently view them.

2. Scale installations shall have available 10 standard 50-lb weights for testing the weighing equipment or suitable weights and devices for other approved equipment.

3. Scales must be tested for accuracy and serviced before use at a new site. Platform scales shall be installed and maintained with the platform level and rigid bulkheads at each end.

4. Scales "overweighing" (indicating more than correct weight) will not be permitted to operate, and all materials received subsequent to the last previous correct weighing-accuracy test will be reduced by the percentage of error in excess of one-half of 1 percent.

5. In the event inspection reveals the scales have been "under-weighing" (indicating less than correct weight), they shall be adjusted, and no additional payment to Contractor will be allowed for materials previously weighted and recorded.

C. All costs in connection with furnishing, installing, certifying, testing, and maintaining scales; for furnishing check weights and scale house; and for all other items specified in this Section for the weighing of materials for proportioning or payment shall be included in the unit Contract prices for the various items of Project.

1.5 PAYMENT FOR MATERIALS ON HAND

A. Partial payments may be made to the extent of the delivered cost of materials to be incorporated into the Work, provided that such materials meet the requirements of the Contract, Drawings, and Specifications and are delivered to acceptable sites on the Airport property or at other sites in the vicinity that are acceptable to COTR. Such delivered costs of stored or stockpiled



materials may be included in the next partial payment application after the following conditions are met:

1. COTR accepts the manner in which the material has been stored at or on an approved site.

2. Contractor provides COTR with acceptable evidence of quantity and quality of the materials.

3. Contractor provides COTR with acceptable evidence that the material and transportation costs have been paid.

4. Contractor provides the Authority legal title, free of liens or encumbrances of any kind, to the material so stored and stockpiled.

5. Contractor provides the Authority evidence that the material so stored or stockpiled is insured against loss by damage to or disappearance of such materials at anytime before use in the Work.

6. Contractor provides the Authority with manufacturer’s installation and maintenance information.

B. It is understood and agreed that the transfer of title and the Authority's payment for such stored or stockpiled materials shall in no way relieve Contractor of responsibilities for furnishing and placing such materials according to the requirements of the Contract Documents.

C. In no case will the amount of partial payments of materials on hand exceed the Contract price for the materials or the Contract price for the Contract item in which the material is intended to be used.

D. No partial payment will be made for living or perishable plant materials.

E. Contractor bears all costs associated with the partial payment of stored or stockpiled materials according to the provisions of this Section.





APPLICATION FOR PAYMENT 012900 - 1

SECTION 012900 – APPLICATION FOR PAYMENT

PART 1 - GENERAL



1.2 SUMMARY

A. This Section specifies administrative and procedural requirements necessary to prepare and process Applications for Payment.

1. Coordinate the Schedule of Values and Applications for Payment with Contract CPM Schedule, List of Subcontracts, and Submittal Log.


1. Division 01 Section “Allowances” for procedural requirements governing handling and processing of allowances.

2. Division 01 Section "Unit Prices" for administrative requirements governing use of unit prices.

3. Division 01 Section "Measurement and Payment" for administrative requirements governing methods of measurement and determination of quantities of materials for use with unit prices.

4. Division 01 Section "Construction Progress Documentation" for administrative requirements governing preparation and submittal of Contractor's Construction Schedule and Submittals Schedule.

5. Division 01 Section “Project Closeout” for submittal of items required before final payment.

6. Division 01 Section “Project Record Documents” for procedural requirements governing the submission of Project Record Documents.

7. Division 01 Section “Operation and Maintenance Data” for submittal of items required before final payment.

1.3 DEFINITIONS

A. Schedule of Values: A statement furnished by Contractor allocating portions of the Contract Price to various portions of the Work and once accepted, to be used as the basis for reviewing Contractor's Applications for Payment.



1.4 SCHEDULE OF VALUES

A. Coordination: Coordinate preparation of the Schedule of Values with preparation of Contractor's Construction Schedule.

1. Correlate line items in the Schedule of Values with other required administrative forms and schedules, including the following:

a. Application for Payment forms with Continuation Sheets.

b. Submittals Schedule.

c. Contract CPM Schedule.

d. Subcontractor Payment Form

e. List of products.

f. List of principal suppliers and fabricators.

2. Submit the Schedule of Values to COTR at earliest possible date, but no later than 21 calendar days after the date of the Notice to Proceed.

a. On projects requiring cost-loaded CPM Schedules, the accepted cost loading will satisfy the requirements for the Schedule of Values.

3. Sub schedules: Where the Work is separated into phases requiring separately phased payments, provide sub schedules showing values correlated with each phase of payment.

B. Format and Content: Use the Project Manual table of contents as a guide to establish line items for the Schedule of Values. Provide at least one line item for each Specification Section.

1. Identification: Include the following Project identification on the Schedule of Values:

a. Project name and location.

b. Name of COTR.

c. Name of Architect/Engineer.

d. The Authority’s Project number.

e. Contractor's name and address.

f. Date of submittal.

2. Arrange the Schedule of Values in tabular form with separate columns to indicate the following for each item listed:

a. Related Specification Section or Division.

b. Description of the Work.

c. Name of subcontractor.

d. Name of manufacturer or fabricator.

e. Name of supplier.

f. Contract Modifications (numbers) that affect value.



g. Dollar value.

1) Percentage of the Contract Price to nearest one-hundredth percent, adjusted to total 100 percent.

3. Provide a breakdown of the Contract Price in enough detail to facilitate continued evaluation of Applications for Payment and progress reports. Coordinate with the Project Manual table of contents. Provide several line items for principal subcontract amounts, where appropriate. Include separate line items under required principal subcontracts for the following items. The value assigned to the total of these line items shall be 5 percent of the Contract Price:

a. Testing and commissioning activities.

b. Operation and Maintenance manuals.

c. Punch list activities.

d. Project Record Documents.

e. Bonds and warranties.

4. Round amounts to nearest whole dollar. Total shall equal the Contract Price.

5. Provide a separate line item in the Schedule of Values for each part of the Work where

Application for Payment may include materials or equipment purchased or fabricated and stored, but not yet installed.

a. Differentiate between potential items stored on-site and items stored off-site. Include evidence of insurance or bonded warehousing if required.

6. Provide separate line items in the Schedule of Values for initial cost of materials, for each subsequent stage of completion, and for total installed value of that part of the Work.

7. Allowances: Provide a separate line item in the Schedule of Values for each allowance. Show line-item value of unit-cost allowances, as a product of the unit cost, multiplied by measured quantity. Use information indicated in the Contract Documents to determine quantities.

8. Each item in the Schedule of Values and Application for Payment shall be complete.

Include total cost and proportionate share of general overhead and profit for each item.

a. At COTR’s option, temporary facilities and other major cost items that are not direct cost of actual work-in-place may be shown either as separate line items in the Schedule of Values or distributed as general overhead expense.

9. Schedule Updating: Update and resubmit the Schedule of Values with the next Applications for Payment when Contract Modifications result in a change in the Contract Price.



1.5 APPLICATION FOR PAYMENT

A. Each Application for Payment shall be consistent with previous applications and payments as certified by Contracting Officer and paid for by the Authority.

1. Initial Application for Payment, Application for Payment at time of Substantial Completion, and final Application for Payment involve additional requirements.

B. Payment Application Times: Application for Payment shall coincide with CPM schedule monthly update, or as otherwise indicated in the Agreement between the Authority and Contractor. The period covered by each Application for Payment starts on the day following the end of the preceding period and shall not exceed one calendar month, unless otherwise approved by COTR.

C. Payment Application Forms: Use forms provided by the Contracting Officer, but supplied by COTR, for Application for Payment.

D. Application Preparation: Complete every entry on form. Notarize and execute by a person authorized to sign legal documents on behalf of Contractor. The Authority will return incomplete applications without action.

1. Entries shall match data on the Schedule of Values and Contractor's Construction Schedule. Use updated schedules if revisions were made.

2. Include amounts of Contract Modifications issued before last day of construction period covered by application.

E. Transmittal: Submit one original and four copies of Application for Payment to the address indicated in the Section VII - Contract Provision, paragraph 04.B, each one signed and notarized. Include waivers of lien and similar attachments if required.

1. Transmit Applications for Payment with a transmittal form listing attachments and recording appropriate information about application in a manner acceptable to Contracting Officer.

F. Waivers of Mechanic's Lien: With Final Application for Payment, submit waivers of mechanic's liens from subcontractors, sub-subcontractors, and suppliers.

1. The Authority reserves the right to designate which entities involved in the Work must submit waivers.

2. Waiver Forms: Submit waivers of lien on forms, executed in a manner acceptable to the Authority.

G. Initial Application for Payment: Administrative actions and submittals that shall precede or coincide with submittal of first Application for Payment include the following:

1. List of subcontractors.

2. Schedule of Values.

3. Contractor's Construction Schedule (preliminary if not final).

4. Products List

5. Schedule of unit prices.



6. Submittals Schedule (preliminary if not final).

7. List of Contractor's staff assignments.

8. List of Contractor's principal consultants.

9. Copies of authorizations and licenses from authorities having jurisdiction for performance of the Work.

10. Initial progress report.

11. Report of pre-construction conference.

12. Performance and payment bonds.

13. Initial settlement survey and damage report if required.

14. Submittal and approval of Contractor Quality Control Plan.

15. Submittal and approval of Contractor Safety Plan.

16. Subcontractor Payment Form: (Form J, "Contract Conditions," Section IX, "LDBE").

H. Monthly Application for Payment: Administrative actions and submittals that shall accompany the submittal of Contractor's monthly Application for Payment include the following:

1. Subcontractor Payment Form.

2. Monthly Progress Report, prepared according to requirements specified in Division 01 Section "Construction Progress Documentation."

3. Evidence of payment for material on-site if reimbursement for such material is being requested.

4. Quality Control inspection checklists covering the work activities for which payment is being requested. Checklists must be complete per Division 1 Section “Quality Requirements” of this Contract.

5. An updated copy of the Quality Control Deficiency Log as of the date of Application for Payment.

6. Update of Contract Record Documents.

I. Application for Payment at Substantial Completion: After issuance of the Certificate of Substantial Completion, submit an Application for Payment showing 100 percent completion for portion of the Work claimed as substantially complete.

1. Include documentation supporting claim that the Work is substantially complete and a statement showing an accounting of changes to the Contract Price.

2. This application shall reflect Certificates of Partial Substantial Completion issued previously for Authority occupancy of designated portions of the Work, if applicable.

3. Advise COTR of change-over in security provisions.

J. Final Payment Application: Submit final Application for Payment with releases and supporting documentation not previously submitted and accepted, including, but not limited, to the following:

1. Evidence of completion of Project closeout requirements.



2. Insurance certificates for products and completed operations where required and proof that taxes, fees, and similar obligations were paid.

3. Updated final statement, accounting for final changes to the Contract Price.

4. Evidence that claims have been settled.

5. Final meter readings for utilities, a measured record of stored fuel, and similar data as of date of Substantial Completion or when the Authority took possession of and assumed responsibility for corresponding elements of the Work.

6. Final, liquidated damages settlement statement.

7. Return of all Airport identification badges and keys.





PROJECT MANAGEMENT AND COORDINATION 013100 - 1

SECTION 013100 - PROJECT MANAGEMENT AND COORDINATION

PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes administrative provisions for coordinating construction operations on Project including, but not limited to, the following:

1. General project coordination procedures.

2. Conservation.

3. Coordination drawings.

4. Administrative and supervisory personnel.

5. Project meetings.

a. Pre-award conference.

b. Pre-construction conference.

c. Pre-installation conference.

d. Progress meetings.

e. Partnering meetings.


1. Division 01 Section: "Execution" for the coordination of general installation and field-engineering services, including establishment of benchmarks and control points.

2. Division 01 Section "Project Closeout" for coordinating Contract closeout.

1.3 COORDINATION

A. Coordination: Coordinate construction operations included in various Sections of the Specifications to ensure efficient and orderly installation of each part of the Work. Coordinate construction operations, included in different Sections that depend on each other for proper installation, connection, and operation.

1. Schedule construction operations in sequence required to obtain the best results where installation of one part of the Work depends on installation of other components, before or after its own installation.



2. Coordinate installation of different components with other contractors to ensure maximum accessibility for required maintenance, service, and repair.

3. Where availability of space is limited, coordinate installation of different components to ensure maximum performance and accessibility for required maintenance, service, and repair of all components, mechanical, electrical, and otherwise. Contractor is cautioned that, where specific dimensions are not indicated or where Drawings are schematic in nature, as with most Electrical and Mechanical Drawings, Contractor shall have sole responsibility to coordinate the work to meet this requirement. Prepare and submit Coordination Drawings to COTR for review and approval as provided in "Coordination Drawings" Paragraph in "Submittals" Article of this Section.

4. Make adequate provisions to accommodate items scheduled for later installation.

B. Prepare memoranda for distribution to each party involved, outlining special procedures required for coordination. Include such items as required notices, reports, and list of attendees at meetings.

1. Prepare similar memoranda for COTR and separate contractors if coordination of their Work is required.

C. Administrative Procedures: Coordinate scheduling and timing of required administrative procedures with other construction activities and activities of other contractors to avoid conflicts and to ensure orderly progress of the Work and completion within the specified Contract duration. Such administrative activities include, but are not limited to, the following:

1. Preparation of Contractor's Construction Schedule.

2. Preparation of the Schedule of Values.

3. Installation and removal of temporary facilities and controls.

4. Delivery and processing of submittals.

5. Progress meetings.

6. Pre-installation conferences.

7. Start-up, check-out, and final acceptance of systems.

8. Project closeout activities.

9. Protection of existing and new work.

D. Conservation: Coordinate construction activities to ensure that operations are carried out with consideration given to conservation of energy, water, and materials.

1. Salvage materials and equipment involved in performance of, but not actually incorporated into, the Work. Refer to other sections for disposition of salvaged materials that are designated as the Authority's property.

E. Temporary Utility Outages: Comply with requirements in Division 01 Section "Summary."



1.4 SUBMITTALS

A. Key Personnel Names: At the pre-construction meeting, submit a list of Contractor's key personnel assignments. Key personnel shall include but not necessarily be limited to Project Manager, Project Superintendent, Safety Manager, Safety Engineer, Quality Control Manager, Project Scheduler, Soil Excavation Engineers, and other personnel in attendance at Project site along with alternates. Identify individuals and their duties and responsibilities; list addresses and telephone numbers, including home and office telephone numbers. Provide names, addresses, and telephone numbers of individuals assigned as standbys in the absence of individuals assigned to Project.

1. Post copies of list in Project meeting room, in temporary field office, and by each temporary telephone. Keep the list current at all times.

1.5 REQUESTS FOR INFORMATION (RFIs)

A. Procedure: Immediately on discovery of the need for interpretation of the Contract Documents, prepare and submit an RFI in the form specified.

1. RFIs shall originate with Contractor. RFIs submitted by entities other than Contractor will be returned with no response.

2. Coordinate and submit RFIs in a prompt manner so as to avoid delays in Contractor's work or work of subcontractors.

B. Content of the RFI: Include a detailed, legible description of item needing interpretation and the following:

1. Contract Name

2. Contract Number

3. Date.

4. Name of Contractor.

5. Name of Resident Engineer

6. Name of Task Manager

7. RFI number, numbered sequentially.

8. Specification Section number and title and related paragraphs, as appropriate.

9. Drawing number and detail references, as appropriate.

10. Field dimensions and conditions, as appropriate.

11. Contractor's suggested solution(s). If Contractor's solution(s) impact the Contract Time or the Contract Sum, Contractor shall state impact in the RFI.

12. Contractor's signature.

13. Attachments: Include drawings, descriptions, measurements, color photos, Product Data, Shop Drawings, and other information necessary to fully describe items needing interpretation.



a. Supplementary drawings prepared by Contractor shall include dimensions, thicknesses, structural grid references, and details of affected materials, assemblies, and attachments.

C. Hard-Copy RFIs:

1. Identify each page of attachments with the RFI number and sequential page number.

2. Hard copy RFI’s must be scanned for electronic transmission using the Authority provided Oracle Primavera Unifier project management system.

D. Software-Generated RFIs: Software-generated form with substantially the same content as indicated above.

1. Attachments shall be electronic files in Adobe Acrobat PDF format.

2. RFI must be signed and scanned for electronic transmission.

3. Electronic copy RFI’s will be transmitted using the Authority provided Oracle Primavera Unifier project management system.

E. COTR’s Action: COTR will review each RFI, determine action required, and return it. Allow seven calendar days for COTR's response for each RFI. RFIs received after 1:00 p.m. will be considered as received the following working day.

1. The following RFIs will be returned without action:

a. Requests for approval of submittals.

b. Requests for approval of substitutions.

c. Requests for coordination information already indicated in the Contract Documents.

d. Requests for adjustments in the Contract Time or the Contract Sum.

e. Requests for interpretation of Engineer’s actions on submittals.

f. Incomplete RFIs or RFIs with numerous errors.

2. COTR's action may include a request for additional information, in which case COTR's time for response will start again.

3. COTR's action on RFIs that may result in a change to the Contract Time or the Contract Sum may be eligible for Contractor to submit Change Proposal.

a. If Contractor believes the RFI response warrants change in the Contract Time or the Contract Sum, notify COTR in writing within 10 days of receipt of the RFI response.

F. On receipt of COTR’s action, update the RFI log and immediately distribute the RFI response to affected parties. Review response and notify COTR within seven days if Contractor disagrees with response.

G. RFI Log: Prepare, maintain, and submit a tabular log of RFIs organized by the RFI number. Submit log weekly prior to progress meeting for inclusion in progress meeting minutes. Include the following:

1. Project name.



2. Name and address of Contractor.

3. Name of COTR.

4. RFI number including RFIs that were dropped and not submitted.

5. RFI description.

6. Date the RFI was submitted.

7. Date COTR’s response was received.

8. Identification of related Minor Change in the Work, Construction Change Directive, and Proposal Request, as appropriate.

H. RFI Transmittal: The Contractor must use the Authority provided web-based Oracle Primavera Unifier project management system (Unifier) to transmit each RFI to the COTR. Response of the COTR’s RFI review and action will be transmitted to the Contractor through Unifier. The Authority will provide the Contractor a Unifier license(s) and training.

1.6 ADMINISTRATIVE AND SUPERVISORY PERSONNEL

A. General: In addition to Project Superintendent, provide other administrative and supervisory personnel as required for proper performance of the Work.

1.7 PROJECT MEETINGS

A. Pre-award Conference:

1. General: At the request of the Contracting Officer, a pre-award conference with Contractor may be held before actual award of the Contract. The meeting will review Contractor's understanding of the Contract Documents, cost and pricing data, contractual requirements, and Contractor's capabilities, financial standing, and past experience prior to award.

a. Minutes: COTR will record and distribute meeting minutes to all attendees and all relevant parties.

2. Attendees: Contracting Officer, COTR, Authority Design Project Manager, Architect/Engineer, Contractor and its key personnel nominated for assignment to the Contract, and major subcontractors if so requested by the Contracting Officer. Concerned parties shall each be represented by persons thoroughly familiar with and authorized to conclude matters relating to the work described in the Contract Documents. The Contracting Officer will chair the pre-award meeting.

3. Agenda: Significant discussion items that could affect award include, but are not limited to, the following:

a. Provision and acceptability of payment and performance bonds.

b. LDBE/MBE/WBE/DBE participation.

c. Qualifications of key individuals.



d. Quality-control experience.

e. Percentage of work performed by own forces.

f. Contractor's experience with similar work, including previous Authority contracts.

g. Scheduling capabilities of Contractor.

h. Financial standing of Contractor.

i. Mobilization plan.

j. Understanding of work described in the Contract Documents and the physical constraints associated with work at the Airport.

k. Equipment and manpower availability.

l. Cost and pricing data.

4. Representations and commitments made by Contractor or its subcontractors shall be construed as binding to the Contract.

B. Pre-construction Conference:

1. General: COTR will schedule pre-construction conference and organizational meeting with Contractor after the Contracting Officer issues a notice of intent to award, or actually awards the Contract. The meeting will review the parties' responsibilities and personnel assignments.

a. Minutes: COTR will record and distribute meeting minutes to all attendees and relevant parties.

2. Attendees: Contracting Officer, COTR, Architect/Engineer, and their sub-consultants; Contractor and its superintendent; major subcontractors; manufacturers; suppliers; and other concerned parties. All participants at the conference shall be familiar with Project and authorized to conclude matters relating to the Work.

3. Agenda: Discuss items of significance that could affect progress, including the following:

a. Airport security.

b. LBDE/MBE/WBE/DBE participation and certifications.

c. Authority-controlled wrap-up insurance program.

d. Airport Operations coordination.

e. Preliminary construction schedule.

f. Phasing.

g. Critical work sequencing.

h. Designation of key personnel.

i. Procedures for processing field decisions and Contract Modifications.

j. Procedures for processing Applications for Payment.



k. Distribution of the Contract Documents.

l. Authority Construction guidelines.

m. Submittal procedures.

n. Preparation of Record Documents.

o. Use of the premises.

p. Responsibility for temporary facilities and controls.

q. Parking availability.

r. Office, work, and storage areas.

s. Equipment deliveries and priorities.

t. Safety procedures.

u. Quality-control requirements.

v. First aid.

w. Progress cleaning.

x. Working hours.

y. Authority Building Code requirements/permits.

4. Refer to Contract Provision "Pre-construction Requirements" for required submittals due at the pre-construction conference.

C. Pre-installation Conferences:

1. General: COTR will conduct a pre-installation conference at Project site before each construction activity that requires coordination with other construction.

a. Minutes: COTR will record and distribute meeting minutes.

2. Attendees: Contractor, Installer, and representatives of manufacturers and fabricators involved in or affected by the installation and its coordination or integration with other materials and installations that have proceeded, or will follow.

3. Agenda: Review progress of other construction activities and preparations for the particular activity under consideration, including requirements for the following:

a. Contract Documents.

b. Options.

c. Related Contract Modifications.

d. Purchases.

e. Deliveries.

f. Submittals.

g. Possible conflicts.

h. Compatibility problems.



i. Time schedules.

j. Weather limitations.

k. Manufacturer's written recommendations.

l. Warranty requirements.

m. Compatibility of materials.

n. Acceptability of substrates.

o. Temporary facilities and controls.

p. Space and access limitations.

q. Governing regulations and permits.

r. Safety.

s. Testing and inspecting requirements.

t. Required performance results.

u. Recording requirements.

v. Protection of construction and personnel.

w. Review material selection.

x. Fabrication and installation procedures.

y. Coordination of involved trades.

4. Do not proceed with installation if the conference cannot be successfully concluded. Initiate whatever actions are necessary to resolve impediments to performance of the Work and reconvene the conference at earliest feasible date.

D. Project Closeout Conference: Schedule and conduct a Project closeout conference, at a time convenient to Owner and Architect, but no later than 30 days prior to the scheduled date of Substantial Completion.

1. Conduct the conference to review requirements and responsibilities related to Project closeout.

2. Attendees: Authorized representatives of Owner, Construction Manager, Contractor and its superintendent; major subcontractors; suppliers; and other concerned parties shall attend the meeting. Participants at the meeting shall be familiar with Project and authorized to conclude matters relating to the Work.

3. Agenda: Discuss items of significance that could affect or delay Project closeout, including the following:

a. Preparation of record documents.

b. Procedures required prior to inspection for Substantial Completion and for final inspection for acceptance.

c. Submittal of written warranties.

d. Requirements for preparing operations and maintenance data.



e. Requirements for demonstration and training.

f. Preparation of Contractor's punch list.

g. Procedures for processing Applications for Payment at Substantial Completion and for final payment.

h. Submittal procedures.

i. Owner's partial occupancy requirements.

j. Installation of Owner's furniture, fixtures, and equipment.

k. Responsibility for removing temporary facilities and controls.

4. Minutes: Entity conducting meeting will record and distribute meeting minutes.

E. Weekly Progress Meetings:

1. General: COTR will conduct progress meetings weekly at regularly scheduled times convenient for all parties involved. Progress meetings are in addition to specific meetings held for other purposes, such as coordination and special pre-installation meetings. Additionally, discussions will address administrative and technical issues of concern, determining resolutions, and development of deadlines for resolution within allowable time frames.

a. Minutes: COTR will record and distribute meeting minutes.

2. Attendees: As may be required by COTR, in addition to representatives of the Authority and Contractor, each subcontractor, supplier, Contractor’s Project Scheduler, and other entities concerned with current progress or involved in planning, coordination, or performance of future activities. All participants at the conference shall be familiar with Project and authorized to conclude matters relating to the Work.

3. Agenda: Review and correct or approve minutes of previous progress meeting. Review other items of significance that could affect progress. Include topics for discussion as appropriate to status of Project.

a. Contractor's Construction Schedule: Review progress since the last meeting. Determine whether each activity is on time, ahead of schedule, or behind schedule, in relation to Contractor's Construction Schedule. Determine how construction behind schedule will be expedited; secure commitments from parties involved to do so. Discuss whether schedule revisions are required to ensure that current and subsequent activities will be completed within the Contract Time.

b. Review present and future needs of each entity present, including the following:

1) Safety and Security.

2) Interface requirements.

3) Time.

4) Sequence of operations.

5) Status of submittals.

6) Deliveries.



7) Off-site fabrication.

8) Storage Areas

9) Access.

10) Site utilization.

11) Requests for information.

12) Submittals.

13) Noncompliance notices.

14) Temporary facilities and controls.

15) Work hours.

16) Resource allocation.

17) Hazards and risks.

18) Progress cleaning.

19) Quality and work standards.

20) Contract Modifications.

21) Documentation of information for payment requests.

22) Preparation of Record Documents.

4. Submit at the weekly progress meeting, a two-week look-ahead schedule. This schedule shall include a three-week period, one week showing actual progress from the previous week and two weeks showing planned work for the two weeks after the meeting date. Include in the schedule all activities in sufficient detail as approved by COTR. A two-week look-ahead schedule form will be distributed at the pre-construction conference. Submit a list of subcontractors identifying dates of when subcontractors will be on-site or off-site. A form for this information will be provided by COTR.

5. Schedule Updating: Revise Contractor's Construction Schedule after each progress meeting where revisions to the schedule have been made or recognized. Issue revised schedule concurrently with the report of each meeting.

F. Schedule Update Meetings:

1. Conduct schedule update meetings before submittal of Contractor's Application for Payment. Determine where each activity is, in relation to Contractor's CPM Schedule. Ensure the incorporation of all changes made to the sequence of work and all change notices issued by the Contracting Officer. Submit the narrative and information specified in Division 01 Section "Construction Progress Documentation" if applicable.

2. Attendees: COTR, Contractor's Project manager or superintendent, the Contractor’s Project Scheduler, and the Authority's representative.

3. Submit the updated schedule, as bilaterally agreed on, along with the Application for Payment.

4. Present delay claims for discussion and, when possible, resolution.








CONSTRUCTION PROGRESS DOCUMENTATION 013200 - 1

SECTION 013200A - CONSTRUCTION PROGRESS DOCUMENTATION

PART 1 - GENERAL



1.2 SUMMARY

A. This Section specifies administrative and procedural requirements for various CPM schedules and reports required for proper performance of the Work.

B. All costs incurred by Contractor to correctly implement and update the schedule shall be borne by Contractor and are part of this Contract.

C. Schedules required include the following:

1. Contract Construction Progress Schedule in CPM format and related narrative and cash flow projection curves.

2. Submittals Schedule.

3. Schedule of Tests and Inspections.

4. Record, As-Built CPM Schedule.

D. Reports required include the following:

1. Daily Construction Reports.

2. Material Location Reports.

3. Field Correction Reports.

4. Special Reports.

5. Monthly Progress Reports.

6. Contractor Quality Control Reports.

E. Related Sections include the following:

1. Division 01 Section "Application for Payment" for Schedule of Values.

2. Division 01 Section "Project Management and Coordination" for Project meeting minutes.

3. Division 01 Section "Quality Requirements" for test and inspection reports.

4. Division 01 Section "Product Requirements" for Product List.

F. Schedule and Reports Transmittals: The Contractor must use the Authority provided web-based Oracle Primavera Unifier project management system (Unifier) to transmit schedule(s) and



required reports to the COTR. Response and/or acknowledgement by the COTR will be transmitted to the Contractor through Unifier. The Authority will provide the Contractor a Unifier license(s) and training.

1.3 DEFINITIONS

A. Activity: The fundamental unit of work in a Project plan and schedule. Each activity has defined geographical boundaries and a detailed estimate of resources required to construct the task. Each activity is assigned a unique description, activity number, activity codes, and dollar value.

B. CPM Network: The structure of the schedule. The network is the representation that defines the construction logic in terms of all the activities with their logical dependencies.

C. Contract CPM Schedule: A cost-loaded CPM schedule covering the entire Contract Duration from the Notice to Proceed through Final Acceptance of the Work.

D. Contract Duration/Time: The total time, in calendar days identified in Section III, "Schedule," representing the duration necessary for completion of all physical and administrative requirements under this Contract and any authorized extension thereof.

E. Critical Path: The critical path is the longest connected chain of interdependent activities in a CPM network that impacts the completion of the Project.

F. Excusable Delay: An unforeseeable delay, beyond the control of Contractor, experienced due to no fault or negligence by Contractor, its subcontractors, or suppliers.

G. Predecessor Activity: An activity that precedes another activity in the network.

H. Cost Loading: The allocation of the Schedule of Values for the completion of an activity as scheduled. The sum of costs for all activities shall equal the total Contract Price, unless otherwise approved by COTR.

I. Successor Activity: An activity that follows another activity in the network.

J. Total Float: The amount of time an activity can be delayed from its earliest start date without delaying the end of Project.

1. Float time is not for the exclusive use or benefit of either the Authority or Contractor, but is a jointly owned, expiring Project resource available to both parties as needed to meet schedule milestones and Contract completion date.

2. Free float is the amount of time an activity can be delayed without adversely affecting the early start of the successor activity.

1.4 PLANNING

A. The total Contract Duration and intermediate milestones if applicable, as indicated in Section III, "Schedule," are the Contract requirements.



B. Contractor shall prepare a practical work plan to complete the Work within the Contract Duration, and complete those portions of work relating to each intermediate milestone date and other Contract requirements. Contractor shall generate a computerized cost-loaded CPM schedule in Precedence Diagram Method (PDM) format for the Work.

C. Failure to include any work item required for performance of this Contract shall not excuse Contractor from completing all work within applicable completion dates, regardless of COTR approval of the Schedule.

D. Failure of Contractor to comply with requirements of this Section may be considered cause for withholding progress payments or termination for default.

1.5 SUBMITTALS

A. General: Contractor shall provide all schedule submittals on computer disk media as well as tabular printouts, resource curves and histograms, and 24-by-36-inch time-scaled logic diagrams. The latest version of Primavera P3 or SureTrak scheduling software shall be used. All costs incurred by Contractor to correctly implement, computerize and update the CPM Schedule shall be borne by Contractor and are included in the Contract Price. The number of copies of each submittal shall be as described in this Section or as may be requested by COTR.

B. Contract CPM Schedule: The Contract CPM Schedule and its related narrative as described in this Section shall be submitted along with the projected cash-flow curve as early as practicable after the Notice to Proceed, but in no event later than 30 calendar days after the Notice to Proceed. Within 15 calendar days, COTR will respond with approval or direction to change and Contractor shall resubmit within 10 calendar days, if required.

C. Daily Progress Report: Submit duplicate copies to COTR by noon on the day following the date of actual progress.

D. Monthly Progress Report: All components of the Monthly Progress Report described in this Section shall be submitted as attachments to Contractor's monthly Application for Payment.

E. Record As-Built CPM Schedule: A Record CPM Schedule accurately reflecting actual progress of Work shall be submitted, as part of this Contract's Record Documents. All activities shall have actual dates that are true and accurate.

F. Qualification Data: For Project Scheduler.

1.6 QUALITY ASSURANCE

A. Project Scheduler Qualifications: Minimum of two years experience and not less than one (1) project of similar size and scope, with capability to produce CPM reports and diagrams within 24 hours of COTR's request. Project Scheduler is classified as one of Contractor's key personnel.




PART 3 - EXECUTION

3.1 PROJECT SCHEDULER

A. Engage a project scheduler, either as Contractor's employee or as Contractor's consultant, to provide planning, evaluation, and reporting using CPM scheduling, and to prepare required schedules.

1. Project Scheduler shall be an active participant at all meetings related to Project progress, alleged delays, and time impact.

3.2 CONTRACT CPM SCHEDULE

A. Scheduling Requirements: The Contract CPM Schedule shall be a computerized cost-loaded, time-scaled CPM Schedule in PDM format that includes the following:

1. The order, sequence, and interdependence of all significant work items including mobilization, demobilization, testing and commissioning, construction, procurement, fabrication, and delivery of critical or special materials and equipment; utility interruption coordination; submittals and approvals of critical Samples, Shop Drawings, procedures, or other reasonable requirements that may be requested by COTR.

2. Work by the Authority, or utility agencies, and other third parties that may affect or be affected by Contractor's activities.

3. Adequate referencing of all work items to identify subcontractors or other performing parties.

4. Activity Coding may be provided by the COTR to establish minimum requirements for structure and values for the first (5) code fields.

5. Activity durations not in excess of 14 calendar days, except nonconstruction activities such as procurement and fabrication. Activities shall be broken down in the level of detail prescribed by COTR.

6. Activities that are cost loaded to show the direct costs required to perform the Work, including work by subcontractors.

7. A narrative that explains the basis for Contractor's determination of construction logic, estimated durations, cost allocations, estimated quantities and production rates, hours per shift, workdays per week, and types, numbers, and capacities of major construction equipment to be used. A listing of nonworking days and holidays incorporated into the schedule shall be provided.

B. Critical Path Activities: The Contract CPM Schedule shall be prepared to include the data for the total Contract and the critical path activities shall be identified, including critical paths for interim completion dates. Scheduled start or completion dates imposed on the schedule by Contractor shall be consistent with Contract milestone dates. Milestone dates shall be the scheduled dates specified in Section III, "Schedule," if applicable, and shall be prominently



identified. The Contract CPM Schedule shall accurately show all as-built activities completed from the issuance of the Notice to Proceed up to the submittal of this schedule.

C. Assignment of Costs to Activities for Progress Payments:

1. Contractor shall assign cost to construction activities on the Contract CPM Schedule. Costs shall not be assigned to submittal activities unless specified otherwise but may, with COTR's approval, be assigned to fabrication and delivery activities. Costs shall be assigned to testing and commissioning activities, O&M manuals, punchlist activities, and Project Record Documents.

2. Each activity cost shall reflect an accurate value subject to approval by COTR.

3. The total cost assigned to activities shall equal the total Contract Price.

4. Activities shall be cost coded as directed by COTR.

D. Required Submittals: On a monthly basis, Contractor shall submit five copies of each of the following components of the Contract CPM Schedule:

1. A time-scaled plot of the schedule network in PDM format showing logic ties for all activities including submittals and procurement activities.

2. Computer-generated CPM Schedule Reports that contain the following data for each work item: activity identification number, description, resource loading, duration, early start and early finish calendar dates, late start and late finish calendar dates, and total float in calendar days. The reports shall also show the logic ties of successor and predecessor work items. The reports shall be sorted as follows, or other sorts as required by COTR:

a. By activity identification.

b. By total float x early start.

c. By early start x early finish x total float.

3. The narrative described in Subparagraph 3.2-A-6 above.

4. A cash-flow report showing monthly expenditures projected over the life of the Contract. A cumulative cash-flow curve based on early and late schedule events shall also be submitted. These reports shall be derived from the Contract CPM Schedule.

3.3 DAILY CONSTRUCTION REPORTS

A. Prepare a daily construction report, recording the following information concerning events at the site, coordinate with requirements in Division 01 Section "Quality Requirements," and submit duplicate copies to COTR by noon of the day following day of actual progress:

1. List of subcontractors (by trade group) at the site.

2. List of separate contractors at the site.

3. Approximate count of personnel (by trade group) at the site.

4. Equipment (by trade group) at the site.

5. High and low temperatures, general weather conditions.

6. Accidents (refer to accident reports).



7. Meetings and significant decisions.

8. Unusual events (refer to special reports).

9. Stoppages, delays, shortages, losses.

10. Meter readings and similar recordings.

11. Emergency procedures.

12. Orders and requests of governing authorities.

13. Change Notices/Directives and Contract Modifications received, implemented.

14. Services connected, disconnected.

15. Equipment or system tests and startups.

16. Partial Completions, occupancies.

17. Substantial Completions authorized.

18. Material deliveries.

3.4 MATERIAL LOCATION REPORTS

A. At weekly intervals, prepare a comprehensive list of materials delivered to and stored at the site. List shall be cumulative, showing materials previously reported plus items recently delivered. Include with list a statement of progress on and delivery dates for all materials or items of equipment being fabricated or stored away from the building site. Submit copies of list to COTR at weekly intervals.

3.5 FIELD CORRECTION REPORT

A. When the need to take corrective action that requires a departure from the Contract Documents arises, prepare a detailed report including a statement describing the problem and recommended changes. Indicate reasons the Contract Documents cannot be followed. Submit a copy to COTR immediately.

3.6 SPECIAL REPORTS

A. When an event of unusual or significant nature occurs at the site, prepare and submit a special report. List the chain of events, persons participating, response by Contractor's personnel, an evaluation of the results or effects, and similar pertinent information. Advise COTR in advance when such events are known or predictable.

1. Include tabular CPM reports, time-scaled logic diagrams, resource curves and histograms, and narratives as requested by COTR.

B. Submit special reports directly to COTR within seven calendar days of an occurrence. Submit a copy to other parties affected by the occurrence.



3.7 MONTHLY PROGRESS REPORTING

A. General: Approval of Contractor's monthly Application for Payment shall be contingent, among other factors, on the submittal of a satisfactory monthly schedule update.

B. Monthly Schedule Update Meetings: Monthly schedule updates shall be the product of joint review meetings between Contractor, COTR, and major active subcontractors. The joint review shall focus on actual progress for the preceding month, planned progress for the upcoming month supported by a Contractor-prepared Four-Week Look-Ahead Schedule, impact to schedule if any due to change notices issued, adverse weather, and any effected changes to the Construction CPM Schedule. The agreed on progress, and changes, if any, shall be incorporated into the schedule update to be submitted. The update shall always represent the actual history of accomplishment of all activities, and will form the basis for Contractor's Application for Payment. Contractor's delay claims shall be presented for discussion and, when possible, resolution.

C. Required Submittals: Every two (2) weeks, Contractor shall submit two (2) copies in electronic format of the updated CPM schedule and five (5) copies of each of the following components of the Monthly Progress Report:

1. A monthly progress narrative, the content of which shall be prescribed by COTR, but shall include as a minimum a description of overall progress for the preceding month, a critical path analysis, a discussion of problems encountered and proposed solution thereof, delays experienced and proposed recovery measures, a monthly reconciliation of weather impact, the status and impact of contract modifications, documentation of any logic changes, and any other changes made to the schedule since the previous monthly update.

2. CPM schedule reports listing completed activities, activities in progress, and remaining activities in the format requested by COTR. For each activity, Contractor shall provide those details identified in Subparagraph 3.2-D-2.

3. Monthly and cumulative cash-flow curves that show actual vs. planned cash-flow status.

4. Documentation of delivered material in the form of paid invoices or other evidence that Contractor has clear title for the material delivered.

D. If critical activities of the schedule are delayed and such delay is not excusable as defined in this Section, the remaining sequence of activities and/or duration thereof shall be adjusted by Contractor through such measures as additional manpower, additional shifts, or the implementation of concurrent operations until the schedule produced indicates Work will be completed on schedule. Except as provided elsewhere in the Contract, all costs incurred by Contractor to recover from inexcusable delays shall be borne by Contractor.

E. The monthly schedule update shall form the basis for Contractor's Application for Payment. The progress payment for an activity shall be based on its agreed on percentage of completion. On unit-priced contracts, the approval of Contractor's monthly requisition is contingent on the submittal of a satisfactory schedule update every two (2) weeks; however, the basis of payment will be the actual measurement of COTR-accepted, in-place units of work.



3.8 DELAYS AND REQUESTS FOR EXTENSION OF TIME

A. The determination for an extension of the Contract Time will be made by the Contracting Officer according to the Contract Provision "Default."

B. Contractor acknowledges and agrees that delays in activities, irrespective of the party causing the delay, which according to the computer mathematical analysis do not affect any critical activity or milestone dates on the CPM network at the time of the delay, shall not become the basis for an extension of the Contract Time. The only basis for any extension of time will be the demonstrated impact of an excusable delay on the critical path. In demonstrating such impact, Contractor shall provide adequate detail as required by the Contract, and Contractor shall prove that:

1. An event occurred.

2. Contractor was not responsible for the event in that the event was beyond the control of Contractor, and was without fault or negligence of Contractor, subcontractor, or supplier, and the event was unforeseeable.

3. The event was the type for which an excuse is granted according to the "Default" provision of this Contract.

4. Activities on the critical path of the Work were delayed.

5. The event in fact caused the delay of the Work.

6. The requested additional time is an appropriate and reasonable extension of the Contract Time, given the actual delay encountered.

C. Time Extensions for Unusually Severe Weather:

1. If unusually severe weather conditions are the basis for a request for an extension of the Contract Time, such request shall be documented by data substantiating that weather conditions were abnormal for the period of time and could not have been reasonably anticipated, and that weather conditions had an adverse effect on the critical activities of the scheduled construction.

2. The schedule of anticipated adverse weather below will constitute the base line for monthly (or a prorated portion thereof) weather/time evaluation by the Contracting Officer. On issuance of the Notice to Proceed and continuing throughout the Contract on a monthly basis, actual adverse weather days will be recorded by Contractor on a calendar day basis (include weekends and holidays) and compared to the monthly anticipated adverse weather days set forth below.

a. For purposes of this clause, the term "actual adverse weather days" shall include days that can be demonstrated to have been impacted by adverse weather.

b. Monthly Anticipated Adverse Weather Calendar Days:

1) January - 7.

2) February - 5.

3) March - 6.

4) April - 6.

5) May - 8.



6) June - 6.

7) July - 6.

8) August - 7.

9) September - 5.

10) October - 5.

11) November - 5.

12) December - 6.

c. The number of actual adverse weather days shall be calculated chronologically from the first to the last day in each month for the duration shown on the construction schedule to substantially complete the project. Contractor shall not be entitled to any claim for time extension based on adverse weather unless the number of actual adverse weather days exceeds the number of anticipated adverse weather days, and unless such adverse weather days prevent work for 50 percent or more of Contractor's workday. In preparing the Contract Schedule, Contractor shall reflect the above anticipated adverse weather days on all weather-dependent activities. Weather-caused delays shall not result in any additional compensation to Contractor.

3. On days where adverse weather is encountered, Contractor shall list all critical activities under progress and shall indicate the impact adverse weather had, if any, on the progress of such activities. This information shall be presented at the end of the adverse weather day to COTR or its authorized representative for its review and approval.

4. If Contractor is found eligible for an extension of the Contract Time, the Contracting Officer will issue a modification extending the time for Contract completion. The extension of time will be made on a calendar day basis.

D. Required Submittals:

1. Provide time-impact analysis that illustrates impact during update period in which event occurred, that event has been mitigated to greatest possible extent, and that event still impacts overall completion of Project.

2. Include with request, two (2) copies of submittal of impacted schedule, in electronic format, and photocopies of all relevant documents that support the claim.

3. Submit all required items within the following time periods:

a. Ten (10) calendar days of event occurrence.

b. Ten (10) calendar days of Contractor's knowledge of impact.

c. Fourteen (14) calendar days of written request by COTR.

4. Expiration of time periods without submittal shall constitute forfeiture of rights for these specific impacts.



3.9 RECORD SCHEDULE

A. After all Contract work items are complete, and as a condition of final payment, Contractor shall submit three copies of a Record, As-Built CPM Schedule showing actual start and finish dates for all work activities and milestones, based on the accepted monthly updates. These schedule submittals shall be in tabular and in time-scaled PDM plot formats.



PHOTOGRAPHIC DOCUMENTATION 013233 - 1

SECTION 013233 - PHOTOGRAPHIC DOCUMENTATION

PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes administrative and procedural requirements for the following:

1. Preconstruction photographs.

2. Periodic construction photographs.

3. Final Completion construction photographs.


1. Division 01 Section "Unit Prices" for procedures for unit prices for extra photographs.

2. Division 01 Section "Submittals" for submitting construction photographs.

3. Division 01 Section "Project Closeout" for submitting photographic negatives as Project Record Documents at Project closeout.

1.3 UNIT PRICES

A. Basis for Proposals: Base number of construction photographs on twenty photographs per month over the duration of Project.

1.4 SUBMITTALS

A. Qualification Data: For firms and persons specified in "Quality Assurance" Article to demonstrate their capabilities and experience. Include lists of completed projects with project names and addresses, names and addresses of architects and owners, and other information specified.

B. Key Plan: Submit key plan of Project site and building including a detailed description of each project area with notation of vantage points marked for location and direction of each photograph. Indicate elevation or story of construction. Include the same label information as the corresponding set of photographs.

C. Construction Photographs: Submit four prints of each photographic view within five days of taking photographs.



1. Format: 8-by-10-inch smooth-surface matte prints on single-weight commercial-grade photographic paper mounted on card stock to allow a 1-inch-wide margin and enclosed back to back in clear plastic sleeves that are punched for standard 3-ring binder.

2. Identification: On back of each print, provide a computer generated applied label with the following information:

a. Name of Project.

b. Name and address of photographer.

c. Name of COTR.

d. Name of Architect/Engineer.

e. Name of Contractor.

f. Date photograph was taken.

g. Description of vantage point, indicating location, direction (by compass point), and elevation or story of construction.

3. Negatives: Submit a complete set of photographic negatives in protective envelopes with each submittal of prints. Identify date photographs were taken.


A. Photographer Qualifications:

Individual of established reputation who has been regularly engaged as a professional construction photographer for not less than three years.

B. Costs: Include photographer's services in the Contract Price.

1.6 COORDINATION

A. Auxiliary Services: Cooperate with photographer. Provide auxiliary services requested, including access to Project site and use of temporary facilities including temporary lighting required to produce clear, well-lighted photographs without obscuring shadows.

1.7 USAGE RIGHTS

A. Obtain and transfer copyright usage rights from photographer to the Authority for unlimited reproduction of photographic documentation.

1.8 EXTRA PRINTS

A. Extra Prints: If requested by COTR, photographer shall prepare extra prints of photographs. Contractor will not be responsible for the cost of such additional prints.



PART 2 - PRODUCTS

2.1 PHOTOGRAPHIC MEDIA

A. Photographic Film: Manual Single Lens Reflex camera using 35 mm 100, 200 or 400 ISO color film. Do not use point and shoot cameras. Use lenses with focal length of either 50 mm or 55 mm.

B. Digital Images: Provide images in JPEG format, with minimum sensor size of 3 megapixels.

PART 3 - EXECUTION

3.1 PHOTOGRAPHS, GENERAL

A. Photographer: Engage a qualified commercial photographer to take construction photographs.

B. Date Stamp: Unless otherwise indicated, date and time stamp each photograph as it is being taken so stamp is integral to photograph.

C. Field Office Prints: Retain one set of prints of progress photographs in the field office at Project site, available at all times for reference. Identify photographs the same as for those submitted to COTR.

3.2 CONSTRUCTION PHOTOGRAPHS

A. Preconstruction Photographs: Before starting construction, take color photographs of Project site and surrounding properties from different vantage points, as directed by COTR.

1. Each work area shall be photographed appropriately in a sufficient quantity to show existing conditions adjacent to the project before starting the Work.

B. Periodic Construction Photographs: Take a minimum of 10 color photographs monthly for each active work area, coinciding with the cutoff date associated with each Application for Payment. The COTR will select vantage points to best show status of construction and progress since the last photographs were taken.

C. Time-Lapse-Sequence Construction Photographs: Take five (5) color photographs as indicated, to best show status of construction and progress since the last photographs were taken.

1. Frequency: Take photographs monthly, coinciding with the cutoff date associated with each Application for Payment.

2. Vantage Points: Following suggestions by COTR and Contractor, photographer shall select vantage points. During each of the following construction phases, take not less than two (2) of the required shots from the same vantage point each time to create a time-lapse sequence as follows:

a. Commencement of the Work, through completion of subgrade construction.

b. Above-grade structural framing.



c. Exterior building enclosure.

d. Interior Work, through date of Substantial Completion.

D. Final Completion Construction Photographs: Take eight (8) color photographs after date of Substantial Completion for submission as Project Record Documents. COTR will direct photographer for desired vantage points.

1. Do not include date stamp.

E. Additional Photographs: COTR may issue requests for additional photographs, in addition to periodic photographs specified. Additional photographs will be paid for by Contract Modification and are not included in the Contract Price.

1. Photographer will be given three days notice, where feasible.

2. In emergency situations, photographer shall take additional photographs within 24 hours of request.

3. Circumstances that could require additional photographs include, but are not limited to, the following:

a. Special events planned at Project site.

b. Immediate follow-up when on-site events result in construction damage or losses.

c. Photographs to be taken at fabrication locations away from Project site. These photographs are not subject to unit prices or unit-cost allowances.

d. Substantial Completion of a major phase or component of the Work.

e. Extra record photographs at time of final acceptance.

f. COTR's request for special publicity photographs.



SUBMITTALS 013300 - 1

SECTION 013300 - SUBMITTALS

PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes administrative and procedural requirements for submitting Shop Drawings, Product Data, Samples, and other miscellaneous submittals.


1. Division 01 Section "Project Closeout" for submitting warranties.

2. Division 01 Section "Project Record Documents" for submitting Record Drawings, Record Specifications, and Record Product Data.

3. Divisions 02 through 33 Sections for specific requirements for submittals in those Sections.

1.3 DEFINITIONS

A. Action Submittals: Written and graphic information that requires COTR's responsive action.

B. Informational Submittals: Written information that does not require COTR's approval. Submittals may be rejected for not complying with requirements.

1.4 SUBMITTAL PROCEDURES

A. General: COTR will provide electronic copies of CADD electronic files of the drawings for Contractor's use in preparing submittals.

B. Coordination: Coordinate preparation and processing of submittals with performance of construction activities.

1. Coordinate each submittal with fabrication, purchasing, testing, delivery, other submittals, and related activities that requires sequential activity.

2. Coordinate transmittal of different types of submittals for related parts of the Work so processing will not be delayed because of need to review submittals concurrently for coordination.



a. Without change to the Contract Duration, COTR reserves the right to withhold action on a submittal requiring coordination with other submittals until related submittals are received.

C. Submittals Schedule: Comply with requirements in Division 01 Section "Construction Progress Documentation" for list of submittals and time requirements for scheduled performance of related construction activities.

D. Contractor's Responsibilities: Contractor is responsible for the scheduling and submission of all submittals. Submit to COTR all required Submittals. The COTR will forward submittals to the appropriate parties for review.

E. Processing Time: Allow enough time for submittal review, including time for re-submittals, as follows. Time for review shall commence on COTR’s receipt of submittal. No extension of the Contract Time will be authorized because of failure to transmit submittals enough in advance of the Work to permit processing, including re-submittals.

1. Initial Review: Allow 15 calendar days for initial review of each submittal. Allow additional time if coordination with subsequent submittals is required. COTR will advise Contractor when a submittal processed must be delayed for coordination. Allow an additional 45 calendar days for submittals related to fire-protection systems.

2. Intermediate Review: If intermediate submittal is necessary, process it in same manner as initial submittal.

3. Re-submittal Review: Allow 15 calendar days for review of each re-submittal.

4. No extension of the Contract Time will be authorized because of failure to transmit submittals to COTR enough in advance of the Work to permit processing. Processing of incomplete or unacceptable submissions by COTR shall not reduce the number of calendar days specified above for COTR's review. Resubmissions shall be treated the same as initial submissions relative to review time.

5. Notations on submittals that increase the Contract cost or time of completion shall be brought to COTR's attention before proceeding with the Work.

F. Identification: Place a permanent label or title block on each submittal for identification.

1. Indicate name of firm or entity that prepared each submittal on label or title block.

2. Provide a space approximately 6 by 8 inches on label or beside title block to record Contractor's review and approval markings and action taken by COTR and Architect.

3. Include the following information on label for processing and recording action taken:

a. Contract name and number.

b. Date.

c. Name and address of Architect/Engineer.

d. Name and address of Contractor.

e. Name and address of subcontractor, if applicable.

f. Name and address of supplier, if applicable.



g. Name of manufacturer, if applicable.

h. Submittal number or other unique identifier, including revision identifier.

1) Submittal number shall use Specification Section number followed by a dash and then a sequential number (e.g., 061000-001 or 070150.19-001). Re-submittals shall include an alphabetic suffix after another dash (e.g., 061000-001-A or 070150.19-001-A).

i. Alphanumeric project Identifier. Identifier is shown on the Project Drawings cover sheet.

j. Number and title of appropriate Specification Section.

k. Drawing number and detail references, as appropriate.

l. Location(s) where product is to be installed, as appropriate.

m. Transmittal number.

n. Allow 15 calendar days for processing each re-submittal.

G. Resubmissions: Re-submittal procedure shall follow the same procedures and same number as the initial submittal with the following exceptions:

1. Transmittal shall contain the same information as the first transmittal and the submission number shall indicate second, third, etc., submission. The drawing number/description shall be identical to the initial submission and the date shall be the revised date for that submission.

2. No new material shall be included on the same transmittal for a resubmission.

3. COTR rejection shall not warrant a claim by Contractor for additional time or cost.

H. Deviations: Highlight, encircle, or otherwise specifically identify deviations from the Contract Documents on submittals. Where significant deviations from the Contract requirements exist, follow the guidelines set forth in Division 01 Section "Product Requirements" for substitutions.

I. Additional Copies: Unless additional copies are required for final submittal, and unless COTR observes noncompliance with provisions of the Contract Documents, initial submittal may serve as final submittal.

1. Additional copies submitted for Operations and Maintenance manuals will be marked with action taken and will be returned.

J. Transmittal: Package each submittal individually and appropriately for transmittal and handling. Transmit each submittal from Contractor to COTR using the approved transmittal form provided by COTR. COTR will return submittals, without review, received from sources other than Contractor.

1. The Contractor must use the Authority provided web-based Oracle Primavera Unifier project management system (Unifier) to transmit each submittal to the COTR. Response of the COTR’s submittal review and action will be transmitted to the Contractor through Unifier. The Authority will provide the Contractor a Unifier license(s) and training.



K. Distribution: Furnish copies of final submittals to manufacturers, subcontractors, suppliers, fabricators, installers, and authorities having jurisdiction, and others as necessary for performance of construction activities. Show distribution on transmittal forms.

1. Bear all costs incurred for such reproduction and distribution. Prints of all reviewed Shop Drawings may be made from transparencies that carry the appropriate review stamps.

L. Use for Construction: Use only final submittals with mark indicating “approved” by COTR in connection with construction.

1.5 SUBMITTAL LOG

A. Prepare a log that contains a complete listing of all submittals required by Contract. Submit the log at the preconstruction meeting along with Contractor's 90-day preliminary schedule specified in Division 01 Section "Construction Progress Documentation." Organize the submittal log by Section number. Assign each submittal a sequential number for identification and tracking purposes.

1. Coordinate the submittal log with Division 01 Section "Construction Progress Documentation." The submittal log shall be submitted for COTR's review. Include the following information:

a. Title of submittal/description.

b. Submittal number (sequential).

c. Scheduled date for the first submittal.

d. Drawing number, if applicable.

e. Applicable Section number.

f. Name of subcontractor/vendor.

g. Scheduled date of COTR's final release or approval.

PART 2 - PRODUCTS

2.1 ACTION SUBMITTALS

A. General: Prepare and submit Action Submittals required by individual Specification Sections

B. Product Data: Collect information into a single submittal for each element of construction and type of product or equipment.

1. If information must be specially prepared for submittal because standard printed data are not suitable for use, submit as Shop Drawings, not as Product Data.

2. Mark each copy of each submittal to show which products and options are applicable.

3. Include the following information, as applicable:

a. Manufacturer's written recommendations.

b. Manufacturer's product specifications.



c. Manufacturer's installation instructions.

d. Manufacturer's catalog cuts.

e. Wiring diagrams showing factory-installed wiring.

f. Printed performance curves.

g. Operational range diagrams.

h. Mill reports.

i. Standard product operating and maintenance manuals.

j. Compliance with recognized trade association standards.

k. Compliance with recognized testing agency standards.

l. Application of testing agency labels and seals.

m. Notation of coordination requirements.

4. Submit Product Data before or concurrent with Samples.

5. Number of Copies: Submit six copies, in addition to the number of copies to be returned to Contractor. Provide one additional copy for submittals related to fire-protection system.

6. Do not submit Product Data until compliance with requirements of the Contract Documents has been confirmed.

C. Shop Drawings: Prepare Project-specific information, drawn accurately to scale. Do not base Shop Drawings on reproductions of the Contract Documents or standard printed data.

1. Preparation: Include the following information, as applicable:

a. Dimensions.

b. Identification of products.

c. Fabrication and installation drawings.

d. Roughing-in and setting diagrams.

e. Wiring diagrams showing field-installed wiring, including power, signal, and control wiring. Differentiate between manufacturer-installed and field-installed wiring.

f. Shopwork manufacturing instructions.

g. Templates and patterns.

h. Schedules.

i. Design calculations.

j. Compliance with specified standards.

k. Notation of coordination requirements.

l. Notation of dimensions established by field measurement.

m. Relationship to adjoining construction clearly indicated.

n. Seal and signature of professional engineer if specified.



2. Sheet Size: Except for templates, patterns, and similar full-size drawings, submit Shop Drawings on sheets at least 8-1/2 by 11 inches but no larger than 30 by 40 inches.

3. Number of Copies: Submit one (1) reproducible transparency and two (2) black-line prints of each submittal. COTR will return the marked up reproducible transparency for Contractor’s distribution.

a. Both the reproducible transparency and the prints shall bear Contractor's approval stamp on each sheet.

D. Coordination Drawings:

1. Coordination Drawings are Shop Drawings prepared by Contractor that detail the relationship and integration of different construction elements that require careful coordination during fabrication or installation. Preparation of Coordination Drawings is specified in Division 01 Section "Project Management and Coordination."

2. Submit Coordination Drawings for integration of different construction elements. Show sequences and relationships of separate components to avoid conflicts in use of space.

.

E. Product Schedule or List: As required in individual Specification Sections, prepare a written summary indicating types of products required for the Work and their intended location. Include the following information in tabular form:

1. Type of product. Include unique identifier for each product.

2. Number and name of room or space.

3. Location within room or space.

4. Number of Copies: Submit three copies of product schedule or list, unless otherwise indicated. COTR will return two copies.

a. Mark up and retain one returned copy as a Project Record Document.

F. Submittals Schedule: Comply with requirements in Division 01 Section "Construction Progress Documentation."

G. Application for Payment: Comply with requirements in Division 01 Section "Application for Payment."

H. Schedule of Values: Comply with requirements in Division 01 Section "Application for Payment."

I. Subcontract List: Prepare a written summary identifying individuals or firms proposed for each portion of the Work, including those who are to furnish products or equipment fabricated to a special design. Include the following information in tabular form:

1. Name, address, and telephone number of entity performing subcontract or supplying products.

2. Number and title of related Specification Section(s) covered by subcontract.

3. Drawing number and detail references, as appropriate, covered by subcontract.



J. Contractor Warranty Letter: Comply with requirements in Contract Provision "Warranty of Construction." Provide the dates of warranty coverage and provide point of contact information for warranty service.

K. Special Warranty Letters: Provide dates of warranty coverage and provide point of contact information for warranty service for special warranties required in Division 02 through 33 Sections.

2.2 INFORMATIONAL SUBMITTALS

A. General: Prepare and submit Informational Submittals required by other Specification Sections.

1. Number of Copies: Submit four copies of each submittal, unless otherwise indicated. COTR will not return copies.

2. Certificates and Certifications: Provide a notarized statement that includes signature of entity responsible for preparing certification. An officer shall sign certificates and certifications or other individual authorized to sign documents on behalf of that entity.

3. Test and Inspection Reports: Comply with requirements in Division 01 Section "Quality Requirements."

B. Contractor's Construction Schedule: Comply with requirements in Division 01 Section "Construction Progress Documentation."

C. Qualification Data: Prepare written information that demonstrates capabilities and experience of firm or person. Include lists of completed projects with project names and addresses, names and addresses of Architects and Owners, and other information specified.

D. Product Certificates: Prepare written statements on manufacturer's letterhead certifying that product complies with requirements.

E. Welding Certificates: Prepare written certification that welding procedures and personnel comply with requirements. Submit record of Welding Procedure Specification (WPS) and Procedure Qualification Record (PQR) on AWS forms. Include names of firms and personnel certified.

F. Installer Certificates: Prepare written statements on manufacturer's letterhead certifying that Installer complies with requirements and, where required, is authorized for this specific Project.

G. Manufacturer Certificates: Prepare written statements on manufacturer's letterhead certifying that manufacturer complies with requirements. Include evidence of manufacturing experience where required.

H. Material Certificates: Prepare written statements on manufacturer's letterhead certifying that material complies with requirements.

I. Material Test Reports: Prepare reports written by a qualified testing agency, on testing agency's standard form, indicating and interpreting test results of material for compliance with requirements.



J. Preconstruction Test Reports: Prepare reports written by a qualified testing agency, on testing agency's standard form, indicating and interpreting results of tests performed before installation of product, for compliance with performance requirements.

K. Compatibility Test Reports: Prepare reports written by a qualified testing agency, on testing agency's standard form, indicating and interpreting results of compatibility tests performed before installation of product. Include written recommendations for primers and substrate preparation needed for adhesion.

L. Field Test Reports: Prepare reports written by a qualified testing agency, on testing agency's standard form, indicating and interpreting results of field tests performed either during installation of product or after product is installed in its final location, for compliance with requirements.

M. Product Test Reports: Prepare written reports indicating current product produced by manufacturer complies with requirements. Base reports on evaluation of tests performed by manufacturer and witnessed by a qualified testing agency, or on comprehensive tests performed by a qualified testing agency.

N. Research/Evaluation Reports: Prepare written evidence from a model code organization acceptable to the Authority that product complies with USBC. Include the following information:

1. Name of evaluation organization.

2. Date of evaluation.

3. Time period when report is in effect.

4. Product and manufacturers' names.

5. Description of product.

6. Test procedures and results.

7. Limitations of use.

O. Maintenance Data: Prepare written and graphic instructions and procedures for operation and normal maintenance of products and equipment. Comply with requirements in Division 01 Section "Operation and Maintenance Data."

P. Design Data: Prepare written and graphic information, including, but are not limited to, performance and design criteria, list of applicable codes and regulations, and calculations. Include list of assumptions and other performance and design criteria and a summary of loads. Include load diagrams if applicable. Provide name and version of software, if any, used for calculations. Include page numbers.

Q. Manufacturer's Instructions: Prepare written or published information that documents manufacturer's recommendations, guidelines, and procedures for installing or operating a product or equipment. Include name of product and name, address, and telephone number of manufacturer. Include the following, as applicable:

1. Preparation of substrates.

2. Required substrate tolerances.



3. Sequence of installation or erection.

4. Required installation tolerances.

5. Required adjustments.

6. Recommendations for cleaning and protection.

R. Manufacturer's Field Reports: Prepare written information documenting factory-authorized service representative's tests and inspections. Include the following, as applicable:

1. Name, address, and telephone number of factory-authorized service representative making report.

2. Statement on condition of substrates and their acceptability for installation of product.

3. Statement that products at Project site comply with requirements.

4. Summary of installation procedures being followed, whether they comply with requirements and, if not, what corrective action was taken.

5. Results of operational and other tests and a statement of whether observed performance complies with requirements.

6. Statement on whether conditions, products, and installation will affect warranty.

7. Other required items indicated in individual Specification Sections.

S. Bonds: Prepare written information indicating current status of bonding coverage. Include name of entity covered by insurance or bond, limits of the coverage, amounts of deductibles, if any and term of coverage.

T. Manufacturers' warranties.

U. Construction Photographs: Comply with requirements in Division 01 Section "Photographic Documentation."

V. Material Safety Data Sheets: Submit information directly to COTR.

PART 3 - EXECUTION

3.1 CONTRACTOR'S REVIEW

A. Review each submittal and check for compliance with the Contract Documents. Note corrections and field dimensions. Mark with approval stamp before submitting to COTR.

1. In checking Shop Drawings and Product Data, verify all dimensions and field conditions and check and coordinate Shop Drawings and Product Data of any Section or trade with the requirements of other sections or trades as related thereto, as required for proper and complete installation of the Work.

B. Approval Stamp: Stamp each submittal with a uniform, approval stamp. Include Project name and location, submittal number, Section title and number, name of reviewer, date of Contractor's approval, and statement certifying that submittal has been reviewed, checked, and approved for compliance with the Contract Documents, which shall include dimensions, clearances,



compatibility, and coordination with Shop Drawings and Product Data submitted for other work.

C. If Contractor has not checked the submittals carefully, even though stamped as checked and approved, submittals shall be returned to Contractor for proper checking before further processing or review by COTR regardless of any urgency claimed by Contractor. In such a situation, Contractor will be responsible for any resulting delays to the scheduled Contract completion. Furthermore, Contracting Officer may hold Contractor responsible for increased Authority costs resulting from Contractor's failure to comply with the requirements set forth herein.

3.2 COTR’S ACTION

A. General: COTR will not review submittals that do not bear Contractor's approval stamp and will return them without action.

B. COTR Responsibilities: The review of Shop Drawings and other submittals by COTR will be for general conformance with the Contract only, and the review shall not be interpreted as a checking of detailed dimensions, quantities, or approval of deviations from the Contract Documents. COTR review shall not relieve Contractor of its responsibility for accuracy of Shop Drawings nor for the furnishing and installation of materials or equipment according to the Contract requirements.

1. Approval of Shop Drawings or other submittals is not to be interpreted as approval of a substitute material. Approval of substitutions will be accomplished according to requirements set forth in Division 01 Section "Product Requirements."

C. Action Submittals: COTR will review each submittal, make marks to indicate corrections or modifications required, and return it. COTR will stamp each submittal with an action stamp and will mark stamp appropriately to indicate action taken, as follows. Do not permit submittals marked "Revise and Resubmit" or "Rejected" to be used at Project site, or elsewhere where Work is in progress.

1. Approved: Means fabrication/installation may be undertaken. Approval does not authorize changes to the Contract Price or the Contract Time.

2. Approved as Corrected: Same as "Approved," providing Contractor complies with corrections noted on submittal. Resubmission required only if Contractor is unable to comply with noted corrections.

3. Revise and Resubmit: Fabrication and/or installation may not be undertaken. Make appropriate revisions and resubmit, limiting corrections to items marked.

4. Rejected: Submittal does not comply with requirements. Fabrication and/or installation may not be undertaken. Prepare a new submittal according to requirements and submit without delay.

D. Informational Submittals: COTR will review each submittal and will not return it, or will reject and return it, if it does not comply with requirements. COTR will forward each submittal to appropriate party.



E. Partial submittals are not acceptable, will be considered non-responsive, and will be returned without review.

F. Submittals not required by the Contract Documents will not be reviewed and may be discarded.




QUALITY REQUIREMENTS 014000 - 1

SECTION 014000 - QUALITY REQUIREMENTS

PART 1 - GENERAL


A. Drawings and Contract Provisions, Special Provisions, Supplementary Conditions, and other Division 01 Specification Sections apply to this Section.

B. Related Sections:

1. Division 01 Section “Submittals” for process required to submit the Contractor’s Quality Control Plan.

2. Division 01 Section “Construction Progress Documentation” for developing a schedule of required tests and inspections.

3. Division 01 Section “Project Management and Coordination”

4. Division 01 Section “Operation and Maintenance Data”

5. Division 01 Section “Project Closeout”

6. Division 01 Section “Cutting and Patching” for repair and restoration of construction disturbed by testing and inspecting activities.

7. Divisions 02 through 34 Sections

1.2 SUMMARY


1. Administrative and procedural requirements for Contractor to provide and maintain an effective Quality-Control Program that complies with this Section and with requirements of the "Contract Provisions," Section VII, "Inspection of Construction and Final Inspection and Acceptance."

2. Establish a QC Program that consists of the following:

a. QC Organization.

b. QC Plan.

c. QC Plan Meeting.

d. Coordination and Mutual Understanding Meeting.

e. QC meetings.

f. Phases of Control.

g. Submittal preparation, review and approval.



h. Operation & Maintenance data and Warranty receipt verification prior to product delivery.

i. Material verification at delivery and material location reports as outlined in a formal Material Receiving Inspection Program.

j. Testing, completion inspections, and QC certifications and documentation necessary to provide materials, equipment, workmanship, fabrication, construction and operations that comply with the requirements of this Contract.

3. Contractor is not responsible for Special Inspections according to requirements of the current Virginia Uniform Statewide Building Code (VUSBC). The Authority’s agent shall provide these Special Inspection services. However, the Contractor is responsible for establishing a Special Inspection schedule. This shall be discussed at weekly progress meetings and two-week look ahead meetings. The Contractor shall be responsible for all coordination and notification of requests for Special Inspections with the Authority.

a. Special inspections are required for, but are not necessarily limited to, the following:

1) Concrete Vault Construction

2) Prepared fill requirements

3) Hydrant Fuel Lines

4. Specific quality-control requirements for individual construction activities are specified in the Sections that require those activities. Requirements in those Sections may also cover production of standard products.

5. Schedule of Values: Contractor shall include all test and inspection activities in its CPM and establish a Schedule of Values for all quality test and inspection activities; and all required reports, and procedures required in the Contract on a Section-by-Section basis. Additionally, Contractor shall include a pay line item specifically for Quality activities and personnel position(s) required by the General Conditions. Quality activities shall be reported per Division 01 Section "Applications for Payment."

6. Testing and inspecting services are required to verify compliance with requirements specified or indicated. These services do not relieve Contractor of its responsibilities for compliance with the Contract Document requirements.

7. Specified tests, inspections, and related actions do not limit Contractor's quality-control procedures that facilitate compliance with the Contract Document requirements.

8. The provisions of this Section shall not limit requirements for Contractor to provide quality-control services required by the Authority or other agencies having jurisdiction.

1.3 REFERENCES

A. 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 SOCIETY FOR TESTING AND MATERIALS (ASTM)

a. ASTM C 1077 Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation latest edition.

b. ASTM D 3666 Minimum Requirements for Agencies Testing and Inspecting Road and Paving Materials latest edition.

c. ASTM D 3740 Minimum Requirements for Agencies Engaged in the Testing and/or Inspection of Soil and Rock as Used in Engineering Design and Construction latest edition.

d. ASTM E 329 Agencies engaged in the Testing and/or Inspection of Materials Used in Construction latest edition.

e. ASTM E 543 Agencies performing Nondestructive Testing latest edition.

2. METROPOLITAN WASHINGTON AIRPORT AUTHORITY

a. Construction Safety Manual, most current edition.

1.4 DEFINITIONS

A. Quality: Conformance to the requirements established by the contract specifications and drawings.

B. Control: To guide and have influence over.

C. Contractor Quality Control (CQC): The construction contractor’s system to manage, control, and document their own, their supplier’s, and their subcontractor’s activities to comply with the contract requirements.

D. Contracting Officers Technical Representative (COTR). Primary on-site representative of the

Contracting Officer for technical matters. Duties and responsibilities of the COTR will be transmitted to the contractor via letter from the Contracting Officer.

E. Definable Feature of Work: A definable feature of work (DFOW) is a task, which is separate and distinct from other tasks, has the same control requirements and work crews.

F. Experienced: When used with an entity, “experienced” means having successfully completed a

minimum of 10 projects similar in size and scope to this Project; being familiar with special requirements indicated; and having complied with requirements of authorities having jurisdiction. Specific experience requirements enumerated in these specifications supersede this requirement.

1.5 CONFLICTING REQUIREMENTS

A. General: If compliance with two standards is specified and the standards establish different or conflicting requirements for minimum quantities or quality levels, comply with the most stringent requirement. Refer uncertainties and requirements that are different, but apparently equal, to the COTR for a decision before proceeding. This paragraph refers to industry and



government standards. In case of a difference between drawings and the specifications, the specifications shall govern.

1.6 SUBMITTALS

A. Submit the following in accordance with Division 01 Section, "Submittals."

1. Action Submittals.

a. Quality Control (QC) Plan.

B. NOTE: Coordinate the submittal requirement dates with the submittal dates in Division 01 Section “Construction Progress Documentation”.

C. Submit a QC plan within 20 calendar days after receipt of Notice to Proceed. The QC Plan shall include a preliminary submittal registry of the list of definable features of work that shall cover the first 90 calendar days of construction.

1. Submit at this time résumés of key personnel to be assigned to this contract and the limits of their authority. Show how this project management structure fits into the Contractor’s corporate management structure.

D. Any approval by the COTR of the QC Plan shall be treated as “accepted, predicated upon successful implementation.” Stop work if the QC Plan becomes disapproved. The exception is the work authorized in the paragraph entitled "Preliminary Work Authorized Prior to Approval," shall stop.

1.7 INFORMATION FOR THE CONTRACTING OFFICER

A. Provide for approval a sample copy of all report forms, as identified below, to the Contracting Officer during the Pre-Construction Conference. The report forms shall consist of the Quality Control Daily Report, Superintendent Daily Report, Material Receiving Inspection Report, Preparatory Phase Report, Initial Phase Report, Inspection Log and Sign-off Sheet, Deficiency Log, and Monthly Quality Control Summary Report. Other reports referenced below may be in formats customarily used by the Contractor; Testing Laboratories, Material Location Reports, etc. and shall contain the information required by this specification.

B. Deliver the following listed items to the COTR at the times specified:

1. Quality Control Daily Report: 1 original electronic and hard copy, turned in by the next calendar day after work is performed.

2. Superintendent’s Daily Report: 1 original electronic and hard copy, turned in by the next calendar day after work is performed. Do not attach to the Quality Control Daily Report.

3. Material Receiving Inspection Report: 1 original electronic and hard copy, turned in by the next calendar day after work is performed. Do not attach to the Quality Control Daily Report.



4. Material Location Reports: 1 original electronic and hard copy, turned in weekly. Do not attach to the Quality Control Daily Report.

5. Preparatory Phase Report: 1 original electronic and hard copy, turned in by the next calendar day after work is performed. Do not attach to the Quality Control Daily Report.

6. Initial Phase Report: 1 original electronic and hard copy, turned in by the next calendar day after work is performed. Do not attach to the Quality Control Daily Report.

7. Field Test Reports: 1 original electronic and hard copy, within 2 working days after the test is performed. Reviewed, signed and certified by P.E. Do not attach to the Quality Control Daily Report.

8. Monthly Summary Report of Tests: 1 original electronic and hard copy. Reviewed, signed and certified by P.E. Do not attach to a Quality Control Daily Report.

9. Inspection Log and Signoff Sheets: one copy, submitted daily within 1 day of the inspection. Do not attach to a Quality Control Daily Report.

10. Testing Plan and Log: 1 original electronic and hard copy, submitted within 2 working days of the end of the month. Do not attach to a Quality Control Daily Report.

11. Deficiency Log: 1 original electronic and hard copy, submitted to the COTR weekly.

12. Monthly Deficiency Report: 1 original electronic and hard copy, within two working days of the end of the month. Do not attach to a Quality Control Daily Report.

13. QC Meeting Minutes: 1 original electronic and hard copy, within 2 working days after the meeting. Do not attach to a Quality Control Daily Report.

14. QC Certifications: As required by paragraph entitled "QC Certifications."

15. Monthly Quality Control Summary Report: 1 original electronic and hard copy. Do not attach to a Quality Control Daily Report. This Executive Brief shall contain these items:

a. Status of the Schedule (Monthly Progress Report) impact to schedule due to change notices, modifications, problems encountered, weather, and any other changes affecting the schedule since the previous month.

b. Status of Submittals.

c. Status of Testing performed that particular month.

d. Status of Inspection Activities performed that particular month.

e. Status of Preparatory meetings and Initial meetings performed that particular month.

f. Status of Deficiencies/Rework items and corrective actions.

g. Status of Non-compliances and corrective actions.

h. Status of Record Drawings.

i. Status or Identification of items affecting Quality.

j. Status of Operation, Maintenance, and Warranty items.

k. Status of Safety and related events.



1.8 QC PROGRAM REQUIREMENTS

A. Establish and maintain a QC Program as described in this Section. The QC Program consists of but is not limited to the following:

1. QC Organization.

2. QC Plan.

3. QC Plan Meeting.

4. Coordination and Mutual Understanding Meeting.

5. QC meetings.

6. Phases of Control.

7. Submittal preparation, review and approval.

8. Operations and Maintenance data.

9. Warranty receipt verification prior to product delivery.

10. Material verification at delivery and material location reports as outlined in a formal Material Receiving Inspection Program.

11. Testing.

12. Completion inspections.

13. QC certifications and documentation necessary to provide materials, equipment, workmanship, fabrication, construction and operations that comply with the requirements of this Contract.

14. The QC Program shall cover on-site and off-site work and shall be keyed to the work sequence.

15. No work or testing may be performed unless the QCM or a pre-approved alternate is on the work site.

16. The QCM shall report to an officer of the firm and shall not be subordinate to the Project Manager, Superintendent or any other member of the QC Organization.

17. The Quality Control Manager is the primary individual responsible for the management and implementation of quality control processes and requirements that identify and establish quality. The QCM is responsible in identifying to the Authority breakdowns in these processes and requirements. The Project Manager shall be responsible for the overall quality of work in the contract. The Project Superintendent shall be held responsible for the quality of all production.

B. Preliminary Work Authorized Prior to Approval

1. The only work that is authorized to proceed prior to the approval of the QC Plan is mobilization of storage and office trailers, temporary utilities, and surveying.

C. Approval

1. Approval of the QC Plan is required prior to the start of any construction. The Contracting Officer reserves the right to require changes in the QC Plan and operations as necessary, including but not limited to removal of personnel, to ensure the specified quality of work.



The Contracting Officer reserves the right to interview any member of the QC organization at any time in order to verify the submitted qualifications. All QC organization personnel shall be subject to acceptance by the Contracting Officer. The Contracting Officer may require the removal of any individual for non-compliance with quality requirements specified in the contract.

D. Notification of Changes

1. Notify the COTR, in writing, of any proposed change, including changes in the QC organization personnel, a minimum of seven calendar days prior to a proposed change. Proposed changes shall be subject to acceptance by the Contracting Officer.

1.9 QC ORGANIZATION

A. The contractor’s QC Organization is responsible for establishing a committed unified team in a positive cooperative environment where all personnel and employees strive to communicate, create, maintain and verify the desired level of quality in all aspects of construction as established in the QC Plan and Contract Specifications.

B. Staffing Levels: Provide sufficient qualified quality-control personnel to monitor each work activity at all times. Scheduling and coordinating of all inspections and testing shall match the type and pace of work activity.

1. In cases where multiple trades, disciplines, or subcontractors are on site at same time, each activity shall be tested and inspected by personnel skilled in that portion of the work.

2. In cases where multiple shifts are employed, the quality-control staff shall be increased to meet all personnel requirements of this section (QC Organization) for each shift when work is performed.

C. The following positions are key personnel as defined by the Authority in this and other Division 01 Specification Sections.

1. Project Manager

a. Duties: Responsible for overall project control, planning, scheduling, cost, project administration, quality, and compliance with local and national codes.

b. Qualifications: Fifteen years of construction supervisory experience, with six years of project management experience on projects of similar size, type, and complexity to this Project in which the individual had overall project responsibility.

c. To enhance the effectiveness of the Quality Control Organization the Project

Manager shall be intimately involved in Quality Control. To this end, the Project Manager shall have successfully completed the Army Corps of Engineers/NAVFAC Contractor Quality Control Course (details in Paragraph “Construction Quality Management Training”, below).

2. Project Superintendent



a. Duties: Serves as the on-site production manager for the Contractor. The superintendent coordinates all site construction activities and supervises all field personnel as required to successfully complete the project on schedule, within budget, while maintaining total responsibility for the quality established in the field for this contract.

b. Qualifications: Fifteen years of construction supervisory experience, with five years’ experience as Superintendent in a supervisory role coordinating various trades at multiple work areas.

c. To enhance the effectiveness of the Quality Control Organization the

Superintendent shall be intimately involved in Quality Control. To this end, the Superintendent shall have successfully completed the Army Corps of Engineers/NAVFAC Contractor Quality Control Course (details in Paragraph “Construction Quality Management Training”, below).

3. Quality Control Manager (QCM)

a. Provide a QCM at the work site to implement and manage the QC Program. The only duties and responsibilities of the QCM are to manage and implement the QC Program on this contract. The QCM shall not be designated as the safety competent person as defined by Construction Safety manual. The QCM is required to attend the QC Plan Meeting, attend the Coordination and Mutual Understanding Meeting, conduct the QC meetings, perform the Phases Control except for those phases of control designated to be performed by QC specialists, perform submittal review and approval, ensure testing is performed and provide QC certifications and documentation required in this contract. The QCM does not prepare Submittals. The QCM is responsible for managing and coordinating the Phases Control and documentation and inspections performed by the QC specialists, Testing Laboratory personnel and any other inspection and testing personnel required by this Contract.

b. Qualifications: An individual with a minimum of 5 years of construction experience as a Project Manager, Superintendent, QCM, Inspector, or Construction Manager on similar size and type construction contracts which included the major trades that are part of this Contract. The individual shall be familiar with the requirements of the Construction Safety Manual, and have experience in the areas of hazard identification and safety compliance. The QCM shall be interviewed by PMC QA Department and the COTR. The COTR will approve the QC Manager.

c. To enhance the effectiveness of the Quality Control Organization the QCM shall

be intimately involved in Quality Control. To this end, the OCM shall have successfully completed the Army Corps of Engineers/NAVFAC Contractor Quality Control Course (details in Paragraph “Construction Quality Management Training”, below).

4. Construction Quality Management Training: a. In addition to the above experience and education requirements, the Project

Manager, Superintendent, and QCM shall have completed the course entitled "Construction Quality Management for Contractors." If these individuals do not have a current certification, they shall obtain the CQM course certification within



60 - calendar days of award. This short course is periodically offered in alternate months by: (1) the Maryland Chapter, Associated General Contractors (AGC), 410-321-7870; [email protected] and by (2) the Virginia Chapter, Associated Builders and Contractors (ABC), 703-968-6205, [email protected]; [email protected]. The training uses Army Corps of Engineers course content. The course is facilitated by instructors from Army Corps of Engineers, North Atlantic Division, Baltimore District, and by instructors from the Naval Facilities Engineering Command, Engineering Field Activity Chesapeake.

5. Alternate QCM Duties and Qualifications

a. Designate an alternate for the QCM at the work site to serve in the event of the designated QCM's absence. The period of absence may not exceed two weeks at one time, and not more than 30 workdays during a calendar year. The qualification requirements for the Alternate QCM shall be the same as for the QCM.

6. QC Administrative Assistant

a. Provide a full time Administrative Assistant at the work site whose primary duty shall be to assist the QCM in processing and maintaining files for submittals, preparing and publishing reports and meeting minutes. After primary duties are accomplished, other duties may be assigned provided the duties do not interfere with primary duties.

7. Submittal Reviewer (s) Duties and Qualifications

a. Provide Submittal Reviewer(s), other than the QCM, qualified in the discipline(s) being reviewed, to review and certify that each and all submittals meet the requirements of the Contract prior to review, certification and approval by the QCM.

b. Qualifications: Each submittal shall be reviewed by a professional engineer with 10 years construction experience.

8. Erosion and Sediment Control Inspector

a. The Erosion and Sediment Control Inspector shall be responsible for inspecting the erosion and sediment controls, reporting requirements, and for ensuring conformance with the approved Storm Water Pollution Prevention Plan (SPPP). The Erosion and Sediment Control Inspector may have other duties, however, the designated individual shall be familiar with the requirements set forth in the Virginia Erosion and Sediment Control Handbook.

9. Project Engineer/Scheduler

a. Qualifications: Minimum of two (2) years’ experience and not less than one (1) project of similar size and scope, with the capability to produce CPM reports and diagrams within 24 hours of COTR’s request. The Project Scheduler shall be classified as one of the Contractor’s key personnel.



1.10 QC PLAN MEETING

A. Within 10 calendar days of notice of award and prior to submission of the QC plan, meet with the COTR to discuss the QC plan requirements of this Contract. The purpose of this meeting is to communicate expectations and facilitate understanding of the QC plan requirements prior to plan development and submission.

1.11 QUALITY CONTROL (QC) PLAN

A. Provide, for approval by the COTR, a QC plan submitted in a 3-ring binder with pages numbered sequentially that covers both on-site and off-site work and includes but may not necessarily be limited to the following:

B. A table of contents listing the major sections identified with tabs in the following order:

1. QC ORGANIZATION

2. PERSONNEL MATRIX

3. NAMES AND QUALIFICATIONS

4. DUTIES, RESPONSIBILITY AND AUTHORITY OF QC PERSONNEL

5. APPOINTMENT LETTERS

6. OUTSIDE ORGANIZATIONS INCLUDING INSPECTION AGENCIES

7. CERTIFICATIONS, QUALIFICATIONS, AND ACCREDITATIONS

8. TESTING PLAN AND LOG

9. SUBMITTAL PROCEDURES, 90 DAY INITIAL SUBMITTAL REGISTER, AND FINAL SUBMITTAL REGISTER WHEN APPROVED BY COTR

10. LIST OF DEFINABLE FEATURES

11. PROCEDURES FOR PERFORMING THE PHASES OF CONTROL

12. IDENTIFY SPECIAL INSPECTIONS, DUTIES AND RESPONSIBILITIES FOR SPECIALTY PERSONNEL AND MANUFACTURER’S REPRESENTATIVES

13. DOCUMENTATION PROCEDURES

14. PROCEDURES TO COMPLETE REWORK AND DEFICIENT ITEMS

15. PROCEDURES FOR COMPLETION INSPECTION

16. FORMS

17. ATTACHMENTS

C. A chart showing the QC organizational structure.

D. A personnel matrix showing for each Section of the specification who, by name, shall review and approve submittals, who, by name, shall perform and document the Phases of Control, and who, by name, shall perform and document the testing.

E. Names and qualifications, in résumé format, for each person in the QC organization. Include

the CQM course certifications for the Project Manager, Superintendent, QCM and Alternate



QCM as required by the paragraphs entitled "Construction Quality Management Training" and "Alternate QCM Duties and Qualifications".

F. Identify duties, responsibilities and authority of each person in the QC organization.

G. Letters signed by an officer of the firm appointing the QCM and Alternate QCM and stating that they are responsible for implementing and managing the QC Program as described in this contract. Include in this letter the responsibility of the QCM and Alternate QCM to implement and manage the three phases of quality control and their authority to stop work that is not in compliance with the contract. The QCM shall issue letters of direction to all other QC staff and specialists under their control outlining their duties, authorities, and responsibilities. Copies of the letters shall be included in the QC plan.

H. A listing of all sub-contractors employed by the General Contractor, a description of each subcontractor’s provided services, each subcontractor’s QC representatives name and contact phone numbers.

I. Testing laboratory information required by the paragraphs entitled "Accreditation

Requirements" or "Construction Materials Testing Laboratory Requirements", as applicable. Include all certification and accreditation requirements required in the contract.

J. Submit all certifications, qualifications, and accreditations as required for each Section of the

Specification.

K. A Testing Plan and Log that includes the tests required, referenced by the specification paragraph number requiring the test, the frequency, the desired results and the person, by name, responsible for each test and shall be identified as a scheduled (CPM) activity.

L. Procedures for preparing, reviewing, approving and managing submittals. Provide the name(s) of the person(s) in the QC organization authorized to prepare, review and certify submittals prior to approval. Provide the initial submittal of the Submittal Register as specified in Section entitled "Submittals." Once Submittal Register is approved, in its entirety, it will become part of the QC Plan.

M. List of definable features of work. The list shall be cross-referenced to the contractor's Construction Schedule and all specification sections. For projects requiring a Progress Chart, the list of definable features of work shall include but not be limited to all items of work on the schedule. For projects requiring a Network Analysis Schedule, the list of definable features of work shall include but not be limited to all critical path activities. Include a chart of common deficiencies for the Definable Feature of work. Detail the control procedures that shall be employed to eliminate this common deficiency.

N. Procedures for Performing the Phases of Control. The contractor shall develop a plan for

incorporating each of the control phases into the work. The plan shall detail who shall be responsible for scheduling the phases, conducting the phase as well as documenting the phase. The use of project specific forms may be helpful. However, the entire plans and specifications establish the quality and not just the checklists. The Preparatory and Initial Phases and meetings shall be conducted with a view towards obtaining quality construction by planning ahead and identifying potential problems for each definable feature of work.



O. Include all activities for which this specification requires Manufacturers Representatives, QC specialists and/or Specialty Inspection Personnel, for any specific definable features of work as identified in the QC Plan and the Specifications.

P. Documentation procedures, including proposed report formats, necessary to provide materials,

equipment, workmanship, fabrication, construction and operations that comply with the requirements of this Contract.

Q. Procedures to identify, record, track and complete rework and deficiency items.

R. Procedures for Identifying and Documenting the Completion Inspection process. Include in these procedures the responsible party for punch out inspection, pre-final inspection, and final acceptance inspection.

S. Submit, for approval, a complete set of report forms to be utilized on this project.

T. All applicable subcontractors and suppliers Quality Control Plans complete with Contactor’s CQC planned involvement.

1.12 COORDINATION AND MUTUAL UNDERSTANDING MEETING

A. After submission and approval of the QC Plan, and prior to the start of any physical construction, meet with the COTR to present the QC Program required by this Contract. The purpose of this meeting is to develop a mutual understanding of the QC details for processes and procedures to assure and control quality, including documentation, administration for on-site and off-site work, and the coordination of the Contractor's management, production and QC personnel. At the meeting, the QC Manager and Contractor shall be required to explain in detail how the Phases of Control shall be implemented for each definable feature of work. As a minimum, the Contractor's personnel required to attend shall include an officer of the firm, the project manager, project superintendent, QCM, Alternate QCM, and subcontractor representatives for each Definable Feature of Work to include all testing agencies required for the contract. Each subcontractor who shall be assigned QC responsibilities shall have a principal of the firm at the meeting. Minutes of the meeting shall be prepared by the QCM and signed by the Contractor. The Contractor shall provide a copy of the signed minutes to all attendees.

1.13 QC MEETINGS

A. After the start of construction, the QCM shall conduct QC meetings weekly at the work site with the project manager, superintendent, QC Specialist(s), subcontractor’s foremen and safety representative. The QCM shall prepare the minutes of the meeting and provide a copy to the COTR within 2 working days after the meeting. The COTR may attend these meetings. The QCM shall notify the COTR at least 48 hours in advance of each meeting. These meetings shall be scheduled to precede weekly progress meeting to review quality items, as listed below. As a minimum, the following shall be accomplished at each meeting:

1. Review the minutes of the previous meeting

2. Review the schedule and the status of work:



a. Work or testing accomplished since last meeting

b. Rework items identified since last meeting

c. Rework items completed since last meeting

3. Review the status of submittals, O & M data and Warranty Manuals:

a. Submittals, O & M data and Warranties reviewed and approved since last meeting

b. Submittals, O & M data and Warranties required in the near future

4. Review the work to be accomplished in the next 3 week(s) and documentation required:

a. Establish completion dates for rework items

b. Update the schedule showing planned and actual dates of the preparatory, initial and follow-up phases, including testing and any other inspection required by this contract

c. Discuss construction methods and the approach that shall be used to provide quality construction by planning ahead and identifying potential problems for each definable feature of work

d. Discuss status of off-site and on-site work, inspections and testing

e. Documentation required for each activity

f. Discuss upcoming Job Hazard Analyses (JHAs)

5. Resolve QC and production problems and assist in resolving Request for Information issues

6. Address items that may require revising the QC plan:

a. Changes in QC organization personnel

b. Changes in procedures.

7. Review health and safety plan

1.14 PHASES OF CONTROL

A. The Phases of Control shall adequately cover both on-site and off-site work and shall include the following for each definable feature of work.

B. Material Receiving Inspection: Contractor shall establish a formal material receiving inspection program to verify material compliance to approved Shop Drawings, approved submittals, and the contract plans and specifications.

C. Material Location Reports: At weekly intervals, prepare a comprehensive list of materials delivered to and stored at the site. List shall be cumulative, showing materials previously reported plus items recently delivered. Include with list a statement of progress on and delivery dates for all materials or items of equipment being fabricated or stored away from the building site. Submit copies of list to COTR at weekly intervals.



D. Preparatory Phase: Notify the COTR at least 2 workdays in advance of each preparatory phase. This phase shall include a meeting conducted by the QCM and attended by the superintendent, the QC Specialist(s), all subcontractor’s foremen responsible for the definable feature of work, the contractor’s Independent 3rd Party Testing Agencies, and the General Contractor’s Safety Representative. Preparatory meetings will not be conducted without having these individuals present at the meeting, having approved submittals, and approved JHAs. Document the results of the preparatory phase actions in the daily Quality Control Daily Report and in the Preparatory Phase Checklist. As a minimum the following should be covered prior to beginning work on each definable feature of work:

1. Review each paragraph of the applicable specification sections.

2. Review the project drawings.

3. Verify that appropriate shop drawings, O & M data, Warranties, and submittals for materials and equipment have been submitted and approved. Verify receipt of approved factory test results, when required.

4. Establish control to be utilized to assure work complies with the contract plans and specifications.

5. Review the testing plan and ensure that provisions have been made to provide the required QC testing.

6. Examine the work area to ensure that the required preliminary work has been completed.

7. Examine the required materials, equipment and sample work to ensure that they are on hand and conform to the approved shop drawings and submitted data.

8. Discuss construction methods, construction tolerances, workmanship standards, and the approach that shall be used to provide quality construction by planning ahead and identifying potential problems for each definable feature of work.

9. Review the safety plan and appropriate job hazard analysis (JHA) to ensure that applicable safety requirements are met, and that required Material Safety Data Sheets (MSDS) are submitted.

E. Initial Phase: Notify the COTR at least 2 workdays in advance of each initial phase. When the Standard of Quality for workmanship has been established for that definable feature of work, conduct the Initial Phase with the superintendent, the QC Specialist(s), all subcontractors’ foremen responsible for the definable feature of work’s quality standard, the contractor’s Independent 3rd Party Testing Agencies, and the General Contractor’s Safety Representative. Initial meetings will not be conducted without having these individuals present at the meeting, having approved submittals, and approved JHAs. Observe the initial segment of the definable feature of work to ensure that the work complies with Contract requirements. Document the results of the initial phase in the daily Quality Control Daily Report and in the Initial Phase Checklist. Repeat the initial phase for each new crew to work on-site, or when acceptable levels of specified quality are not being met. As a minimum the following should be covered for each definable feature of work:

1. Ensure controls established during Preparatory Phase are adequate to allow work to proceed in compliance with the plans and specifications.

2. Establish the Standard of Quality required for workmanship.



3. Resolve conflicts.

4. Ensure that testing is performed by an approved Independent 3rd Party Testing Agency.

5. Check work procedures for compliance with the Safety Plan and the appropriate job hazard analysis to ensure that applicable safety requirements are met.

F. Follow-Up Phase: Perform the following for on-going daily work, or more frequently as necessary until the completion of each definable feature of work and document in the daily Quality Control Daily Report:

1. Ensure the work is in compliance with Contract requirements.

2. Maintain the Standard of Quality of workmanship established at the Preparatory and Initial.

3. Ensure that testing is performed by an approved Independent 3rd Party Testing Agency.

4. Ensure that rework items are being corrected

5. Eliminate repetitive Deficiencies

6. Perform safety inspections.

G. Code-Required Inspections:

1. Comply with current edition approved by the Commonwealth of Virginia of the VUSBC, "Special Inspections” or other agencies having jurisdiction. Special Inspections are to be performed by the Authority’s agent. Perform and document all tests, inspections, notifications to the Authority, coordination with the Authority’s agent and other activities listed in the VUSBC or other agencies having jurisdiction.

2. Notice to COTR: Notify COTR, in writing, at least 48 hours in advance of all code-required inspections. COTR should be apprised in advance of every preparatory and initial inspection. All preparatory, initial, and follow-up inspections shall be made a matter of record in Contractor's quality-control documentation.

H. Additional Preparatory and Initial Phases

1. Additional Preparatory and Initial Phases shall be conducted on the same definable features of work if the quality of on-going work is unacceptable, if there are changes in the applicable QC organization, changes in weather or season that affects the quality of work, if there are changes in the on-site production supervision or work crew, if work on a definable feature is resumed after substantial period of inactivity, or if other problems develop as directed by the COTR in writing.

I. Notification of Phases of Control for Off-Site Work

1. On determination by COTR that an item shall require surveillance by the Authority at the point of production, manufacture, or shipment, Contractor shall be notified, in writing, of such determination. Contractor shall furnish to COTR three copies of all purchase orders or subcontracts, for all tiers of subcontractors or suppliers for each item. In addition, copies of documented quality-control operations, tests, and inspections shall be made available to the Authority's representative at the point of production, manufacture, or shipment. The CQC shall notify the COTR at least two weeks prior to the start of the preparatory and initial phases.



1.15 SUBMITTAL REVIEW AND APPROVAL

A. Procedures for preparation, review, approval, and submission of submittals are described in Division 01 Section “Submittals”.

B. The QC Manager will not prepare submittals, but shall review, certify, and approve submittals.

1.16 TESTING

A. Except as stated otherwise in the technical specification sections, perform sampling and testing required under this Contract.

B. Independent Testing Laboratory: When codes or requirements of the contract require tests or inspections by civil, mechanical, electrical, VUSBC or other entities, a corporately and financially independent testing organization shall be contracted by the Contractor to perform these contractually required tests. These testing agencies shall function as an unbiased testing authority; professionally independent of manufacturers, suppliers, and installers of equipment; or systems evaluated by the testing organization. The various types of independent accrediting agencies and requirements are listed below:

C. Accreditation Requirements: Construction materials testing laboratories performing work on

Authority construction contracts shall be accredited by one of the laboratory accreditation authorities. The laboratory's scope of accreditation shall include the ASTM standards listed in the paragraph titled "Construction Materials Testing Laboratory Requirements" as appropriate to the testing field. The policy applies to the specific laboratory performing the actual testing and the testing technicians performing the tests and inspections, not just the "Corporate Office".

D. Electrical testing of components, equipment and systems: The testing firm shall be regularly engaged in the testing of electrical equipment, devices, installations, and systems. The testing firm shall have at least five years experience in the testing of electrical equipment of the type, rating, and voltage used on this Project. The testing laboratories shall be a current full-member company of the International Electrical Testing Association (http://www.neta.org/). This independent testing firm shall perform duties as required under the terms of this Contract.

E. Structural and Pipe Welding: An independent testing firm shall perform all structural and pipe welding examinations as required by this Contract. The inspectors employed by the firm shall hold current certification as an AWS Certified Welding Inspector (CWI) for visual weld examinations and ASNT-TC-1A Certification for nondestructive examination of welds. ASNT-TC-1A certifications shall be by an ASNT-TC-1A ACCP Level III.

F. Construction Materials Testing Laboratory Requirements: Provide an independent construction material testing laboratory accredited by an acceptable laboratory accreditation authority to perform sampling and tests required by this Contract. Testing laboratories that have obtained accreditation by an acceptable laboratory accreditation authority listed in the paragraph entitled "Laboratory Accreditation Authorities" submit with the Quality Control Plan, a copy of the Certificate of Accreditation and Scope of Accreditation. The scope of the laboratory's accreditation shall include the test methods required by the Contract. On and Off-site testing facilities shall submit a certified statement by the Supervising Professional Engineer, licensed in the Commonwealth of Virginia, as meeting the requirements of the following minimum ASTM standards listed below as appropriate to the testing field.



1. Laboratories engaged in testing of construction materials shall meet the requirements of ASTM E 329.

2. Laboratories engaged in testing of concrete and concrete aggregates shall meet the requirements of ASTM C 1077.

3. Laboratories engaged in testing of bituminous paving materials shall meet the requirements of ASTM D 3666.

4. Laboratories engaged in testing of soil and rock, as used in engineering design and construction, shall meet the requirements of ASTM D 3740.

5. Laboratories engaged in nondestructive testing (NDT) shall meet the requirements of ASTM E 543.

6. Laboratories engaged in Hazardous Materials Testing shall meet the requirements of OSHA and EPA.

G. Laboratory Accreditation Authorities: Laboratory Accreditation Authorities are the National Voluntary Laboratory Accreditation Program (NVLAP) administered by the National Institute of Standards and Technology, the American Association of State Highway and Transportation Officials (AASHTO) program, ICBO Evaluation Service, Inc. (ICBO ES), and the American Association for Laboratory Accreditation (A2LA) program and the Washington Area Council of Engineering Laboratories (WACEL). Furnish to the COTR, a copy of the current Certificate of Accreditation and Scope of Accreditation. The scope of the laboratory's accreditation shall include the test methods required by the Contract. Submit all testing technicians’ qualifications and certifications.

H. Capability Check: The COTR retains the right to check the laboratory equipment in the proposed laboratory, the laboratory’s managers and technicians testing qualifications, procedures, techniques, and other items for compliance with the standards set forth in this Contract.

I. Capability Recheck: If non-conformities are discovered during the capability check or any succeeding recheck, Contractor shall be assessed a charge of $750.00 to reimburse the Authority for each recheck of the laboratory or the checking of a subsequently selected laboratory. These charges shall be deducted from the total amount due Contractor.

J. Test Results: Cite applicable Contract requirements, tests or analytical procedures used. Provide actual results and include a statement that the item tested or analyzed conforms or fails to conform to specified requirements. IF THE ITEM FAILS TO CONFORM, NOTIFY COTR IMMEDIATELY. Conspicuously stamp the cover sheet for each report in large red letters "CONFORMS" or "DOES NOT CONFORM" to the specification requirements, whichever is applicable. A certified testing laboratory manager shall sign all test results. Submit within 2 working days after the test is performed. All test reports shall be reviewed, certified, and signed by a professional engineer, licensed in the Commonwealth of Virginia, before submission to MWAA.

K. Test Reports and Monthly Summary Test Reports:

1. The QCM shall submit the daily signed test reports for the entire month with PE certifications, and summarization of all tests reports broken down by Definable Features of Work at the end of each month to the COTR. All Monthly Summary Test Reports shall be



reviewed, certified, and signed by a professional engineer, licensed in the Commonwealth of Virginia."

L. Control and Verification Tests: The Contractors control testing are those tests conducted by the Contractor that assist in maintaining the standard of quality for all operations and procedures, for each Feature of Work, as identified in the Quality Control Plan and the Specifications. As described above, the Contractor shall procure the services of an independent commercial laboratory to perform the required control tests. The Specifications contain the minimum of the following:

1. Testing criteria

2. Frequency of testing

3. Procedures

4. Methods of construction

5. Number of control tests to be made for each phase of the Work.

6. Notify COTR a minimum of 48 hours in advance of the time samples shall be taken by Contractor for quality control testing. COTR shall then notify its own testing laboratory contractor so that verification test samples may be taken.

M. Check Tests: Contractor shall furnish to COTR the quantities of materials to be used for check testing as required in the Specifications. Check testing shall be performed by the Authority at an independent laboratory at no cost to Contractor. No direct payment shall be made to Contractor for the furnishing of materials used for check testing.

N. Staffing: All laboratory and technician personnel shall work under the supervision of a Professional Engineer licensed in the Commonwealth of Virginia.

1.17 QC CERTIFICATIONS

A. Quality Control Daily Report Certification

1. Each Quality Control Daily Report shall contain the following statement:

a. “On behalf of (Name of Contractor), I certify that this report and the Inspector's Daily Reports are complete and correct, and that all materials and equipment used, as well as work performed during this reporting period are in compliance with Drawings, Specifications, and Contract provisions, except as noted in this report or attached reports.”

B. Application for Payment Certification

1. Refer to Division 01 Section "Application for Payment" for address to which the Applications shall be sent.

C. Completion Certification:



1. Upon completion of work under this Contract, the QCM shall furnish a certificate to the Contracting Officer attesting that "the work has been completed, inspected, tested and is in compliance with the Contract."

1.18 COMPLETION INSPECTIONS

A. Punch-Out Inspection: Near the completion of all work or any increment thereof established by a completion time stated in the Contract Clause entitled "Commencement, Prosecution, and Completion of Work," or stated elsewhere in the specifications, the QCM shall conduct an inspection of the work and develop a "punch list" of items which do not conform to the approved drawings and specifications. Include in the punch list any remaining items on the "Rework Items List" which were not corrected prior to the Punch-Out Inspection. The punch list shall include the estimated date by which the deficiencies will be corrected. A copy of the punch list shall be provided to the COTR. The QCM and staff shall make follow-on inspections to ascertain that all deficiencies have been corrected before requesting a Pre-Final Inspection. Once this is accomplished the Contractor shall notify the COTR that the facility is ready for the Authority "Pre-Final Inspection."

B. Pre-Final Inspection: The Authority will perform this inspection to verify that the facility is complete and ready to be occupied. An Authority "Pre-Final Punch List" may be developed as a result of this inspection. The QCM shall ensure that all items on this list are corrected prior to notifying the Authority of a request for a "Final" Acceptance Inspection. Any items noted on the "Pre-Final" inspection shall be corrected in timely manner and shall be accomplished before the contract completion date for the work or any particular increment thereof if the project is divided into increments by separate completion dates.

C. Final Acceptance Inspection: The QCM, the QC specialists, the superintendent and other primary contractor management personnel shall be in attendance at this inspection. The COTR will be in attendance at this inspection. Additional Authority personnel may be in attendance. The Contracting Officer based upon results of the “Pre-Final” inspection will formally schedule the Final Acceptance Inspection. Notice shall be given to the COTR at least 14 calendar days prior to the final inspection stating that all specific items previously identified to the Contractor, as being unacceptable, along with all the remaining work performed under the contract, shall be complete and acceptable by the date scheduled for the final acceptance inspection. Failure of the Contractor to have all contract work acceptably complete for this inspection shall be reason for the Contracting Officer to bill the Contractor for the Authority's additional inspection cost in accordance with the clause in the Contract Provisions entitled "Inspection of Construction." When the Contracting Officer takes possession of partially completed work, it shall be in accordance with clause in the Contract Provisions entitled "Use and Possession Prior to Completion".

1.19 DOCUMENTATION

A. Contractor shall maintain current quality control records, on approved forms, of all control activities, production, tests and inspections performed. These records shall include factual evidence that required tests or inspections have been performed, including type and number of tests or inspections involved; results of tests or inspections; nature of defects, causes for rejection, etc.; proposed remedial action; and corrective actions taken. These records shall cover both conforming and defective or deficient features (non-conforming work) and shall



include a statement that all supplies and materials incorporated into the Work are in full compliance with terms of the Contract as documented in the Contractor’s materials receiving inspection program. Legible copies of these records shall be furnished to COTR daily. The records shall cover all work placed subsequent to the previously furnished records and shall be verified by Contractor's QCM. Contractor shall document tests and inspections as specified in the technical provisions of the Specifications, and these records shall be available for review by COTR throughout the life of the Contract.

B. Maintain current and complete records of on-site and off-site QC Program operations and activities. Establish and maintain the following in a series of 3 ring binders. Binders shall be divided and tabbed as shown below. These binders shall be readily available to the Authority's Quality Assurance Team upon request.

1. All completed Preparatory and Initial Phase Reports, arranged by specification Section.

2. All milestone inspections, arranged by Activity/Event Number.

3. A current up-to-date copy of the Testing Plan and Log with supporting field test reports, arranged by date and each Definable Feature per specification section.

4. Copies of all contract modifications, arranged in numerical order. Also include documentation that modified work was accomplished.

5. A current, up-to-date copy, of the Deficiency List.

C. Report Forms - A copy of all approved forms shall be included with the Quality Control Plan. The forms shall be designed to assist in the control of the quality. The following minimum requirements are listed for specific reports:

1. Quality Control Daily Report: Reports are required for each day that work is performed and for every seven consecutive calendar days of no work and on the last day of a no-work period. Account for each calendar day throughout the life of the Contract. The reporting of work shall be identified by terminology consistent with the construction schedule. Quality Control Daily Reports are to be prepared, signed and dated by the QCM and shall contain the following information:

a. Date of report, report number, Contract Number, and Contract Title.

b. Identify Schedule Activity No., Submittal # and list equipment/material received each day that is incorporated into the job.

c. Indicate if Preparatory Phase work was performed today (Yes/No checkboxes).

d. If Preparatory Phase work was performed today (including on-site and off-site work), identify its Schedule Activity Number and Definable Feature of Work. The Index number is a cross reference to the Preparatory Phase Checklist. An example of the Index number is: 0025-P01, where "0025" is the Quality Control Daily Report Number, "P" indicates Preparatory Phase, and "01" is the Preparatory Phase Checklist number(s) for this date. Each entry in this Section shall be accompanied with a corresponding Preparatory Phase Checklist.

e. Indicate if Initial Phase work was performed today (Yes/No checkboxes).

f. If Initial Phase work was performed today (including on-site and off-site work), identify its Schedule Activity Number and Definable Feature of Work. The Index Number is a cross reference to the Initial Phase Checklist. An example of the



Index Number is: 0025-I01, where "0025" is the Quality Control Daily Report Number, "I" indicates Initial Phase, and "01" is the Initial Phase Checklist number(s) for this date. Each entry in this Section shall be accompanied with a corresponding Initial Phase Checklist.

g. Results of the Follow-up Phase inspections held today (including on-site and off-site work), including Schedule Activity Number, location of definable feature of work, Specification Sections, etc. Indicate in the report for this definable feature of work that the work complies with the Contract as approved in the Initial Phase, work complies with safety requirements, and that required testing has been performed. Include a list of who performed the tests.

h. List the rework items identified, but not corrected by close of business, along with its associated Schedule Activity Number.

i. List the rework items corrected from the rework items list along with the corrective action taken and its associated Schedule Activity Number.

j. Include a "remarks" section in this report that shall contain pertinent information including but not limited to:

1) Directions received.

2) Quality control problem areas.

3) Deviations from the QC plan.

4) Construction deficiencies encountered.

5) QC meetings held

6) Acknowledgement that record drawings, specifications, O & M data, and Warranty Manuals, have been updated.

7) Corrective direction given by the QC Organization and corrective action taken by the Contractor.

8) For each remark given, identify the Schedule Activity Number that is associated with the remark.

k. Quality Control Daily Report certification, signature and date.

2. Preparatory Phase Checklist: Each Definable Feature of Work that is in the Preparatory Phase shall have this report filled out for it. The report shall be identified by terminology consistent with the construction schedule. Do not attach this report to the Quality Control Daily Report of the same date.

a. Specification Section, date of report, and Contract number shall be filled out. Duplicate this information in the header of the second page of the report.

b. Definable Feature of Work, Schedule Activity Number and Index Number entry and format shall match entry in the Preparatory Phase section of the Quality Control Daily Report. Duplicate this information in the header of the second page of the report.

c. Personnel Present: Indicate the number of hours of advance notice that was given to the COTR and indicate (Yes/No checkboxes) whether or not the COTR was notified. Indicate the Names of Preparatory Phase Meeting attendees, their



position and their company affiliation. The meeting is conducted by the QCM and attended by the superintendent, all subcontractor’s foremen responsible for the definable feature of work, the contractor’s Independent 3rd Party Testing Agencies, and the General Contractor’s Safety Representative. If all personnel are not present, cancel meeting.

d. Submittals: Indicate if submittals have been approved (Yes/No checkboxes), if no indicate what has not been submitted. Are materials on hand (Yes/No checkboxes) and if not, what items are missing. Check delivered material/equipment against approved submittals and comment as required. If the submittal is not approved, cancel Preparatory meeting.

e. Material Storage: Indicate if materials/equipment is stored properly (Yes/No checkboxes) and if not, what action is/was taken.

f. Specifications: Review and comment on Specification Paragraphs that describe the material/equipment, procedure for accomplishing the work and clarify any differences.

g. Preliminary Work & Permits: Ensure preliminary work is in accordance with the contract documents and necessary permits are on file, if not, describe the action taken.

h. Testing: Identify who performs tests, the frequency, and where tests are to occur. Review the testing plan, report abnormalities, and if the test facilities have been approved.

i. Discuss Control Procedures that shall be employed to consistently obtain the required specified quality.

j. Safety: Indicate if the job hazard analysis (JHA) has been approved (Yes/No checkboxes) and comment on the review of the applicable portions of the Construction Safety Manual. If the JHA is not approved, cancel Preparatory meeting.

k. Meeting Comments: Note comments and remarks during the Preparatory Phase Meeting that was not addressed in previous sections of this checklist.

l. Other Items or Remarks: Note any other remarks or items that were a result of the Preparatory Phase.

m. QCM shall sign and date the report.

3. Initial Phase Checklist: Complete this report for each Definable Feature of Work that is in the Initial Phase. The report shall be identified by terminology consistent with the construction schedule. Do not attach this report to the Quality Control Daily Report of the same date.

a. Specification Section, date of report, and Contract number shall be entered.

b. Definable Feature of Work, Schedule Activity Number and Index Number entry and format shall match entry in the Initial Phase section of the Quality Control Daily Report.

c. Personnel Present: Indicate the number of hours of advance notice that was given to the COTR and indicate (Yes/No checkboxes) whether or not the COTR was notified. Indicate the Names of Initial Phase Meeting attendees, their position and



company/Authority they are with. This meeting is conducted by the QCM and attended by the superintendent, all subcontractor’s foremen responsible for the definable feature of work, the contractor’s Independent 3rd Party Testing Agencies, and the General Contractor’s Safety Representative. If all personnel are not present, cancel meeting.

d. Control Procedures: Comment on control procedures identified at Preparatory Phase of Control and assurance that work is in accordance with plans, specifications and submittals. Control procedures not producing the required compliance shall be adjusted until the procedures consistently obtain the required quality.

e. Preliminary Work: Ensure preliminary work being placed is in compliance and if not, what action is/was taken.

f. Workmanship: Identify whether the Standard of Control was established and accepted. Identify where the initial Standard of Control work is located; if a sample panel is required (Yes/No checkboxes); is the initial work the sample (Yes/No checkboxes); and if Yes, describe the panel location and precautions taken to preserve the sample.

g. Resolution: Comment on any differences and the resolutions reached.

h. Check Safety: Comment on the safety review of the job conditions.

i. Other: Note any other remarks or items that were a result of the Initial Phase.

j. QCM shall sign and date the report.

D. Testing Log: As tests are performed, the QCM shall record on the "Testing Log" the date the test was conducted, the date the test results were forwarded to the COTR, remarks and acknowledgement that an accredited or Contracting Officer approved testing laboratory was used. Forward a copy of the updated "Testing Plan and Log" on the last day of each month. Do not attach to the Quality Control Daily Report.

E. Deficiency Log: The QCM shall maintain a list of work that does not comply with the Contract, identifying what items need to be reworked, the date the item was originally discovered, the date the item shall be corrected by, and the date the item was corrected. There is no requirement to report a rework item that is corrected the same day it is discovered. Provide a copy of the deficiency log to the COTR at the weekly progress meeting. The Contractor shall be responsible for including on this list items needing rework including those identified by the COTR and their staff. Do not attach to the Quality Control Daily Report.

F. Special Inspection Control Log: If Special Inspections are required, the Contractor shall maintain a Special Inspection Control Log chronologically recording each Special test and inspection performed under the VUSBC, or other agencies having jurisdiction on-site, including the nature of the test or inspection, the date performed, the results, causes for rejection, corrective action taken, and dates of subsequent tests and final acceptance.

G. Test Reports: Contractor shall be responsible for establishing a system that shall record all tests results. Information on test designation, location, date of test, specification requirements, results and retest results, causes for rejection and recommended remedial actions shall be documented. A copy of the test results shall be sent directly from the Agency performing the testing services to COTR. Submit within 2 working days after the test is performed. The COTR will be notified immediately of any failing tests. All test reports shall be reviewed, certified,



and signed by a professional engineer, licensed in the Commonwealth of Virginia. Do not attach to the Quality Control Daily Report.

H. Inspection Log and Signoff Sheets: Contractor shall be responsible for establishing and coordinating with all trades, for each Definable Feature of Work, a system of inspections and signoff sheets certifying that all work required has been coordinated with other trades, constructed, and installed according to the plans and specifications. This requirement will be conducted before the startup or construction of any separate work element. Do not attach to the Quality Control Daily Report.

I. Monthly Deficiency Report: Contractor shall submit a monthly deficiency report to COTR identifying all substandard tests and inspections taken during the month including the nature of the test or inspection, location and nature of defects, causes for rejection, and remedial actions taken or proposed for any open items on prior deficiency reports including the date scheduled for resolution of the item. Do not attach to the Quality Control Daily Report.

J. Record Drawings: The QCM is required to ensure the record drawings, required by Division 01 Section "Project Record Documents," are kept current on a daily basis and marked to show deviations which have been made from the construction drawings. Ensure each deviation has been identified with the appropriate modifying documentation (e.g. CN No., Modification No., Request for Information No., etc.). The QCM shall initial each deviation and each revision. Upon completion of work, the QCM shall furnish a certificate attesting to the accuracy of the record drawings prior to submission to the COTR.

K. Operation, Maintenance, and Warranty Manuals: The QCM shall ensure that the Operation and Maintenance data required by Division 01 Section “Operation and Maintenance Data” and the Warranties specified in Division 01 Section “Project Closeout” are inserted on a daily basis in the appropriate sections of the approved formatted manuals after they have been approved by the COTR.

L. Materials Receiving Inspection Report: Contractor shall establish a formal materials receiving inspection program to verify material compliance to approved Shop Drawings, approved submittals, and the contract plans and specifications. Do not attach to the Quality Control Daily Report.

M. Material Location Report: At weekly intervals, prepare a comprehensive list of materials delivered to and stored at the site. List shall be cumulative, showing materials previously reported plus items recently delivered. Include with list a statement of progress on and delivery dates for all materials or items of equipment being fabricated or stored away from the building site. Submit copies of list to COTR at weekly intervals.

1.20 NOTIFICATION ON NON-COMPLIANCE

A. The COTR will notify the contractor of any detected non-compliance with the foregoing requirements. The Contractor shall take immediate corrective action after the receipt of such notice. Such notice, when delivered to the Contractor via the Authority provided Oracle Primavera Unifier project management system shall be deemed sufficient for the purpose of notification. If the Contractor fails or refuses to comply promptly the Contracting Officer may:



1. Issue an order stopping all or part of the work until satisfactory corrective action has been taken. The Contractor shall make no part of the time lost due to such stop orders the subject of a claim for extension of time for excess costs or damages.

2. Repair, replace or otherwise remedy the defective work at the Contractor’s expense. Cost incurred by the Authority to correct defective work shall be deducted from the total amount due the Contractor.

3. Withhold an amount from the payment due the Contractor as may be deemed necessary at the discretion of the Contracting Officer.

4. Terminate the Contractor’s right to proceed for Default after providing required notice.

B. In cases where implementation of the Quality Control Program does not comply with the Contractor’s Quality Control Plan, the contract provisions, or the Contractor fails to properly operate and maintain an effective Quality Control Program, the Contracting Officer may:

1. Order the Contractor to replace ineffective or unqualified Quality Control Personnel or subcontractors.

2. Issue an order stopping all or part of the work until acceptable personnel are on site and a new Quality Control Plan is approved by the COTR. The Contractor shall make no part of the time lost due to such stop orders the subject of claim for extension of time for excess costs or damages.

3. Take a credit from the contract for Quality Control Activities not performed.

4. Terminate the Contractors right to proceed for Default after providing required notice.

C. The Contractor shall maintain a detailed record of every non-compliance and corrective action taken.

D. Non-Compliance Notification: The COTR will use the Authority provided web-based Oracle Primavera Unifier project management system (Unifier) to notify the Contractor on Non-Compliance work or material. Acknowledgement and corrective action by the Contractor will be transmitted to the COTR through Unifier. The Authority will provide the Contractor a Unifier license(s) and training.






REFERENCES 014200 - 1

SECTION 014200 - REFERENCES

PART 1 - GENERAL



1.2 SUMMARY

A. This Section defines many of the terms used elsewhere in the Construction Documents and lists complete names and telephone numbers for many of the associations and agencies identified elsewhere in the Construction Documents by their acronym.

B. Abbreviations, where not defined in the Contract Documents, will be interpreted by the Contracting Officer to mean the normal construction industry terminology.

C. Plural words will be interpreted as singular and singular words will be interpreted as plural where applicable for context of the Contract Documents.

1.3 DEFINITIONS

A. General: Basic Contract definitions are included in Sections I and II of the Authority Solicitation Offer and Award. Certain terms used in the Contract Documents are defined generally in this Article. Definitions and explanations contained in this Section are not necessarily either complete or exclusive, but are general for the Work to the extent that they may not be stated more explicitly in another element of the Contract Documents.

B. Approve: The term "approved," where used in regard to COTR's action on Contractor's submittals, applications, and requests, is limited to COTR's duties and responsibilities as delegated by the Contracting Officer in the Contract and Special Provisions.

C. Architect/Engineer: For the purpose of this Project, the "Design Professional of Record." To distinguish from the Contracting Officer and Contracting Officer's Technical Representative (COTR).

D. Authority: Metropolitan Washington Airports Authority

E. Award: The acceptance, by the Authority, of the successful offeror's proposal.

F. Award Date: The date on which the Authority gives notice of acceptance to the successful offeror.

G. AOA (or A.O.A.): Air Operations Area. The area of the Airport used or intended to be used for landing, taking off, surface maneuvering, loading, unloading, or servicing aircraft. This security area requires security badging. Workers in this area are required to obtain and display an AOA



photo I.D. credential. Drivers in this area are required to obtain an Airport Vehicle Operator's Permit for the Air Operations Area.

H. Beneficial Use: Use by the Authority prior to 100 percent completion and final acceptance.

I. Contract Documents: Documents containing requirements of the Work. These include all Contract provisions and attachments made thereto or referenced therein.

J. Contract Provisions: The administrative and procedural requirements starting at Award Date and ending at Final Acceptance, as provided for in Section VII, "Contract Provisions."

K. Contract Time or Duration (Time Limit): The number of calendar days established in Section III, "Schedule," indicating the time allowed for the completion of all physical and administrative work contemplated in the Contract, including any authorized extensions thereto.

L. Contracting Officer's Technical Representative (COTR): The Contracting Officer's designated representative, as defined in Section VII, "Contract Provisions."

M. Contractor: Individual, partnership, corporation or joint venture under Contract to the Authority for performance of prescribed Work.

N. Drawings: Erection/installation/construction plans, or any other supplementary plans or similar graphic data, illustrating work to be performed that are provided to Contractor as part of the Contract Documents.

O. Directed: A command or instruction by the Authority. Other terms including "requested," "authorized," "selected," "required," and "permitted" have the same meaning as "directed."

P. Final Acceptance: Refer to Division 01 Section "Project Closeout."

Q. "Indicated": Requirements expressed by graphic representations or in written form on drawings, in Specifications, and in other Contract Documents. Other terms including "shown," "noted," "scheduled," and "specified" have the same meaning as "indicated."

R. "Regulations": Laws, ordinances, statutes, and lawful orders issued by authorities having jurisdiction, and rules, conventions, and agreements within the construction industry that control performance of the Work.

S. "Furnish": Supply and deliver to Project site, ready for unloading, unpacking, assembly, installation, and similar operations.

T. "Install": Operations at Project site including unloading, temporarily storing, unpacking, assembling, erecting, placing, anchoring, applying, working to dimension, finishing, curing, protecting, cleaning, and similar operations.

U. "Provide": Furnish and install, complete and ready for the intended use.

V. "Installer": Contractor or another entity engaged by Contractor as an employee, Subcontractor, or Sub-subcontractor, to perform a particular construction operation, including installation, erection, application, and similar operations.



1. Using a term such as "carpentry" does not imply that certain construction activities must be performed by accredited or unionized individuals of a corresponding generic name, such as "carpenter." It also does not imply that requirements specified apply exclusively to trades people of the corresponding generic name.

W. "Experienced": When used with an entity, "experienced" means having successfully completed a minimum of ten previous projects similar in size and scope to this Project; being familiar with special requirements indicated; and having complied with requirements of authorities having jurisdiction.

X. "Project Site": Space available for performing construction activities. The extent of Project site is shown on the contract drawings.

Y. Punch list Work: Minor corrective actions required to achieve "Final Acceptance." Occurs after "Substantial Completion" of the Work in strict compliance with quality-control requirements.

Z. Roadway: General term denoting a public way for purposes of vehicular travel, including the entire area within the right-of-way.

AA. Special Provisions: For the purpose of this Contract, the directions and requirements provided for in Section VI of the Contract Documents.

BB. Shop Drawings: Refer to Division 01 Section "Submittals."

CC. Specifications: General term comprising all directions, provisions and requirements contained herein, together with any other contractual requirements such as may be added or adopted as the Contract Provisions, Special Provisions, or Supplementary Conditions, all of which are necessary for the proper performance of the Contract.

DD. Substantial Completion: Refer to Division 01 Section "Project Closeout."

EE. Factory-Authorized Service Representative: An authorized representative of a manufacturer who is trained and approved by the manufacturer to inspect and approve the installation of manufacturer’s products and that are similar in material, design, and extent to those indicated for this Project and who is authorized by the manufacturer to confirm the issuance of appropriate warranties.

1.4 INDUSTRY STANDARDS

A. Applicability of Standards: Unless the Contract Documents include more stringent requirements, applicable construction industry standards have the same force and effect as if bound or copied directly into the Contract Documents to the extent referenced. Such standards are made a part of the Contract Documents by reference.

B. Publication Dates: Comply with standards in effect as of date of the Contract Documents, unless otherwise indicated.

C. Conflicting Requirements: Refer to Division 01 Section "Quality Requirements" for additional information regarding conflicting requirements.



1. Minimum Quantity or Quality Levels: The quantity or quality level shown or specified shall be the minimum provided or performed. The actual installation may comply exactly with the minimum quantity or quality specified, or it may exceed the minimum within reasonable limits. To comply with these requirements, indicated numeric values are minimum or maximum, as appropriate, for the context of requirements. Refer uncertainties to COTR for a decision before proceeding.

D. Copies of Standards: Each entity engaged in construction on Project shall be familiar with industry standards applicable to its construction activity. Copies of applicable standards are not bound with the Contract Documents.

1. Where copies of standards are needed to perform a required construction activity, obtain copies directly from publication source and make them available on request.

E. Abbreviations and Acronyms for Standards and Regulations: Where abbreviations and acronyms are used in Specifications or other Contract Documents, they shall mean the recognized name of the standards and regulations in the following list. Names, telephone numbers, and Web site addresses are subject to change and are believed to be accurate and up-to-date as of the date of the Contract Documents.

ADAAG Americans with Disabilities Act (ADA) (800) 872-2253 Accessibility Guidelines for Buildings and Facilities (202) 272-0080 Available from Access Board www.access-board.gov CFR Code of Federal Regulations (888) 293-6498 Available from Government Printing Office (202) 512-1530 www.access.gpo.gov/nara/cfr CRD Handbook for Concrete and Cement (601) 634-2355 Available from Army Corps of Engineers Waterways Experiment Station www.wes.army.mil DOD Department of Defense Military Specifications and Standards (215) 697-6257 Available from Department of Defense Single Stock Point www.dodssp.daps.mil DSCC Defense Supply Center Columbus (See FS) FED-STD Federal Standard (See FS) FS Federal Specification (215) 697-6257 Available from Department of Defense Single Stock Point.

www.dodssp.daps.mil

Available from General Services Administration

www.fss.gsa.gov (202) 501-1021



Available from National Institute of Building Sciences www.nibs.org

(202) 289-7800

FTMS Federal Test Method Standard (See FS) ICC-ES ICC Evaluation Service, Inc. (800) 423-6587 www.icc-es.org MIL See MILSPEC MS MIL See MILSPEC MILSPEC Military Specification and Standards (215) 697-6257 Available from Department of Defense Single Stock Point www.dodssp.daps.mil MUTCD Manual on Uniform Traffic Control Devices

Department of Transportation Federal Highway Administration (See FHA. Located in Paragraph Federal Government Agencies").

UFAS Uniform Federal Accessibility Standards (800) 872-2253 Available from Access Board (202) 272-0080 www.access-board.gov

1.5 ABBREVIATIONS AND ACRONYMS

A. Industry Organizations: Where abbreviations and acronyms are used in Specifications or other Contract Documents, they shall mean the recognized name of the entities in the following list. Names, telephone numbers, and Web site addresses are subject to change and are believed to be accurate and up-to-date as of the date of the Contract Documents.

AASHTO American Association of State Highway and (202) 624-5800 Transportation Officials http://www.transportation.org ACI ACI International (248) 848-3700 (American Concrete Institute) www.aci-int.org ACPA American Concrete Pipe Association (972) 506-7216 http://www.concrete-pipe.org AGA American Gas Association (202) 824-7000 www.aga.org



AGC Associated General Contractors of America (The) (703) 548-3118 www.agc.org AI Asphalt Institute (859) 288-4960 http://www.asphaltinstitute.org AISC American Institute of Steel Construction (800) 644-2400 www.aisc.org (312) 670-2400 AISI American Iron and Steel Institute (202) 452-7100 www.steel.org ANSI American National Standards Institute (202) 293-8020 www.ansi.org API American Petroleum Institute (202) 682-8000 www.api.org ASCE American Society of Civil Engineers (800) 548-2723 www.asce.org (703) 295-6300 ASME ASME International (800) 843-2763 (The American Society of Mechanical Engineers International) (212) 591-7722 www.asme.org ASTM ASTM International (610) 832-9585 (American Society for Testing and Materials International) www.astm.org AWS American Welding Society (800) 443-9353 www.aws.org (305) 443-9353 CRSI Concrete Reinforcing Steel Institute (847) 517-1200 www.crsi.org CSI Construction Specifications Institute (The) (800) 689-2900 www.csinet.org (703) 684-0300 FMG FM Global (401) 275-3000 (Formerly: FM - Factory Mutual System) www.fmglobal.com IEEE Institute of Electrical and Electronics Engineers, Inc. (The) (212) 419-7900 www.ieee.org IESNA Illuminating Engineering Society of North America (212) 248-5000 www.iesna.org NECA National Electrical Contractors Association (301) 657-3110 http://www.necanet.org/



NEMA National Electrical Manufacturers Association (703) 841-3200 www.nema.org NFPA NFPA (800) 344-3555 www.nfpa.org (617) 770-3000 UL Underwriters Laboratories Inc. (800) 285-4476 www.ul.com (847) 272-8800

B. Code Agencies: Where abbreviations and acronyms are used in Specifications or other Contract Documents, they shall mean the recognized name of the entities in the following list. Names, telephone numbers, and Web site addresses are subject to change and are believed to be accurate and up-to-date as of the date of the Contract Documents.

VUSBC Virginia Uniform Statewide Building Code (804) 371-7180 www.dhcd.virginia.gov

C. Federal Government Agencies: Where abbreviations and acronyms are used in Specifications or other Contract Documents, they shall mean the recognized name of the entities in the following list. Names, telephone numbers, and Web site addresses are subject to change and are believed to be accurate and up-to-date as of the date of the Contract Documents.

CE Army Corps of Engineers www.usace.army.mil EPA Environmental Protection Agency (202) 260-2090 www.epa.gov FAA Federal Aviation Administration (202) 366-4000 www.faa.gov FHA Federal Highway Administration (410) 962-0093 www.fhwa.dot.gov NIST National Institute of Standards and Technology (301) 975-6478 www.nist.gov OSHA Occupational Safety & Health Administration (800) 321-6742 www.osha.gov (202) 693-1999 TRB Transportation Research Board (202) 334-2934 www.nas.edu/trb TSA Transportation Security Administration 1(866)-289-9673 www.tsa.gov/public/index.jsp



D. State Government Agencies: Where abbreviations and acronyms are used in Specifications or other Contract Documents, they shall mean the recognized name of the entities in the following list. Names, telephone numbers, and Web site addresses are subject to change and are believed to be accurate and up-to-date as of the date of the Contract Documents.

DCR Virginia Department of Conservation and Recreation (804) 786-1712 http://www.dcr.state.va.us VDH Virginia Department of Health (540) 829-7340 Culpepper District www.vdh.state.va.us USBC The Virginia Statewide Building Code (USBC)

The Commonwealth of Virginia – Uniform Statewide Building Code

(804) 371- 7160

VDOT Virginia Department of Transportation (703) 383-8368 www.virginiadot.org VDEQ Virginia Department of Environmental Quality 1-800-592-5482 www.deq.state.va.us

1.6 GOVERNING REGULATIONS/AUTHORITIES

A. Contact authorities having jurisdiction directly for information and decisions having a bearing on the work. Names and addresses are subject to change; they are believed to be but are not assured to be accurate and up to date as of the date of the Contract Documents.

B. Codes: The contractor shall adhere to all applicable portions of code standards and specifications in the construction of the work. Unless otherwise noted (reference Division 01 Section “Quality Requirements”), the Authority will review the Contractor’s submittals and construction of the work for code compliance. The Authority’s acceptance of completed construction does not relieve the Contractor from strict compliance with all applicable regulations and codes. 1. Definition: The Metropolitan Washington Airports Authority has a “building department”

recognized by the Commonwealth of Virginia. This department is charged with enforcing the Virginia Uniform Statewide Building Code (VUSBC). Where the words “code official”, “department having jurisdiction” or “agency having jurisdiction” is referenced in any code, including the VUSBC or its adopted model codes (ICC), those terms shall mean the Authority Building Official and/or his designated representative.

2. Standards that influence the construction of the project include, but are not limited to, all applicable federal and Commonwealth laws, all applicable codes, rules, regulations and standards applicable to this project.








TEMPORARY FACILITIES AND CONTROLS 015000 - 1

SECTION 015000 - TEMPORARY FACILITIES AND CONTROLS

PART 1 - GENERAL


A. Drawings and Contract Provisions, Special Provisions, Supplementary Conditions, and other Division 01 Specification Sections apply to this Section.

1.2 SUMMARY

A. This Section includes requirements for temporary facilities and controls, including temporary utilities, support facilities, security, and protection facilities for Contractor staging area.

B. Temporary utilities include, but are not limited to, the following:

1. Sewers and drainage.

2. Water service and distribution.

3. Sanitary facilities, including toilets, wash facilities, and drinking-water facilities.

4. Heating and cooling facilities.

5. Ventilation.

6. Electric power service.

7. Telephone and other communication services.

8. Airfield Lighting

C. Support facilities include, but are not limited to, the following:

1. Temporary roads and paving.

2. Dewatering facilities and drains.

3. Project identification and temporary signs.

4. Waste disposal facilities.

5. Field offices.

6. Storage and fabrication sheds.

7. Lifts and hoists.

8. Construction aids and miscellaneous services and facilities.

D. Security and protection facilities include, but are not limited to, the following:

1. Environmental protection.

2. Storm water control.

3. Site enclosure fence.



4. Security enclosure and lockup.

5. Barricades, warning signs, and lights.

E. Related Sections include the following:

1. Division 01 Section "Submittals" for procedures for submitting copies of implementation and termination schedule and utility reports.

1.3 DEFINITIONS

A. Permanent Enclosure: As determined by COTR, permanent or temporary roofing is complete, insulated, and weather tight; exterior walls are insulated and weather tight; and all openings are closed with permanent construction or substantial temporary closures.

1.4 USE CHARGES

A. General: Temporary utilities are available from the Authority at no charge unless otherwise noted. Provide necessary labor and materials to connect to the Authority's utilities at points designated by COTR and extend utilities to trailers, offices, sheds, etc.

1. Provide COTR approved meters for water, natural gas, electricity, and each other utility used for Project. Supply utilities to Subcontractors' temporary facilities through Contractor's meters. The requirement to provide meters for utilities does not imply that the Contractor will be charged for these utilities, except under provisions outlined in this and other Sections.

2. Report consumption of each utility to COTR each month. Contractor is expected to consume reasonable amounts of each utility. Should Contractor, in COTR's opinion, use excessive amounts of any utility or waste a utility, Contractor may be required to pay for temporary utilities.

B. Allow other entities to use temporary services and facilities without cost, including, but are not limited to, the following:

1. The Authority’s construction forces.

2. Occupants of Project.

3. COTR.

4. Architect/Engineer.

5. Testing agencies.

6. Personnel of authorities having jurisdiction.

1.5 SUBMITTALS

A. Shop Drawings: Submit to COTR, for the Authority's review and approval, site plans indicating all temporary facilities, support and security; utility connections and traffic flows. Provide detailed drawings of utility connections and special facilities.



B. Temporary Utility Reports: Submit reports of tests, inspections, meter readings, and similar procedures performed on temporary utilities at both staging area and the Project site. Make all structures weather proof when heated and air-conditioned. Should Contractor, in COTR's opinion fail to keep the heated and cooled structures sealed and weather proof, Contractor may be required to pay for temporary utilities.

C. Implementation and Termination Schedule: Within 15 calendar days of date established for submittal of Contractor's first Construction Schedule, submit a schedule indicating implementation and termination of each temporary utility.


A. Regulations: Comply with industry standards and applicable laws and regulations of authorities having jurisdiction, that include but are not limited to, the following:

1. Building Code requirements.

2. Health and safety regulations.

3. Police and Fire Department regulations.

4. Environmental protection regulations.

5. ADA Compliance: All temporary facilities shall be ADA compliant.

B. Standards: Comply with ANSI A10.6, NECA's "Temporary Electrical Facilities," and NFPA 241.

1. Trade Jurisdictions: Assigned responsibilities for installation and operation of temporary utilities are not intended to interfere with trade regulations and union jurisdictions.

2. Electrical Service: Comply with NECA, NEMA, and UL standards and regulations for temporary electrical service. Install service to comply with NFPA 70.

C. Tests and Inspections: Arrange for the Authority's Building Codes/Environmental Department to test and inspect each temporary utility before use. Coordinate with the Authority’s Building Codes/Environmental Department for requirements for certifications, permits, and inspections.

1. Obtain permits from the Authority's Building Codes/Environmental Department for temporary construction and temporary utilities.

1.7 PROJECT CONDITIONS

A. Temporary Utilities: At earliest feasible time, when acceptable to COTR, change over from use of temporary service to use of permanent service.

1. Temporary Use of Permanent Facilities: Installer of each permanent service shall assume responsibility for operation, maintenance, and protection of each permanent service during its use as a construction facility before the Authority's acceptance, regardless of previously assigned responsibilities.



B. Conditions of Use: The following conditions apply to use of temporary services, permanent services, and facilities by all parties engaged in the Work:

1. Keep temporary services and facilities clean and neat.

2. Relocate temporary services and facilities as required by progress of the Work.

3. Take necessary fire-prevention measures.

4. Do not overload facilities.

5. Do not allow hazardous, dangerous, or unsanitary conditions, or public nuisances to develop or persist on-site.

1.8 CONTRACTOR PERSONNEL PARKING

A. The Contractor field offices will be located in the South Construction Staging Area and the Contractor's personnel will be allowed to park their personal vehicles in this Staging Area.

PART 2 - PRODUCTS

2.1 MATERIALS

A. General: Provide new materials. Undamaged, previously used materials in serviceable condition may be used if approved by COTR. Provide materials suitable for use intended.

B. Portable Chain-Link Fencing: Minimum 2-inch, 9-gage, galvanized steel, chain-link fabric fencing; minimum 6 feet high with galvanized steel pipe posts; minimum 2-3/8-inch-OD line posts and 2-7/8-inch-OD corner and pull posts, with 1-5/8-inch-OD top and bottom rails. Provide concrete bases for supporting posts.

C. Tarpaulins: Fire-resistive labeled with flame-spread index of 15 or less.

D. Water: Potable.

E. Temporary Fuel Tanks: For requirements for temporary fuel tanks see Division 31 Section “Storm Water Pollution Protection Plan.” Comply with applicable safety and environmental regulations for temporary surface fuel tanks. Location and installation of tanks will be subject to review and approval of COTR and the Authority's Fire Marshal.

2.2 EQUIPMENT

A. General: Provide new equipment suitable for use intended. If acceptable to COTR, undamaged, previously used equipment in serviceable condition may be used.

B. Field Offices: Mobile units with lockable entrances, operable windows, and serviceable finishes; heated and air conditioned; on foundations adequate for normal loading, and provided with proper tie-downs.



C. Self-Contained Toilet Units: Single-occupant units of chemical, aerated re-circulation, or combustion type; vented; fully enclosed with a glass-fiber-reinforced polyester shell or similar nonabsorbent material.

D. Drinking-Water Fixtures: Containerized, tap-dispenser, bottled-water drinking-water units, including paper cup supply.

1. Where power is accessible, provide electric water coolers to maintain dispensed water temperature at 45 to 55 deg F.

E. Heating Equipment: Unless COTR authorizes use of permanent heating system, provide temporary heating units with individual space thermostatic control.

1. Use of gasoline-burning space heaters, open-flame heaters, or salamander-type heating units is prohibited.

2. Heating Units: Listed and labeled, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use for type of fuel being consumed.

F. Electrical Outlets: Properly configured, NEMA-polarized outlets that will prevent insertion of 110v or 120v plugs into higher-voltage outlets, and equipped with ground-fault circuit interrupters with reset button.

G. Power Distribution System Circuits: Where permitted, overhead, and visible wiring circuits, not exceeding 125-V ac, 20-A rating, and lighting circuits may be nonmetallic-sheathed cable.

PART 3 - EXECUTION

3.1 INSTALLATION, GENERAL

A. Use qualified personnel for installation of temporary facilities. Locate facilities where they will serve Project adequately and result in minimum interference with performance of the Work. Relocate and modify facilities as required.

B. Provide each facility ready for use when needed to avoid delay. Maintain and modify as required. Do not remove until facilities are no longer needed or are replaced by authorized use of completed permanent facilities.

3.2 CONTRACTOR STAGING AREA - GENERAL

A. Contractor will be allowed to store and stage his materials in a staging area located on Airport property as indicated or as designated by the COTR for such purposes. Space is limited to area indicated. COTR and Contractor will make a joint site visit to document condition of staging area prior to occupancy. Take photos for the record.

B. Upon completion of Construction, remove all temporary staging area facilities and return the areas to their original condition.

C. Park construction equipment in the storage site or storage area identified by the COTR when equipment is not engaged in construction activity.



D. Do not stockpile construction materials, spoils, debris or refuse in any area other than that specifically approved for such purpose by the COTR.

E. Constrain stockpiled material in a manner to prevent its movement by wind, jet blast or propeller wash.

3.3 TEMPORARY UTILITY INSTALLATION

A. General: Provide temporary service for each utility required. Comply with requirements of the Authority's Building Codes Manual, the Authority's Construction Safety Manual, and the requirements of all Sections of these specifications.

1. Arrange with COTR for time when service can be interrupted, if necessary, to make connections for temporary services. For additional information on utility outages see Division 01 Section, "Summary."

2. Provide adequate capacity at each stage of construction. Before temporary utility is available, provide trucked-in services.

3. Perform work associated with utilities owned by the Authority as approved by the Authority.

4. See additional information in Contract Provisions entitled "Availability and Use of Utility Service."

B. Sewers and Drainage: If sewers are available, provide temporary connections to remove effluent that can be discharged lawfully. If sewers are not available or cannot be used, provide drainage ditches, dry wells, stabilization ponds, and similar facilities. If neither sewers nor drainage facilities can be lawfully used for discharge of effluent, provide containers to remove and dispose of effluent off-site in a lawful manner.

C. When using Authority sewers:

1. Filter out excessive soil, construction debris, chemicals, oils, and similar contaminants that might clog sewers or pollute waterways before discharge.

2. Connect temporary sewers to the Authority's system as directed by COTR.

3. Maintain temporary sewers and drainage facilities in a clean, sanitary condition. After heavy use, restore normal conditions promptly.

4. Provide temporary filter beds, settlement tanks, separators, and similar devices to purify effluent to levels acceptable to authorities having jurisdiction.

D. Water Service: Provide temporary water service and distribution piping in sizes and pressures adequate for construction until permanent water service is in use. Sterilize temporary water piping before use. Provide Badger Recordall, Turbo II Utility type water meter to meter all water usage for 2-inch water feed lines and above. Provide Badger Recordall bronze disc water meter for to meter all water usage for water feed lines under 2-inches. COTR will approve water meters, in writing prior to installation of water meters. Do not install water meters until written approval has been received from COTR. Provide Watts Model 909, Type RPZ backflow preventers. Do not install backflow preventers until written approval of backflow preventers has been received from the COTR.



E. Heating and Cooling: Provide temporary heating and cooling required by construction activities for curing or drying of completed installations or for protecting installed construction from adverse effects of low temperatures or high humidity. Select equipment from that specified that would not have a harmful effect on completed installations or elements being installed.

1. Maintain a minimum temperature of 50 degrees F in permanently enclosed portions of building for normal construction activities, and 65 degrees F for finishing activities and areas where finished Work has been installed.

F. Ventilation and Humidity Control: Provide temporary ventilation and humidity control required by construction activities for curing or drying of completed installations or for protecting installed construction from adverse effects of high humidity. Select equipment from that specified that would not have a harmful effect on completed installations or elements being installed. Coordinate ventilation requirements to produce ambient condition required and minimize energy consumption. Provide and operate either exhaust or supply fans/blowers, or both, sufficient to ventilate work areas adequately.

G. Electric Power Service: Provide weatherproof, grounded electric power service and distribution system of sufficient size, capacity, and power characteristics during construction period. Include meters, transformers, overload-protected disconnecting means, automatic ground-fault interrupters, and main distribution switchgear. Provide kilowatt-hour meters with demand capability.

1. Install electric power service underground, unless overhead service is authorized by COTR.

2. Connect temporary service to the Authority's existing power source, as directed by COTR.

3. Install power distribution wiring overhead and rise vertically where least exposed to damage

H. Electrical Distribution: Provide receptacle outlets adequate for connection of power tools and equipment.

1. Provide waterproof connectors to connect separate lengths of electrical power cords if single lengths will not reach areas where construction activities are in progress. Do not exceed safe length-voltage ratio.

2. Provide warning signs at power outlets other than 110 to 120 V.

3. Provide metal conduit, tubing, or metallic cable for wiring exposed to possible damage. Provide rigid steel conduits for wiring exposed on grades, floors, decks, or other traffic areas.

4. Provide metal conduit enclosures or boxes for wiring devices.

5. Provide 4-gang outlets, spaced so 100-foot extension cord can reach each area for power hand tools and task lighting. Provide a separate 125-V ac, 20-A circuit for each outlet.

I. Lighting: Provide temporary lighting with local switching that provides adequate illumination for construction operations and traffic conditions.



1. Provide and operate temporary lighting that fulfills security and protection requirements without operating entire system.

2. Provide exterior-yard site lighting that will provide adequate illumination for construction operations, traffic conditions, and signage visibility when the Work is being performed. Provide exterior yard and site lighting aligned as directed by the COTR. Provide lighting so as not to interfere with ground, air traffic and air traffic control.

3. Install lighting for Project identification signs.

J. Telephone Service: Provide temporary telephone service for key personnel engaged in construction activities, throughout the construction period. Install telephones on separate lines for each temporary office and first aid station. Where an office has more that two occupants, install a telephone for each additional occupant or pair of occupants. Provide telephones with exchanges within the Metropolitan Washington service area. The Authority owns and operates an airport-wide Airport Communication System (ACS). This system accommodates all normal telecommunications service requirements, i.e., local, long distance, fax, data, etc. The Contractor may obtain information about and choose to utilize this service by contacting the ACS Help Desk at (703) 417-8300.

1. At each telephone, post a list of emergency telephone numbers approved by COTR.

2. Provide a portable cellular telephone for superintendent's use in making and receiving telephone calls when away from field office.

3.4 SUPPORT FACILITIES INSTALLATION

A. General: Comply with the following:

1. Locate field offices, storage sheds, sanitary facilities, and other temporary construction and support facilities for easy access.

2. Provide incombustible construction for offices, shops, and sheds located within construction area or within 30 feet of building lines. Comply with NFPA 241 and USBC.

B. Dewatering Facilities and Drains: Comply with requirements in applicable Division 31 and Division 32 Sections for temporary drainage and dewatering facilities and operations not directly associated with construction activities included in individual Sections. Where feasible, use same facilities. Maintain Project site, excavations, and construction free of water.

1. Dispose of rainwater in a lawful manner that will not result in flooding Project or adjoining property nor endanger permanent Work or temporary facilities.

2. Before connection and operation of permanent drainage piping system, provide temporary drainage where roofing or similar waterproof deck construction is completed.

3. Remove snow and ice as required to minimize accumulations.

C. Project Identification and Temporary Signs: Prepare Project identification and other signs in sizes indicated. Install signs where indicated or where directed by COTR to inform public and persons seeking entrance to Project. Provide two Project signs.



1. Engage an experienced sign painter to apply graphics for Project identification signs. Comply with details indicated.

2. Prepare temporary signs to provide directional information to construction personnel and visitors.

3. Construct signs of exterior-type, Grade B-B, high-density concrete form overlay plywood in sizes and thickness indicated. Support on nominal 4-inch-by-4-inch-by-10-foot-long posts or framing of preservative-treated wood or steel.

4. Paint sign panel and applied graphics with exterior-grade alkyd gloss enamel over exterior primer.

5. The following signs will be allowed on the Project:

a. Identifying captions over offices.

b. Other signs as required by the Contract Documents.

6. Take necessary steps to prevent installation of unauthorized signs and, should any appear, remove them immediately. Repair and repaint damage caused thereby at no additional cost to the Authority.

7. No more than two Project Identification Signs will be permitted. Project identification signs are the only signs on which the Contractors name and logo will be permitted.

D. Waste Disposal Facilities: Provide waste-collection containers in sizes adequate to handle waste from construction operations. Containerize and clearly label hazardous, dangerous, or unsanitary waste materials separately from other waste. Comply with Division 01 Section "Execution " for progress cleaning requirements.

1. If required by COTR, provide separate containers, clearly labeled, for each type of waste material to be deposited.

2. Develop a waste management plan for Work performed on Project. Indicate types of waste materials Project will produce and estimate quantities of each type. Provide detailed information for on-site waste storage and separation of recyclable materials. Provide information on destination of each type of waste material and means to be used to dispose of all waste materials.

E. Janitorial Services: Provide janitorial services on a daily basis for temporary offices, first-aid stations, toilets, wash facilities, lunchrooms, and similar areas.

F. Storage and Fabrication Sheds: Provide sheds sized, furnished, and equipped to accommodate materials and equipment involved, including temporary utility services. Sheds may be open shelters or, if permitted by COTR, fully enclosed spaces within building or elsewhere on-site subject to approval of COTR.

1. Construct framing, sheathing, and siding using fire-retardant-treated lumber and plywood.

2. Paint exposed lumber and plywood with exterior-grade acrylic-latex emulsion over exterior primer.

3. Submit the design of storage structures of more than 150 sq. ft. to COTR for review and approval by the Authority's Building Codes/Environmental Department.



3.5 SECURITY AND PROTECTION FACILITIES INSTALLATION

A. Environmental Protection: Provide protection, operate temporary facilities, and conduct construction in ways and by methods that comply with environmental regulations and that minimize possible air, waterway, and subsoil contamination or pollution or other undesirable effects.

B. Storm water Control: Provide earthen embankments and similar barriers in and around excavations and subgrade construction, sufficient to prevent flooding by runoff of storm water from heavy rains.

C. Security Fencing:

1. Minimum 2-inch, 0.148-inch-thick, galvanized steel, chain-link fabric fencing; minimum 8 feet high with galvanized steel pipe posts; minimum 2-3/8-inch-OD line posts and 2-7/8-inch-OD corner and pull posts, with 3 galvanized barbed-wire top strands, unless otherwise indicated.

D. Site Enclosure Fence: Before construction operations begin, provide portable chain-link site enclosure fence. Minimum 2-inch, 9-gage, galvanized steel, chain-link fabric fencing; minimum 8 feet high with galvanized steel pipe posts; minimum 2-3/8-inch-OD line posts and 2-7/8-inch-OD corner and pull posts, with 1-5/8-inch-OD top and bottom rails. Provide concrete bases for supporting posts. Contractor is responsible for providing support to protect against wind damage and meeting safety requirements.

1. Entrance into the site: Only through the lockable entrance gates.

2. Set fence posts in concrete bases.

3. Provide gates in sizes and at locations necessary to accommodate delivery vehicles and other construction operations.

4. Maintain security by limiting number of keys and restricting distribution to authorized personnel. Provide COTR with three set of keys.

E. Barricades, Warning Signs, and Lights: Comply with standards and code requirements for erecting structurally adequate barricades. Paint with appropriate colors, graphics, and warning signs to inform personnel and public of possible hazard. Where appropriate and needed, provide lighting, including flashing red or amber lights. See the Authority's Construction Safety Manual for additional requirements.

F. Storage: Where materials and equipment are stored, and are of value or attractive for theft, provide secure lockup. Enforce discipline in connection with installation and release of material to minimize opportunity for theft and vandalism.

3.6 OPERATION, TERMINATION, AND REMOVAL

A. Supervision: Enforce strict discipline in use of temporary facilities. Limit availability of temporary facilities to essential and intended uses to minimize waste and abuse.

B. Maintenance: Maintain facilities in good operating condition until removal. Protect from damage caused by freezing temperatures and similar elements.



1. Maintain operation of temporary enclosures, heating, cooling, humidity control, ventilation, and similar facilities on a 24-hour basis where required to achieve indicated results and to avoid possibility of damage.

2. Prevent water-filled piping from freezing. Maintain markers for underground lines. Protect from damage during excavation operations.

C. Operate Project-identification-sign lighting daily any time from dusk until dawn when personnel are on the site. Should no personnel be on the site after 12:00 midnight the project – identification lighting may be turned off at 12:00 midnight.

D. Termination and Removal: Remove each temporary facility when need for its service has ended, when it has been replaced by authorized use of a permanent facility, or no later than Substantial Completion. Complete or, if necessary, restore permanent construction that may have been delayed because of interference with temporary facility. Repair damaged Work, clean exposed surfaces, and replace construction that cannot be satisfactorily repaired.

1. Properly recondition and restore those portions of the site occupied by temporary facilities and controls to condition acceptable to COTR, at least equal to condition at time of start of Work, unless otherwise authorized in writing by COTR.

2. Materials and facilities that constitute temporary facilities are the property of Contractor. Owner reserves right to take possession of Project identification signs.

3. Remove temporary paving not intended for or acceptable for integration into permanent paving. Where area is intended for landscape development, remove soil and aggregate fill that do not comply with requirements for fill or subsoil. Remove materials contaminated with road oil, asphalt and other petrochemical compounds, and other substances that might impair growth of plant materials or lawns. Repair or replace roadway paving, curbs, and sidewalks at temporary entrances, as required by authorities having jurisdiction.

4. At Substantial Completion, clean and renovate permanent facilities used during construction period. Comply with final cleaning requirements in Division 01 Section "Project Closeout."

PART 4 - MEASUREMENT

4.1 METHOD OF MEASUREMENT

A. Payment for Temporary Facilities and Controls will be made on a lump sum basis wherein no measurement will be made.

PART 5 - PAYMENT

5.1 BASIS OF PAYMENT

A. Payment for Temporary Facilities and Controls will be made in 5 installments, the sum of which shall not exceed 5 percent of the total Contract Amount, excluding the amount of this item. The first payment of 40 percent of the lump sum price will be made on the first estimate and shall be



partial compensation for performing the work specified and the furnishing of all materials, labor, tools, equipment, and incidentals necessary for temporary facilities and controls, including temporary utilities, support facilities, security, and protection facilities for Contractor staging area. Payments of 15 percent of the lump sum price item will be made on the subsequent estimates. The final 15 percent of the lump sum price will be made after temporary facilities have been removed and the site has been restored to its original or final condition.

Payment will be made under:

Item 015000-5.1 Temporary Facilities and Controls – per lump sum.



HAUL ROADS AND STAGING AREAS 015516 - 1

SECTION 015516 - HAUL ROADS AND STAGING AREAS

PART 1 - GENERAL


A. Drawings and general provisions of the Contract, including General and Supplementary Conditions, and Division 1 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This item shall consist of construction and removal of temporary haul roads, and restoration of all areas disturbed by these activities, restoration of staging areas, and improvement and restoration of existing roads used as haul roads during construction.

PART 2 - MATERIALS

2.1 AGGREGATE.

A. Aggregate shall conform to the requirements of AASHTO M 43. The use of crushed Portland cement concrete will be permitted for use as aggregate.

2.2 ENGINEERING FABRIC.

A. Engineering fabric shall conform to the requirements of AASHTO M 288.

2.3 BITUMINOUS TACK COAT.

A. Bituminous tack coat shall conform to the requirements of Item P-603.

2.4 BITUMINOUS PAVEMENT.

A. Bituminous pavement shall conform to the requirements of Section P-405.

2.5 TOPSOIL.

A. Topsoil shall conform to the requirements of Section 32 92 00.

2.6 SEED.

A. Seeding shall conform to the requirements of Section 32 92 00.


HAUL ROADS AND STAGING AREAS 015516 - 2

2.7 MULCH.

A. Mulch shall conform to the requirements of Section 32 92 00.

PART 3 - EXECUTION

3.1 TEMPORARY HAUL ROADS.

A. The number and locations of temporary haul roads shall be approved by the COTR. The temporary haul roads shall be constructed using engineering fabric and aggregate in accordance with the detail on the plans. Upon completion of the need for the temporary haul road, it shall be removed and the area restored to its original condition. Removal and restoration of the temporary haul roads, including but not limited to bituminous repairs to the runway shoulder and topsoiling, seeding and mulching of the affected haul road areas, shall be incidental to the various items of construction.

3.2 IMPROVING AND RESTORING EXISTING ROADS.

A. Existing roads designated to be improved for haul road use shall be constructed as shown and detailed on the plans. Existing roads to be used as haul roads, but not designated for improvements, shall be video taped and photographed by the Contractor prior to the start of construction to document the existing conditions. At the conclusion of the project, the existing roads that were used as haul routes shall be restored to their original condition as detailed on the plans and to the satisfaction of the COTR.

3.3 MAINTAINING HAUL ROADS.

A. Haul roads as shown on the Construction Phasing Plans are to be maintained during construction to such condition that they are passable by a standard passenger vehicle. All maintenance of the haul roads during construction is incidental to this Item.

PART 4 - CONTRACTOR QUALITY CONTROL

A. QUALITY CONTROL PROGRAM. The Contractor shall develop a Quality Control Program in accordance with Section 01 40 00 “Quality Requirements.” The program shall address all elements which affect the quality of the work including, but not limited to:

1. Quality and gradation of the material



PRODUCT REQUIREMENTS 016000 - 1

SECTION 016000 - PRODUCT REQUIREMENTS

PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes the following administrative and procedural requirements: selection of products for use in Project; product delivery, storage, and handling; manufacturers' standard warranties on products; special warranties; product substitutions; and comparable products.

1. This Section includes substitutions made for "or as approved by the Authority" items.


1. Division 01 Section "References" for applicable industry standards for products specified.

2. Divisions 02 through 33 Sections for specific requirements for warranties on products and installations specified to be warranted.

1.3 DEFINITIONS

A. Products: Items purchased for incorporating into the Work, whether purchased for Project or taken from previously purchased stock. The term "product" includes the terms "material," "equipment," "system," and terms of similar intent.

1. Named Products: Items identified by manufacturer's product name, including make or model number or other designation, shown or listed in manufacturer's published product literature that is current as of date of the Contract Documents.

2. New Products: Items that have not previously been incorporated into another project or facility. Products salvaged or recycled from other projects are not considered new products.

3. Comparable Product: Product that is demonstrated and approved through submittal process, or where indicated as a product substitution, to have the indicated qualities related to type, function, dimension, in-service performance, physical properties, appearance, and other characteristics that equal or exceed those of specified product.

B. Substitutions: Changes in products, materials, equipment, and methods of construction from those required by the Contract Documents and proposed by Contractor.



C. Basis-of-Design Product Specification: Where a specific manufacturer's product is named and accompanied by the words "basis of design," including make or model number or other designation, to establish the significant qualities related to type, function, dimension, in-service performance, physical properties, appearance, and other characteristics for purposes of evaluating comparable products of other named manufacturers.

1.4 SUBMITTALS

A. Product List: Submit a list, in tabular form acceptable to COTR, showing specified products. Include generic names of products required. Include manufacturer's name and proprietary product names for each product.

1. Coordinate product list with Contractor's Construction Schedule and Submittals Schedule.

2. Form: Tabulate information for each product under the following column headings:

a. Specification Section number and title.

b. Generic name used in the Contract Documents.

c. Proprietary name, model number, and similar designations.

d. Manufacturer's name and address.

e. Supplier's name and address.

f. Installer's name and address.

g. Projected delivery date or time span of delivery period.

h. Identification of items that require early submittal approval for scheduled delivery date.

3. Initial Submittal: Within 90 calendar days after the Notice to Proceed, submit three (3) copies of initial product list. Include a written explanation for omissions of data and for variations from the Contract requirements.

4. COTR's Action: COTR will respond in writing to Contractor within 15 calendar days of receipt of initial product list. COTR's response will include a list of unacceptable product selections and a brief explanation of reasons for this action. COTR's response, or lack of response, does not constitute a waiver of requirement that products comply with the Contract Documents.

5. Updated submittal: Submit updated product list every 90 days following initial submittal. The updated list shall be submitted in approved electronic spread sheet format with additional fields as required by COTR.

6. Completed List: Submit ten (10) hard copies and one electronic copy of completed product list 90 calendar days before requesting inspection for substantial completion. Include a written explanation for omissions of data and for variations from the Contract requirements.

B. Substitution Requests: Submit six (6) copies of each request for consideration. Identify product or fabrication or installation method to be replaced. Include Section number and title and Drawing numbers and titles.



1. Substitution Request Form: Submit requests in the form and according to procedures required for Contract Modification proposals supplied to Contractor at the pre-construction meeting or as directed by COTR. Do not submit requests for substitutions as "Requests for Information" (RFIs).

2. Documentation: Show compliance with requirements for substitutions and the following, as applicable:

a. Statement indicating why specified material or product cannot be provided.

b. Coordination information, including a list of changes or modifications needed to other parts of the Work and to construction performed by the Authority and separate contractors that will be necessary to accommodate proposed substitution.

c. Detailed comparison of significant qualities of proposed substitution with those of the Work specified. Significant qualities may include attributes such as performance, weight, size, durability, visual effect, and specific features and requirements indicated.

d. Product Data, including drawings and descriptions of products and fabrication and installation procedures.

e. Samples, where applicable or requested.

f. List of similar installations for completed projects with project names and addresses and names and addresses of architects and owners.

g. Material test reports from a qualified testing agency indicating and interpreting test results for compliance with requirements indicated.

h. Research/evaluation reports evidencing compliance with building code in effect for Project, from a model code organization acceptable to authorities having jurisdiction.

i. Detailed comparison of Contractor's Construction Schedule using proposed substitution with products specified for the Work, including effect on the overall Contract Time. If specified product or method of construction cannot be provided within the Contract Time, include letter from manufacturer, on manufacturer's letterhead, stating lack of availability or delays in delivery.

j. Cost information, including a proposal of change, if any, in the Contract Price.

k. Contractor's certification that proposed substitution complies with requirements in the Contract Documents and is appropriate for applications indicated.

l. Contractor's waiver of rights to additional payment or time that may subsequently become necessary because of failure of proposed substitution to produce indicated results.

m. Failure by Contractor to include the above requirements in the submittal may cause rejection of the submittal in its entirety.



3. COTR's Action: If necessary, COTR will request additional information or documentation for evaluation within 15 calendar days of receipt of a request for substitution. COTR will notify Contractor of acceptance or rejection of proposed substitution within 15 calendar days of receipt of request, or two weeks of receipt of additional information or documentation, whichever is later.

a. Form of Acceptance: Change notice.

b. Use product specified if COTR couldn’t make a decision on use of a proposed substitution within time allocated.

C. Comparable Product Requests: Submit three (3) copies of each request for consideration. Identify product or fabrication or installation method to be replaced. Include Specification Section number and title and Drawing numbers and titles.

1. COTR’s Action: If necessary, COTR will request additional information or documentation for evaluation within 7 working days of receipt of a comparable product request. COTR will notify Contractor of approval or rejection of proposed comparable product request within 15 calendar days of receipt of request, or 7 calendar days of receipt of additional information or documentation, whichever is later.

a. Form of Approval: As specified in Division 01 Section "Submittals."

b. Use product specified if COTR couldn’t make a decision on use of a comparable product request within time allocated.

D. Basis-of-Design Product Specification Submittal: Comply with requirements in Division 01 Section "Submittals." Show compliance with requirements.


A. Compatibility of Options: If Contractor is given option of selecting between two or more products for use on Project, product selected shall be compatible with products previously selected, even if previously selected products were also options.

1.6 PRODUCT DELIVERY, STORAGE, AND HANDLING

A. Deliver, store, and handle products using means and methods that will prevent damage, deterioration, and loss, including theft. Comply with manufacturer's written instructions.

B. Delivery and Handling:

1. Schedule delivery to minimize long-term storage at Project site and to prevent overcrowding of construction spaces.

2. Coordinate delivery with installation time to ensure minimum holding time for items that are flammable, hazardous, easily damaged, or sensitive to deterioration, theft, and other losses.



3. Deliver products to Project site in an undamaged condition in manufacturer's original sealed container or other packaging system, complete with labels and instructions for handling, storing, unpacking, protecting, and installing.

4. Inspect products on delivery to ensure compliance with the Contract Documents and to ensure that products are undamaged and properly protected.

C. Storage:

1. Store products to allow for inspection and measurement of quantity or counting of units.

2. Store materials in a manner that will not endanger Project structure.

3. Store products that are subject to damage by the elements, under cover in a weather tight enclosure above ground, with ventilation adequate to prevent condensation.

4. Comply with product manufacturers written instructions for temperature, humidity, ventilation, and weather-protection requirements for storage.

5. Store cementitious products and materials on elevated platforms.

6. Protect stored products from damage.

7. Replace products and materials damaged by the elements due to improper storage at no additional cost to the Authority. This damage can be, but not limited to, oxidization, mold, mildew, warping, and rust.

1.7 PRODUCT WARRANTIES

A. Warranties specified in other Sections shall be in addition to, and run concurrent with, other warranties required by the Contract Documents. Manufacturer's disclaimers and limitations on product warranties do not relieve Contractor of obligations under requirements of the Contract Documents.

1. Manufacturer's Warranty: Preprinted written warranty published by individual manufacturer for a particular product and specifically endorsed by manufacturer to Authority.

2. Special Warranty: Written warranty required by or incorporated into the Contract Documents, either to extend time limit provided by manufacturer's warranty or to provide more rights for Authority.

B. Special Warranties: Prepare a written document that contains appropriate terms and identification, ready for execution. Submit a draft for approval before final execution.

1. Manufacturer's Standard Form: Modified to include Project-specific information and properly executed.

2. Specified Form: When specified forms are included with the Specifications, prepare a written document using appropriate form properly executed.

3. Refer to Divisions 02 through 33 Sections for specific content requirements and particular requirements for submitting special warranties.

C. Submittal Time: Comply with requirements in Division 01 Section "Project Closeout."



PART 2 - PRODUCTS

2.1 PRODUCT OPTIONS

A. General Product Requirements: Provide products that comply with the Contract Documents, that are undamaged and, unless otherwise indicated, that are new at time of installation.

1. Provide products complete with accessories, trim, finish, fasteners, and other items needed for a complete installation and indicated use and effect.

2. Standard Products: If available, and unless custom products or nonstandard options are specified, provide standard products of types that have been produced and used successfully in similar situations on other projects.

3. The Authority reserves the right to limit selection to products with warranties not in conflict with requirements of the Contract Documents.

4. Where products are accompanied by the term "as selected," COTR will make selection.

5. Where products are accompanied by the term "match sample," sample to be matched is COTR's.

6. Descriptive, performance, and reference standard requirements in the Specifications establish "salient characteristics" of products.

7. "Or as approved by the Authority": Note that products submitted under an "or as approved by the Authority” provision are considered to be substitutions. Substitutions shall follow the requirements of Paragraph VII-42 of Contract Provisions and provisions in "Comparable Products" Article to obtain approval for use of an unnamed product.

B. Product Selection Procedures:

1. Product: Where Specifications name a single product and manufacturer, provide the named product that complies with requirements.

2. Manufacturer/Source: Where Specifications name a single manufacturer or source, provide a product by the named manufacturer or source that complies with requirements.

3. Products: Where Specifications include a list of names of both products and manufacturers, provide one of the products listed that complies with requirements.

4. Manufacturers: Where Specifications include a list of manufacturers' names, provide a product by one of the manufacturers listed that complies with requirements.

5. Available Products: Where Specifications include a list of names of both products and manufacturers, provide one of the products listed, or an unnamed product, that complies with requirements. Comply with provisions in Part - 2 "Comparable Products" Article for consideration of an unnamed product.

6. Available Manufacturers: Where Specifications include a list of manufacturers, provide a product by one of the manufacturers listed, or an unnamed manufacturer, that complies with requirements. Comply with provisions in Part - 2 "Comparable Products" Article for consideration of an unnamed product.

7. Product Options: Where Specifications indicate that sizes, profiles, and dimensional requirements on Drawings are based on a specific product or system, provide the



specified product or system. Comply with provisions in Part 2 "Product Substitutions" Article for consideration of an unnamed product or system.

8. Basis-of-Design Product: Where Specifications name a product and include a list of manufacturers, provide the specified product or a comparable product by one of the other named manufacturers. Drawings and Specifications indicate sizes, profiles, dimensions, and other characteristics that are based on the product named. Comply with provisions in Part 2 "Comparable Products" Article for consideration of an unnamed product by the other named manufacturers.

9. Visual Matching Specification: Where Specifications require matching an established Sample, select a product that complies with requirements and matches COTR's sample. COTR's decision will be final on whether a proposed product matches.

a. If no product available within specified category matches and complies with other specified requirements, comply with provisions in Part 2 "Product Substitutions" Article for proposal of product.

10. Visual Selection Specification: Where Specifications include the phrase "as selected from manufacturer's colors, patterns, textures" or a similar phrase, select a product that complies with other specified requirements.

a. Standard Range: Where Specifications include the phrase "standard range of colors, patterns, textures" or similar phrase, COTR will select color, pattern, density, or texture from manufacturer's product line that does not include premium items.

b. Full Range: Where Specifications include the phrase "full range of colors, patterns, textures" or similar phrase, COTR will select color, pattern, density, or texture from manufacturer's product line that includes both standard and premium items.

2.2 PRODUCT SUBSTITUTIONS

A. Timing: COTR will consider requests for substitution if received within 60 calendar days after issuance of the Notice to Proceed. Requests received after that time may be considered or rejected at the sole discretion of the Contracting Officer.

B. Conditions: COTR will consider Contractor's request for substitution when the following conditions are satisfied. If the following conditions are not satisfied, COTR will return requests without action, except to record noncompliance with these requirements:

1. Requested substitution does not require extensive revisions to the Contract Documents.

2. Requested substitution is consistent with the Contract Documents and will produce indicated results.

3. Substitution request is fully documented and properly submitted.

4. Requested substitution will not adversely affect Contractor's Construction Schedule.

5. Requested substitution has received necessary approvals of authorities having jurisdiction.



6. Requested substitution is compatible with other portions of the Work.

7. Requested substitution has been coordinated with other portions of the Work.

8. Requested substitution provides specified warranty.

9. If requested substitution involves more than one contractor, requested substitution has been coordinated with other portions of the Work, is uniform and consistent, is compatible with other products, and is acceptable to all contractors involved.

C. Contractor's submittal and COTR's review or approval of Shop Drawings, Product Data, or Samples that relate to a substitute does not by itself constitute a final approval of the requested substitution, nor does it relieve Contractor from fulfilling existing Contract requirements.

D. If a substitution offers a substantial advantage to the Authority, in terms of cost, time, energy conservation, or other considerations of merit, after deducting offsetting responsibilities the Authority may be required to bear, the substitution shall be submitted as a Value Engineering Change Proposal.

2.3 COMPARABLE PRODUCTS

A. Conditions: COTR will consider Contractor's request for comparable product when the following conditions are satisfied. If the following conditions are not satisfied, COTR will return requests without action, except to record noncompliance with these requirements:

1. Evidence that the proposed product does not require extensive revisions to the Contract Documents, it is consistent with the Contract Documents, it will produce the indicated results, and that it is compatible with other portions of the Work.

2. Detailed comparison of significant qualities of proposed product with those named in the Specifications. Significant qualities include attributes such as performance, weight, size, durability, visual effect, and specific features and requirements indicated.

3. Evidence that proposed product provides specified warranty.

4. List of similar installations for completed projects with project names and addresses and names and addresses of architects and owners, if requested.

5. Samples, if requested.




MOBILIZATION/DEMOBILIZATION 017113 - 1

SECTION 017113 - MOBILIZATION/DEMOBILIZATION

PART 1 - GENERAL


A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This work shall consist of the performance of construction preparatory operations, including the movement of personnel, equipment, and materials to the project site, and for establishment and maintenance of the Contractor's offices and other facilities necessary to begin and sustain work on the Contract. In addition, the following items are to be included in the cost of mobilization:

(1) Obtaining personnel identification and other items as necessary to facilitate work.

(2) Stabilizing Contractor’s access routes as shown on the plans. Stabilization of the existing haul roads shall be as outlined in Section 015516.

(3) Other work items necessary to begin construction, as shown in the plans.

(4) Demobilization efforts at completion of the Project.

PART 2 - PRODUCTS

2.1 BARRICADES

A. Barricades shall be furnished as discussed in Section 017114.

2.2 PERSONNEL

A. Security guards, flagmen, radios and other items necessary to facilitate work shall be furnished as discussed in Section 017114 and other specification sections.



A. Mobilization/Demobilization will be measured on a lump sum basis.


MOBILIZATION/DEMOBILIZATION 017113 - 2

PART 5 - PAYMENT

A. This item will be paid for at the Contract lump sum price, which shall be full compensation for performing the work specified and the furnishing of all materials, labor, tools, equipment, and incidentals necessary to mobilize and subsequently demobilize the construction operations.

B. Payment for this item will be made in six (6) installments, the sum of which shall not exceed 5 percent of the total Contract Amount, excluding the amount of this item. The first payment of 40 percent of the lump sum price item will be made on the first estimate following partial mobilization and the initiation of construction work including the placement or erection of all Contractor's offices. Payments of 10 percent of the lump sum price item will be made on the four (4) subsequent estimates following the completion of substantial mobilization. The final 20 percent of the lump sum price will be made after demobilization has been completed and the site has been cleared to the satisfaction of the COTR.


Item 017113-5.1 Mobilization/Demobilization--per lump sum.



AIRPORT SAFETY AND SECURITY 017114 - 1

SECTION 017114 - AIRPORT SAFETY AND SECURITY

PART 1 - GENERAL



1.2 SUMMARY

A. The Contractor shall be required to carry out his operations in a manner that will cause a minimum of interference with aircraft traffic, and shall be required to cooperate with the FAA, the Authority, the airlines, and other contractors working in the area. All work shall be completed in accordance with the General Requirements and Technical Specifications, the Construction Phasing Plans, and the MWAA Construction Safety Manual, latest edition.

B. The Contractor shall be required to supply medium and low level barricades with red lights, safety area markers with omnidirectional yellow flashers.

C. The Contractor shall be required to supply, place, maintain, move and store the items listed herein, as appropriate, to facilitate construction and protect air traffic. Keep on site an adequate extra supply of these items.

PART 2 - MATERIAL

2.1 OMNIDIRECTIONAL YELLOW WARNING LIGHTS

A. Yellow warning lights for the safety area markers shall be flashing yellow lights meeting the requirements of the “Manual on Uniform Traffic Control Devices for Streets and Highways” for Type A and Type B flashers.

2.2 SAFETY AREA MARKERS

A. Warning markers shall be of the type and size detailed on the plans. Markers shall be equipped with a yellow warning light per paragraph 2.1.

2.3 LOW AND MEDIUM LEVEL BARRICADES

A. Low level barricades shall be the Airport Runway Safety Barricade Model AR-2 Multi-Barrier, as manufactured by Off The Wall Products, LLC, or approved equal. The AR-2 low level barricade sections shall be 8 feet long and 10 inches high. Sections shall be interlocking and shall be ballasted to prevent damage from jet blast. Each barricade



section shall be equipped with a Model: SL-H867R red lens safety light, as manufactured by Leotek Electronics USA Corp., or approved equal. At the completion of the Contract, the barricades shall become the property of the Contractor and shall be removed from the site.

B. Medium level barricades shall be the Airport Runway Safety Barricade Model AR-1 Multi-Barrier, as manufactured by Off The Wall Products, LLC, or approved equal. The AR-1 medium level barricade sections shall be 8 feet long and 2 feet high. Sections shall be interlocking and shall be ballasted to prevent damage from jet blast. Each barricade section shall be equipped with a Model: SL-H867R red lens safety light, as manufactured by Leotek Electronics USA Corp., or approved equal. At the completion of the Contract, the barricades shall become the property of the Contractor and shall be removed from the site.

2.4 VACUUM SWEEPER

A. Vacuum Sweeper shall be Tymco, Model HSP-600 or Elgin Model crosswind, or approved equal.

PART 3 - EXECUTION

3.1 CONTROL REQUIREMENTS

A. The Contractor’s responsibilities for work areas are as follows:

(1) The Contractor shall be held responsible for controlling his employees, subcontractors, and their employees with regard to traffic movement.

(2) The Contractor shall rebuild, repair, restore, and make good at his own expense all damages to any portion of the work occasioned by his use of these facilities before completion and acceptance of his work.

(3) The Contractor shall submit to the COTR in writing a detailed work plan for each construction phase. The work plan shall include, but not be limited to, installation sequence of traffic control items and installation sequence. This plan shall be submitted 14 calendar days prior to the start of each construction phase. No work within the construction phase may commence until the phase work plan is approved.

(4) The Contractor shall submit to the COTR in writing a plan, by construction phase, for controlling construction equipment and vehicular movements in the Air Operations Area (AOA). This plan shall be submitted at the Pre-Construction Meeting. No work may commence until this plan is approved. The Plan must include material haul roads.

(5) The Contractor shall provide a responsible Traffic Manager whose duty shall be to direct all traffic on or near active taxilanes, taxiways and haul roads. Paved surfaces shall be kept clean at all times and specifically must be kept free from all debris that might damage aircraft.



(6) The Contractor shall prepare a security badge control plan for review by the COTR. The plan shall be submitted prior to or at the Pre-Construction Meeting. No work may commence until this plan is approved. The plan shall be prepared on the Contractor’s company letterhead and signed by the company representative who is authorized to sign the badge applications. The plan shall describe in detail the Contractor’s and/or subcontractor’s plan to control badges.

3.2 VEHICLE AND PEDESTRIAN CONTROL

A. Vehicle and access routes for airport construction shall be controlled as necessary to prevent inadvertent or unauthorized entry of persons, vehicles or animals onto air operations areas (AOA). No vehicle shall enter the air operations area except at predetermined locations. The single point of entry to the AOA for this project will be as directed by the Authority.. The amount of construction traffic may require that a security guard be present at the access point at all times during construction activity..

B. The use of any other gate for access to the AOA must be approved in writing by the COTR prior to its use as an entry point. The use of alternative gates for AOA access will require all the elements described in Paragraph 2.6.

C. Contractor personnel who operate vehicles in the AOA shall comply with the airport operator’s rules and regulations for vehicle marking, lighting, and operation. Failure to comply with these requirements may result in fines.

3.3 CONTROL AND WARNING DEVICES

A. During construction operations near active taxiways or runways the Contractor shall furnish and maintain medium and low level barricades, as shown on the plans or as directed by the COTR. The Contractor shall place and maintain safety area markers with yellow warning lights along the edges of the taxiway safety area, as designated and detailed on the plans. The Contractor shall place and maintain safety area markers with yellow warning lights around all equipment, stockpiles, or other areas as directed by the COTR.

B. The Contractor will be required to have an additional twenty (20) low level barricades on site at all times to be used at the discretion of the COTR.

C. The Contractor shall have a designated person on call 24 hours a day for emergency maintenance of airport barricades and warning devices.

D. All airport barricades and warning devices shall be removed from the site upon completion of the project and shall become the property of the Contractor.

3.4 VEHICLE MARKING AND IDENTIFICATION

A. Any vehicle operating in the AOA shall be equipped with a flashing yellow dome-type light, mounted on top of the vehicle and of such intensity to conform to local codes for maintenance and emergency vehicles. All vehicles operating within the airfield boundary



shall be identified with a sign on each side of the vehicle bearing the Contractor's name with an 8-inch minimum letter height.

B. Vehicles making only occasional visits to the job site are exempt from the identification requirements contained above, provided that a properly identified vehicle escorts them into, through, and out of the AOA. These and other vehicles needing intermittent identification may be marked with tape or with magnetically attached markers that are commercially available.

3.5 VEHICLE TRAFFIC AND OPERATIONS

A. When any vehicle other than those approved for use in the AOA is required to travel to or from the work area or over any portion of the work area, it shall be escorted by a vehicle properly identified to operate in the area. All construction vehicles/equipment shall have automatic signaling devices to sound an alarm when moving in reverse. All equipment shall be operated within the approved speed limit(s).

3.6 EMERGENCY CONTACT PERSONNEL

A. The Contractor shall provide the phone numbers of three (3) personnel, including the project superintendent, who may be contacted in an emergency. Personnel shall be on call 24 hours per day for maintaining construction hazard lighting and barricades.

3.7 RADIO COMMUNICATIONS

A. The control of vehicular activity on the AOA is of the highest importance and requires coordination with the airport users and the Air Traffic Control Tower (ATCT). The Contractor shall have no direct contact with ATCT Ground Control. All communications with ATCT shall be coordinated through the COTR. However, the Contractor shall properly train his/her personnel, particularly flagpersons, on the proper procedures for monitoring radio frequencies.

B. All vehicles and/or construction equipment operating inside the active AOA, but outside of the designated haul roads, shall be escorted by an approved escort who will maintain radio contact with the ATCT. Crossing the active runway shall not be permitted. Aircraft always have the right-of-way and construction equipment must always yield to aircraft.

3.8 AIRPORT SECURITY REQUIREMENTS

A. The airport is operated in strict compliance with Federal Aviation Regulation – Part 107, which prohibits unauthorized persons or vehicles in the Air Operations Area. Equipment and personnel will be restricted to the work area defined on the plans. Any violations by Contractor’s personnel will subject the Contractor to penalties imposed by the FAA and the Authority’s Airport Security Office.



B. The Contractor shall maintain the security integrity on theAOA. All barrier designs and their phasing shall be submitted to the COTR and approved in writing prior to erection.

C. All construction personnel assigned to the project, except for escorted in-transit material suppliers, shall make application for and wear personnel security badges. All construction vehicles routinely entering the AOA shall be required to obtain a vehicle security badge. The prime contractor and each subcontractor can make application for these items. The Contractor shall be responsible for assuring that all of his employees have background checks performed in accordance with IAD security badging procedures. In addition, finger printing will also be required. Photo identification badges will be made for each employee. A fee, as established by IAD security and badging office, is required for federal fingerprinting and an additional fee is required for each personnel badge. Badges must be surrendered upon termination of the employee or contract, at which time a refund will be granted for each badge returned.

D. All Contractor’s employees who are designated to have unescorted access to any area on the airport for security reasons shall have an employment history check in accordance with IAD security badging procedures. Each employee background check requires the following:

(1) Employee completes an employment history form and submits form to the Contractor/Employer. History must explain any gaps in employment of more than 12 months. Employer is responsible for documenting and verifying the employment history and maintaining the information in a file (may use a company form, or 10-year employment history form).

(2) Employee is required to complete a “Disqualifying Crimes List” Form. All questions must be answered “yes” or “no”. Applicants may be subject to a criminal history records check and fingerprinting. Completed form must be submitted to the Security Badging office along with the employee’s Security Badge Application Form (form available in Security Badging Office).

(3) Badging applicant must submit two (2) forms of current identification, at least one (1) of which must bear the individual’s photograph.

(4) Company official/officials listed on the company application for Air Operations Area Access must sign each individual employee badge application form stating company is in compliance with the 10-year history verification, and state why the individual badge is required.

E. The Contractor shall maintain an up-to-date record of all badge holders showing name, address, sex, height, weight, eye color and badge number. The Contractor will be required to furnish this information to the Airport upon request.

F. The Contractor shall restrict passage into the Security Area to badged persons, vehicles and equipment displaying their identification or that of the Airport. Should the Contractor wish to allow visitors, vendors or delivery through his access point, he shall provide for the following:

(1) A method, acceptable to the COTR, of temporarily placing the Contractor’s identification on each person or vehicle. (An acceptable alternate will be to provide an escort for each person or vehicle).



(2) Each person or vehicle entering the Security Area displaying the Contractor’s identification or under its escort shall carry the full coverage of its liability and property damage.

G. The Contractor is required to submit a plan on how he/she will safely operate within the AOA. This plan shall be submitted and approved by the COTR before the commencement of any construction activity.

3.9 SAFETY REQUIREMENTS

A. Before entering upon or crossing any active airfield pavements, the Contractor shall receive proper clearance. Emergencies and airfield operating conditions may necessitate sudden changes, both in Airport operations and in the operations of the Contractor. Aircraft operations shall always have priority over any and all of the Contractor’s operations. Should taxilanesor taxiways be required for the use of aircraft and should Airport operations, the ATCT, or the COTR deem the Contractor to be too close to active taxilanes or taxiways the Contractor shall suspend its operations, remove its personnel, plant, equipment, and materials to a safe distance and stand by until the runways and taxiways are no longer required for use by aircraft. There will be no compensation for delays or inefficiencies resulting from such actions.

B. Throughout the duration of the job, any practice or situation that the COTR determines to be unsafe or a hindrance to regular Airport operations shall be immediately rectified.

C. The standard terms defined below pertain to airfield safety requirements and are referenced throughout the Contract Documents:

(1) Object Free Area (OFA) – An area on the ground centered on a taxiway, or taxilane centerline provided to enhance the safety of aircraft operations by having the area free of objects, except for objects that need to be located in the OFA for air navigation or aircraft ground maneuvering purposes.

(2) Taxiway Safety Area (TSA) – A defined surface alongside the taxiway prepared or suitable for reducing the risk of damage to an airplane unintentionally departing the taxiway. If additional information is desired, it can be obtained from the FAA website at www.faa.gov.circind.htm.

D. The Contractor shall acquaint his supervisors and employees with the airport and operations that are inherent to Washington Dulles International Airport and shall conduct his/her construction activities to conform to all routine and emergency air traffic requirements and guidelines for safety specified herein. The Contractor shall be responsible for providing all safety devices as required for the protection of his personnel.

E. Protection of all persons shall be provided throughout the progress of the work. The work shall proceed in such a manner as to provide safe conditions for all workers and personnel. The sequence of operations shall be such that maximum protection is afforded to ensure that personnel and workers in the work area are not subject to any dangerous conditions. The Contractor must provide safety measures to guard against injury.



F. During the performance of this contract, the airport facility shall remain in use to the maximum extent possible. Use of areas near the Contractor's work will be controlled to minimize disturbance to the Airport's operation. The contractor shall not allow employees, subcontractors, suppliers, or any other unauthorized persons to enter or remain in any airport area that would be hazardous to persons.

G. All work to be performed that is too close to an active taxilane or taxiway under operational conditions shall be performed when the taxilane or taxiway is not in use. Such work shall not be accomplished without prior permission from the COTR. Requested closings shall be directed to the COTR in writing at least 72 hours in advance. The COTR will then notify the Airport of the upcoming closure.

H. The Contractor shall be aware of the following types of safety problems and/or hazards. These problems or hazards shall not be permitted. Should any of these problems or hazards arise during construction, the Contractor shall immediately rectify/correct the problem or hazard to the satisfaction of the COTR and Operations Personnel:

(1) Trenches, holes, or excavations on or adjacent to any safety areas.

(2) Unmarked/unlighted holes or excavation in any open taxilane open taxiway, or

related safety area.

(3) Mounds or piles of earth, construction materials, temporary structures, or other objects in the vicinity of any open taxilane, open taxiway, or related safety area.

(4) Vehicles or equipment (whether operating or idle) on any open taxilane, open

taxiway, or related safety area. (5) Vehicles, equipment, excavations, stockpiles, or other materials which could

degrade or otherwise interfere with electronic signals from radios or electronic navigational aids (NAVAIDS).

(6) Unmarked utility, NAVAID, weather service, runway lighting, or other power or signal cables that could be damaged during construction.

(7) Objects (whether or not marked or flagged) or activities anywhere on or in the

vicinity of the airport which could be distracting, confusing, or alarming to pilots during aircraft operations.

(8) Unflagged/unlighted low visibility items (such as tall cranes, drills, and the like)

anywhere in the vicinity of active taxiways or taxilanes.

(9) Inadequate, confusing or misleading (to user pilots) marking/lighting of runways or taxiways.

(10) Water, dirt, debris, or other transient accumulation which temporarily obscures

pavement marking, pavement edges, or derogates visibility of taxiway/taxilane marking or lighting.



(11) Inadequate or improper methods of marking, barricading, and lighting of

temporarily closed portions of airport operations area.

(12) Trash or other materials with foreign object damage (FOD) potential, whether on taxilanes, taxiways, or in related safety areas.

(16) Inadequate barricading or other marking which is placed to separate construction

or maintenance areas from open aircraft operating areas. (17) Failure to control vehicle and human access to open aircraft operating areas.

(18) Failure to maintain radio communication between construction/maintenance

vehicles and ATCT.

(19) Construction/maintenance activities or materials which could hamper the response of aircraft rescue and firefighting (ARFF) equipment from reaching all aircraft or any part of the runway/taxiway system, runway approach and departure areas, and aircraft parking locations.

(20) Bird attractants on airport, such as edibles (food scraps, etc.), miscellaneous

trash, or ponded water.

I. The Contractor shall conduct activities so as not to violate any safety standards contained herein. The Contractor shall inspect all construction and storage areas as often as necessary and promptly take all steps needed to prevent/remedy any unsafe or potentially unsafe conditions/activities discovered.

J. Before actual commencement of construction activity, the Contractor shall notify in writing, at least 72 hours in advance, the COTR of his intentions to begin construction, stating the proposed time, date, and area in which commencement is to occur in order for the appropriate Notice-to-Airmen (NOTAM) to be issued. Upon completion of work and return of all related areas to standard conditions, the Contractor shall again notify the COTR in writing, and describe the area that is complete and available for normal airport operations.

K. Debris. Debris, waste and loose material or any other FOD (including dust and dirt) capable of causing damage to aircraft landing gear, propellers or being ingested in jet engines shall not be allowed on active aircraft movement areas or adjacent infield areas. Materials observed to be within these areas shall be removed immediately and/or continuously by the Contractor. The Contractor shall be required to have a minimum of two (2) sweeping machines and operators on site and operating continuously at all times during construction activity. Where travel on or across runways or taxiways is required, the Contractor shall provide adequate personnel and equipment to keep such surfaces clear of debris at the discretion of the COTR. Closed pavements shall be swept clean prior to reopening to aircraft traffic. Exposed earth in excavation areas within 75 feet of the centerline immediately adjacent to active taxiways shall be covered to prevent dust from jet blast. Cover material shall be weighted to prevent movement from jet blast.



L. Flaggers. In accordance with the specifications, the Contractor shall furnish, at his own expense, flaggers as necessary to control his traffic unless otherwise directed by the COTR.

M. Trenches, Excavations and Stockpiled Material. Open trenches or excavations exceeding 3 inches in depth and 3 inches in width or stockpiled material will not be permitted within the limits of restricted areas of operational taxilanes or taxiways. Covering for open trenches or excavations shall be of sufficient strength to support the weight of the heaviest aircraft operating on the taxilane or taxiway.

N. Equipment Height Restrictions. Maximum equipment height requirements are indicated on the Construction Phasing Plans and shall not be exceeded unless prior written approval is obtained from the COTR. Atop all equipment booms shall be mounted the white and orange checkered flag described in Paragraph 3.4. The top 10 feet of these booms shall be painted fluorescent orange and they shall be equipped with a red obstruction light. Any crane erections shall be coordinated with IAD Operations and the COTR during every shift.

O. Miscellaneous. (1) Open flame, welding, or torch cutting operations are prohibited unless adequate

fire and safety precautions have been taken and the procedure has been approved by the COTR. Under no circumstances will flare pots be permitted near aircraft turning areas.

(2) All materials and equipment when not in use shall be placed in approved staging

areas where they will not constitute a hazard to aircraft operations and not penetrate clearance height restrictions as discussed on the Construction Phasing Plan(s).

(3) The Contractor shall provide the COTR with a current list of all employees

working on the project. The list shall be maintained current by the Contractor and Subcontractors.

(4) Except for emergencies, all contact with airport personnel shall be made through

the COTR. For emergencies involving safety (injuries, fires, security breaches, etc.), the Contractor shall make direct contact with IAD Airport Operations, followed by notification to the COTR as soon as possible.

3.10 CLOSED TAXILANE AND TAXIWAY MARKING AND LIGHTING

A. Closed taxilane and taxiway markings shall be as shown on the plans. Closed taxilane and taxiway marking and lighting materials shall be approved for use by the COTR prior to placement. Construction activities shall not begin until the layout of such marking and lighting has been approved by the COTR.



3.11 CONSTRUCTION NEAR NAVIGATIONAL AIDS

A. Construction materials and equipment shall not be placed or parked where they may interfere with the line-of-sight of the ATCT and navigational aids in operation. The COTR shall determine if any materials or equipment will cause any type of interference.

3.12 CONSTRUCTION SITE ACCESS AND HAUL ROADS

A. The Contractor will not be permitted to use any access or haul roads other than those designated on the contract drawings. The Contractor should submit specific proposed ingress and egress routes associated with specific construction activities to the COTR for evaluation and approval prior to commencing construction activities. Aircraft Rescue and Firefighting (ARFF) right-of-way on access roads, haul roads, taxiways, and runways shall not be impeded at any time.

3.13 CONSTRUCTION MATERIALS STOCKPILING AND EQUIPMENT STORAGE

A. Stockpiling of construction materials and equipment storage is not permitted within 160 feet of the taxiway centerline. The COTR should ensure that stockpiled construction materials and equipment do not cause degraded or hazardous conditions to airport operational safety. This includes determining and verifying that stockpiled materials and equipment are stored or parked at an approved location, that they are properly stowed to prevent foreign object debris (FOD), attraction by wildlife, or obstruction of air operations, either by their proximity to NAVAIDs or to aircraft movement areas.

3.14 WORK SCHEDULING AND ACCOMPLISHMENT

A. The Contractor shall contact the COTR each day before beginning work to coordinate the status and nature of work to be done that day. The Contractor shall also report to the COTR at the end of each day to schedule the work planned for the following day.

3.15 VIOLATION OF RESPONSIBILITIES

A. Any violation of paragraphs 3.1 through 3.10 shall be considered a violation of the Contract itself and shall be sufficient cause for halting the work without extending the time limit of the contract.


A. All items specified in this section will be measured as one (1) lump sum.



PART 5 - PAYMENT

A. Airport safety and security shall be paid for at the contract lump sum price in accordance with the following schedule of partial payments. This price shall constitute full compensation for furnishing all materials and equipment, including but not limited to security checkpoint items, medium and low level barricades, safety area markers, other traffic control devices and necessary equipment, safety area support material, and other materials and equipment listed herein, and the maintenance thereof and all other labor, materials, equipment, tools and incidentals necessary to accomplish this item.

(1) Thirty percent (30) of the contract lump sum amount proposed for Airport Safety

and Security will be released to the Contractor with the first estimate payable, but not sooner than 15 days after the start of work at the project site.

(2) An additional 15 percent of the contract lump sum amount proposed for Airport

Safety and Security will be released on a monthly basis up to 90 percent of the total lump sum amount proposed for Airport Safety and Security.

(3) The remaining 10 percent of the lump sum amount proposed for Airport Safety

and Security will be released upon completion of all airfield work.


Item 017114-5.1 Airport Safety and Security -- per lump sum




EXECUTION 017300 - 1

SECTION 017300 - EXECUTION

PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes general procedural requirements governing execution of the Work including, but not limited to, the following:

1. Construction layout.

2. Field engineering and surveying.

3. General installation of products.

4. Progress cleaning.

5. Starting and adjusting.

6. Protection of installed construction.

7. Correction of the Work.


1. Division 01 Section "Project Management and Coordination" for procedures for coordinating field engineering with other construction activities.

1.3 SUBMITTALS

A. Qualification Data: Submit qualification data for land surveyors.

B. Certificates: Submit certificate signed and sealed by land surveyor certifying that location and elevation of improvements comply with requirements.

C. Certified Surveys: Submit 2 copies signed and sealed by land surveyor.

D. Project Record Documents: Submit a record of Work performed (materials tests, inspections, acceptance tests, etc.) and record survey data as required under provisions in Division 01 Sections "Submittals" and "Project Closeout."




A. Land Surveyor Qualifications: A professional land surveyor who is legally qualified to practice in the Commonwealth of Virginia and who is experienced in providing land-surveying services of the kind indicated.


PART 3 - EXECUTION

3.1 EXAMINATION

A. Existing Conditions: The existence and location of site improvements, utilities, and other construction indicated as existing are not guaranteed. Before beginning work, investigate and verify the existence and location of mechanical and electrical systems and other construction affecting the Work, including all site utility systems.

1. Before construction, verify the location and points of connection of utility services.

B. Existing Utilities: The existence and location of underground and other utilities and construction indicated as existing are not guaranteed. Before beginning site work, investigate and verify the existence and location of underground utilities and other construction affecting the Work.

1. Before construction, verify the location and invert elevation at points of connection of sanitary sewer, storm sewer, and water-service piping; and underground electrical and communication services.

2. For additional requirements for locating and marking existing utilities, see Division 01 Section "Summary."

3.2 PREPARATION

A. Existing Utility Information: Furnish information to COTR that is necessary to adjust, move, or relocate existing utility structures, utility poles, lines, services, or other utility appurtenances located in or affected by construction.

B. Field Measurements: Take field measurements as required to fit the Work properly. Recheck measurements before installing each product. Where portions of the Work are indicated to fit to other construction, verify dimensions of other construction by field measurements before fabrication. Coordinate fabrication schedule with construction progress to avoid delaying the Work.

C. Space Requirements: Verify space requirements and dimensions of items shown diagrammatically on Drawings.

D. Review of Contract Documents and Field Conditions: Immediately on discovery of the need for clarification of the Contract Documents, submit a request for information (RFI) to COTR.



Include a detailed description of problem encountered, together with recommendations for changing the Contract Documents.

3.3 CONSTRUCTION LAYOUT

A. Verification: Before proceeding to lay out the Work, verify layout information shown on Drawings, in relation to the property survey and existing benchmarks. If discrepancies are discovered, notify COTR promptly.

B. General: Engage a land surveyor to layout the Work using accepted surveying practices.

1. Establish benchmarks and control points to set lines and levels at each story of construction and elsewhere as needed to locate each element of Project.

2. Establish dimensions within tolerances indicated. Do not scale Drawings to obtain required dimensions.

3. Inform installers of lines and levels to which they must comply.

4. Check the location, level and plumb, of every major element as the Work progresses.

5. Notify COTR when deviations from required lines and levels exceed allowable tolerances.

6. Close site surveys with an error of closure equal to or less than one inch in 10,000 feet.

C. Site Improvements: Locate and lay out site improvements, including pavements, grading, fill and topsoil placement, utility slopes, and invert elevations.

D. Record Log: Maintain a log of layout control work. Record deviations from required lines and levels. Include beginning and ending dates and times of surveys, weather conditions, name and duty of each survey party member, and types of instruments and tapes used. Make the log available for reference by COTR.

3.4 FIELD ENGINEERING

A. Identification: Existing control points and property line corner stakes are as identified on the Contract Documents.

B. Reference Points: Locate existing permanent benchmarks, control points, and similar reference points before beginning the Work. Preserve and protect permanent benchmarks and control points during construction operations.

1. Do not change or relocate existing benchmarks or control points without prior written approval of COTR. Report lost or destroyed permanent benchmarks or control points promptly. Report the need to relocate permanent benchmarks or control points to COTR before proceeding.

2. Replace lost or destroyed permanent benchmarks and control points promptly with the approval of COTR. Base replacements on the original survey control points.



C. Benchmarks: Establish and maintain a minimum of two permanent benchmarks on Project site, referenced to data established by survey control points. Comply with the Authority for type and size of benchmark.

1. Record benchmark locations, with horizontal and vertical data, on Project Record Documents.

2. Where the actual location or elevation of layout points cannot be marked, provide temporary reference points sufficient to locate the Work.

3. Remove temporary reference points when no longer needed. Restore marked construction to its original condition.

D. Certified Survey: On completion of foundation walls, major site improvements, and other work requiring field-engineering services, including utilities, prepare a certified survey showing coordinates, dimensions, locations, angles, and elevations of construction and site work. Coordinates shall be ACS and elevations shall be NGVD 29.

3.5 PROGRESS CLEANING

A. General: Clean Project site and work areas daily, including common areas. Coordinate progress cleaning for joint-use areas where more than one installer has worked. Enforce requirements strictly. Dispose of materials lawfully.

1. Comply with requirements in NFPA 241 for removal of combustible waste materials and debris.

2. Remove combustible debris from the site daily.

3. Do not hold materials more than 7 days during normal weather or 3 days if the temperature is expected to rise above 80 degrees F.

4. Containerize hazardous and unsanitary waste materials separately from other waste. Mark containers appropriately and dispose of legally, according to regulations.

B. Site: Maintain Project site free of waste materials and debris.

C. Work Areas: Clean areas where work is in progress to the level of cleanliness necessary for proper execution of the Work.

1. Remove liquid spills promptly.

2. Where dust would impair proper execution of the Work, broom-clean or vacuum the entire work area, as appropriate.

D. Exposed Surfaces: Clean exposed surfaces and protect as necessary to ensure freedom from damage and deterioration at time of Substantial Completion.

E. Cutting and Patching: Clean areas and spaces where cutting and patching are performed. Completely remove paint, mortar, oils, putty, and similar materials.



1. Thoroughly clean piping, conduit, and similar features before applying paint or other finishing materials. Restore damaged pipe covering to its original condition.

F. Waste Disposal: Burying or burning waste materials on-airport property will not be permitted. Washing waste materials down sewers or into waterways will not be permitted.

G. During handling and installation, clean and protect construction in progress and adjoining materials already in place. Apply protective covering where required to ensure protection from damage or deterioration at Substantial Completion.

H. Limiting Exposures: Supervise construction operations to ensure that no part of the construction completed or in progress, is subject to harmful, dangerous, damaging, or otherwise deleterious exposure during the construction period.

I. Grass Mowing: Mow grass areas contained in Project site, or made inaccessible to the Authority's mowing contractors.

3.6 STARTING AND ADJUSTING

A. Follow equipment manufacturer's startup procedures, unless otherwise directed by COTR.

B. Start equipment and operating components to confirm proper operation. Remove malfunctioning units, replace with new units, and retest.

C. Adjust operating components for proper operation without binding. Adjust equipment for proper operation.

D. Test each piece of equipment to verify proper operation. Test and adjust controls and safeties. Replace damaged and malfunctioning controls and equipment.

E. Manufacturer's Field Service: If a factory-authorized service representative is required to inspect field-assembled components and equipment installation, comply with qualification requirements in Division 01 Section "Quality Requirements."

3.7 PROTECTION OF INSTALLED CONSTRUCTION

A. Provide final protection and maintain conditions that ensure that installed Work is without damage or deterioration at time of Substantial Completion.

3.8 CORRECTION OF THE WORK

A. Repair or remove and replace defective construction. Restore damaged substrates and finishes. Comply with requirements in Division 01 Section "Cutting and Patching."

1. Repairing includes replacing defective parts, refinishing damaged surfaces, touching up with matching materials, and properly adjusting operating equipment.

B. Restore permanent facilities used during construction to their specified condition.



C. Remove and replace damaged surfaces that are exposed to view if surfaces cannot be repaired without visible evidence of repair.

D. Repair components that do not operate properly. Remove and replace operating components that cannot be repaired.



CUTTING AND PATCHING 017329 - 1

SECTION 017329 - CUTTING AND PATCHING

PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes procedural requirements for cutting and patching.

B. Related Sections include the following: 1. Divisions 02 through 33 Sections for specific requirements and limitations applicable to

cutting and patching individual parts of the Work.

1.3 DEFINITIONS

A. Cutting: Removal of in-place construction necessary to permit installation or performance of other Work.

B. Patching: Fitting and repair work required to restore surfaces to original conditions after installation of other Work.

1.4 SUBMITTALS

A. Cutting and Patching Proposal: Submit a proposal, requesting approval from COTR to proceed, describing procedures at least 10 days before the time cutting and patching will be performed,. Include the following information:

1. Extent: Describe cutting and patching, show how they will be performed, and indicate why they cannot be avoided.

2. Products: List products to be used and firms or entities that will perform the Work.

3. Dates: Indicate when cutting and patching will be performed.

4. Utility Services and Mechanical/Electrical Systems: List utilities that cutting and patching procedures will disturb or affect. List utilities that will be relocated and those that will be temporarily out of service. Indicate how long service will be disrupted. Approval for such shall be obtained from the COTR two (2) weeks before interruptions.

5. Structural Elements: Where cutting and patching involve adding reinforcement to structural elements, submit details and engineering calculations showing integration of reinforcement with original structure. When cutting and patching involves welding or



open flame cutting, obtain the approval of the Authority's Fire Marshal for such work prior to its start.

6. COTR's Approval: Obtain COTR’s approval in writing of cutting and patching proposal before cutting and patching. Approval does not waive COTR’s right to later require removal and replacement of unsatisfactory work.


A. Structural Elements: Do not cut and patch structural elements in a manner that could change their load-carrying capacity or load-deflection ratio.

B. Operational Elements: Do not cut and patch the following operating elements and related components in a manner that results in reducing their capacity to perform as intended or that results in increased maintenance or decreased operational life or safety. Obtain COTR's written approval of the cutting and patching of the following operating elements or safety related items:

1. Control systems.

2. Communication systems.

3. Electrical wiring systems.

4. Shoring, bracing, and sheeting.

C. Cutting and Patching Conference: Before proceeding, meet at Project site with parties involved in cutting and patching, including mechanical and electrical trades. Review areas of potential interference and conflict. Coordinate procedures and resolve potential conflicts before proceeding.

1.6 WARRANTY

A. Existing Warranties: Remove, replace, patch, and repair materials and surfaces cut or damaged during cutting and patching operations, by methods and with materials so as not to void existing warranties.

PART 2 - PRODUCTS

2.1 MATERIALS

A. General: Comply with requirements specified in other Sections of these Specifications.

B. Existing Materials: Use materials identical to existing materials. For exposed surfaces, use materials that visually match existing adjacent surfaces to the fullest extent possible.

1. If identical materials are unavailable or cannot be used, use materials that, when installed, will match the visual and functional performance of existing materials.



PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine surfaces to be cut and patched and conditions under which cutting and patching are to be performed.

1. Compatibility: Before patching, verify compatibility with and suitability of substrates, including compatibility with existing finishes or primers.

2. Proceed with installation only after unsafe or unsatisfactory conditions have been corrected.

3.2 PREPARATION

A. Temporary Support: Provide temporary support of Work to be cut.

B. Protection: Protect existing construction during cutting and patching to prevent damage. Provide protection from adverse weather conditions for portions of Project that might be exposed during cutting and patching operations.

C. Adjoining Areas: Avoid interference with use of adjoining areas or interruption of free passage to adjoining areas.

D. Existing Utility Services and Mechanical/Electrical Systems: Where existing services/systems are required to be removed, relocated, or abandoned; bypass such services/systems before cutting to prevent interruption to occupied areas.

3.3 PERFORMANCE

A. General: Employ skilled workers to perform cutting and patching. Proceed with cutting and patching at the earliest feasible time, and complete without delay.

1. Cut existing construction to provide for installation of other components or performance of other construction, and subsequently patch as required to restore surfaces to their original condition.

B. Cutting: Cut existing construction by sawing, drilling, breaking, chipping, grinding, and similar operations, including excavation, using methods least likely to damage elements retained or adjoining construction. If possible, review proposed procedures with original Installer; comply with original Installer's written recommendations.

1. In general, use hand or small power tools designed for sawing and grinding, not hammering and chopping. Cut holes and slots as small as possible, neatly to size required, and with minimum disturbance of adjacent surfaces. Temporarily cover openings when not in use.

2. Concrete: Cut using a cutting machine, such as an abrasive saw or a diamond-core drill.



3. Excavating and Backfilling: Should excavating and backfilling be required by cutting and patching operations comply with requirements in applicable Division 31 Sections.

4. Mechanical and Electrical Services: Cut off pipe or conduit in walls or partitions to be removed. Cap, valve, or plug and seal remaining portion of pipe or conduit to prevent entrance of moisture or other foreign matter after cutting. Remove conductors back to source of supply.

5. Proceed with patching after construction operations requiring cutting are complete.

C. Patching: Patch construction by filling, repairing, refinishing, closing up, and similar operations following performance of other Work. Patch with durable seams that are as invisible as possible. Provide materials and comply with installation requirements specified in other Sections of these Specifications.

1. Inspection: Where feasible, test and inspect patched areas after completion to demonstrate integrity of installation.

2. Exposed Finishes: Restore exposed finishes of patched areas and extend finish restoration into retained adjoining construction in a manner that will eliminate evidence of patching and refinishing.



PROJECT CLOSEOUT 017700-1

SECTION 017700 - PROJECT CLOSEOUT

PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes administrative and procedural requirements for Project closeout, including, but not limited to, the following:

1. Inspection procedures.

2. Warranties.

3. Final cleaning.

4. Final Acceptance


1. Division 01 Section “Quality Requirements” for final requirements of the Warranty Manual.

2. Division 01 Section "Photographic Documentation" for submitting Final Acceptance construction photographs and negatives.

3. Division 01 Section "Project Record Documents" for submitting Record Drawings, Record Specifications, Record Product Data, and other Record Documents.

4. Division 01 Section "Operation and Maintenance Data" for operation and maintenance manual requirements.

5. Divisions 02 through 33 Sections for specific closeout and special cleaning requirements for products of those Sections.

1.3 SUBSTANTIAL COMPLETION

A. Definition: "Substantial Completion" is the stage in the progress of the work when COTR determines that all the Work, or a designated portion thereof, is sufficiently complete and functional according to the Contract Documents so that the Authority can occupy or utilize the Work for its intended use. The only remaining physical work shall be the completion of punch list work prior to Final Acceptance.

B. Preliminary Procedures: Before requesting inspection for determining date of Substantial Completion, complete the following. List items below that are incomplete in request.



1. Prepare a list of items to be completed and corrected (punch list), the value of items on the list, reasons why the Work is not complete, and a schedule for completing punch list work according to Section III of the Contract.

2. Ensure previously outstanding technical submittals and Shop Drawings have been submitted and approved.

3. Advise COTR of pending insurance changeover requirements.

4. Submit warranties required by Contract Documents, workmanship bonds, maintenance service agreements, final certifications, and similar documents.

a. Submit Contractor Warranty Letter, for review and approval, a minimum of 60 days before requesting inspection for determining date of Substantial Completion. After date of Substantial Completion has been determined revise the Contractor’s Warranty Letter to include that date as start of Warranty period.

5. Obtain and submit releases permitting the Authority unrestricted use of the Work and access to services and utilities. Include occupancy permits, operating certificates, and similar releases.

6. Prepare and submit Project Record Documents except Record Contract CPM Schedule; also prepare and submit Operation and Maintenance manuals, Final Completion construction photographs and photographic negatives, damage or settlement surveys, and similar final record information.

7. Prepare and submit proof that specified testing and code inspections have been completed, accepted and certified, including, but not limited to, structural work, sprinkler piping systems, fire alarm and FPS systems, bacteriological testing of domestic lines, back-flow prevention, electrical system testing, and hydrostatic pressure testing of sanitary lines. Submit approvals of Health Department or the FDA as applicable.

8. Deliver tools, spare parts, extra materials, and similar items to location designated by COTR. Label with manufacturer's name and model number where applicable.

9. Make final changeover of permanent locks and deliver keys to COTR. Advise the Authority's personnel of changeover in security provisions.

10. Complete startup testing of systems.

11. Submit test/adjust/balance records.

12. Terminate and remove temporary facilities from Project site, along with mockups, construction tools, and similar elements.

13. Advise the Authority of changeover in utilities.

14. Submit changeover information related to the Authority's occupancy, use, operation, and maintenance.

15. Instruct the Authority's personnel in operation, adjustment, and maintenance of products, equipment, and systems, as required by Division 01 Section "Demonstration and Training

16. Complete final cleaning requirements, including touchup painting.

17. Touch up and otherwise repair and restore marred exposed finishes to eliminate visual defects.



C. Inspection: Submit a written request for inspection for Substantial Completion. On receipt of request, COTR will either proceed with inspection or notify Contractor of unfulfilled requirements. COTR will prepare the Certificate of Substantial Completion after inspection or will notify Contractor of items, either on Contractor's list or additional items identified by COTR, that must be completed or corrected before certificate will be issued.

1. Re-inspection: Request re-inspection when the Work identified in previous inspections as incomplete is completed or corrected.

2. Punch list work must be completed within the duration specified in Section III, "Schedule." Failure to complete the punch list work within the duration specified may result in the Contracting Officer ordering the work to be completed by others at the cost to Contractor.

3. Results of completed inspection will form the basis of requirements for Final Acceptance.

1.4 FINAL COMPLETION AND ACCEPTANCE

A. Definition: "Final Completion" is the stage in the Contract when the Contracting Officer determines that all Work has been 100 percent completed according to the terms and conditions of the Contract Documents, including administrative obligations. The date of Final Acceptance is the date of execution by the Contracting Officer of a Certificate of Final Acceptance.

B. Preliminary Procedures: Before requesting final inspection for determining date of Final Completion, complete the following:

1. Submit a final Application for Payment according to Division 01 Section "Application for Payment."

2. Submit certified copy of COTR's Substantial Completion inspection list of items to be completed or corrected (punch list), endorsed and dated by COTR. The certified copy of the list shall state that each item has been completed or otherwise resolved for acceptance.

3. Submit a Contractor/COTR joint statement evidencing that all Record Documents, Operation and Maintenance Manuals, warranties, and similar required submittals have been approved.

4. Complete demobilization and removal of temporary facilities from the site including construction equipment and facilities, mockups, and other similar elements. Restore areas to previously existing condition, if applicable.

5. Execute final Contract Modification and submit final Subcontractor Payment Form.

6. Return all AOA badging and all Authority IDs.

7. Submit evidence of final, continuing insurance coverage complying with insurance requirements.

8. Submit Record Contract CPM Schedule.

9. Submit warranty book.

C. Inspection: Submit a written request for final inspection for acceptance. On receipt of request, COTR will either proceed with inspection or notify Contractor of unfulfilled requirements.



COTR will prepare a final Certificate for Payment after inspection or will notify Contractor of construction that must be completed or corrected before certificate will be issued.

1. Re-inspection: Request re-inspection when the Work identified in previous inspections as incomplete is completed or corrected.

1.5 LIST OF INCOMPLETE ITEMS (PUNCH LIST)

A. Preparation: Submit four (4) copies of list. Include name and identification of each space and area affected by construction operations for incomplete items and items needing correction including, if necessary, areas disturbed by Contractor that are outside the limits of construction.

1. Include the following information at the top of each page:

a. Contract name and number.

b. Date.

c. Name of COTR.

d. Name of Architect/Engineer.


f. Page number.

1.6 WARRANTIES

A. Submittal Time: Submit one (1) draft copy of proposed Warranty Manual Specified below within 90 days of Notice to Proceed. COTR will return comments to the Contractor no later than 30 calendar days after receipt.

1. Provide Manufacturer’s Standard Warranties, made out to the Authority, and statement of willingness to provide any applicable Special Warranties required by the Contract Documents 14 calendar days prior to shipping of materials and equipment. Products and Equipment shall not be considered delivered (for payment purposes) until the approved warranties have been received.

2. Submit written warranties on request of COTR for designated portions of the Work where commencement of warranties other than date of Substantial Completion is indicated.

B. Partial Occupancy: Submit properly executed warranties within 15 days of completion of designated portions of the Work that are completed and occupied or used by the Authority during construction period by separate agreement with Contractor.

C. Warranty Manual: Organize warranty documents into an orderly sequence based on the table of contents of the Contract Specifications. Warranty documents include Contractor and major subcontractors warranty letters, special warranty documents, and manufacturer's warranties.

1. Binders: Heavy-duty, 3-ring, vinyl-covered, loose-leaf binders, in thickness necessary to accommodate contents, sized to hold 8-1/2-by-11-inch paper; with clear plastic sleeve on spine to hold label describing contents. Binders shall not be filled beyond 75 percent



of their rated capacity. Binders shall also have boomerang plastic sheet lifters, metal backbone, concealed rivet construction, and three-trigger position locking mechanism (lock, unlock, open) on top and bottom. Binder color shall be black unless another color is selected by COTR.

a. Provide maximum 3-inch binder thickness.

b. Identify each binder on front and spine, with printed title "PROJECT WARRANTIES," Contract number and name, and subject matter of contents. If identification cannot be attached to the front include it as the first page in the manual. Indicate volume number for multiple-volume sets. The use of business labels is prohibited.

2. Dividers: Provide three-hole, heavyweight, plastic tabbed dividers, (, or as approved by the Authority) for each separate section. Provide laser printed description for each tabbed section on the front and back of tabs. Tabs shall indicate the appropriate Specification Section. Provide a description of the warranty or heading for sub tabs using the same laser printed format on the dividers. Provide an index of the contents in each section on the first page behind each section divider. The index shall be generated using a word processor and printed on a laser printer. Include a matching master table of contents for each volume using the same indexing system. Install a colored sheet between each different warranty within a tabbed section.

D. Provide additional copies of each warranty that shall be included in Operation and Maintenance Manuals.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Cleaning Agents: For final cleaning, use cleaning materials and agents recommended by manufacturer or fabricator of the surface to be cleaned. Do not use cleaning agents that are potentially hazardous to health or property or that might damage finished surfaces.

PART 3 - EXECUTION

3.1 FINAL CLEANING

A. General: Provide final cleaning. Conduct cleaning and waste-removal operations to comply with Authority requirements, local laws and ordinances and Federal and local environmental and antipollution regulations. General cleaning during construction is included in Division 01 Section "Execution."

B. Cleaning: Employ experienced workers or professional cleaners for final cleaning. Clean each surface or unit to condition expected in an average commercial building cleaning and maintenance program. Comply with manufacturer's written instructions.



1. Complete the following cleaning operations before requesting inspection for certification of Substantial Completion for entire Project or for a portion of Project:

a. Clean Project site, yard, and grounds, in areas disturbed by construction activities, including landscape development areas, of rubbish, waste material, litter, and other foreign substances.

b. Sweep paved areas broom clean. Remove petrochemical spills, stains, and other foreign deposits.

c. Rake grounds that are neither planted nor paved to a smooth, even-textured surface.

d. Remove tools, construction equipment, machinery, and surplus material from Project site.

e. Leave Project clean and ready for occupancy.

C. Comply with safety standards for cleaning. Do not burn waste materials. Do not bury debris or excess materials on the Authority's property. Do not discharge volatile, harmful, or dangerous materials into drainage systems. Remove waste materials from Project site and dispose of lawfully.

1. Where extra materials of value remaining after completion of associated Work have become the Authority's property, arrange for disposition of these materials as directed by COTR.



OPERATION AND MAINTENANCE DATA 017823-1

SECTION 017823 - OPERATION AND MAINTENANCE DATA

PART 1 - GENERAL



1.2 SUMMARY

A. This Section includes administrative and procedural requirements for preparing operation and maintenance manuals, including the following:

1. Operation and Maintenance Documentation Directory and formatting. 2. Manuals, General and formatting 3. Emergency Information Manuals and formatting. 4. Operation Information Manuals and formatting for systems, subsystems, and equipment. 5. Maintenance Information Manuals and formatting for the care and maintenance of

products, materials, finishes, systems, and equipment.


1. Division 01 Section “Application for Payment” for values assigned to Operation and Maintenance Manuals

2. Division 01 Section “Quality Requirements” for ensuring the development and continuing update of the Operation and Maintenance Documentation Directory and Operation and Maintenance Manual.

3. Division 01 Section “Submittals” for submitting copies of submittals for operation and maintenance manuals.

4. Division 01 Section “Project Closeout” for submitting operation and maintenance manuals.

5. Division 01 Section “Project Record Documents” for preparing Record Drawings for operation and maintenance manuals.

6. Divisions 02 through 33 Sections for specific operation and maintenance manual requirements for products in those Sections.

C. For purposes of payment, O & M and Material and Finishes Manuals are to be valued at 3% of Contract.

D. Payment for materials and equipment will be withheld if complete O & M manual material is not received from the contractor at time of material or equipment delivery. Namely, instruction sheets, operation manuals, installation instructions, and other documents received from the manufacturer at the time of delivery.



1.3 DEFINITIONS

A. System: An organized collection of parts, equipment, or subsystems united by regular interaction.

B. Subsystem: A portion of a system with characteristics similar to a system.

C. Equipment: An instrument or appliance designed for a specific operation.

D. Product: Items purchased for incorporating into the Work, whether purchased for Project or taken from previously purchased stock. The term "product" includes the terms "material," "equipment," "system," and terms of similar intent.

E. Location: A defined area such as roof, room, hallway, ceiling, pavement, wall, or floor that has special maintenance requirements that are documented in the Operation and Maintenance Data.

1.4 SUBMITTALS

A. Operation and Maintenance Manual Format: Submit to COTR within 90 calendar days of Notice to Proceed one draft copy of the proposed Operation and Maintenance Manual Format. Format shall include a table of contents and be as specified in Part 2 of this Section. COTR will return comments regarding the Operation and Maintenance Manual Format and planned contents of the completed manual within 30 calendar days of receipt. Throughout the construction period of the project, Operation and Maintenance data shall be continually inserted in the appropriate sections/parts of the Manual as it is approved.

B. Operation and Maintenance Manuals Revised Submittals: Submit 4 revised copies of each manual in final form, including one CD containing electronic O & M documentation, at least 45 calendar days before substantial completion or training, whichever occurs first. COTR will return a copy with comments within 15 calendar days after receipt.

C. Operation and Maintenance Manuals Final Submittal: Correct or modify each manual to comply with COTR’s comments. Submit 6 copies of the Document Directory and each corrected manual at least 15 calendar days before substantial completion or training whichever occurs first.

1. Provide four copies of all Operation and Maintenance Data in electronic format on CD-ROM consistent with the organization and format in the “Manuals, General” section. All electronic files shall be in Adobe PDF format and limited to 10 megabytes in size per file.

1.5 COORDINATION

A. Where operation and maintenance documentation includes information on installations by more than one factory-authorized service representative, the General Contractor shall assemble and coordinate information furnished by representatives and prepare manuals.



PART 2 - PRODUCTS

2.1 OPERATION AND MAINTENANCE DOCUMENTATION DIRECTORY

A. Provide the Operation and Maintenance Documentation Directory in separate binder from operation and maintenance information. Binders, dividers and all portions of the Directory shall comply with requirements of “Manuals, General” as applicable. Size of binder for directory shall be appropriate for quantity of contents. Information in O & M Directory shall be in alphabetical order with references to contract Division and Specification Section.

B. Organization: Include a section in the directory for each of the following:

1. General Information. 2. List of systems and subsystems. 3. List of equipment. 4. List of Products 5. Table of contents.

C. General Information: Include documents that are pertinent to the project, including, but not limited to, a detailed description of the facility or project, general safety information and a users guide to the project operation and maintenance manuals.

D. List of Systems and Subsystems: List systems alphabetically. Include references to operation and maintenance manuals that contain information about each system.

E. List of Equipment: List equipment for each system, organized alphabetically by system. For pieces of equipment not part of system, list alphabetically in separate list. Include references to operation and maintenance manuals that contain information about each system.

F. List of Products: List products alphabetically to include all products not part of a system, subsystem, or component of equipment. Include references to operation and maintenance manuals that contain information about each product.

G. Tables of Contents: Include a complete table of contents for each volume of the Operation and Maintenance Manuals.

H. Identification: In the documentation directory and in each operation and maintenance manual, identify each system, subsystem, and piece of equipment and products with the same designation used by the Authority. If no designation is provided for equipment, systems, sub-systems, or equipment assign a designation according to ASHRAE Guideline 4, “Preparation of Operating and Maintenance Documentation for Building Systems.”

I. Provide a draft of the proposed “Operation and Maintenance Documentation Directory” at least 90 calendar days before requesting inspection for Substantial Completion. Submit draft to COTR for approval in writing.



2.2 MANUALS, GENERAL

A. Organization: Unless otherwise indicated, organize information by Division and then into a separate section for each system and subsystem, and a separate section for each piece of equipment not part of a system. Each manual shall contain the following in the order listed:

1. Title page. 2. Table of contents. 3. Manual contents.

B. Title Page: Enclose title page in transparent plastic sleeve. Include the following information on the title page:

1. Specific subject matter included in manual such as Division number and title, Specification Section number and title, equipment, systems and subsystems.

2. Name and number of the Contract. 3. Date of submittal. 4. Name, address, telephone number, and contact person of Contractor, Subcontractor, and

supplier. 5. Name and address of Architect/Engineer. 6. Cross-reference to related systems in other portions of the Operation and Maintenance

Manuals.

C. Table of Contents: Include a printed, printed by a laser printer, table of contents for each volume, arranged according to the specification format. List each product included in manual, identified by product name, indexed to the content of the volume, and cross-referenced to Specification Section number in the Contract Documents.

1. If operation or maintenance documentation requires more than one volume to accommodate data, include comprehensive table of contents for all volumes in each volume of the set.

D. Manual Contents: Organize into sets of manageable size. Arrange contents by Division then by system, subsystem, and equipment. If possible, assemble instructions for subsystems, equipment, and components of one system into a single binder.

1. Binders: Heavy-duty, 3-ring thermoplastic loose-leaf binders, in thickness necessary to accommodate contents, sized to hold 8-1/2-by-11-inch paper; with clear plastic sleeve on spine to hold label describing contents. Binders shall not be filled beyond 75 percent of their rated capacity. Binders shall also have boomerang plastic sheet lifters, concealed rivet construction, and three-trigger position Dublock mechanism (lock, unlock, open) on top and bottom of binders. Binder color shall be black unless another color is selected by COTR.

a. Provide maximum 3 inch binder thickness. Smaller binders are acceptable as long as 75 percent rated binder capacity is not exceeded.



b. If two or more binders are necessary to accommodate data for a system, organize data in each binder into groupings by subsystem and related components. Cross-reference other binders if necessary to provide essential information for proper operation or maintenance of equipment or system.

c. Identify each binder on front (If Identification cannot be placed on the front provide as the first page) and spine, with printed title “OPERATION AND MAINTENANCE MANUAL,” Contract number and name, and specific subject matter of contents, such as “Division 23 Heating Ventilating and Air Conditioning,” to include Specification Section. Indicate volume number for multiple-volume sets. The use of business labels is prohibited.

2. Dividers: Provide three-hole, heavyweight, plastic tabbed dividers, for each separate section. Provide laser printed description for each tab section (front and back of tabs), to indicate the appropriate Specification Section. Provide a description of the product or heading for sub tabs using the same laser printed format on the dividers.

3. Provide a typed index describing each product, equipment, and subject addressed in each section on the first page behind each section divider. Include a matching master table of contents for each volume using the same indexing system. Install a colored sheet between major topics and each different device within a tabbed section.

4. Protective Plastic Sleeves: Provide protective transparent plastic sheet protectors to enclose the Title Page, all Table of Content pages, and photographs.

a. For CD-ROMs, provide transparent plastic three-ring sleeves designed to accommodate CD-ROMs.

5. Text: Prepared on 8-1/2-by-11-inch, 20-lb/sq. ft. white bond paper. Copies of faxed materials may be rejected. Two-sided text shall be provided on 24-lb/sq. ft. white bond paper to eliminate “bleed through” of text with a minimum brightness of 96.

6. Drawings: Attach reinforced, punched binder tabs on drawings and bind with text.

a. If oversize drawings are necessary, fold drawings to same size as text pages and use as foldouts.

b. If drawings are too large to be used as foldouts, fold and place drawings in transparent envelopes and bind envelopes with text. Insert typewritten pages indicating drawing titles, descriptions of contents, in the transparent envelopes along with drawings. Drawings shall cross-reference the appropriate manual volume and Specification Section. Drawing holding envelopes are not acceptable.

c. Provide operation and maintenance material on CD-ROM.

E. Transfer Cases: Manuals shall be submitted in durable, multiple thickness fiberboard transfer boxes (legal-size boxes, 15 inches wide by 24 inches long by 10 inches high) with plastic tote handles string and button closures, reinforced poly edge, and a large labeling area that accurately describes the contents. Banker box, Fast Hold Liberty Plus P-12112 or as approved by the Authority.



2.3 OPERATION INFORMATION MANUAL

A. Content: In addition to requirements in this Section, include operation data required in individual Specification Sections and the following information. Organize manuals into separate and distinct volumes by Division.

1. Safety instruction and related issues. 2. Operating standards. 3. Operating procedures. 4. Operating logs. 5. Piped system diagrams. 6. Precautions against improper use. 7. Material Safety Data Sheets.

B. Operating Procedures: Include the following, as applicable:

1. Routine and normal operating instructions. 2. Regulation and control procedures. 3. Instructions on stopping. 4. Normal shutdown instructions. 5. Procedures or operations that may void warranty. 6. Copies of equipment warranties.

C. Piped Systems: Diagram piping as installed and color-coding shall be used where required for identification.

D. Provide a draft of the proposed Operation Information Manual. Submit draft at least 90 calendar days before requesting inspection for Substantial Completion to COTR for approval in writing.

2.4 PRODUCT MAINTENANCE INFORMATION MANUAL

A. This Section shall contain information for all products with the exception of Systems and Equipment, which shall be provided as indicated elsewhere in this Section.

B. Content: Organize information into a separate section for each product, material, and finish. Provide one section for architectural products, including applied materials and finishes, and a second for products designed for moisture protection and products exposed to the weather. Include source information, product information, maintenance procedures, repair materials and sources, schedule of products, location of products and warranties and bonds, as described below.

C. Source Information: List each product included in manual identified by product name and arranged to match manual’s table of contents. For each product, list name, address, and telephone number of Installer or supplier and maintenance service agent, and cross-reference Specification Section number and title in Project Manual.

D. Product Information: Include the following, as applicable:

1. Product name and model number.



2. Manufacturer’s name. 3. Color, pattern, and texture. 4. Material and chemical composition. 5. Reordering information for specially manufactured products. 6. Fire/flame-spread test certificates. 7. Material Safety Data Sheets.

E. Maintenance Procedures: Include manufacturer’s written recommendations and the following:

1. Inspection procedures. 2. Types of cleaning agents to be used and methods of cleaning. 3. List of cleaning agents and methods of cleaning detrimental to product. 4. Schedule for routine cleaning and maintenance. 5. Repair instructions.

F. Repair Materials and Sources: Include lists of materials and local sources of materials and related services.

G. Schedule of Products and Locations: Provide complete information, including reference drawings, in the materials and finishes manual on all products specified in Divisions 02 through 33.

H. Warranties and Bonds: Provide copies of all applicable warranties and bonds and lists of circumstances and conditions that would affect validity of warranties or bonds.

1. Include procedures to follow and required notifications for warranty claims. 2. Clearly indicate commencement and expiration dates.

I. Provide a draft of the proposed Product Maintenance Information Manual. Submit draft at least 90 calendar days before requesting inspection for Substantial Completion to COTR for approval in writing.

2.5 SYSTEMS AND EQUIPMENT MAINTENANCE INFORMATION MANUAL

A. Content: For each system, subsystem, and piece of equipment not part of a system, include source information, manufacturers’ maintenance documentation, preventative maintenance program, maintenance procedures, maintenance and service schedules, spare parts list and source information, maintenance service contracts, and warranty and bond information, as described below. Organize information into separate and distinct volumes by Division, and further divided into separate volumes by system (for example, HVAC systems and plumbing systems).

B. Source Information: List each system, subsystem, and piece of equipment included in manual identified by product name and arranged to match manual’s table of contents. For each product, list name, address, and telephone number of Installer or supplier and maintenance service agent, and cross-reference Specification Section number and title in Project Manual.

C. Descriptions: Include the following:



1. Product name, model number, and location. 2. Manufacturer’s name. 3. Equipment identification with serial number of each component. 4. Equipment function. 5. Operating characteristics. 6. Limiting conditions. 7. Complete nomenclature and number of replacement parts. 8. Charts of valve tag numbers, with the room number location and function of each valve.

D. Manufacturers’ Maintenance Documentation: Manufacturers’ maintenance documentation including the following information for each component part or piece of equipment:

1. Safety information. 2. Standard printed maintenance instructions and bulletins. 3. Identification and nomenclature of parts and components. 4. List of items recommended to be stocked as spare parts.

E. Preventative Maintenance Plan: Provide an annual preventative maintenance plan indicating when maintenance tasks should be performed, such that work is spread evenly as possible throughout the year. Preventative Maintenance should not be misconstrued as reconditioning, or major repairs or replacement of components, but designed to reveal through certain procedures and inspection the need for such actions in time to prevent malfunctions during operation.

F. Preventative Maintenance and Maintenance and Repair Procedures: Include the following information and items that detail essential preventative maintenance and maintenance and repair procedures:

1. Preventative Maintenance:

a. Provide instructions and location diagrams for the following:

1) Checking general condition of System and Components. 2) Inspecting for accumulation of dust, dirt or any foreign matter, and clean as

needed. 3) . 4) Lubricating mechanisms, contacts, and other moving component parts. 5) Specific procedures applicable to specialized equipment and systems.

2. Maintenance and Repairs:

a. Include information and detailed diagnostic testing and inspection instructions, and procedures that detail essential system and equipment maintenance procedures including but not limited to:



1) Examination of shaft seal for excessive leakage. 2) Monitoring of systems for excessive bearing noise. 3) Verifying lubrication requirements. 4) Realignment of shaft coupling. 5) . 6) Inspection of internal equipment components for unusual wear of failure. 7) Procedures for maintenance including precautions against improper

maintenance.

b. Include the following information and items that detail essential system and equipment repair procedures:

1) Complete troubleshooting guide. 2) Complete repair instructions including equipment and component removal,

disassembly, repair, and replacement; and reassembly instructions. 3) Aligning, adjusting, and checking instructions including noise, vibration and

efficiency adjustments.

G. Maintenance Service Schedules

1. Provide recommended frequencies, inspections, service and lubrication requirements, list of required lubricants for equipment, and separate schedules for preventive and maintenance and service with standard time allotment.

a. Scheduled Maintenance and Service: Tabulate actions for daily, weekly, monthly, quarterly, semiannual, and annual frequencies.

b. Maintenance and Service Record: Include manufacturers’ forms for recording maintenance.

H. Spare Parts List, Recommended Inventory Requirements and Source Information: Include lists of replacement and repair parts, with parts identified and cross-referenced to manufacturers’ maintenance documentation and local sources of maintenance materials and related services.

I. Schedule of Products and Locations: Provide complete information, including reference drawings if necessary, in the Equipment and Systems manual on all products specified in Divisions 02 through 33.

J. Warranties and Bonds: Include copies of all applicable warranties and bonds and lists of circumstances and conditions that would affect validity of warranties or bonds.

1. Include procedures to follow and required notifications for warranty claims. 2. Clearly indicate commencement and expiration dates.

K. Provide a draft of the proposed Product Maintenance Information Manual. Submit draft at least 90 calendar days before requesting inspection for Substantial Completion to COTR for approval in writing.



2.6 WARRANTY INFORMATION MANUAL

A. Organize warranty documents into an orderly sequence based on the table of contents of the Contract Specifications. Warranty documents include Contractor and Major Subcontractors warranty letters, special warranty documents, and manufacturer's warranties.

B. Binders: Heavy-duty, 3-ring thermoplastic loose-leaf binders in thickness necessary to accommodate contents, sized to hold 8-1/2-by-11-inch paper; with clear plastic sleeve on spine to hold label describing contents. Binders shall not be filled beyond 75 percent of their rated capacity. Binders shall also have boomerang plastic sheet lifters, metal backbone, concealed rivet construction, and three-trigger position DublLock mechanism (lock, unlock, open) on top and bottom. Binder color shall be black unless another color is selected by COTR.

C. Identify each binder on front (If identification can not be attached to the front include it as the first page in the manual) and spine, with printed title "PROJECT WARRANTIES," Contract number and name. The use of business labels is prohibited.

D. Dividers: Provide three-hole, heavyweight, tabbed dividers, for each separate section. Provide laser printed description front and back of tabs, to indicate the appropriate Specification Section. Provide a typed index of the contents in each section on the first page behind each section divider. Include a matching master table of contents for the manual using the same indexing system. Install a colored sheet between each different warranty within a tabbed section.

E. Provide additional copies of each warranty to include in operation and maintenance manuals.

F. Provide a draft of the proposed Warranty Manual. Submit draft at least 90 calendar days before requesting inspection for Substantial Completion to COTR for approval in writing.

PART 3 - EXECUTION

3.1 MANUAL PREPARATION

A. Compile all required information, as it is approved, into volumes grouped first by specification Division and then by Section in accordance with the information requirements outlined in Part 2 of this specification section and the approved Operation and Maintenance Manual Format.

B. Product Maintenance Information: Assemble a complete set of maintenance data indicating manufacturer’s product information, part numbers, description and care and maintenance instructions for each product, material, and finish incorporated into the Work.

C. Operation and Maintenance Information: Assemble a complete set of operation and maintenance and repair data providing complete information for each system, subsystem and piece of equipment. Include complete operation, preventative maintenance, maintenance and repair instructions, and parts listing with sources indicated; recommended parts inventory listing, and similar information. Include all diagnostic and repair information available to manufacturer’s and Installer’s maintenance personnel.



1. Engage a factory-authorized service representative to assemble and prepare information for each system, subsystem, and piece of equipment not part of a system.

2. Prepare a separate manual for each system and subsystem, in the form of an instructional manual for use by the Authority’s operating personnel.

D. Manufacturers’ Data: Where manuals contain manufacturers’ standard printed data, include only sheets pertinent to product or component installed. Mark each sheet with black arrows to identify each product or component incorporated into the Work. If data include more than one item in a tabular format, identify each item using appropriate references from the Contract Documents. Identify data applicable to the Work and delete references to information not applicable.

1. Provide supplementary text if manufacturers’ standard printed data are not provided by the manufacturer. Provide supplementary text where the information is necessary for proper operation and maintenance of equipment or systems.

E. Drawings: Prepare drawings supplementing manufacturers’ printed data to illustrate the relationship of component parts of equipment and systems and to illustrate control sequence and flow diagrams and their relation to the structure or facility. Coordinate these drawings with information contained in Record Drawings to ensure correct illustration of completed installation.

1. Do not use original Project Record Documents as part of Operation and Maintenance Manuals.

2. Comply with requirements of newly prepared Record Drawings in Division 01 Section “Project Record Documents.”

F. Comply with Division 01 Section “Project Closeout” for a schedule for submitting operation and maintenance documentation.




PROJECT RECORD DOCUMENTS 017839-1

SECTION 017839 - PROJECT RECORD DOCUMENTS

PART 1 - GENERAL


A. Drawings, Contract Provisions, Special Provisions, Supplementary Conditions and other Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Section includes administrative and procedural requirements for Project Record Documents, including the following:

1. Record Drawings.

2. Record Specifications

3. Record Product Data.

4. Record Schedule.

5. Miscellaneous Record Submittals.

6. Computer Aided Design and Drafting (CADD) requirements for Record Drawings.


1. Division 01 Section “Construction Progress Documentation" for construction schedules as basis for Record Schedule.

2. Division 01 Section “Quality Requirements” for ensuring the record drawings and specifications are kept current on a daily basis and marked to show deviations which have been made from the original Contract documents

3. Division 01 Section "Project Closeout " for general closeout procedures

4. Division 01 Section "Operation and Maintenance Data" for operation and maintenance manual requirements.

5. Divisions 02 through 33 Sections for specific requirements for Project Record Documents of products in those Sections.

1.3 SUBMITTALS

A. CADD Record Drawings. Comply with the following:

1. Submit copies of CADD Record Drawings as follows:

a. Initial Submittal: Submit one set of complete, full-sized, CADD Record Drawings. Additional sets of drawings are not to be copied and submitted until after substantial completion to insure all changes are shown on the drawings. The COTR will facilitate review of drawings and indicate whether the CADD Record



Drawings are acceptable. The COTR will return review comments indicating any corrections that need to be made to the drawings. The corrected CADD Record Drawings may then be reproduced, and organized into sets, printed, bound, and submitted as final submittal.

b. Final Submittal: After construction is complete and changes are recorded, submit six complete, full-sized, printed sets of CADD Record Drawings. Include each sheet, whether or not changes and additional information were recorded. Submit two copies of the CADD Record drawings in the approved electronic format. In addition, submit the original set of marked-up record drawings onto which the mark-ups were made.

B. Record Specifications: Submit two copies of Project Specifications, including addenda and contract modifications.

C. Record Product Data: Submit one copy of each Product Data submittal at the direction of the COTR.

1. Where Record Product Data is required as part of operation and maintenance manuals, submit marked-up Product Data as an insert in the manual instead of submittal as Record Product Data.

D. Record Schedule: Submit three copies of Record Schedule.

E. Miscellaneous Record Submittals: Submit miscellaneous Record Submittals as specified.

PART 2 - PRODUCTS

2.1 RECORD DRAWINGS

A. Record Prints: During construction, maintain one complete, full sized, set of blue- or black-line prints of the Drawings, applicable shop drawings, and coordination drawings for record purposes. These drawings shall be updated periodically, by the contractor, in CADD to replace the hand mark-ups. The mark-ups shall be preserved for the record. A complete set of Conformed Drawings in CADD will be provided to the Contractor for his use in maintaining the CADD Record Drawings. The CADD files will be provided in Bentley Microstation v8.

1. Maintenance of Drawings: Maintain the drawings in a clean, dry, legible condition. Keep drawings available during normal working hours for inspection by the COTR.

2. Preparation: Routinely mark Record Prints to show the actual installation where installation varies from that shown originally. Require individual or entity who obtained record data, whether individual or entity is Installer, subcontractor, or similar entity, to prepare the mark-ups on the record set.

a. Give particular attention to information on concealed elements that would be difficult to identify or measure and record later especially underground structures.

b. Record information in an understandable drawing technique. Ensure mark-ups are legible and reproducible.



c. Record data as soon as possible after obtaining it. Record and check markups before enclosing concealed installations.

3. Content: Types of items requiring marking include, but are not limited to, the following:

a. Dimensional changes to Drawings.

b. Revisions to details shown on Drawings.

c. Depths of foundations below first floor.

d. Locations and depths of underground utilities.

e. Revisions to routing of piping and conduits.

f. Revisions to electrical circuitry.

g. Actual equipment locations.

h. Duct size and routing.

i. Locations of concealed internal utilities.

j. Changes made by Change Notice and RFI.

k. Changes made following COTR's written orders.

l. Details not on the original Drawings.

m. Field records for variable and concealed conditions.

n. Record information on the Work that is shown only schematically.

4. Mark the Drawings or Shop Drawings, whichever is most capable of showing actual physical conditions, completely and accurately. If Shop Drawings are marked, insert them into drawing set and assign an appropriate sheet number (one that follows the number sequence of the contract drawings). Show cross-references to the new sheets on the Drawings. Update drawing index as needed to reflect new sheets.

5. Mark record drawings with red pen that will reproduce clearly. Use different colors to distinguish between changes for different categories of the Work at the same location.

6. Mark important additional information that was either shown schematically or not indicated on the original Drawings.

7. Note applicable Construction Change Notices, Requests for Information, Technical Support Requests, and similar identification numbers, where applicable. Copies of change documentation shall be inserted into the set for clarification but are not a substitute for mark-ups. If identification numbers for documentation are marked on the drawing when no change resulted, indicate "No Change".

B. Newly Prepared Project Record Drawing Sheets: The contractor may add new sheets with supporting sketches and change documentation instead of marking original sheets when neither the original Drawings nor Shop Drawings are suitable to show actual installation or if the new sheets can show the changes more clearly or additional space is required for markup information.

1. Assign a number to each new sheet and cross-reference on the appropriate related sheets.

2. Consult with COTR for proper scale and scope of detailing and notations required to record the actual physical installation and its relation to other construction.



3. Integrate newly prepared sheets into Record Drawing sets and update drawing index to reflect new sheets.

C. Format:

1. Identify and date each Record Drawing. Include the designation “PROJECT RECORD DRAWING” in a prominent location on each sheet.

2. Cover Sheet shall have the designation “PROJECT RECORD DRAWINGS”, Date, Name of Contractor, and signature.

3. Record CADD Drawings:

a. CADD files provided by COTR and utilized for recording of record mark-ups shall maintain the format of the files provided. Place electronic mark-ups in a newly created layer on each drawing.

b. CADD files created by Contractor: Organize CADD information into separate electronic files that correspond to each sheet of the Record Drawing set. Name each file with the sheet identification. Include identification in each CADD file.

4. Include the following identification on newly prepared Project Record Drawing Sheets:

a. Project name.

b. Date.

c. Designation "PROJECT RECORD DRAWING."

d. Name of Architect/Engineer (if applicable).


f. Initials of person incorporating the change.

g. Drawing identification number. (Ixx)

5. Organization of Newly Prepared Project Record Drawing Prints: Organize newly prepared Record Drawings into manageable sets. Include any contract required coordination drawings and applicable shop drawings. Bind each set with durable paper cover sheets. Include identification on cover sheets.

D. ADDITIONAL REQUIREMENTS FOR RECORD DRAWINGS

1. When there are multiple copies of the same sheet with different mark-ups on each copy, the General Contractor is responsible for consolidating all mark-ups onto a single copy of each individual sheet.

2. The information from all RFI's, Change Notices, Design Clarifications, field adjustments, or any other changes, must be noted on the appropriate drawing. These mark-ups must include enough information to clearly show the actual constructed conditions resulting from the change. The information may be drawn onto the drawing, copied onto the drawing or copied onto a new full size sheet. Every change in construction must have RFI’s, Change Orders or similar supplementary documents; therefore they must be copied in original size and attached to the back of the preceding drawing or at the end of the drawing set, as an appendix, as a full size sheet, same in size as the drawing set. Multiple RFI’s, CN’s and other supplemental documents may be copied in each single sheet.



3. All changes made on the drawings shall reference the appropriate RFI, Change Notices, Design Clarification, or details from the contractor prepared shop drawings. If the mark-up is due to a field adjustment, it shall be indicated as such.

4. Additional Sheets such as shop drawings and sheets showing copies of applicable change documentation must be inserted into the set as necessary. Such sheets shall have a title block.

5. Notes and sketches printed by hand are acceptable but shall be neat, legible, and reproducible. Hand lettering shall be 3/8" high minimum.

6. All shop drawings showing information not on the construction drawings (with the exception of concrete embedded steel reinforcement bending drawings and steel reaction and fabrication drawings) shall be marked up and included in the record drawing set. They shall be the same size (changes in scale noted) as all other drawings, include a title block, and clearly indicate that they are record shop drawings. When the shop drawings more accurately show locations and conditions, they may be marked in lieu of referenced on the original drawings. This does not relieve the contractor from the shop drawing inclusion requirements in the Operation and Maintenance Manuals that are a separate item

7. Include contract required coordination drawings in the record drawing set.

2.2 RECORD SPECIFICATIONS

A. Preparation: Mark Specifications to indicate the actual product installation where installation varies from that indicated in Specifications, addenda, and contract modifications. Print marked specifications, addenda, and contract modifications on paper any color but white and ensure that black font is clearly legible on the color chosen. Use the same paper color throughout the project. Use black font for these changes.

1. Give particular attention to information on concealed products and installations that cannot be readily identified and recorded later.

2. Mark copy with the brand name and model number of products, materials, and equipment furnished, including substitutions and product options selected.

3. Record the name of the manufacturer, supplier, Installer, and other information necessary to provide a record of selections made.

4. For each principal product, indicate whether Record Product Data has been submitted in operation and maintenance manuals instead of submitted as Record Product Data.

5. Note related Change Orders, Record Drawings, and Product Data where applicable.

2.3 RECORD PRODUCT DATA

A. Preparation: Mark Product Data to indicate the actual product installation where installation varies substantially from that indicated in Product Data submittal.

1. Give particular attention to information on concealed products and installations that cannot be readily identified and recorded later.

2. Include significant changes in the product delivered to Project site and changes in manufacturer's written instructions for installation.



3. Note related Change Orders, Record Drawings, and Product Data where applicable.

4. Upon completion of mark-up, submit a complete set of record Product Data to COTR for the Authority's records.

5. Where Record Product Data is required as part of maintenance manuals, submit marked-up product data as an insert in the manual.

2.4 RECORD SCHEDULE

A. Record Schedule Submittal: Immediately prior to date of inspection for Final Acceptance, submit a copy of the As-built Contract CPM Schedule (if applicable) to the COTR.

B. Mark the Contractor’s Construction Schedule to show actual start and finish dates for all work activities and milestones, based on the accepted monthly updates. This Record Schedule shall be in same format as Contractor’s Construction Schedule. This Record Schedule shall be in tabular and in time-scaled PDM plot formats.

2.5 MISCELLANEOUS RECORD SUBMITTALS

A. Assemble miscellaneous records required by other Specification Sections for miscellaneous record keeping and submittal in connection with actual performance of the Work. Bind or file miscellaneous records and identify each, ready for continued use and reference. Submit to COTR.

1. Categories of requirements resulting in miscellaneous records include, but are not limited to the following:

a. Field records on excavations and foundations.

b. Field records on underground construction and similar Work.

c. Survey showing locations and elevations of underground lines.

d. Invert elevations of drainage piping.

e. Authorized measurements utilizing unit prices or allowances.

f. Ambient and substrate condition tests.

g. Certifications received in lieu of labels on bulk products.

h. Batch mixing and bulk delivery records.

i. Testing and qualification of tradesmen.

j. Documented qualification of installation firms.

k. Load and performance testing.

l. Inspections and certifications by governing authorities.

m. Leakage and water-penetration tests.

n. Final inspection and correction procedures.

o. Final inspections of all trades.

PART 3 - EXECUTION



3.1 RECORDING AND MAINTENANCE

A. Recording: Maintain one copy of each submittal during the construction period for Project Record Document purposes. Post changes and modifications to Project Record Documents as they occur.

B. Maintenance of Record Documents and Samples: Store Record Documents and Samples in the field office apart from the Contract Documents used for construction. Do not use Project Record Documents for construction purposes. Maintain Record Documents in good order and in a clean, dry, legible condition, protected from deterioration and loss. Repair or reproduce torn or dirty sheets. Provide access to Project Record Documents for COTR's reference during normal working hours.



WASHINGTON DULLES INTERNATIONAL AIRPORT IA1302 HYDRANT FUEL LINE IMPROVEMENTS FEBRUARY 24, 2014

FUEL SYSTEM PIPING ABANDONMENT AND REMOVAL 026500.01 10-1

SECTION 026500.01 10 - FUEL SYSTEM PIPING ABANDONMENT AND REMOVAL

PART 1 - GENERAL

1.1 SUMMARY

A. This Section covers general procedures to be followed for fuel line drain down at tie-ins, piping to be abandoned in-place, and piping to be removed.

B. RELATED WORK SPECIFIED ELSEWHERE:

1. Excavation and Embankment: P-152

2. Dewatering: 312319

1.2 REFERENCES

A. American Petroleum Institute

1. Bulletin 1604-10 – Closure of Underground Storage Tanks.

2. Publication 1628-80 – Underground Spill Cleanup Manual.

3. Bulletin 2201-95 – Procedures for Welding or Hot tapping on Equipment Containing Flammables.

B. American National Standards Institute (ANSI)

1. B16.9-12 – 1986 Factory-Made Wrought Steel Buttwelding Fittings.

C. American Society for Testing and Materials (ASTM)

1. ASTM A234-11a - Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service.

D. Air Transportation Association (ATA)

1. 103-09 – Standards for Jet Fuel Quality Control at Airport.

E. Code of Federal Regulations (CFR)

1. 29 CFR 1910.120-07 – Hazardous Waste Operations and Emergency Response.

2. 29 CFR 1910.1200-12 – Hazard Communication.

3. 29 CFR Part 1926-07 – Safety and Health Regulations for Construction.

F. Virginia Department of Environmental Quality (VDEQ)



1. 9 VAC 25-91 – Aboveground Storage Tanks

G. Metropolitan Washington Airports Authority (MWAA)

1. Orders and Instructions – Fuel System Work Coordination at Washington Dulles International Airport (IAD 6-2-2)

1.3 SUBMITTALS:

A. Submit as specified in Section 33 52 43.10 10, Fuel System General Provisions.

B. Submit proposed methods for fuel draining, material handling, and fuel, water and pipe disposal for review prior to start of Work.

C. Provide certifications for all proposed recycling and/or disposal facilities.

D. Submit certifications for all trucks used to collect drained fuel.

E. Submit a copy of all permits and notifications obtained or required as part of the Work including the IAD Fuel System Permit to Work.

F. Submit copies of applicable licenses, certifications, and training certificates to document compliance with the Quality Assurance requirements of this section.

G. Provide waste manifests and bills of lading for all fuel, flushing fluids and piping material removed from the project site.

H. Submit proposed grout mix, pipe fittings and other miscellaneous materials.

I. Submit record document survey of pipelines removed and abandoned in place.

1.4 QUALITY ASSURANCE:

A. Contractor shall be licensed and certified as required by state and local authorities to perform work of the type described.

B. Contractors shall certify that employees and subcontractors responsible for pipe abandonment and excavation have been properly trained in the following:

1. Use of equipment and procedures for flammable atmosphere testing, gas purging and cutting fuel piping.

2. Handling and disposal of jet fuel and its by-products and residues.

C. Identification and procedures for handling ignition sources and other safety hazards.

D. All applicable safety rules and regulations.

E. Contractor shall maintain a site specific Health and Safety Plan addressing all work related hazards associated with work of this type.



1. Comply with the notification and closure requirements of 9 VAC 25-91 and MWAA’s Orders and Instructions – Fuel System Work Coordination at Washington Dulles International Airport (IAD 6-2-2).

F. The Authority’s Environmental Consultant will be responsible for collecting environmental samples from the pipe trench to document proper closure.

G. In the case of pipeline removal, the Environmental Consultant will collect samples from the trench and excavated material. Backfilling of the trench cannot proceed until sample results are received and proper direction is provided by the Environment Consultant.

H. Contractor shall provide safe access to the trench for environmental sampling purposes.

PART 2 - PRODUCTS

2.1 MATERIALS

A. At a minimum, materials to be provided by the Contractor for fuel line abandonment include:

1. Caps and Blinds

a. Caps shall be of suitable material for welding to the pipeline in which they are installed and blinds shall be of a size consistent with the pipe to be abandoned. The wall thickness, pressure rating, and temperature rating of caps and blinds shall not be less than the adjoining pipe.

2. Transport Truck

a. Where it is necessary to drain the existing fuel piping to complete the project work, the Contractor shall provide clean uncontaminated trucks, pumping equipment and ancillary materials for removing and collecting fuel.

b. Contractor shall submit certification from the trucking company documenting the tank cleaning activities and certifying the equipment is clean.

3. Pigging Equipment

a. If pigs are used, the Contractor shall provide pigs to remove all fuel, water and solids from the pipeline. Pigs shall be five pounds per cubic foot density foam. Pigs shall be designed to remove paraffin and to navigate 90° bends. Pigs shall be manufactured by TD Williams, the Girard Polly-Pig Company, Inc., or approved equivalent.

4. Pig Launcher and Receiver:

a. Contractor shall provide pig launching and receiving equipment.

b. Pig receiver must be equipped to safely vent the line while pigging and safely capture all fuel product removed during pigging and grouting.



5. Portland Cement Grout

a. Contractor shall provide a grout mixture consisting of an appropriate combination of Portland cement, fly ash, bentonite and sand for the placement requirements.

b. While low grout strength is not an issue of concern, a minimum amount of Portland cement or other materials is necessary to make the grout pumpable over the specific length of pipe being grouted. The Contractor should utilize a local ready-mix supplier and concrete pumping company experienced in selecting mix proportions. Mixture shall be of a consistency such that Contractor provided pumping equipment can grout the entire length of pipeline shown on the Contract Drawings.

c. When abandoning long segments of piping (over 300 feet ±), grout shall be made using natural sand where possible. Manufactured sand can significantly limit the pumping distance due to particle interaction and increased friction at the pipe wall.

B. Pumping Equipment

1. The Contractor shall utilize pumping equipment with sufficient pumping capacity and pressure to completely fill the line being abandoned before the grout begins to set.

PART 3 - EXECUTION

3.1 GENERAL

A. The removal and abandonment of piping as specified and indicated shall be in strict accordance with all federal, state, and local regulations and codes including, but not limited to, those developed by the Environmental Protection Agency (EPA), Occupational Safety and Health Administration (OSHA), Virginia Department of Environmental Quality (VDEQ) and other applicable federal, state and local codes. Other recommended practices and standards pertaining to this type of demolition and removal include the American Petroleum Institute (API) Bulletins and National Fire Protection Association Codes.

B. Contractor shall identify and obtain Hot Work and other associated permits for the work. Contractor shall coordinate with the COTR to prepare and submit proper notification of the fuel line closure activities for the VDEQ.

C. Contractor shall comply with all provisions of the Authorities - Orders and Instructions – Fuel System Work Coordination at Washington Dulles International Airport (IAD 6-2-2).

3.2 CONTAMINATED MATERIALS

A. Contractor shall immediately notify the COTR if contaminated soils, backfill materials or water are observed during the work activities.

B. Contractor shall be responsible for all costs associated with the cleanup of any fuels spilled as a result of Contractor’s actions.



3.3 FUEL REMOVAL AND DRAINING

A. This section describes the procedures to be used on the existing pipeline to be temporarily or permanently taken out of service in preparation for fuel line tie-ins, removal or abandonment. The Fuel Removal and Draining provisions of this specification are also applicable to flushing activities. The Contractor shall provide all labor, equipment, and materials necessary to remove fuel from sections of the pipeline shown on the plans for tie-ins or where lines are to be removed or filled with grout.

B. The Contractor shall submit an “IAD Permit to Work on Fuel System Request Form” at least fifteen days prior to scheduling his work and shall have the approval of the Authority as to the time and date for isolating any fuel line to be drained. Work shall be completed within the time frame specified. Contractor shall ensure appropriate spill response and fire protection measures are present during the draining operation. Coordination with the Fuel System Operator is required.

C. The Contractor shall locate and identify the proper low points, vaults, pits, or other access points associated with the fuel line to be drained. After gravity draining, the Contractor shall use a vacuum truck to remove all residual fuel from each line being drained. The Contractor shall provide all labor, materials and equipment for venting and draining the sections of fuel line as indicated on the drawings.

D. The Fuel System Operator will collect fuel sample(s) from the pipe segment to be drained prior to beginning the work to document fuel quality.

E. The Contractor shall provide new hoses to be used for all project related fuel drain down activities. The hoses shall be clearly marked to identify them for “Clean Jet Fuel Only” and used solely for the purpose of draining or flushing the jet fuel piping system on this project. Upon completion of the day’s activities, the Contractor shall collect the hoses and store them in a secure location to ensure they are not used for any purpose other than drain down or flushing.

F. The Contractor shall provide clean, uncontaminated vacuum and transport trucks for collecting the fuel and transporting the fuel back to the Tank Farm. Equipment used for storing or transporting jet fuel to be reclaimed needs to be inspected by the Contractor and Fuel System Operator before each days use to ensure the equipment is clean and dry.

G. To reclaim jet fuel, the Contractor needs to transport the fuel to the Settling Tank Farm Reclaim Tank T-25. The fuel needs to settle for 10 minutes at the offloading island. A fuel sample will then be collected by the Contractor and the Fuel System Operator for visual inspection. If it passes a visual inspection, the fuel can then be moved into Tank T-25. Tank T-25 has an operating capacity of 11,800 gallons and is in continuous use as part of the Settling Tank Farm operation. The Contractor will need to coordinate discharge times into Tank T-25 with the Fuel System Operator.

H. Fuel that is contaminated as a result of Contractor’s activities and is unacceptable for reuse must be removed from the site and replaced by the Contractor. The cost of fuel spilled, wasted, or contaminated by any Contractor related activities shall be paid for by Contractor at the Fuel System Operator’s purchase rate times a 1.15 multiplier.

I. It shall be the Contractor’s responsibility to vent air out of new and existing fuel lines that are to be put into service after the drain down activities are complete as required to comply with the



Fuel system Handover Inspection Form (Orders and Instructions – Fuel System Work Coordination at Washington Dulles International Airport).

3.4 PIGGING

A. All fuel lines to be abandoned or removed shall either be pigged in accordance with this Paragraph or flushed with water as outlined below.

B. Prior to filling with grout, the Contractor shall pig the pipelines after draining any remaining fuel. The pigging shall include one pass with a cleaning pig to completely remove the fuel. Dry nitrogen shall be used to propel the pig in the presence of fuel. The Contractor shall provide pig launchers and receivers.

C. The pig receiver shall be constructed with valved vent for venting air and a valved low point for collecting fuel in front of the pig.

D. The Contractor shall provide clean, uncontaminated vacuum and transport trucks for collecting the fuel and transporting the fuel to the approved offsite reuse or disposal location. All drained fuel shall be removed from the site on a daily basis.

3.5 WATER FLUSHING

A. All fuel lines to be abandoned or removed shall either be pigged as outlined above or flushed with water as outlined in this Paragraph.

B. A minimum of two pipe volumes of water shall be flushed through the piping at approximately 3 to 5 feet/second. Upon completion of the flushing activities, residual water in the pipe shall be drained from low points in preparation for grouting.

C. Flush water shall be collected and transported offsite for treatment and disposal. Contractor shall provide all materials and equipment required for the water flush including, but not limited to, clean water, pumps, hoses, collection tanks, temporary frac tanks at the construction site, transportation from the water source to the work site, transportation to the approved offsite water treatment facility, and disposal costs.

D. Clean water for flushing can be obtained from an on airport hydrant at no cost to the Contractor.

3.6 WASTE MATERIAL

A. Unacceptable fuel, debris, loose scale, liquid and sludge shall be removed by the Contractor from the piping and handled in accordance with EPA, state and local regulations at a properly permitted treatment, storage and disposal facility subject to approval of the Authority. Contractor shall be responsible for waste sampling as necessary to satisfy the disposal facility requirements.

B. Hazardous and special waste removed from piping shall be packaged and transported in accordance with state and Federal Department of Transportation regulations and disposed of, or stored, in accordance with federal and state of Virginia regulations. Contractor shall prepare



shipping papers, including manifests, to be signed by a representative of the Authority, who is the generator, before any shipments leave the premises.

C. Generator copies of the waste shipping manifests shall be returned to a specified representative of the Authority. COTR shall provide copies of the documents to the Contractor. Any disposal discrepancies identified by COTR or others, shall be the responsibility of the Contractor and shall be resolved by the Contractor, the waste transporter and the disposal facility.

D. Contractor shall assume piping is not coated with an asbestos wrap.

E. Contactor shall be responsible for all costs associated with disposal of general construction debris including pits, piping, vaults, and other miscellaneous waste generated as part of the construction.

F. Remove all valves within pits and vaults scheduled to abandoned in place or removed and return equipment to the Fuel System Operator.

3.7 FILLING LINE WITH GROUT

A. After fuel removal is complete, the Contractor shall completely fill all pipes designated to be abandoned with a Portland cement grout. If necessary, the Contractor shall sectionalize the pipe to ensure complete filling of the pipeline. Any fuel/water residue that has accumulated in front of the pig and grout shall be collected and disposed of by the Contractor.

B. The COTR shall make the final determination whether the line has been properly and completely filled with grout.

3.8 PIPELINE REMOVAL

A. After fuel removal is complete, fully expose piping to be removed and use proper cutting techniques for pipelines containing flammable or combustible materials. Provide proper caps at phase limits.

B. Prior to removing piping, Contractor shall complete a record survey of the piping noting the general pipe configuration, depth and alignment of piping. This shall include noting the location and number of pipes and the location of bends, fittings and pits/vaults along the system. Survey may be completed by traditional surveying techniques or by using a GPS based system with an accuracy of 1’+/-.

C. Fuel line removal shall include removing the pipe, pits, and vaults. Pipe shall be cut into manageable lengths and transported to an approved metal recycling facility.

3.9 NITROGEN CHARGE 18-INCH PIPING

A. Cut and cap the 18-inch piping near isolation vault C1IVV in Area C as shown on the Contract Drawings.

B. Bleed nitrogen charge off of the existing piping from isolation valve vault RMIDIVV to the south and east. Rotate the spectacle flange in RMIDIVV to the open position.



C. Provide a 5 psig nitrogen charge on the existing piping being taken out of service.

3.10 VAULT/PIT MODIFICATIONS FOR GROUTING

A. Complete appropriate drain down activities in Area B in order to cut the existing piping and install a new spool piece using plidco couplings. Weld the plidco couplings and complete required testing in accordance with Section 335243.11 10. Return the active piping to service.

B. Remove all valves, piping, access hatches and other miscellaneous equipment within vault/pit scheduled to be taken out of service. Return valves and hatches to the Fuel System Operator.

C. Provide spool piping, blind flanges, and other miscellaneous materials to accommodate continuous grouting operations through the vault.

D. Grout the piping to be taken out of service. Fill the pit/vault with grout and concrete as shown on the Contract Drawings.

3.11 ISOLATION VALVE PIT DEMOLITION

A. Excavate and expose the existing fiberglass valve pits in Area D. Demolish the existing fiberglass valve pit and concrete backfill material taking care not to damage the existing piping.

B. Complete appropriate drain down activities in order to cut the existing piping. Remove all valves, piping and other miscellaneous equipment within the fiberglass isolation pit scheduled to be removed as shown on the plans. Return valves and access hatches to the Fuel System Operator. Install a new spool piece using plidco couplings. Weld the plidco couplings and complete required testing in accordance with Section 335243.11 10. Return the active piping to service.

3.12 BACKFILL AND COMPACTION

A. Backfill, compact and test excavated areas in accordance with the requirements of Item P-152.

PART 4 - FIELD QUALITY CONTROL

4.1 Conform to all applicable provisions of Division 01 Section “Quality Requirements", Section 335243.10 10 and the requirements of this Section. Be responsible for periodic inspections for conformance with the approved SPPP. The results of the periodic inspections shall be submitted to the COTR upon completion.

END OF SECTION 026500.01 10


EXCAVATION AND EMBANKMENT P-152-1

ITEM P-152 EXCAVATION AND EMBANKMENT

DESCRIPTION

152-1.1 This item covers excavation, disposal, placement, and compaction of all materials within the limits of the work required to construct pavements and hydrant fuel lines in accordance with these specifications and in conformity to the dimensions and typical sections shown on the plans.

152-1.2 CLASSIFICATION. All material excavated shall be classified as defined below:

a. Unclassified Excavation. Unclassified excavation shall consist of the excavation and disposal of all material, regardless of its nature, which is not otherwise classified and paid for under the following items.

b. Rock Excavation. Rock excavation shall include all solid rock in ledges, in bedded deposits, in unstratified masses, and conglomerate deposits which are so firmly cemented they cannot be removed without blasting or using rippers. All boulders containing a volume of more than 1/2 cubic yard will be classified as “rock excavation.”

c. Muck Excavation. Muck excavation shall consist of the removal and disposal of deposits or mixtures of soils and organic matter not suitable for foundation material. Muck shall include materials that will decay or produce subsidence in the embankment. It may be made up of decaying stumps, roots, logs, humus, or other material not satisfactory for incorporation in the embankment.

d. Portland Cement Concrete Pavement Removal. Portland cement concrete pavement removal shall include saw cutting, removal and disposal of various depths of Portland cement concrete pavements within the project limits. In addition to the pavements defined above, Pavement Removal shall include aggregate and stabilized subbase materials and any soil materials located above the proposed subgrade elevation.

e. Bituminous Pavement Removal. Bituminous pavement removal shall consist of the excavation and disposal of existing bituminous pavement and associated base course(s). This material shall be removed to permit the installation of the hydrant fuel line as shown on the plans.

f. Utility Construction. All excavation, trench, or otherwise as needed to complete the installation of the utilities.

152-1.3 UNSUITABLE EXCAVATION. Any material containing vegetable or organic matter, such as muck, peat, organic silt, fat clay (CH), or sod shall be considered unsuitable for use in embankment construction. Material, when approved by the COTR as suitable to support vegetation, may be used on the embankment slope.

a. Contaminated Soil. Soils that have levels of contamination in excess of applicable state standards shall be considered as contaminated and disposed of as directed by the COTR. The contractor will be responsible for the disposal of the contaminated soils and shall be fully equipped to perform this work.



CONSTRUCTION METHODS

152-2.1 GENERAL.

The suitability of material to be placed in embankments shall be subject to approval by the COTR. All unsuitable material shall be disposed of in waste areas shown on the plans. All waste areas shall be graded to allow positive drainage of the area and of adjacent areas. The surface elevation of waste areas shall not extend above the surface elevation of adjacent usable areas of the airport, unless specified on the plans or approved by the COTR.

When the Contractor’s excavating operations encounter artifacts of historical or archaeological significance, the operations shall be temporarily discontinued. At the direction of the COTR, the Contractor shall excavate the site in such a manner as to preserve the artifacts encountered and allow for their removal. Such excavation will be paid for as extra work.

Those areas outside of the pavement areas in which the top layer of soil material has become compacted by hauling or other activities of the Contractor shall be scarified and disked to a depth of 4 in. in order to loosen and pulverize the soil.

If it is necessary to interrupt existing surface drainage, sewers or under-drainage, conduits, utilities, or similar underground structures, the Contractor shall be responsible for and shall take all necessary precautions to preserve them or provide temporary services. When such facilities are encountered, the Contractor shall notify the COTR, who shall arrange for their removal if necessary. The Contractor shall, at his/her own expense, satisfactorily repair or pay the cost of all damage to such facilities or structures that may result from any of the Contractor’s operations during the period of the contract.

152-2.2 EXCAVATION. No excavation shall be started until the work has been staked out by the Contractor and the COTR has obtained elevations and measurements of the ground surface. All suitable excavated material shall be used in the formation of embankment, subgrade, or for other purposes shown on the plans. All unsuitable material shall be disposed of as shown on the plans.

When the volume of the excavation exceeds that required to construct the embankments to the grades indicated, the excess shall be used to grade the areas of ultimate development or disposed of as directed. When the volume of excavation is not sufficient for constructing the fill to the grades indicated, the deficiency shall be obtained from borrow areas.

The grade shall be maintained so that the surface is well drained at all times. When necessary, temporary drains and drainage ditches shall be installed to intercept or divert surface water that may affect the work.

a. Undercutting. Rock, shale, hardpan, loose rock, boulders, or other material unsatisfactory for safety areas, subgrades, shoulders, or any areas intended for turfing shall be excavated to the depth specified by the COTR, below the subgrade. Muck, peat, matted roots, or other yielding material, unsatisfactory for subgrade foundation, shall be removed to the depth specified. The excavated area shall be refilled with suitable material obtained from the grading operations and thoroughly compacted by rolling.

b. Bituminous Pavement Removal. Bituminous pavement designated for removal shall be excavated using equipment designed and built for this type of work and shall be removed to the depth specified on the plans.



The pavement removal equipment shall be operated to effectively minimize the amount of dust being emitted from the machine. Pre-wetting of the pavement may be required.

The Contractor shall use care to remove the existing bituminous material around all utility facilities within the work area. Utility facilities that are damaged by the pavement removal operation shall be repaired to the satisfaction of the COTR.

c. Overbreak. Overbreak, including slides, is that portion of any material displaced or loosened beyond the finished work as planned or authorized by the COTR. The COTR shall determine if the displacement of such material was unavoidable and his/her decision shall be final. All overbreak shall be graded or removed by the Contractor and disposed of as directed; however, payment will not be made for the removal and disposal of overbreak that the COTR determines as avoidable. Unavoidable overbreak will be classified as “Unclassified Excavation.”

d. Removal of Utilities. The removal of existing structures and utilities required to permit the orderly progress of work will be accomplished by the Contractor, unless otherwise shown on the plans. All existing foundations shall be excavated for at least 2 feet below the top of subgrade or as indicated on the plans, and the material disposed of as directed. All foundations thus excavated shall be backfilled with suitable material and compacted as specified herein.

e. Excavation Support Systems. Excavation support shall be in accordance with Section 315000.

f. Dewatering. The Contractor shall be aware of the presence of groundwater based on the soil borings provided and shall maintain a dry excavated condition for structure and utility construction. Dewatering shall be in accordance with Section 312319.

g. Trench Excavation. The width of the utility trench shall be sufficient to permit satisfactory jointing of the pipe and thorough tamping of the bedding material under and around the pipe, but it shall not be less than the external diameter of the pipe plus 12 inches on each side. The trench walls shall be approximately vertical.

Where rock, hardpan, or other unyielding material is encountered, the Contractor shall remove it from below the foundation grade for a depth of at least 12 inches or one-half inch for each foot of fill over the top of the pipe (whichever is greater) but for no more than three-quarters of the nominal diameter of the pipe. The width of the excavation shall be at least 1 foot greater than the horizontal outside diameter of the pipe. The excavation below grade shall be backfilled with selected fine compressible material, such as silty clay or loam, and lightly compacted in layers not over 6 inches in uncompacted depth to form a uniform but yielding foundation.

Where a firm foundation is not encountered at the grade established, due to soft, spongy, or other unstable soil, the unstable soil shall be removed and replaced with embankment material, as per Item P-152. The COTR shall determine the depth of removal necessary. The material shall be compacted to provide adequate support for the pipe.

Trenches and other excavated areas may be excavated and/or backfilled by machinery or by hand as the Contractor may elect; however, the COTR is empowered to direct the Contractor to employ hand excavation, hand backfilling, and/or hand compaction as



deemed necessary. As such, the Contractor shall not have claim to extra compensation for any and all hand work performed.

Backfill with concrete all trenches that carry below or pass under footings and that are excavated within 18 inches of footings. Place concrete to level of bottom of footings. The contractor has the option to backfill with Controlled Low-Strength Material (Flowable fill) in trenches that are supported by the utility bridge.

h. Contaminated Soil. Soils that have levels of contamination in excess of applicable state standards shall be disposed of as directed by the COTR and not to be stockpiled on site. If during earth moving operations, there is evidence of any unusual odor, color, or visual indicators, such as free product, that would lead the Contractor to suspect the soil is contaminated, work should stop and the COTR notified.

i. Compaction Requirements. The subgrade and/or backfill placed within areas to be paved shall be compacted to a density of not less than 95 percent of the maximum dry density for cohesive soils and 90 percent of the maximum density for non-cohesive soils as determined by ASTM1557. The material to be compacted shall be within +/- 2 percent of optimum moisture content before rolled to obtain the prescribed compaction (except for expansive soils).

Non-cohesive materials include materials classified in ASTM D2487 as GW, GP, SW, and SP. Cohesive materials include materials classified as GC, SC, and CL. Materials classified as GM, SM and ML will be identified as cohesive only when the fines are plastic. Perform testing, required for classifying materials, in accordance with ASTM D4318, ASTM C136, ASTM D422, and ASTM D1140.

The in-place field density shall be determined in accordance with ASTM D 1556, ASTM D 2167, or ASTM D 6938. Stones or rock fragments larger than 4 inches in their greatest dimension will not be permitted in the top 6 inches of the subgrade. The finished grading operations, conforming to the typical cross section, shall be completed and maintained at least 200 feet ahead of the paving operations or as directed by the COTR.

In cuts, all loose or protruding rocks on the back slopes shall be barred loose or otherwise removed to line of finished grade of slope. All cut-and-fill slopes shall be uniformly dressed to the slope, cross section, and alignment shown on the plans or as directed by the COTR.

Blasting will not be permitted.

152-2.3 FORMATION OF EMBANKMENTS. Embankments shall be formed in successive horizontal layers of not more than 8 in in loose depth for the full width of the cross section, unless otherwise approved by the COTR.

The grading operations shall be conducted, and the various soil strata shall be placed, to produce a soil structure as shown on the typical cross section or as directed. Materials such as brush, hedge, roots, stumps, grass and other organic matter, shall not be incorporated or buried in the embankment.

Operations on earthwork shall be suspended at any time when satisfactory results cannot be obtained because of rain, freezing, or other unsatisfactory conditions of the field. The Contractor shall drag, blade, or slope the embankment to provide proper surface drainage.



The material in the layer shall be within +/-2 percent of optimum moisture content before rolling to obtain the prescribed compaction. In order to achieve a uniform moisture content throughout the layer, wetting or drying of the material and manipulation shall be required when necessary. Should the material be too wet to permit proper compaction or rolling, all work on all of the affected portions of the embankment shall be delayed until the material has dried to the required moisture content. Sprinkling of dry material to obtain the proper moisture content shall be done with approved equipment that will sufficiently distribute the water. Sufficient equipment to furnish the required water shall be available at all times. Samples of all embankment materials for testing, both before and after placement and compaction, will be taken for each lift. Based on these tests, the Contractor shall make the necessary corrections and adjustments in methods, materials or moisture content in order to achieve the correct embankment density.

Rolling operations shall be continued until the embankment is compacted to not less than 95 percent of maximum density for noncohesive soils, and 90 percent of maximum density for cohesive soils as determined by ASTM D 1557. Under all areas to be paved, the embankments shall be compacted to a depth of 12 inches and to a density of not less than 100 percent of the maximum density as determined by ASTM D 1557.

On all areas outside of the pavement areas, no compaction will be required on the top 4 inches.

The in-place field density shall be determined in accordance with ASTM D 1556, ASTM D 2167, or ASTM D6938.

Compaction areas shall be kept separate, and no layer shall be covered by another until the proper density is obtained.

During construction of the embankment, the Contractor shall route his/her equipment at all times, both when loaded and when empty, over the layers as they are placed and shall distribute the travel evenly over the entire width of the embankment. The equipment shall be operated in such a manner that hardpan, cemented gravel, clay, or other chunky soil material will be broken up into small particles and become incorporated with the other material in the layer.

In the construction of embankments, layer placement shall begin in the deepest portion of the fill; as placement progresses, layers shall be constructed approximately parallel to the finished pavement grade line.

When rock and other embankment material are excavated at approximately the same time, the rock shall be incorporated into the outer portion of the embankment and the other material shall be incorporated under the future paved areas. Stones or fragmentary rock larger than 4 inches in their greatest dimensions will not be allowed in the top 6 inches of the subgrade. Rockfill shall be brought up in layers as specified or as directed and every effort shall be exerted to fill the voids with the finer material forming a dense, compact mass. Rock or boulders shall not be disposed of outside the excavation or embankment areas, except at places and in the manner designated by the COTR.

When the excavated material consists predominantly of rock fragments of such size that the material cannot be placed in layers of the prescribed thickness without crushing, pulverizing or further breaking down the pieces, such material may be placed in the embankment as directed in layers not exceeding 2 feet in thickness. Each layer shall be leveled and smoothed with suitable leveling equipment and by distribution of spalls and finer fragments of rock. These type lifts shall not be constructed above an elevation 4 feet below the finished subgrade.

Frozen material shall not be placed in the embankment nor shall embankment be placed upon frozen material.

There will be no separate measurement of payment for compacted embankment, and all costs incidental to placing in layers, compacting, disking, watering, mixing, sloping, and other necessary operations for construction of embankments will be included in the contract price for excavation, borrow, or other items.



152-2.4 FINISHING AND PROTECTION OF SUBGRADE. After the subgrade has been substantially completed the full width shall be conditioned by removing any soft or other unstable material that will not compact properly. The resulting areas and all other low areas, holes or depressions shall be brought to grade with suitable select material. Scarifying, blading, rolling and other methods shall be performed to provide a thoroughly compacted subgrade shaped to the lines and grades shown on the plans.

Grading of the subgrade shall be performed so that it will drain readily. The Contractor shall take all precautions necessary to protect the subgrade from damage. He/she shall limit hauling over the finished subgrade to that which is essential for construction purposes.

All ruts or rough places that develop in a completed subgrade shall be smoothed and recompacted.

No subbase, base, or surface course shall be placed on the subgrade until the subgrade has been approved by the COTR.

152-2.5 HAUL. All hauling will be considered a necessary and incidental part of the work. Its cost shall be considered by the Contractor and included in the contract unit price for the pay of items of work involved. No payment will be made separately or directly for hauling on any part of the work.

152-2.6 TOLERANCES. In those areas upon which a subbase or base course is to be placed, the top of the subgrade shall be of such smoothness that, when tested with a 16 feet straightedge applied parallel and at right angles to the centerline, it shall not show any deviation in excess of 1/2 inch, or shall not be more than 0.05 feet from true grade as established by grade hubs or pins. Any deviation in excess of these amounts shall be corrected by loosening, adding, or removing materials; reshaping; and recompacting by sprinkling and rolling.

CONTRACTOR QUALITY CONTROL

152-3.1 QUALITY CONTROL PROGRAM. The Contractor shall develop a Quality Control Program in accordance with Section 01400 of the General Provisions. The program shall address all elements which affect the quality of the work including, but not limited to:

1. Field Density Testing

2. Surface Smoothness

3. Finishing

4. Suitability and Classification of Soils

TESTING REQUIREMENTS

ASTM D 1556 Test for Density of Soil In Place by the Sand-Cone Method



ASTM D 1557 Test for Laboratory Compaction Characteristics of Soil Using Modified Effort

ASTM D 2167 Test for Density and Unit Weight of Soil In Place by the Rubber Balloon Method.

ASTM D 6938 In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods

END OF ITEM P-152



CONTROLLED LOW-STRENGTH MATERIAL (CLSM) P-153-1

ITEM P-153 CONTROLLED LOW-STRENGTH MATERIAL (CLSM)

DESCRIPTION

153.1.1 This item shall consist of furnishing, transporting, and placing a controlled low-strength material (CLSM) as flowable backfill in trenches or at other locations shown on the plans or as directed by the COTR.

MATERIALS

153-2.1 MATERIALS

a. Portland Cement. Portland cement shall conform to the requirements of ASTM C 150 Type 1. If for any reason, cement becomes partially set or contains lumps of caked cement, it shall be rejected. Cement salvaged from discarded or used bags shall not be used.

b. Flyash. Flyash shall conform to ASTM C 618, Class C or F.

c. Fine Aggregate (Sand). Fine aggregate shall conform to the requirements of ASTM C 33 except for aggregate gradation. Any aggregate gradation which produces performance characteristics of the CLSM specified herein will be accepted, except as follows.

Sieve Size Percent Passing by weight

3/4 in 100

No. 200 0 - 12

d. Water. Water used in mixing shall be free of oil, salt, acid, alkali, sugar, vegetable matter, or other substances injurious to the finished product.

MIX DESIGN

153-3.1 PROPORTIONS. The contractor shall submit, to the COTR, a mix design including the proportions and source of materials, admixtures, and dry cubic yard batch weights. The mix shall contain a minimum of 50 pounds of cement and 250 pounds flyash per cubic yard, with the remainder of the volume composed of sand, water, and any approved admixtures.

a. Compressive Strength. CLSM shall be designed to achieve a 28-day compressive strength of 100 to 200 psi when tested in accordance with ASTM D 4832. There should be no significant strength gain after 28 days. Test specimens shall be made in accordance with ASTM D 4832.

b. Consistency. Consistency of the fresh mixture shall be such that the mixture may be placed without segregation. A desired consistency may be approximated by filling an open-ended 3 in diameter cylinder, 6 in high to the top, with the mixture and the cylinder immediately



pulled straight up. The correct consistency of the mixture will produce an approximate 8 in diameter circular-type spread without segregation. Adjustments of the proportions of materials should be made to achieve proper solid suspension and flowable characteristics, however the theoretical yield shall be maintained at one cubic yard for the given batch weights.


153-4.1 PLACEMENT

a. Placement. CLSM may be placed by any reasonable means from a mixing unit into the space to be filled. Agitation is required during transportation and waiting time. Placement shall be performed in such a manner that structures or pipes are not displaced from their desired final position and intrusion of CLSM into undesirable areas is avoided. The material shall be brought up uniformly to the fill line shown on the plans or as directed to the COTR. Each placement of CLSM shall be as continuous an operation as possible. If CLSM is placed in more than one layer, the base layer shall be free of surface water and loose of foreign material prior to placement of the next layer.

b. Limitations of Placement. CLSM shall not be placed on frozen ground. Mixing and placing may begin when the air or ground temperature is at least 35 degrees F and rising. At the time of placement, CLSM shall have a temperature of at least 40 degrees F. Mixing and placement shall stop when the air temperature is 40 degrees F and falling or when the anticipated air or ground temperature will be 35 degrees F or less in the 24 hour period following proposed placement.

153-4.2 CURING AND PROTECTION

a. Curing. The air in contact with the CLSM should be maintained at temperatures above freezing for a minimum of 72 hours. If the CLSM is subjected to temperatures below 32 degrees F, the material may be rejected by the COTR if damage to the material is observed.

b. Protection. The CLSM shall not be subject to loads and shall remain undisturbed by construction activities for a period of 48 hours or until a compressive strength of 15 psi is obtained. The Contractor shall be responsible for providing evidence to the COTR that the material has reached the desired strength. Acceptable evidence shall be based upon compressive tests made in accordance with paragraph 153-3.1a.

MATERIAL ACCEPTANCE

153-5.1 ACCEPTANCE. Acceptance of CLSM delivered and placed as shown on the plans or as directed by the COTR shall be based upon mix design approval and batch tickets provided by the Contractor to confirm that the delivered material conforms to the mix design. The Contractor shall verify by additional testing, each 5,000 cubic yards of material used. Verification shall include confirmation of material proportions and tests of compressive strength to confirm that the material meets the original mix design and the requirements of CLSM as defined in this specification. Adjustments shall be made as necessary to the proportions and materials prior to further production.



153-5.2 QUALITY CONTROL. If, at any time during construction, the installation method proves unsatisfactory to the COTR, the Contractor must cease operations and correct and revise the method of placement. Conditions where the Contractor will be forced to cease operations include, but are not limited to, poor workmanship and poor finish quality.


ASTM D 4832 Standard Test Method for Preparation and Testing of Controlled Low Strength Material (CLSM) Test Cylinders

MATERIAL REQUIREMENTS

ASTM C 33 Specification for Concrete Aggregates

ASTM C 150 Specification for Portland Cement

ASTM C 618 Specification for Coal Flyash and Raw or Calcined Natural Pozzolan for Use as a Mineral Admixture in Concrete

END OF ITEM P-153


WASHINGTON DULLES INTERNATIONAL AIRPORT IA1302 IAD HYDRANT FUEL LINE IMPROVEMENTS FEBRAURY 24, 2014

CRUSHED AGGREGATE BASE COURSE P-209-1

ITEM P-209 CRUSHED AGGREGATE BASE COURSE

DESCRIPTION

209-1.1 This item consists of a base course composed of crushed aggregates constructed on a prepared subgrade in accordance with these specifications and in conformity to the dimensions and typical cross sections shown on the plans.

MATERIALS

209-2.1 AGGREGATE. Aggregates shall consist of clean, sound, durable particles of crushed stone, crushed gravel, or crushed slag and shall be free from coatings of clay, silt, vegetable matter, and other objectionable materials and shall contain no clay balls. Fine aggregate passing the No. 4 sieve shall consist of fines from the operation of crushing the coarse aggregate. If necessary, fine aggregate may be added to produce the correct gradation. The fine aggregate shall be produced by crushing stone, gravel, or slag that meet the requirements for wear and soundness specified for coarse aggregate. The crushed slag shall be an air-cooled, blast furnace slag and shall have a unit weight of not less than 70 pounds per cubic foot when tested in accordance with ASTM C 29. The coarse aggregate portion, defined as the material retained on the No. 4 sieve and larger, shall contain no more than 15 percent, by weight, of flat or elongated pieces as defined in ASTM D 693 and shall have at least 90 percent by weight of particles with at least two fractured faces and 100 percent with at least one fractured face. The area of each face shall be equal to at least 75 percent of the smallest mid-sectional area of the piece. When two fractured faces are contiguous, the angle between the planes of fractures shall be at least 30 degrees to count as two fractured faces. The percentage of wear shall not be greater than 45 percent when tested in accordance with ASTM C 131. The sodium sulfate soundness loss shall not exceed 12 percent, after 5 cycles, when tested in accordance with ASTM C 88. The fraction passing the No. 40 sieve shall have a liquid limit no greater than 25 and a plasticity index of not more than 4 when tested in accordance with ASTM D 4318. The fine aggregate shall have a minimum sand equivalent value of 35 when tested in accordance with ASTM D 2419.

a. Sampling and Testing. Aggregates for preliminary testing shall be furnished by the Contractor prior to the start of production. All tests for initial aggregate submittals necessary to determine compliance with the specification requirements will be made by the Contractor. Tests may also be performed by the COTR to verify compliance of the material.

Samples of aggregates shall be furnished by the Contractor at the start of production and at intervals during production. The sampling points and intervals will be designated by the COTR. The samples will be the basis of approval of specific lots of aggregates from the standpoint of the quality requirements of this section.

In lieu of testing, the COTR may accept certified state test results indicating that the aggregate meets specification requirements. Certified test results shall be less than 6 months old.



Samples of aggregates to check gradation shall be taken by the COTR at least two per lot. The lot will be consistent with acceptable sampling for density. The samples shall be taken from the in-place, compacted material. Sampling shall be in accordance with ASTM D 75, and testing shall be in accordance with ASTM C 136 and ASTM C 117.

b. Gradation Requirements. The gradation (job mix) of the final mixture shall fall within the design range indicated in Table 1, when tested in accordance with ASTM C 117 and ASTM C 136. The final gradation shall be continuously well graded from coarse to fine and shall not vary from the low limit on one sieve to the high limit on an adjacent sieve or vice versa. Where environmental conditions (temperature and availability of free moisture) indicate potential damage due to frost action, the maximum percent of material by weight of particles smaller than 0.02 mm shall be 3 percent when tested in accordance with ASTM D 422.

Table 1 Requirements For Gradation Of Aggregate

Sieve Size Design Range

Percentage by Weight

Job Mix Tolerances

Percent

2 in 100 0

1-1/2 95-100 +/- 5

1 in 70-95 +/- 8

3/4 in 55-85 +/- 8

No. 4 30-60 +/- 8

No. 30 12-30 +/- 5

No. 200 0-8 +/- 3

The job mix tolerances in Table 1 shall be applied to the job mix gradation to establish a job control grading band. The full tolerance still will apply if application of the tolerances results in a job control grading band outside the design range.

The fraction of the final mixture that passes the No. 200 sieve shall not exceed 60 percent of the fraction passing the No. 30 sieve.


209-3.1 PREPARING UNDERLYING COURSE. The underlying course shall be checked and accepted by the COTR before placing and spreading operations are started. Any ruts or soft yielding places caused by improper drainage conditions, hauling, or any other cause shall be corrected at the Contractor’s expense before the base course is placed thereon. Material shall not be placed on frozen subgrade.

209-3.2 MIXING. The aggregate shall be uniformly blended during crushing operations or mixed in a plant. The plant shall blend and mix the materials to meet the specifications and to secure the proper moisture content for compaction.



209-3.3 PLACING. The crushed aggregate base material shall be placed on the moistened subgrade in layers of uniform thickness with a mechanical spreader. Mechanical spreaders contain hoppers and a distribution system to ensure a uniform spread rate and to completely cover the entire lane width. The maximum depth of a compacted layer shall be 6 in. If the total depth of the compacted material is more than 6 in, it shall be constructed in two or more layers. In multi-layer construction, the base course shall be placed in approximately equal-depth layers. The previously constructed layer should be cleaned of loose and foreign material prior to placing the next layer. The surface of the compacted material shall be kept moist until covered with the next layer.

209-3.4 COMPACTION. Immediately upon completion of the spreading operations, the crushed aggregate shall be thoroughly compacted. The number, type, and weight of rollers shall be sufficient to compact the material to the required density. The moisture content of the material during compaction shall not be below, nor more than 2 percentage points above, the optimum moisture content as determined by ASTM D 1557.

209-3.5 ACCEPTANCE SAMPLING AND TESTING FOR DENSITY. Aggregate base course shall be accepted for density on a lot basis. A lot will consist of one day’s production where it is not expected to exceed 2400 square yards. A lot will consist of one-half day’s production where a day’s production is expected to consist of between 2,400 and 4,800 square yards. Each lot shall be divided into four equal sublots. Two tests shall be made for each sublot. Sampling locations will be determined by the COTR on a random basis in accordance with statistical procedures contained in ASTM D 3665. Each lot will be accepted for density when the field density is at least 100 percent of the maximum density of laboratory specimens prepared from samples of the base course material delivered to the job site. The specimens shall be compacted and tested in accordance with ASTM D 1557. The in-place field density shall be determined in accordance with ASTM D 1556 or D 2167. If the specified density is not attained, the entire lot shall be reworked and/or recompacted and additional random tests made. This procedure shall be followed until the specified density is reached. In lieu of the core method of field density determination, acceptance testing may be accomplished using a nuclear gauge in accordance with ASTM D 6938. The gauge should be field calibrated in accordance with ASTM D 6938. Calibration tests shall be conducted on the first lot of material placed that meets the density requirements. When using the nuclear method ASTM D 6938 shall be used to determine the moisture content of the material. The calibration curve furnished with the nuclear gauges shall be checked in accordance with ASTM D 6938. The calibration checks shall be made at the beginning of a job and at regular intervals. If a nuclear gauge is used for density determination, two random readings shall be made and averaged for each sublot.

209-3.6 FINISHING. The surface of the aggregate base course shall be finished by blading or with automated equipment especially designed for this purpose.



In no case will the addition of thin layers of material be added to the top layer of base course to meet grade. If the elevation of the top layer is 1/2 inch or more below grade, the top layer of base shall be scarified to a depth of at least 3 inches, new material added, and the layer shall be blended and recompacted to bring it to grade. If the finished surface is above plan grade, it shall be cut back to grade and rerolled.

209-3.7 SURFACE TOLERANCES. The finished surface shall not vary more than 3/8 inch when tested with a 16 foot straightedge applied parallel with or at right angles to the centerline. Any deviation in excess of this amount shall be corrected by the Contractor at the Contractor’s expense.

209-3.8 THICKNESS CONTROL. The completed thickness of the base course shall be within 1/2 inch of the design thickness. Four determinations of thickness shall be made for each lot of material placed. The lot size shall be consistent with that specified in paragraph 3.5. Each lot shall be divided into four equal sublots. Two tests shall be made for each sublot. Sampling locations will be determined by the COTR on a random basis in accordance with procedures contained in ASTM D 3665. Where the thickness is deficient by more than 1/2 inch, the Contractor shall correct such areas at no additional cost by excavating to the required depth and replacing with new material. Additional test holes may be required to identify the limits of deficient areas.

209-3.9 MAINTENANCE. The base course shall be maintained in a condition that will meet all specification requirements until the work is accepted. Equipment used in the construction of an adjoining section may be routed over completed portions of the base course, provided no damage results and provided that the equipment is routed over the full width of the base course to avoid rutting or uneven compaction. The Contractor shall remove all survey and grade hubs from the base courses prior to placing any bituminous surface course.


209-4.1 QUALITY CONTROL

A. Conform to all applicable provisions of Section 01400 "Contractor Quality Control Program." Provide the following tests:

1. Material Requirements. The Contractor shall perform all preliminary testing and testing during production of all material used as crushed aggregate base course. The Quality and gradation of the crushed aggregate base course shall meet the requirements specified herein.

2. Maximum Density Optimum Moisture. The Contractor shall obtain a maximum density-optimum moisture curve in accordance with ASTM D 1557 for the crushed aggregate base course.

3. Compaction Tests. The Contractor shall obtain in-place field densities, at the sampling rate specified in paragraph 209-3.5 Acceptance Sampling and Testing for Density.

4. Surface Tolerance. The Contractor shall measure and document the surface smoothness in accordance with paragraph 209-3.7 Surface Tolerance.

5. Thickness Control. The Contractor shall determine complete thickness in accordance with paragraph 209-3.8 Thickness Control.

6. Reports. A report of all preliminary test results and maximum density-optimum moisture curves shall be made and given to the COTR prior to use of the material as crushed aggregate base course. A report of all production testing, in-place densities, surface tolerances and thickness shall be made and given to the COTR within 48 hours of making the tests.




ASTM C 29 Unit Weight of Aggregate

ASTM C 88 Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate

ASTM C 117 Materials Finer than 75 μm (No. 200) Sieve in Mineral Aggregates by Washing

ASTM C 131 Resistance to Degradation of Small-Size Coarse Aggregate by abrasion and impact in the Los Angeles Machine

ASTM C 136 Sieve Analysis of Fine and Coarse Aggregates

ASTM D 75 Sampling Aggregate

ASTM D 422 Particle Size Analysis of Soils

ASTM D 693 Crushed Aggregate for Macadam Pavements

ASTM D 1556 Density of Soil in Place by the Sand-Cone Method

ASTM D 1557 Test for Laboratory Compaction Characteristics of Soil Using Modified Effort

ASTM D 2167 Density and Unit Weight of Soil in Place by the Rubber Balloon Method

ASTM D 2419 Sand Equivalent Value of Soils and Fine Aggregate

ASTM D 6938 In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods

ASTM D 3665 Random Sampling of Construction Materials

ASTM D 4318 Liquid Limit, Plastic Limit, and Plasticity Index of Soils

END OF ITEM P-209



CHOKE STONE INTERLAYER P-221-1

SECTION P-221 – CHOKE STONE INTERLAYER PART 1 - DESCRIPTION 1.1 This item shall consist of a choke stone interlayer comprised of fine aggregate applied to the

surface of a stabilized and/or permeable base layer placed beneath Portland cement concrete (PCC). The material shall be applied to the surface of the subject layer in accordance with these specifications and in conformity to the lines, grades, dimensions, and typical cross sections shown on the plans.

PART 2 - MATERIALS 2.1 AGGREGATE

The method used in producing the aggregate shall be such that the finished product is as consistent as practicable. The aggregate shall consist of clean, sound, hard, durable particles that meet the specification requirements. The aggregate shall be free from clay balls, organic matter, and other deleterious substances in accordance with ASTM C 33. Choke stone shall be made of hard, durable, fine aggregate. The aggregate shall conform to the gradation shown in Table 1 or the gradation requirements for VDOT Coarse Aggregate No. 10, VDOT Fine Aggregate Class A, B, C or F or ASTM C 33 No. 9, when tested in accordance with ASTM C 136.

Table 1. Aggregate Gradation for Choke Stone Material

Sieve Size Percentage by Weight Passing Sieves ½ in 100

3/8 in 100 No. 4 84-100

No. 100 10-30 2.2 SUBMITTALS

At least 15 days prior to the placement of the choke stone, the Contractor shall submit certified test reports to the COTR for the material proposed for use during construction. The certification shall show the appropriate ASTM specifications or tests for the material, the name of the company performing the tests, the date of the tests, the test results, and a statement that the material did or did not comply with the applicable specifications. Tests older than 6 months shall not be used. Submittals shall comply with procedures set forth in the “Shop Drawing and Sample Submittals” section of the General Conditions. No choke stone shall be placed until the submittal is approved by the COTR.



PART 3 – CONSTRUCTION METHODS 3.1 WEATHER LIMITATIONS

The choke stone may not be placed when rainfall is occurring or where rain is imminent. 3.2 PLACEMENT

The choke stone aggregate shall be spread into a single uniform layer of such width and thickness that, it conforms to the required grade and cross-section. The choke stone shall be placed no sooner than 24 hours prior to placement of the P-501 concrete. The choke stone shall be spread in a thin layer no thicker than 1/4 inch using spreading equipment approved by the COTR.

3.3 ACCEPTANCE SAMPLING AND TESTING

Unless otherwise specified, all acceptance sampling and testing necessary to determine conformance with the requirements specified in this section will be performed by the COTR at no cost to the Contractor. Testing organizations performing these tests shall meet the requirements of ASTM D 3666. All equipment in Contractor-furnished laboratories shall be calibrated by the testing organization prior to the start of operations. Aggregate samples shall be furnished by the Contractor in accordance with ASTM D 75 for laboratory testing prior to the start of production. Additionally, the Contractor shall furnish aggregate samples at specified intervals during production. Sampling for gradation shall be in accordance with ASTM D 75, and testing shall be in accordance with ASTM C 136 and C 117.

3.4 ACCEPTANCE CRITERIA

Completed choke stone layers shall be determined as “acceptable” or "unacceptable" on the basis of visual inspection. The COTR shall immediately notify the Contractor of visual defects, such as improper thickness, non-uniform texture, evidence of material segregation, and surface irregularities.


4.1.1 FIELD QUALITY CONTROL

A. Division 1 Section 01 40 00 “Quality Requirements” specifies the general requirements for the Contractor’s Quality Control Program.

B. The following describes the minimum inspection and testing required in the Contractor’s Quality Control (CQC) Plan and Program for the work of this section and is for CQC only. The implementation of the Contractor Quality Control Program does not relieve the Contractor from the responsibility to provide the work in accordance with the Contract Documents, applicable codes, regulations, and governing authorities. The CQC Plan and Program shall include, but not be limited to, the following testing and inspection elements. These elements are provided only as a minimum starting point for the Contractor to use to generate his complete CQC Program.

1. Aggregate Sampling



2. Aggregate Gradation 3. Layer Inspection

TESTING REQUIREMENTS ASTM C 117 Materials Finer than 75-µm (No. 200) Sieve in Mineral Aggregates by Washing ASTM C 136 Sieve or Screen Analysis of Fine and Course Aggregates ASTM D 75 Sampling Aggregates ASTM D 3665 Random Sampling of Paving Materials ASTM D 3666 Minimum Requirements for Agencies Testing and Inspecting Road and Paving Materials

MATERIAL REQUIREMENTS ASTM C 33 Standard Specification for Concrete Aggregates END ITEM P-221



CEMENT TREATED BASE COURSE P-304-1

SECTION P-304 - CEMENT-TREATED BASE COURSE

PART 1 - DESCRIPTION

304-1.1 GENERAL

A. This item shall consist of a base course composed of mineral aggregate and cement uniformly blended and mixed with water. The mixed material shall be spread, shaped, and compacted in accordance with these specifications and in conformity to the lines, grades, dimensions, and typical cross sections shown on the plans. Taxiway, taxilane, and apron pavements shall be built in a series of parallel lanes using a plan of processing that reduces longitudinal and transverse joints to a minimum.

304-1.2 QUALITY ASSURANCE

A. Reference Standards: Meet requirements of the referenced standards except to the extent more detailed or stringent requirements are indicated by the Contract Documents, including requirements of this Section and of governing codes and regulations.

B. Compliance with Laws, Codes, Rules, and Regulations: Comply with all local, State, and Federal laws, rules, and regulations applicable to this Section and to the selective demolition work to be done.

304-1.3 SUBMITTALS

A. Furnish shop drawings, manufacturer's data, test reports and materials certifications for all materials required in the referenced section, including:

1. Cement

2. Water

3. Aggregate

4. Curing Compound

5. Mix Design

6. Field Density Reports

7. Straightedge Test Report

PART 2 - MATERIALS

304-2.1 PORTLAND CEMENT

A. Portland cement shall conform to the requirements of ASTM C 150, Type I or Type II.



304-2.2 WATER

A. Water shall be clean, clear, and free from injurious amounts of sewage, oil, acid, strong alkalies, or vegetable matter, and it shall be free from clay or silt. If the water is of questionable quality, it shall be tested in accordance with the requirements of AASHTO T 26. Water known to be of potable quality may be used without testing.

304-2.3 AGGREGATE

A. The aggregate shall be select granular materials meeting the gradation requirements given in Table 1. The material shall be free of roots, sod, and weeds. The crushed or uncrushed aggregate shall consist of hard durable particles of accepted quality, free from an excess of flat, elongated, soft, or disintegrated pieces, or objectionable matter. The method used in producing the aggregate shall be such that the finished product shall be as consistent as practicable. All stones and rocks of inferior quality shall be wasted. The use of crushed Portland cement concrete will not be permitted.

B. Aggregates suspected of containing injurious quantities of sulfates shall be examined petrographically in accordance with ASTM C 295.

C. The aggregate shall conform to the gradation shown in Table 1 (VDOT 21A) when tested in accordance with ASTM C 136.

TABLE 1 - AGGREGATE CEMENT-TREATED BASE COURSE

Sieve Size Percentage by Weight

Passing Sieves 2 in. 1 in. 3/8 in. No. 10 No. 40 No. 200

100 94-100 63-72 32-41 14-24 6-12

D. The gradations in the table represent the limits that shall determine suitability of aggregate for use from the sources of supply. The final gradations decided on, within the limits designated in the table, shall be well graded from coarse to fine and shall not vary from the low limit on one sieve to the high limit on adjacent sieves, or vice versa. The portion of the base aggregate, including any blended material, passing the No. 40 sieve shall have a liquid limit of not more than 25 and a plasticity index of not more than 6 when tested in accordance with ASTM D 4318.

E. All aggregate samples required for testing shall be furnished by the Contractor at the expense of the Contractor. Sampling shall be in accordance with ASTM D 75 and will be observed by the COTR. No aggregate shall be used in production of mixtures without prior approval.

304-2.4 COVER MATERIAL FOR CURING

A. Curing material shall be an approved white pigmented wax-based liquid membrane-forming compound conforming to the requirements of ASTM C 309, Type 2, Class A or B.



PART 3 - CEMENT CONTENT

304-3.1 The cement content for construction shall be 6 percent by weight of the aggregate.

PART 4 - CONSTRUCTION METHODS

304-4.1 WEATHER LIMITATIONS

A. The cement-treated base shall not be mixed or placed while the atmospheric temperature is below 40 degrees F or when conditions indicate that the temperature may fall below 35 degrees F within 24 hours or when the weather is rainy. Cement-treated base shall not be placed on frozen subgrade or mixed when aggregate is frozen.

304-4.2 OPERATION AT PITS

A. All work involved in clearing and stripping pits, including handling unsuitable material shall be performed by the Contractor. The Contractor shall notify the COTR sufficiently in advance of opening of any designated pit to permit staking of boundaries at the site, to take elevations and measurements of the ground surface before material is produced, to permit the COTR to take samples of the material for tests to determine its quality and gradation, and to prepare a preliminary design of base mixture.

B. The pits, as utilized, shall be opened immediately to expose vertical faces of the various strata of acceptable material and, unless otherwise directed, the material shall be secured in successive vertical cuts extending through all the exposed strata in order to secure a uniform material.

304-4.3 PREPARING UNDERLYING COURSE

A. The underlying course shall be checked and accepted by the COTR before placing and spreading operations are started. Any ruts or soft yielding places caused by improper drainage conditions, hauling, or any other cause shall be corrected before the base course is placed thereon.

B. To protect the subbase and to ensure proper drainage, the spreading of the base shall begin along the centerline of the pavement on a crowned section or on the greatest contour elevation of the pavement.

304-4.4 MIXING (CENTRAL AND CONTINUOUS)

A. The aggregate shall be proportioned and mixed with cement and water in a central mixing plant. The plant shall be equipped with feeding and metering devices that will introduce the cement, aggregate, and water into the mixer in the quantities specified. Mixing shall continue until a thorough and uniform mixture has been obtained.



B. The continuous mixing Plant method of mixing the aggregate and cement will be allowed provided the following criteria are achieved. The COTR will be the sole evaluator of the process and will make the final determination.

1. Plant Approved for mixing Cement Treated Base Material by VDOT

2. Cement Addition System is capable of injecting a minimum of 6 percent cement. The plant shall be capable of producing the total matrix at a minimum rate of 250 tons per hour.

3. The plant shall be set at the cement content approved by the COTR and shall not be altered. If the cement content is altered for any reason, all operations for the established project will cease for that day or until the cement content is recalibrated.

4. The cement content shall be determined by the titration method. The Contractor shall provide for the testing of the cement content in accordance with VTM 40.

304-4.5 PLACING

A. The mixture shall be transported to the job site in suitable vehicles and shall be deposited on the moistened subbase in uniform layers by means of approved mechanical spreaders. The use of blade equipment such as graders or bulldozers will not be permitted. Not more than 60 minutes shall elapse between the start of moist mixing and the start of compaction of the cement-treated mixture on the prepared subgrade.

B. Final grading shall be accomplished by survey control established at 50-foot stations. Control shall be checked at centerline, pavement edges and a maximum of 50-foot intervals between, by elevation checks on the section. All elevations shall be submitted to the COTR for acceptance.

304-4.6 ACCEPTANCE SAMPLING AND TESTING OF CEMENT-TREATED BASE COURSE (COMPACTION & THICKNESS)

A. Immediately upon completion of the spreading operations, the mixture shall be thoroughly compacted. The number, type, and weight of rollers shall be sufficient to compact the mixture to the required density.

B. The cement-treated base course shall be accepted for density on a lot basis. A lot will consist of 1200 square yards or one day’s production if less than 1200 square yards, and will be divided into four (4) equal sublots. One test shall be made for each sublot. Sampling locations will be determined by the COTR on a random basis in accordance with statistical procedures contained in ASTM D 3665. The COTR will be performing all acceptance testing and the results obtained will be used as a basis of payment.

C. Each lot of compacted material will be accepted, with respect to density, when the average field density is equal to or greater than 98 percent of the maximum density of laboratory specimens prepared from samples of cement-treated base course taken from the material in place.

D. The laboratory specimens shall be compacted and tested in accordance with ASTM D 558. The in-place field density shall be determined in accordance with ASTM D 1556 or ASTM D 6938. The lot will be accepted without adjustment in payment if the average density, based on four (4) acceptance tests of the lot, is greater than or equal to 98 percent. If the average density does not



meet this requirement, the Contractor may elect to leave the lot in place at a reduced unit price determined in accordance with Table 2.

TABLE - 2 SLIDING SCALE PAY FACTORS

Average Percent Density Recommended Percent Payment

98.0 and greater 97.0-97.9 96.0-96.9 95.0-95.9

Less than 95.0

100 95 90 75

reject

E. Any mixture that has not been compacted shall not be left undistributed for more than 30 minutes. The moisture content of the mixture at the start of compaction shall not be below nor more than 2 percentage points above the optimum moisture content. The optimum moisture content shall be determined in accordance with ASTM D 558 and shall be less than that amount which will cause the mixture to become unstable during compaction and finishing.

F. The thickness of the Cement treated base course shall be determined from measurements of the depths of mixing at the time intervals so that each test shall represent no more than 300 square yards. The Contractor shall conduct the depth measurements, record the results on daily inspection reports, and supply the daily reports to the COTR. The average thickness of the subbase constructed during one day shall be within ½-inch of the thickness shown on the plans, except that the thickness of any one (1) point may be within ¾-inch of that shown on the plans. Where the average thickness shown by the measurements made in one (1) day’s construction is not within the tolerance given the COTR shall evaluate the area and determine if, in his opinion, it shall be reconstructed at the Contractor’s expense or the deficiency deducted from the total material in place. The determination evaluation and final payment shall rest solely with the COTR. Deficiencies in depth exceeding those tolerances listed hereinbefore shall result in a downward adjustment of payments as following:

½” to 1” - 50% 1” to 1-1/2” - 90% or rejection (at COTR’s option) Greater than 1-1/2” - Rejection (will require reconstruction)

304-4.7 LAYER THICKNESS

A. No layer shall be in excess of 9 inches or less than 4 inches when compacted. In multilayer construction, the surface of the compacted material shall be kept moist until covered with the next layer. Successive layers shall be placed and compacted so that the required total depth of the base course is completed the same day.

304-4.8 FINISHING

A. Completed base course shall conform to the required lines, grades, and cross section. If necessary, the surface shall be lightly scarified to eliminate any imprints made by the compacting or shaping equipment. The surface shall then be recompacted to the required density. The compaction and



finishing operations shall be completed within 2 hours of the time water is added to the mixture and shall produce a smooth, dense surface that is free of surface checking, ridges, or loose material. Should work be performed at night, adequate lighting shall be provided by the Contractor.

B. The equipment used for final grading shall be self-propelled machine with a mold board cutting edge 12-foot minimum width which is automatically controlled by sensors in conjunction with an independent grade control from a taut stringline (nylon cord or wire). The automatic control system shall be actuated from the stringline through a system of mechanical sensor or sensor-directed mechanisms that will maintain the cutting edge at a predetermined transverse slope and at the proper elevation to obtain the required base course surface. Stringline will be required on both sides of the sensor controls for all lanes. Under no circumstances will a “lock-in” device be allowed to control the automatic grading machine from the existing subgrade or previously completed lane.

304-4.9 SURFACE TOLERANCE

A. The finished surface shall not vary more than 3/8 inch when tested with a 16-foot straightedge applied parallel with, or at right angles to, the centerline of the stabilized area. The Contractor, at the Contractor’s expense, shall correct any deviation in excess of this amount.

304-4.10 CONSTRUCTION JOINTS

A. At the end of each day's construction, a transverse construction joint shall be formed by a header or by cutting back into the compacted material to form a true vertical face free of loose material.

B. Longitudinal joints shall be formed by cutting back 6 inches into the compacted material to form a true vertical edge. The material removed from the 6-inch section shall be spread across the subgrade or incorporated into the adjacent lane of material or disposed of as directed by the COTR.

C. Longitudinal and transverse joints in the cement-treated base shall be a minimum of two feet apart.

304-4.11 PROTECTION AND CURING

A. The completed cement-treated base to be overlain with concrete shall be cured with a white-pigmented curing compound applied as soon as possible and in no case later than 24 hours after completion of the finishing operations. The surface of the base course shall be kept moist until the curing compound is applied.

B. Curing compound shall be uniformly applied by mechanical sprayers under pressure at a rate of one (1) gallon to not more than 200 square feet of surface. The rate of application shall be approved by the COTR. The spraying equipment shall be of the fully atomizing type equipped with a tank agitator. At the time of use, the compound shall be in a thoroughly mixed condition with the pigment uniformly dispersed throughout the vehicle. During application the compound shall be stirred continuously by effective mechanical means. Hand spraying of odd widths or shapes will be permitted. The curing compound shall be of such character that the film will harden within 30 minutes after application. Should the film become damaged from any cause within the required curing period, the damaged portions shall be repaired immediately with additional compound.



C. The curing seal shall be maintained and protected until Portland Cement Concrete or Asphalt Concrete Pavement is placed.

D. Finished portions of the base course that are used by equipment in the construction of an adjoining section shall be protected to prevent marring or damaging the completed work. The stabilized area shall be protected from freezing during the curing period.


304-5.1 QUALITY CONTROL

A. Conform to all applicable provisions of Section 01400 "Contractor Quality Control Program." Provide the following tests:

1. Material Requirements. The Contractor shall perform all preliminary testing and testing during production of all material used as cement-treated base course. The Quality and gradation of the cement-treated base course shall meet the requirements specified herein.

2. Maximum Density Optimum Moisture. The Contractor shall obtain a maximum density-optimum moisture curve in accordance with ASTM D 558 for the cement-treated base course.

3. Compaction Tests. The Contractor shall obtain in-place field densities, at the sampling rate specified in paragraph 304-4.6 Acceptance Sampling and Testing of Cement-Treated Base Course (Compaction and Thickness).

4. Surface Tolerance. The Contractor shall measure and document the surface smoothness in accordance with paragraph 304-4.9 Surface Tolerance.

5. Thickness Control. The Contractor shall determine complete thickness in accordance with paragraph 304-4.7 Layer Thickness.

6. Reports. A report of all preliminary test results and maximum density-optimum moisture curves shall be made and given to the COTR prior to use of the material as cement-treated base course. A report of all production testing, in-place densities, surface tolerances and thickness shall be made and given to the COTR within 48 hours of making the tests.

7. Titration tests for plant mixed material shall be in accordance with VTM 40; one test for each lot.

PART 6 - METHOD OF MEASUREMENT

304-6.1 The quantity of Cement-Treated Base Course, 9-inch and 10-inch depth to be paid for will be determined by measurement of the number of square yards of base actually constructed and accepted by the COTR as complying with the plans and specifications.

304-6.2 The cement-treated base course, 8-inch depth, under the P-405, will not be measured for

payment.



PART 7 - BASIS OF PAYMENT

304-7.1 Payment shall be made at the contract unit price per square yard for Cement-Treated Base Course, 9-inch and 10-inch depth. This price shall be full compensation for furnishing all materials including Portland cement; for all preparation, manipulation, and placing of these materials; and for all labor, equipment, tools, and incidentals necessary to complete the item.

304-7.2 No direct payment will be made for the cement-treated base course, 8-inch depth, under the P-405, as it is incidental to Section 335243.11 10.


Item P-304-7.1 Cement-Treated Base Course, 9-inch depth -- per square yard

Item P-304-7.2 Cement Treated Base Course, 10-inch depth – per square yard


ASTM C 136 Sieve or Screen Analysis of Fine and Coarse Aggregate

ASTM C 295 Petrographic Examinations of Aggregates for Concrete

ASTM D 75 Sampling Aggregates

ASTM D 558 Moisture-Density Relations of Soil-Cement Mixtures

ASTM D 560 Freezing-and-Thawing Tests of Compacted Soil-Cement Mixtures

ASTM D 1556 Density of Soil in Place by the Sand-Cone Method

ASTM D 1633 Compressive Strength of Molded Soil-Cement Cylinders

ASTM D 3665 Random Sampling of Paving Materials

ASTM D 4318 Liquid Limit, Plastic Limit, and Plasticity Index of Soils

ASTM D 6938 Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth)

AASHTO T 26 Quality of Water to be Used in Concrete


ASTM C 150 Portland Cement

ASTM C 309 Specification for Liquid Membrane-Forming Compounds for Curing Concrete

END OF SECTION P-304


BITUMINOUS CONCRETE PAVEMENT P-405 - 1

SECTION P-405 – BITUMINOUS CONCRETE PAVEMENT

DESCRIPTION 405-1.1 GENERAL. This Work shall consist of constructing one or more courses of bituminous (asphalt) concrete, SUPERPAVE type, on the prepared foundation in accordance with these specifications and in reasonably close conformity with the lines, grades, thicknesses, and typical cross sections shown on the plans or as established by the Contracting Officer's Technical Representative (COTR). 405-1.2 QUALITY ASSURANCE.

A. Reference Standards: Meet requirements of the referenced standards except to the extent more detailed or stringent requirements are indicated by the Contract Documents, including requirements of this Section and of governing codes and regulations.

B. Compliance with Laws, Codes, Rules, and Regulations: Comply with all local, State,

and Federal laws, rules, and regulations applicable to this Section and to the selective demolition work to be done.

405-1.3 SUBMITTALS. Furnish shop drawings, manufacturer's data, test reports and materials certifications as required in the referenced section, including:

1. Job Mix Formula.

2. Field Density Reports.

3 Straightedge Test Report.

4. Material delivery weight slips. MATERIALS 405-2.1 AGGREGATE. A. Coarse Aggregate: Sound, angular crushed stone or crushed gravel, complying with

AASHTO M43 and AASHTO M283 for Type A, stone. Soundness loss shall be a maximum of 6 percent per AASHTO T103 or 15 percent per AASHTO T104. The coarse aggregate sizes retained on and above the No. 4 sieve shall meet the coarse aggregate requirements shown in Table 1 - Aggregate Properties below. Flat and Elongated (F&E) shall be tested in accordance with ASTM D 4791 and coarse aggregate angularity (CAA) shall be tested, on crushed gravel only, in accordance with ASTM D 5821.

B. Fine Aggregate: Sharp-edged natural sand or sand prepared from stone, gravel, or

combinations thereof, complying with AASHTO M6. Soundness loss shall be a maximum of 15 percent per AASHTO T103 or 25 percent (for surface and intermediate courses) or 30 percent (for base courses) per AASHTO T104. The fine aggregate requirements are shown in Table 1 - Aggregate Properties below. Fine aggregate angularity (FAA) shall be tested in accordance with AASHTO T 304 (Method A) and sand equivalent (SE) in accordance with AASHTO T 176.



C. Mineral Filler: Rock, hydraulic cement, or other inert material complying with ASTM D

242.

D. Bituminous Cement: Cements shall be Performance Graded 64-22 conforming to the requirements of AASHTO Provisional Specification MP-1.

Table 1 – Aggregate Properties

Mix Type

1 Fractured Face

2 Fractured Faces

F&E

Percent by Weight

SE

FAA

IM-19.0A 85% Min 80% Min 10% Max* 45% Min 45% Min

* Ten Percent measured at 5:1 on maximum to minimum dimension

E. After performing a gradation:

1. If 10 percent or more of the material is retained on the No. 4 sieve, then that portion will be tested in accordance with Section 2.1 A. herein.

2. If 10 percent or more of the material passes the No. 4 sieve, then that portion will be tested for Sand Equivalent.

3. If 10 percent or more of the material passes the No. 8 sieve, then that portion will be tested for Fine Aggregate Angularity.

F. Fine or coarse aggregates that tend to polish under traffic will not be permitted in any

final surface exposed to traffic. G. An antistripping additive shall be used in all asphalt mixes. It may be hydrated lime

in accordance with the requirements of (H.) below or an approved chemical additive from the VDOT’s approved list found in VDOT’s Materials Division's Manual of Instructions, or a combination of both.

The mixture shall produce a tensile strength ratio (TSR) value not less than 0.80 for the design and production tests. The TSR value shall be determined in accordance with AASHTO T283, including a freeze-thaw cycle, (4 inch specimens compacted with Marshall hammer or 3.5 x 6 inch specimens when compacted with a gyratory), except that the 16 hour curing time requirement and 72 to 96 hour storage period will be waived. Design tests shall use the same materials that are to be used in the production mix and shall be conducted in a VDOT approved laboratory. When a chemical additive is used, it shall be added to the asphalt cement prior to introduction into the mix. Any chemical additive or particular concentration of chemical additive found to be harmful to the asphalt material or which changes the viscosity of the original asphalt cement more than 400 poises or the penetration more than -4 or +10 shall be changed to obtain compliance with these values.



H. Hydrated lime shall conform to the requirements of ASTM C977. Hydrated lime

shall be added at a rate of not less than 1 percent by weight of the total dry aggregate. 405-2.2 BITUMINOUS - AGGREGATE MIXTURE

A. Provide the hot mix bituminous concrete mix indicated on the drawings and Tables 2 and 3. Aggregate gradation shall be tested in accordance with ASHTO T27.

Table 2 – Asphalt Concrete Mixtures-Design Range Percentage by Weight Passing Square Mesh Sieves (in)

Mix Type

1

3/4

1/2

No.8

No. 200

IM-19.0A Intermediate Course

100 90-100 90 Max 23-49 2-8

TABLE 2A MINIMUM AND MAXIMUM BOUNDARIES OF RESTRICTED GRADATION

Minimum and Maximum Percent Passing Nominal Maximum Aggregate Size

Sieve 3/4 Size Min. Max. No. 4 -- -- No. 8 34.6 34.6 No. 16 22.3 28.3 No. 30 16.7 20.7 No. 50 13.7 13.7


BITUMINOUS CONCRETE PAVEMENT P-405-4

TABLE 3

MIX DESIGN CRITERIA VTM

(%) VFA (%)

VFA (%) Production

Min. VMA

Fines/A Number of Gyrations Density (%) at

Mix Type (Note 1) Design (Note 2) (%) (Note 3) N Design N Initial N Max N Initial IM-19.0 A 2.5-5.5 69-76 64-81 13 0.6-1.2 65 7 100 < 90.5

Note 1: Asphalt content should be selected at the mid point of the VTM range. Note 2: During production of an approved job mix, the VFA shall be controlled within these limits. Note 3: Fines-Asphalt Ratio is based on effective asphalt content.

B. The job-mix-formula (JMF) shall be submitted to the COTR for approval prior to the start of paving operations. In support of the JMF, the Contractor shall submit SUPERPAVE design test data for the following minimum list:

1. aggregate sieve analysis

2. percent of aggregate component comprising the aggregate blend

3. aggregate gradation after stripping bituminous from the mix for sample preparation

4. VTM, VMA, VFA, and F/A percentages

5. mix specific gravity to 3 decimal places

6. mix temperature for testing minus 300o F to 300o F; compaction temperature for testing shall be 285o F to 290o F.

7. field correction factor

8. SUPERPAVE design data shall be plotted on graphs provided by the software of the test equipment manufacturer illustrating that the JMF requirements have been met.

C. The JMF shall establish a single percentage of aggregate passing each required

sieve, a single percentage of asphalt material to be added to the aggregate, a temperature at which the mixture is to be produced, and a temperature at which the mixture is to be compacted for SUPERPAVE testing according to the requirements of AASHTO PP28-99. All formulas shall remain in effect until modified in writing by the COTR.

D. SUPERPAVE mixes shall be designed and controlled according to the requirements of AASHTO PP28-99. The contractor shall have available all of the equipment outlined in AASHTO TP-4 (Section 4-6) and a VDOT certified SUPERPAVE Level I Mix Design Technician. The SUPERPAVE Gyratory Compactor (SGC) shall be one from the approved list maintained by the VDOT Materials Division. The SUPERPAVE mixes shall conform to the criteria



outlined in Table 2 and 3. Section 7.1.2 of AASHTO PP-2-99 shall be modified such that the compaction temperature is as specified in Section 405-2.2B.

The mixture shall be designed and compacted at the N design gyrations specified in Table 3. The N max requirement shall be verified as part of the design process by compacting a minimum of 2 specimens at the design asphalt content.

E. Type IM19.0A asphalt concrete shall consist of crushed stone, crushed slag, or crushed gravel and fine aggregate, slag or stone screenings or a combination thereof combined with asphalt cement. No more than 5 percent of the aggregate retained on the No. 4 sieve may be polish susceptible. All material passing the No. 4 sieve may be polish susceptible.

405-2.3 EQUIPMENT

A. Hauling Equipment: Trucks used for hauling bituminous mixtures shall have tight, clean, smooth metal bodies equipped with a positive locking metal tailgate. Metal surfaces in contact with bituminous mixtures shall be given a thin coat of an aliphatic hydrocarbon invert emulsion release agent (nonpuddling), a lime solution, or other material approved by the COTR. Except where a nonpuddling release agent is used, the beds of dump trucks shall be raised to remove excess agent prior to loading. Only a nonpuddling agent shall be used in truck beds that do not dump. Each truck shall be equipped with a tarpaulin or other cover that will protect the mixture from moisture and foreign matter and prevent the rapid loss of heat during transportation.

B. Asphalt Pavers: The asphalt paver shall be designed and recommended by the manufacturer for the type of asphalt to be placed and shall by operated in accordance with the manufacturer’s recommendations. Written recommendations pertaining to handling and placing of the mix shall be made readily available on the project site to the COTR. In the absence of manufacturer’s recommendations, the recommendations of the National Asphalt Pavement Association shall be followed. The paver (including when screed extensions are used) shall be capable of producing a smooth uniform texture, dense joints and a smooth riding surface.

C. Rollers: Rollers shall be steel wheel, static or vibratory, or pneumatic tire rollers and

shall be capable of reversing without backflash. Rollers shall be operated at speeds slow enough to avoid displacement of the mixture. The number and weight of rollers shall be sufficient to compact the mixture to the required density while it is still in workable condition. The use of equipment that results in excessive crushing of aggregate or marring of the pavement surface will not be permitted. NOTE: ONLY PNEUMATIC TIRED ROLLERS MAY BE USED TO COMPACT MATERIAL ADJACENT TO EXISTING CONCRETE EDGES.

D. Infrared Measuring Instrument: The Contractor shall furnish a properly calibrated infrared instrument for the purpose of measuring the surface temperature and shall measure the surface temperature.

405-2.4 PLACEMENT LIMITATIONS. Bituminous concrete mixtures shall not be placed when weather or surface conditions would prevent proper handling, finishing, or compacting of the mixture. The surface upon



which bituminous mixtures are to be placed shall be reasonably free from standing water at the time materials are spread. Table 5 shall be used to determine the minimum laydown temperature of the bituminous concrete, except as follows:

1. When the bituminous concrete course is less than 1-1/2 inches (165 pounds per square yard) and one roller is used for the 15-minute breakdown rolling, the surface temperature of the base shall be 80 degrees F or above.

2. When the base temperature is above 80 degrees F, laydown will be permitted at any mixture

temperature within the specification limits. 3. When the ambient air temperature is below 50 degrees F, the COTR may approve an increase

in the mixing temperature shown on the approved job mixture provided the temperature does not result in exceeding the maximum temperature allowed by the specifications.

4. At no time should the minimum laydown temperature be less than 250 degrees F. 5. The maximum temperature of the mix at the plant shall not exceed 350 degrees F.

Bituminous concrete intermediate course that exceed the rate of application given in Table 5 shall conform to the requirement for a 2-1/2 inch course when two rollers are used or the requirements of a 2-inch course when one roller is used. The rate of application is based on an average weight of 115 pounds per square yard per inch of depth. If the Contractor is unable to complete the breakdown within the applicable 8-minute or 15-minute period, the placing of the bituminous mixture shall cease until sufficient rollers are available or other corrective action is taken to complete the breakdown rolling within the specified time. All compaction rolling shall be completed prior to the mat cooling down to 175 degrees F. Finish rolling may be performed at lower mat temperature.



TABLE 5 COLD WEATHER PAVING LIMITATIONS Rate of Application (lbs/sy)

CONSTRUCTION METHODS 405-3.1 CONDITIONING EXISTING SURFACE. When the surface of the existing pavement or base is irregular, it shall be brought to a uniform grade and cross section as directed by the COTR. The surface on which the bituminous concrete is to be applied shall be prepared in accordance with Item P-209 or Section P-304. Contact surfaces of curbing, gutters, manholes, and other structures projecting into or abutting the pavement and cold joints of bituminous shall be painted with a thick, uniform coating of bituminous material conforming to Item P-603 prior to bituminous placement. Application of tack at joints, adjacent to curbs, gutters, or other appurtenances shall be applied with a hand wand at the rate of 0.2 gallons per square yard. At joints, the hand wand applied tack shall be 2 feet in width with 4 to 6 inches protruding beyond the joint for the first pass. Tack for the adjacent pass shall completely cover the vertical face of the mat edge, so that slight puddling of asphalt occurs at the joint, and extends a minimum of 1 foot into the lane to be paved. Milled faces that are to remain in place shall be tacked as above for the adjacent pass. Use of tack at longitudinal joint vertical faces will not be required when paving in echelon.



Bituminous materials classified as cutbacks or emulsions shall be applied ahead of the paving operations, and the time interval between applying and placing the paving mixture shall be sufficient to ensure a tacky residue providing maximum adhesion of the paving mixture to the base. Where irregularities in the existing surface would result in a course more than 3 inches in thickness after compaction, the surface shall be brought to a uniform profile by patching with bituminous concrete and thoroughly tamping or rolling until it conforms with the surrounding surface. The mixture used shall be the same as that specified for the course to be placed. When the Contractor elects to conduct operations to eliminate depressions, elevate curves, and place the surface course simultaneously, he shall furnish such additional spreading and compacting equipment as required to maintain the proper interval between the operations. 405-3.2 PLACING AND FINISHING. Bituminous concrete shall not be placed until the surface upon which it is to be placed has been approved by the COTR. The edge of the pavement shall be marked by means of a continuous line placed and maintained a sufficient distance ahead of the paving operation to provide proper control of the pavement width and horizontal alignment. A bituminous paver shall be used to distribute bituminous concrete over the widest pavement width practicable. Wherever practicable and when the capacity of sustained production and delivery is such that more than one paver can be operated, pavers shall be used in echelon to place the wearing course in adjacent lanes. Crossovers, as well as areas containing manholes or other obstacles that prohibit the practical use of mechanical spreading and finishing equipment, may be constructed using hand tools. However, care shall be taken to obtain the required thickness, jointing, compaction, and surface smoothness. Offsetting layers will not be required when adjoining lanes are paved in echelon and the rolling of both lanes occurs within 15 minutes after laydown. The Contractor shall have a certified Bituminous Concrete Paving Technician present during paving operations. Immediately after placement and screeding, the surface and edges of each layer shall be inspected and straightedged by the technician and necessary corrections performed prior to compaction. The finished pavement shall be uniform and smooth. The placement of bituminous concrete shall be as continuous as possible and shall be scheduled such that the interruption occurring at the completion of each day's work will not detrimentally affect the partially completed work. Material that cannot be spread and finished in daylight shall not be dispatched from the plant unless the use of artificial lighting has been approved. When paving is performed at the night, sufficient light shall be provided to properly perform and thoroughly inspect every phase of the operation. During compaction of bituminous concrete, the roller shall not pass over the end of freshly placed material except when a construction joint is to be formed. Edges shall be finished true and uniform. 405-3.3 COMPACTING. Immediately after the bituminous mixture is placed and struck off and surface irregularities are corrected, the mixture shall be thoroughly and uniformly compacted by rolling. The surface shall be rolled when the mixture is in the proper condition. Rolling shall not cause undue displacement, cracking, or shoving.



The number, weight, and type of rollers furnished shall be sufficient to obtain the required compaction while the mixture is in a workable condition. The sequence of rolling operations and the selection of roller types shall provide the specified pavement density. Immediately after the hot mixture is placed, it shall be sealed with rollers. Thereafter, rolling shall be a continuous process, insofar as practicable, and all parts of the pavement shall receive uniform compaction. On shoulders, rolling shall begin at the low side and progress to the high side by overlapping by at least 1/2 the roller width of longitudinal trips parallel to the center line. When abutting a previously placed lane, the longitudinal joint shall be rolled first, followed by the regular rolling procedure. Displacements occurring as a result of reversing the direction of a roller, or from other causes, shall be corrected at once by the use of rakes or lutes and addition of fresh mixture when required. Care shall be taken in rolling not to displace the line and grade of the edges of the bituminous mixture. To prevent adhesion of the mixture to the rollers, the wheels shall be kept properly moistened with water or water mixed with a very small quantity of detergent or other approved material. Excess liquid will not be permitted. Along forms, curbs, headers, walls, and other places not accessible to rollers, the mixture shall be thoroughly compacted with hot hand tampers, smoothing irons, or mechanical tampers. Edges of bituminous pavement surfaces shall be true curves or tangents. Irregularities shall be corrected. The surface of the compacted course shall be protected until the material has cooled sufficiently to support normal traffic without marring. 405-3.4 DENSITY. Density shall be determined by the use of a thin-lift nuclear density gage, with printer, using the backscatter method of testing and shall be furnished and operated by the Contractor. The nuclear density gage shall be calibrated in accordance with AASHTO test method T238-86. Submit certification of annual calibration of gages and documentation of licensed operator's training to the COTR. The required density of the compacted surface and intermediate courses shall be at least 94.0 but not more than 98.0 percent of the compacted unit weight of the mixture, at the job-mix asphalt content and design voids, as established by the SUPERPAVE design gyrations for the mixture. For the purpose of acceptance (density and depth), each day's production shall be divided into lots. A lot will consist of:

a) one day's production not to exceed 2,000 tons, or

b) a half day's production where a day's production is expected to consist of between 2,000 and 4,000 tons.

Each lot shall be divided into five (5) sublots of equal area. When a partial lot occurs at the end of a day's production or upon completion of the project, the lot size shall be redefined to be an entire lot. Each lot shall be checked for density by taking a nuclear density reading from two random locations selected by the COTR within each sublot. When readings are taken to determine acceptance any payment of the lot, the readings shall be taken in the presence of the COTR. Readings taken without the presence of the COTR will not be accepted in determining acceptance any payment. Reading shall not be taken within 2 feet of the edge of any



application width. The average of the sublot nuclear density readings will be compared to the target nuclear theoretical density, as a guide, to determine the integrity of the lot. Once the average nuclear density of the lot has been determined, the Contractor will not be permitted to provide additional compaction to raise the average. If two consecutive sublots produce nuclear density results less than 94 or greater than 98 percent of the target nuclear density, the Contractor shall immediately notify the COTR and institute corrective action. By the end of each day, the Contractor shall furnish the test data developed during the day's paving to the COTR. Payment will be based on the depth and density of pavement core samples described in Paragraph 405-3.5. 405-3.5 PAVEMENT CORE SAMPLES. The Contractor shall cut core samples from the compacted pavement and test for depth and density. A minimum one core shall be obtained per sublot. Cores shall be taken for the full depth of the course at the locations selected by the COTR. The cores will be measured for depth and density by the COTR. The removed pavement shall be replaced with new mixture and refinished. No additional compensation will be allowed for furnishing test cores, testing, and reconstructing areas from which they were taken. Payment will be adjusted for density variations in accordance with Table 6: TABLE 6 PAYMENT SCHEDULE FOR LOT DENSITIES

Percent of Target Density Percent of Payment

(per lot) Greater than 98 95 94 to 98 100 93 to less than 94 95 92 to less than 93 90 Less than 92 75

405-3.6 JOINTS. Transverse joints shall be formed by cutting back on the previous run to expose the full depth of the course. A coat of bituminous material shall be applied to contact surfaces of transverse joints just before additional mixture is placed against the previously rolled material. Joints adjacent to curbs, gutters, or adjoining pavement shall be formed by hand placing sufficient mixture to fill any space left uncovered by the paver. The joint shall then be set up with rakes or lutes to a height sufficient to receive full compression under the rollers. 405-3.7 PAVEMENT TOLERANCES.

A. Surface Tolerances: The pavement surface shall not vary more than 1/4 inch for surface course nor more than 3/8 inch for base course when measured using a 12 foot straight edge. Measurements shall be made for every day's production. Measurements shall be taken perpendicular and parallel to the direction of paving at less than 50 foot intervals. Not more than 15 percent of the tests for the lot shall exceed the tolerance otherwise



pavement shall be removed and replaced. No skin patching shall be permitted. High points may be ground to meet the required tolerances.

Corrective actions shall be performed at the Contractor's expense and shall be completed prior to determining the pavement thickness. Corrections shall consist of cold milling/grinding, overlaying, or removing and replacing. Cold milling and grinding shall be performed until the required surface tolerance is achieved and shall produce a uniform cross section. Milled areas shall be neat and of uniform surface appearance. Overlays shall be subject to the testing requirements of this section and the minimum overlay thickness will be two inches (2"). Only one overlay will be permitted.

B. Thickness Tolerance: The thickness (depth) of each course will be determined by the

measurement of cores as described in ASTM D3549.

Acceptance of bituminous concrete for depth will be based on the mean result of measurements of samples taken from each lot of material placed. Lot sizes are described in paragraph 405-3.4.

The COTR will measure the depth of extracted cores. Pavement more than 1/4 inch deficient in depth and which cannot be satisfactorily corrected, will be considered defective.

When tests show that the pavement is uniformly deficient by more than 1/8-inch depth in three or more adjoining sections and the deficiency cannot be satisfactorily corrected, the affected area will be considered defective work.

Backfill, compact, and seal test holes with acceptable material after depth measurements have been completed. Additional test holes may be required to determine the extent of the deficient areas.

Areas which are found to be defective shall be corrected by means of overlays or removal and replacement in accordance with paragraph 405-3.7 A. above.

Start the immediate correction of sections which are deficient in depth at the point of the determined deficiency and proceed longitudinally and transversely until the depth meets the requirements.

A lot will be considered acceptable for depth if the mean result of the tests is within the tolerances listed above.

Depths which exceed the indicated tolerances will be corrected as approved by the COTR.

C. Grading Tolerance: The finished surface of all courses shall not vary from design grade

more than 1/2 inch for level runs not exceeding 50 feet longitudinally or transversely for lot sizes of 2,000 square yards. Not more than 15 percent of the measurements per lot shall exceed the tolerance otherwise pavement shall be removed and replaced as specified in Paragraph 405-3.7 A. above.




405-4.1 FIELD QUALITY CONTROL. Conform to all applicable provisions of Section 01 40 00 "Quality Requirements." Provide the following tests.

1. Field Density.

2. Depth Tests.

3. Straightedge Tests.

4. Percent of Asphalt Content

5. Gradation

6. Temperature

MEASUREMENT AND PAYMENT 405-5.1 Bituminous concrete pavement shall not be measured for payment. BASIS OF PAYMENT 405-6.1 NO DIRECT PAYMENT WILL BE MADE FOR BITUMINOUS CONCRETE PAVEMENT UNDER THIS SECTION. PAYMENT FOR BITUMINOUS CONCRETE PAVEMENT IS INCIDENTAL TO SECTION 335243.11 10. TESTING REQUIREMENTS

ASTM D 2950 Density of Bituminous Concrete in Place by Nuclear Method

ASTM D 3549 Standard Test Method for Thickness or Height of Compacted Bituminous

Paving Mixture Specimens ASTM D 4791 Standard Test Method for Flat Particles, Elongated Particles, or Flat and

Elongated Particles in Coarse Aggregate ASTM D 5821 Standard Test Method for Determining the Percentage of Fractured Particles

in Coarse Aggregate AASHTO PP2 Practice for Mixture Conditioning of Hot-Mix Asphalt (HMA) AASHTO PP28 Practice for Superpave Volumetric Design for Hot-Mix Asphalt (HMA) AASHTO T 27 Sieve Analysis of Fine and Coarse Aggregates AASTHO T 103 Soundness of Aggregates by Freezing and Thawing AASHTO T 104 Soundness of Aggregate by Use of Sodium Sulfate or Magnesium Sulfate



AASHTO T 176 Plastic Fines in Graded Aggregates and Soils by Use of the Sand Equivalent

Test AASHTO T 238 Density of Soil and Soil-Aggregate In-Place by Nuclear Methods (Shallow

Depth) AASHTO T 283 Resistance of Compacted Asphalt Mixtures to Moisture-Induced Damage AASHTO T 304 Uncompacted Void Content of Fine Aggregate Virginia Test Control Strip Density and Roller Pattern and Control Strip Procedure Using Method 76 a Thin-Lift Nuclear Density Gauge for Asphalt Concrete Mixtures


ASTM C 977 Standard Specification for Quicklime and Hydrated Lime for Soil Stabilization

ASTM D 242 Standard Specification for Mineral Filler for Bituminous Paving Mixtures AASHTO M 6 Fine Aggregate for Portland Cement Concrete AASHTO M 43 Sizes of Aggregate for Bituminous Paving Mixtures AASHTO M 283 Coarse Aggregate for Highway and Airport Construction AASHTO MP1 Specification for Performance Graded Asphalt Binder AASHTO TP4 Preparing and Determining the Density of Hot-Mix Asphalt (HMA)

Specimens by Means of the Superpave Gyratory Compactor

END OF ITEM P-405



PORTLAND CEMENT CONCRETE PAVEMENT P-501-1

SECTION P-501 - PORTLAND CEMENT CONCRETE PAVEMENT

DESCRIPTION 501-1.1 This work shall consist of pavement composed of Portland cement concrete, with and without reinforcement constructed on a prepared underlying surface in accordance with these specifications and shall conform to the lines, grades, thickness, and typical cross sections shown on the plans.

501-1.2 QUALITY ASSURANCE A. Reference Standards. Meet requirements of the referenced standards except to the extent more

detailed or stringent requirements are indicated by the Contract Documents, including requirements of this Section and of governing codes and regulations.

B. Compliance with Laws, Codes, Rules, and Regulations. Comply with all local, State, and

Federal laws, rules, and regulations applicable to this Section and to the selective demolition work to be done.

501-1.3 SUBMITTALS

A. Furnish shop drawings, manufacturer's data, test reports and materials certifications for all

materials required in the referenced section, including:

(1) Aggregates

(2) Cement

(3) Cementitious Materials

(4) Premolded Joint Filler

(5) Steel Reinforcement

(6) Dowel and Tie Bars

(7) Dowel Bar Paint

(8) Dowel Bar Assembly

(9) Water

(10) Liquid Curing Compound

(11) Admixtures

(12) Epoxy-resin

(13) Mix-design

(14) Testing Laboratory Certification

(15) Testing laboratory personnel qualifications

(16) Proposed Paving Plan



MATERIALS 501-2.1 AGGREGATES

a. Reactivity. Aggregate shall be free of substances that are deleteriously reactive with the alkalies in the cement in an amount sufficient to cause excessive expansion of the concrete. Acceptable aggregate shall be based on satisfactory evidence furnished by the Contractor that the aggregate is free from such materials. This evidence shall include service records of concrete of comparable properties under similar conditions of exposure and/or certified records of tests by a testing laboratory that meets the requirements of ASTM C 1077. Tests shall be made in accordance with ASTM C 295 and ASTM C 289.

b. Fine Aggregate. Fine aggregate shall conform to the requirements of ASTM C 33. Gradation

shall meet the requirements of Table 1 when tested in accordance with ASTM C 136, except as may otherwise be qualified under Section 5 of ASTM C 33.

TABLE 1. GRADATION FOR FINE AGGREGATE (ASTM C 33)

Sieve Designation (Square Openings)

Percentage by Weight Passing Sieves

3/8 in. No. 4 No. 8 No. 16 No. 30 No. 50 No. 100

100 95-100 80-100 50-85 25-60 10-30 2-10

c. Coarse Aggregate. Coarse aggregate shall conform to the requirements of ASTM C 33.

Gradation, within the separated size groups, shall meet the requirements of Table 2 when tested in accordance with ASTM C 136. When the nominal maximum size of the aggregate is greater than 1 inch, the aggregates shall be furnished in two size groups.

Aggregates delivered to the mixer shall consist of crushed stone, crushed or uncrushed gravel, air-cooled blast furnace slag, or a combination thereof. The aggregate shall be composed of clean, hard, uncoated particles and shall meet the requirements for deleterious substances contained in ASTM C 33, Class 4S. Dust and other coating shall be removed from the aggregates by washing. The aggregate in any size group shall not contain more than 8 percent by weight of flat or elongated pieces when tested in accordance with ASTM D 4791. A flat or elongated particle is one having a ratio between the maximum and the minimum dimensions of a circumscribing rectangular prism exceeding 5 to 1.

The percentage of wear shall be no more than 40 when tested in accordance with ASTM C 131 or ASTM C 535.

TABLE 2. GRADATION FOR COARSE AGGREGATE (ASTM C 33)



Sieve Designations (square openings) in.

Percentage/Weight 1-1/2"-3/4"

Passing Sieves 3/4"-No.4

2-1/2 2 1-1/2 1 3/4 1/2 3/8 No. 4 No. 8

--- 100 90-100 20-55 0-15 --- 0-5 --- ---

--- --- --- 100 90-100 --- 20-55 0-10 0-5

(Locally available coarse aggregate material meeting the requirements of Table 2 may be substituted).

d. Aggregate Certifications. Certifications and testing results shall be provided for the referenced

criteria and standards. The certification and test results shall be no older than 1 year. 501-2.2 CEMENT

a. Cement shall conform to the requirements of ASTM 150 Type I or II. Only cements containing less than 0.6 percent equivalent alkali or cements which can demonstrate a positive reduction in the expansion created by alkali-silica reactions shall be used.

b. If for any reason, cement becomes partially set or contains lumps of caked cement, it shall be

rejected. Cement salvaged from discarded or used bags shall not be used. 501-2.3 CEMENTITIOUS MATERIALS

a. Fly Ash. Fly ash shall meet the requirements of ASTM C 618, Class F, or N with the exception of loss of ignition, where the maximum shall be less than 6 percent for Class F or N. The supplementary optional chemical and physical properties of Tables 1A and 2A contained in ASTM C 618 shall apply. Fly ash as is produced in furnace operations utilizing liming materials or soda ash (sodium carbonate) as an additive shall not be acceptable.

b. Blast Furnace Slag. Ground blast furnace slag shall meet the requirements of ASTM C 989,

Grade 100 or 120.

501-2.4 PREMOLDED JOINT FILLER

a. Premolded joint filler for expansion joints shall conform to the requirements of ASTM D 1751, and shall be punched to admit the dowels where called for on the plans. The filler for each joint shall be furnished in a single piece for the full depth and width required for the joint, unless otherwise specified by the COTR. When the use of more than one piece is required for a joint,



the abutting ends shall be fastened securely and held accurately to shape by stapling or other positive fastening means satisfactory to the COTR.

501-2.5 JOINT SEALER

a. The joint sealer for the joints in the concrete pavement shall meet the requirements of Item P-605 and shall be of the type(s) specified in the plans.

501-2.6 STEEL REINFORCEMENT

a. Reinforcing shall consist of welded steel wire fabric conforming to the requirements of ASTM A185, as shown on the plans. Reinforcing bars shall consist of deformed steel conforming to the requirements of ASTM A 615, Grade 60, as shown on the plans, if required.

501-2.7 DOWEL AND TIE BARS

a. Tie bars shall be deformed steel bars and conform to the requirements of ASTM A 615, ASTM A 616, or ASTM A 617, except that rail steel bars, Grade 50 or 60, shall not be used for tie bars that are to be bent or restraightened during construction. Tie bars designated as Grade 40 in ASTM A 615 can be used for construction requiring bent bars.

b. Dowel bars shall be plain steel bars conforming to ASTM A 615, ASTM A 616 or ASTM A

617 and shall be free from burring or other deformation restricting slippage in the concrete. High strength dowel bars shall conform to ASTM A714, Class 2, Type S, Grade I, II or III, Bare Finish. Before delivery to the construction site each dowel bar shall be painted on all surfaces with one coat of paint meeting Federal Specification TT-P-664. If plastic or epoxy-coated steel dowels are used no paint coating is required, except when specified for a particular situation on the plans. Coated dowels shall conform to the requirements of AASHTO M 254.

The sleeves for dowel bars used in expansion joints shall be metal or other material, of an approved design to cover 2 to 3 inches of the dowel, with a closed end and with a suitable stop to hold the end of the bar at least 1 inch from the closed end of the sleeve. Sleeves shall be of such design that they will not collapse during construction.

501-2.8 WATER

a. Water used in mixing or curing shall be clean and free of oil, salt, acid, alkali, sugar, vegetable, or other substances injurious to the finished product. Water will be tested in accordance with the requirements of AASHTO T 26. Water known to be of potable quality may be used without testing.

501-2.9 COVER MATERIAL FOR CURING

a. Only the following curing material shall be used:

(1) Liquid membrane-forming compounds for curing concrete shall conform to the requirements of ASTM C 309, Type 2, Class B.

501-2.10 ADMIXTURES



a. The use of any material added to the concrete mix shall be approved by the COTR. The

Contractor shall submit certificates indicating that the material to be furnished meets all of the requirements indicated below. In addition, the COTR may require the Contractor to submit complete test data from an approved laboratory showing that the material to be furnished meets all of the requirements of the cited specifications. Subsequent tests may be made of samples taken by the COTR from the supply of the material being furnished or proposed for use on the work to determine whether the admixture is uniform in quality with that approved.

b. Air-Entraining Admixtures. Air-entraining admixtures shall meet the requirements of ASTM C

260 and shall consistently entrain the air content in the specified ranges under field conditions. The air-entrainment agent and any water reducer admixture shall be compatible.

c. Chemical Admixtures. Water-reducing, set retarding, and set-accelerating admixtures shall meet

the requirements of ASTM C 494, including the flexural strength test. 501-2.11 EPOXY-RESIN

a. Epoxy-resin used to anchor dowels and tie bars in pavements shall conform to the requirements of ASTM C 881, Type I, Grade 3, Class C. Class A or B shall be used when the surface temperature of the hardened concrete is below 60 degrees F. In addition, the materials shall meet the following requirements:

(1) All materials shall have a 24-hour absorption not greater than 1.0 percent.

(2) Epoxy Resin Materials for bonding freshly mixed Portland cement concrete or mortar

or freshly mixed epoxy resin concrete or mortar to hardened concrete shall be Type II materials, grade as approved.

(3) Epoxy Resin Materials for use as patching materials for complete filling of spalls,

wide cracks and other voids, for use for embedding dowels and anchor bolts, and for use as a binder in preparing epoxy resin mortars and concretes shall be Type III materials and shall in addition meet the following requirements:

A. The bond strength at 14 days (moist cure) shall be at least 1000 psi.

B. The volatile content, cured system, shall not exceed 3.0 percent. Grade shall be

approved except that Grade 3 shall be used for embedding dowels in hardened concrete.

501-2.12 MATERIAL ACCEPTANCE

a. Prior to use of materials, the Contractor shall submit certified test reports to the COTR for those materials proposed for use during construction. The certification shall show the appropriate ASTM and AASHTO test(s) for each material, the test results, and a statement that the material passed or failed.

b. The COTR may request samples for testing, prior to and during production, to verify the quality

of the materials and to ensure conformance with the applicable specifications.



MIX DESIGN 501-3.1 PROPORTIONS

a. Concrete shall be designed to achieve a 28-day flexural strength such that meets or exceeds the acceptance criteria contained in paragraph 501-5.2 for a flexural strength of 700 psi. The mix shall be designed using the procedures contained in Chapter 7 of the Portland Cement Association's manual, "Design and Control of Concrete Mixtures".

b. The Contractor shall note that to ensure that the concrete actually produced will meet or exceed

the specified strength, the mix design average strength must be considerably higher than the specified strength. The amount of overdesign necessary to meet specification requirements depends on the producer's standard deviation of flexural test results and the accuracy which that value can be estimated from historic data for the same or similar materials.

c. The minimum cementitious material (cement plus fly ash) shall be 611 pounds per cubic yard.

The ratio of water to cementitious material, including free surface moisture on the aggregates but not including moisture absorbed by the aggregates shall not be more than 0.45 by weight.

d. Prior to the start of paving operations and after approval of all material to be used in the concrete,

the Contractor shall submit a mix design showing the proportions and flexural strength obtained from the concrete at 7 and 28 days. The mix design shall include copies of test reports, including test dates, and a complete list of materials including type, brand, source, and amount of; cement, fly ash, ground slag, coarse aggregate, fine aggregate, water, and admixtures. The fineness modulus of the fine aggregate and the air content shall also be shown. The mix design shall be submitted to the COTR at least 15 days prior to the start of operations. Production shall not begin until the mix design is approved in writing by the COTR.

e. Should a change in sources be made, or admixtures added or deleted from the mix, a new mix

design must be submitted to the COTR for approval. Mix designs older than 90 days shall not be used.

f. Flexural strength test specimens shall be prepared in accordance with ASTM C 31 and tested in

accordance with ASTM C 78. The mix determined shall be workable concrete having a slump for side-form concrete between 1 and 2 inches as determined by ASTM C 143. For vibrated slip-form concrete, the slump shall be between 1/2 inch and 1 1/2 inches.

Note to Contractor: For slip-form construction, a high degree of uniformity in the plastic concrete is required. Caution should be exercised in establishing the air-entrainment percentage as excessive air entrainment will aggravate edge slumping and insufficient air entrainment will result in poor concrete durability. Some edge slump of the wet concrete behind the side form on the paving machine will occur, even with low slump concrete. This may continue, though very slowly, until initial set has taken place. 501-3.2 CEMENTITIOUS MATERIALS



a. Fly Ash. Fly ash may be used in the mix design. When fly ash is used as a partial replacement for cement, the minimum cement content may be met by considering Portland cement plus fly ash as the total cementitious material. The replacement rate shall be determined from laboratory trial mixes, but shall not exceed 15 percent by weight of the total cementitious material.

b. Ground Slag. Ground blast-furnace slag may be used in a mix design containing Type I or Type

II cement. The slag, or slag plus fly ash if both are used, may constitute between 25 to 55 percent of the total cementitious material by weight. If the concrete is to be used for slipforming operations and the air temperature is expected to be lower than 55 degrees F the percent slag shall not exceed 30 percent by weight.

501-3.3 ADMIXTURES

a. Air-Entraining. Air-entraining admixture shall be added in such a manner that will insure uniform distribution of the agent throughout the batch. The air content of freshly mix air-entrained concrete shall be based upon trial mixes with the materials to be used in the work adjusted to produce concrete of the required plasticity and workability. The percentage of air in the mix shall be 5.0 percent. Air content shall be determined by testing in accordance with ASTM C 231 for gravel and stone coarse aggregate and ASTM C 173 for slag and other highly porous coarse aggregate.

b. Chemical. Water-reducing, set-controlling, and other approved admixtures shall be added to the

mix in the manner recommended by the manufacturer and in the amount necessary to comply with the specification requirements. Tests shall be conducted on trial mixes, with the materials to be used in the work, in accordance with ASTM C 494.

501-3.4 TEST BATCH

a. At least 28 days prior to the start of production the contractor and/or producer shall prepare a Test Batch under the direction of the COTR. The Test Batch shall be prepared at the concrete plant proposed for use in the production of the concrete mix for the project and the test batch proportions shall be in accordance with the approved Job Mix Formula (JMF). The plant shall have been surveyed and approved by the COTR prior to preparation of the Test Batch. As required by these Special Provisions, the Contractor shall provide all Quality Control for production of the concrete. The Test Batch shall be prepared as follows:

(1) Proportioning. The Contractor shall proportion the plant in accordance with Section

501-6.1, “Contractor Quality Control Program” prior to preparation of the mix.

(2) Preparation of the Mix.

A. Prepare a minimum Test Batch of at least four (4) cubic yards of concrete in accordance with the approved JMF, adjusted for moisture.

B. Mixing.

1. Stationery Plant: Minimum of 90 seconds. 2. Transit Mixer: 70-100 Revs. @ 5-16 RPM

C. After initial mixing, agitate mix at 2-5 RPM for the approximate time anticipated



from when the water contacts the cement and deposit of the concrete in the forms.

D. Check slump and air. If the air content is approximately 5.5% and the slump is 1

inch, the COTR will make beams for testing at 3,7,14 and 28 days while the COTR observes. If the slump is below 1 inch, the Contractor may add additional water to increase the slump 1 inch. Additional mixing of at least 40 Revs will be required with each addition of water. Beams will be made for testing at 3,7,14 and 28 days when the 1 inch slump is obtained at approximate 5.5% air content. If the Contractor wishes to have a higher slump concrete for formed concrete, additional water and mixing will be permitted to produce a slump up to 3 inches. The Contractor may add additional water reducing admixture to obtain the higher slump. Beams will be made for testing the higher slump concrete at 3,7,14 and 28 days. The COTR may require the preparation of a new batch of four (4) cubic yards of concrete in order to make the high slump Test Batch. The higher slump concrete will be considered part of the test batch.

E. The concrete test beams shall be tested at 3,7,14 and 28 days to establish a

growth curve of concrete strength vs. age. The flexural strength shall be at least 100 psi over the specified strength at 28 days.

(3) The Test Batch shall be paid for under Section 501-8.1. Only one Test Batch

consisting of both low and high slump concrete will be paid for per project. Any additional Test Batches shall be paid for by the Contractor.

501-3.5 TESTING LABORATORY

a. The laboratory used to develop the mix design shall meet the requirements of ASTM C 1077. A certification that it meets these requirements shall be submitted to the COTR prior to the start of mix design and shall contain as a minimum:

b. Qualifications of personnel; laboratory manager, supervising technician, and testing technicians.

c. A statement that the equipment used in developing the mix design is in calibration. d. A statement that each test specified in developing the mix design is offered in the scope of the

laboratory's services.

e. A copy of the laboratory's quality control system. CONSTRUCTION METHODS 501-4.1 EQUIPMENT

a. The Contractor shall furnish all equipment and tools necessary for handling materials and performing all parts of the work.

b. Batch Plant and Equipment. The batch plant and equipment shall conform to the requirements of

ASTM C 94.



c. Mixers and Transportation Equipment.

(1) General. Concrete may be mixed at a central plant, or wholly or in part in truck

mixers. Each mixer shall have attached in a prominent place a manufacturer's nameplate showing the capacity of the drum in terms of volume of mixed concrete and the speed of rotation of the mixing drum or blades.

(2) Central plant mixer. Central plant mixers shall conform to the requirements of ASTM

C 94.

A. The mixer shall be examined daily for changes in condition due to accumulation of hard concrete or mortar or wear of blades. The pickup and throwover blades shall be replaced when they have worn down 3/4 inch or more. The Contractor shall have a copy of the manufacturer's design on hand showing dimensions and arrangement of blades in reference to original height and depth.

(3) Truck mixers and truck agitators. Truck mixers used for mixing and hauling concrete

and truck agitators used for hauling central-mixed concrete shall conform to the requirements of ASTM C 94.

(4) Nonagitator trucks. Nonagitating hauling equipment shall conform to the

requirements of ASTM C 94.

d. Finishing Equipment. The finishing equipment shall be of sufficient weight and power for proper finishing of the concrete. The finishing machine shall be designed and operated to strike off, screed and consolidate the concrete such that laitance on the surface is less than 1/8-inch thick.

e. Vibrators. Vibrator shall be either internal type with immersed tube or multiple spuds. They

may be attached to the spreader or the finishing machine, or they may be mounted on a separate carriage. Operating frequency for internal vibrators shall be between 8,000 and 12,000 vibrations per minute. Average amplitude for internal vibrators shall be 0.025-0.05 inches. The internal vibrators may be supplemented by vibrating screeds operating on the surface of the concrete.

The number, spacing, and frequency shall be as necessary to provide a dense and homogeneous pavement. Adequate power to operate all vibrators shall be available on the paver. The vibrators shall be automatically controlled so that they shall be stopped as forward motion ceases.

Hand held vibrators may be used in irregular areas.

f. Concrete Saws. The Contractor shall provide sawing equipment adequate in number of units and power to complete the sawing to the required dimensions. The Contractor shall provide at least one standby saw in good working order and a supply of saw blades at the site of the work at all times during sawing operations. The Contractor shall provide adequate lighting facilities for night sawing. All of this equipment shall be on the job both before and at all times during concrete placement.



g. Side Forms. Straight side forms shall be made of steel and shall be furnished in sections not less than 10 feet in length. Forms shall have a depth equal to the pavement thickness at the edge. Flexible or curved forms of proper radius shall be used for curves of 100-foot radius or less. Forms shall be provided with adequate devices for secure settings so that when in place they will withstand, without visible spring or settlement, the impact and vibration of the consolidating and finishing equipment. Forms with battered top surfaces and bent, twisted or broken forms shall not be used. Built-up forms shall not be used, except as approved by the COTR. The top face of the form shall not vary from a true plane more than 1/8 inch in 10 feet, and the upstanding leg shall not vary more than 1/4 inch. The forms shall contain provisions for locking the ends of abutting sections together tightly for secure setting. Wood forms may be used under special conditions, when approved by the COTR.

h. Pavers. The paver shall be fully energized, self-propelled, and designed for the specific purpose of placing, consolidating, and finishing the concrete pavement, true to grade, tolerances, and cross section. It shall be of sufficient weight and power to construct the maximum specified concrete paving lane width as shown in the plans, at adequate forward speed, without transverse, longitudinal or vertical instability or without displacement. The paver shall be equipped with electronic or hydraulic horizontal and vertical control devices.

(1) The request for the use of roller screeds must be submitted to the COTR for approval.

The submittal must include the training the contractor has received on the use of roller screeds. Vibrators must not be operational if the screed is not advancing.

501-4.2 FORM SETTING

a. Forms shall be set sufficiently in advance of the concrete placement to insure continuous paving operation. After the forms have been set to correct grade, the underlying surface shall be thoroughly tamped, either mechanically or by hand, at both the inside and outside edges of the base of the forms. Forms shall be staked into place sufficiently to maintain the form in position for the method of placement.

b. Form sections shall be tightly locked and shall be free from play or movement in any direction.

The forms shall not deviate from true line by more than 1/8 inch at any joint. Forms shall be so set that they will withstand, without visible spring or settlement, the impact and vibration of the consolidating and finishing equipment. Forms shall be cleaned and oiled prior to the placing of concrete.

c. The alignment and grade elevations of the forms shall be checked and corrections made by the

Contractor immediately before placing the concrete. 501-4.3 CONDITIONING OF UNDERLYING SURFACE, SLIP-FORM CONSTRUCTION

a. The compacted underlying surface on which the pavement will be placed shall be widened approximately 3 feet to extend beyond the paving machine track to support the paver without any noticeable displacement. After the underlying surface has been placed and compacted to the required density, the areas which will support the paving machine and the area to be paved shall be trimmed or graded to the plan grade elevation and profile by means of a properly designed machine. The grade of the underlying surface shall be controlled by a positive grade control system using lasers, stringlines, or guide wires. If the density of the underlying surface is disturbed by the trimming operations, it shall be corrected by additional compaction and retested



at the option of the COTR before the concrete is placed except when stabilized subbases are being constructed. If damage occurs on a stabilized subbase, it shall be corrected full depth by the Contractor. If traffic is allowed to use the prepared grade, the grade shall be checked and corrected immediately before the placement of concrete. The prepared grade shall be moistened with water, without saturating, immediately ahead of concrete placement to prevent rapid loss of moisture from concrete. The underlying surface shall be protected so that it will be entirely free of frost when concrete is placed. The use of chemicals to eliminate frost in the underlying surface shall not be permitted.

501-4.4 CONDITIONING OF UNDERLYING SURFACE, SIDE-FORM AND FILL-IN LANE

CONSTRUCTION

a. The prepared underlying surface shall be moistened with water, without saturating, immediately ahead of concrete placement to prevent rapid loss of moisture from the concrete. Damage caused by hauling or usage of other equipment shall be corrected and retested at the option of the COTR. If damage occurs to a stabilized subbase, it shall be corrected full depth by the Contractor. A template shall be provided and operated on the forms immediately in advance of the placing of all concrete. The template shall be propelled only by hand and not attached to a tractor or other power unit. Templates shall be adjustable so that they may be set and maintained at the correct contour of the underlying surface. The adjustment and operation of the templates shall be such as will provide an accurate retest of the grade before placing the concrete thereon. All excess material shall be removed and wasted. Low areas shall be filled and compacted to a condition similar to that of the surrounding grade. The underlying surface shall be protected so that it will be entirely free from frost when the concrete is placed. The use of chemicals to eliminate frost in the underlying surface shall not be permitted.

b. The template shall be maintained in accurate adjustment, at all times by the Contractor, and shall

be checked daily. 501-4.5 HANDLING, MEASURING, AND BATCHING MATERIAL

a. The batch plant site, layout, equipment, and provisions for transporting material shall assure a continuous supply of material to the work. Stockpiles shall be constructed in such a manner that prevents segregation and intermixing of deleterious materials.

b. Aggregates that have become segregated or mixed with earth or foreign material shall not be

used. All aggregates produced or handled by hydraulic methods, and washed aggregates, shall be stockpiled or binned for draining at least 12 hours before being batched. Rail shipments requiring more than 12 hours will be accepted as adequate binning only if the car bodies permit free drainage.

c. Batching plants shall be equipped to proportion aggregates and bulk cement, by weight, automatically using interlocked proportioning devices of an approved type. When bulk cement is used, the Contractor shall use a suitable method of handling the cement from weighing hopper to transporting container or into the batch itself for transportation to the mixer, such as a chute, boot, or other approved device, to prevent loss of cement. The device shall be arranged to provide positive assurance that the cement content specified is present in each batch.

501-4.6 MIXING CONCRETE



a. The concrete may be mixed at the work site, in a central mix plant or in truck mixers. The mixer shall be of an approved type and capacity. Mixing time shall be measured from the time all materials, except water, are emptied into the drum. All concrete shall be mixed and delivered to the site in accordance with the requirements of ASTM C 94. Mixed concrete from the central mixing plant shall be transported in truck mixers, truck agitators, or nonagitating trucks. The elapsed time from the addition of cementitious material to the mix until the concrete is deposited in place at the work site shall not exceed 30 minutes when the concrete is hauled in nonagitating trucks, nor 90 minutes when the concrete is hauled in truck mixers or truck agitators. Retempering concrete by adding water or by other means will not be permitted, except when concrete is delivered in transit mixers. With transit mixers additional water may be added to the batch materials and additional mixing performed to increase the slump to meet the specified requirements provided the addition of water is performed within 45 minutes after the initial mixing operations and provided the water/cementitious ratio specified in the mix design is not exceeded.

b. Each truckload of Ready Mix Cement Concrete shall furnish a ticket or tape as generated at the

concrete plant. 501-4.7 LIMITATIONS ON MIXING AND PLACING

a. No concrete shall be mixed, placed, or finished when the natural light is insufficient, unless an adequate and approved artificial lighting system is operated.

b. Cold Weather. Unless authorized in writing by the COTR, mixing and concreting operations

shall be discontinued when a descending air temperature in the shade and away from artificial heat reaches 40 degrees F and shall not be resumed until an ascending air temperature in the shade and away from artificial heat reaches 35 degrees F.

(1) The aggregate shall be free of ice, snow, and frozen lumps before entering the mixer.

The temperature of the mixed concrete shall not be less than 50 degrees F at the time of placement. Concrete shall not be placed on frozen material nor shall frozen aggregates be used in the concrete.

(2) When concreting is authorized during cold weather, water and/or the aggregates may

be heated to not more than 150 degrees F. The apparatus used shall heat the mass uniformly and shall be arranged to preclude the possible occurrence of overheated areas which might be detrimental to the materials.

c. Hot Weather. During periods of hot weather when the maximum daily air temperature exceeds

85 degrees F, the following precautions shall be taken.

(1) The forms and/or the underlying surface shall be sprinkled with water immediately before placing the concrete. The concrete shall be placed at the coolest temperature practicable, and in no case shall the temperature of the concrete when placed exceed 95 degrees F. The aggregates and/or mixing water shall be cooled as necessary to maintain the concrete temperature at or not more than the specified maximum.

(2) The finished surfaces of the newly laid pavement shall be kept damp by applying a

water-fog or mist with approved spraying equipment until the pavement is covered by the curing medium. If necessary, wind screens shall be provided to protect the



concrete from an evaporation rate in excess of 0.2 psf per hour as determined in accordance with Figure 2.1.5 in ACI 305R, Hot Weather Concreting, which takes into consideration relative humidity, wind velocity, and air temperature.

(3) When conditions are such that problems with plastic cracking can be expected, and

particularly if any plastic cracking begins to occur, the Contractor shall immediately take such additional measures as necessary to protect the concrete surface. Such measures shall consist of wind screens, more effective fog sprays, and similar measures commencing immediately behind the paver. If these measures are not effective in preventing plastic cracking, paving operations shall be immediately stopped.

501-4.8 PLACING CONCRETE a. Prior to commencement of paving operations, the Contractor shall submit for review and

approval by the COTR a tabulation of elevations of the paving land edge elevations. These elevations shall be presented to the nearest hundredth (0.01) of a foot at intervals not exceeding 25 feet on center.

b. The Contractor has the option of placing the concrete with either side (fixed) forms or slip-forms.

At any point in concrete conveyance, the free vertical drop of the concrete from one point to another or to the underlying surface shall not exceed 3 feet.

c. Prior to Panel Replacement. Existing tie bars and dowels that were damaged or bent during

pavement removal operations shall be straightened or replaced as directed by the COTR. All embedments such as tie bars, dowels, transformer bases, conduits, sleeves, underdrains, and all other items indicated on the plans or directed to be embedded shall be placed and/or securely anchored before concrete is placed. Concreting shall not be started until the embedment items have been checked and approved for alignment and location. All embedded items must be secured and/or protected so as not to be disturbed by concrete operations.

d. Hauling equipment or other mechanical equipment can be permitted on adjoining previously

constructed pavement when the concrete strength reaches a flexural strength of 550 psi based on the average of four (4) field cured specimens per 2,000 cubic yards of concrete placed. Also, subgrade and subbase planers, concrete pavers, and concrete finishing equipment may be permitted to ride upon the edges of previously constructed pavement when the concrete has attained a minimum flexural strength of 400 psi.

e. Side-form Method. For the side-form method, the concrete shall be deposited on the moistened

grade to require as little rehandling as possible. Unless truck mixers, truck agitators, or nonagitating hauling equipment are equipped with means for discharge of concrete without segregation of the materials, the concrete shall be placed and spread using an approved mechanical spreading device that prevents segregation of the materials. Placing shall be continuous between transverse joints without the use of intermediate bulkheads. Necessary hand spreading shall be done with shovels--not rakes. Workmen shall not be allowed to walk in the freshly mixed concrete with boots or shoes coated with earth or foreign substances.

(1) Concrete shall be deposited as near to expansion and contraction joints as possible

without disturbing them but shall not be dumped from the discharge bucket or hopper onto a joint assembly unless the hopper is centered above the joint assembly.



(2) Concrete shall be thoroughly consolidated against and along the faces of all forms and

previously placed concrete and along the full length and on both sides of all joint assemblies by means of vibrators inserted in the concrete. Vibrators shall not be permitted to come in contact with a joint assembly, the grade, or a side form. In no case shall the vibrator be operated longer than 20 seconds in any one location, nor shall the vibrators be used to move the concrete.

f. Slip-form Method. For the slip-form method, the concrete shall be placed with an approved

crawler-mounted, slip-form paver designed to spread, consolidate and shape the freshly placed concrete in one complete pass of the machine so that a minimum of hand finishing will be necessary to provide a dense and homogeneous pavement in conformance with requirements of the plans and specifications. The concrete shall be placed directly on top of the joint assemblies to prevent them from moving when the paver moves over them. Side forms and finishing screeds shall be adjustable to the extent required to produce the specified pavement edge and surface tolerance. The side forms shall be of dimensions, shape, and strength to support the concrete laterally for a sufficient length of time so that no edge slumping exceeds the requirements of paragraph 501-5.2.i. Final finishing shall be accomplished while the concrete is still in the plastic state.

g. In the event that slumping or sloughing occurs behind the paver or if there are any other

structural or surface defects which, in the opinion of the COTR, cannot be corrected within permissible tolerances, paving operations shall be immediately stopped until proper adjustment of the equipment or procedures have been made. In the event that satisfactory procedures and pavement are not achieved after not more than 2,000 linear feet of single lane paving, the Contractor shall complete the balance of the work with the use of standard metal forms and the formed method of placing and curing. Any concrete not corrected to permissible tolerances shall be removed and replaced at the Contractor's expense.

501-4.9 STRIKE-OFF OF CONCRETE AND PLACEMENT OF REINFORCEMENT

a. Following the placing of the concrete, it shall be struck off to conform to the cross section shown on the plans and to an elevation such that when the concrete is properly consolidated and finished, the surface of the pavement shall be at the elevation shown on the plans. When reinforced concrete pavement is placed in two layers, the bottom layer shall be struck off to such length and depth that the sheet of reinforcing steel fabric or bar mat may be laid full length on the concrete in its final position without further manipulation. The reinforcement shall then be placed directly upon the concrete, after which the top layer of the concrete shall be placed, struck off, and screeded. If any portion of the bottom layer of concrete has been placed more than 30 minutes without being covered with the top layer or if initial set has taken place, it shall be removed and replaced with freshly mixed concrete at the Contractor's expense. When reinforced concrete is placed in one layer, the reinforcement may be positioned in advance of concrete placement or it may be placed in plastic concrete by mechanical or vibratory means after spreading.

b. Reinforcing steel, at the time concrete is placed, shall be free of mud, oil, or other organic matter

that may adversely affect or reduce bond. Reinforcing steel with rust, mill scale or a combination of both will be considered satisfactory, provided the minimum dimensions, weight, and tensile properties of a hand wire-brushed test specimen are not less than the applicable ASTM specification requirements.



501-4.10 JOINTS

a. Joints shall be constructed as shown on the plans and in accordance with these requirements. All joints shall be constructed with their faces perpendicular to the surface of the pavement and finished or edged as shown on the plans. Joints shall not vary more than 1/2 inch from their designated position and shall be true to line with not more than 1/4-inch variation in 10 feet. The surface across the joints shall be tested with a 10-foot straightedge as the joints are finished and any irregularities in excess of 1/4 inch shall be corrected before the concrete has hardened. All joints shall be so prepared, finished, or cut to provide a groove of uniform width and depth as shown on the plans.

b. Construction. Longitudinal construction joints shall be slip-formed or formed against side forms

without keyways, as shown in the plans.

c. Transverse construction joints shall be installed at the end of each day's placing operations and at any other points within a paving lane when concrete placement is interrupted for more than 30 minutes or it appears that the concrete will obtain its initial set before fresh concrete arrives. The installation of the joint shall be located at a planned contraction or expansion joint. If placing of the concrete is stopped, the Contractor shall remove the excess concrete back to the previous planned joint.

d. Contraction. Contraction joints shall be installed at the locations and spacing as shown on the

plans. Contraction joints shall be installed to the dimensions required by forming a groove or cleft in the top of the slab while the concrete is still plastic or by sawing a groove into the concrete surface after the concrete has hardened. When the groove is formed in plastic concrete the sides of the grooves shall be finished even and smooth with an edging tool. If an insert material is used, the installation and edge finish shall be according to the manufacturer's instructions. The groove shall be finished or cut clean so that spalling will be avoided at intersections with other joints. Grooving or sawing shall produce a slot at least 1/8 inch wide and to the depth shown on the plans.

e. Expansion. Expansion joints shall be installed as shown on the plans. The premolded filler of

the thickness as shown on the plans shall extend for the full depth and width of the slab at the joint, except for space for sealant at the top of the slab. The filler shall be securely staked or fastened into position perpendicular to the proposed finished surface. A cap shall be provided to protect the top edge of the filler and to permit the concrete to be placed and finished. After the concrete has been placed and struck off, the cap shall be carefully withdrawn leaving the space over the premolded filler. The edges of the joint shall be finished and tooled while the concrete is still plastic. Any concrete bridging the joint space shall be removed for the full width and depth of the joint.

f. Tie bars. Tie bars shall consist of deformed bars installed in joints as shown on the plans. Tie

bars shall be placed at right angles to the centerline of the concrete slab and shall be spaced at intervals shown on the plans. They shall be held in position parallel to the pavement surface and in the middle of the slab depth. When tie bars extend into an unpaved lane, they may be bent against the form at longitudinal construction joints, unless threaded bolt or other assembled tie bars are specified. These bars shall not be painted, greased, or enclosed in sleeves. When slip-form operations call for tie bars, two-piece hook bolts can be installed in the female side of



the keyed joint provided the installation is made without distorting the keyed dimensions or causing edge slump.

g. Dowel bars. Dowel bars or other load-transfer units of an approved type shall be placed across

joints in the manner as shown on the plans. They shall be of the dimensions and spacings as shown and held rigidly in the middle of the slab depth in the proper horizontal and vertical alignment by an approved assembly device to be left permanently in place. The dowel or load-transfer and joint devices shall be rigid enough to permit complete assembly as a unit ready to be lifted and placed into position. The portion of each dowel painted with rust preventative paint, as required under paragraph 501-2.7, shall be thoroughly coated with asphalt MC-70, or an approved lubricant, to prevent the concrete from bonding to that portion of the dowel. If free-sliding plastic-coated or epoxy-coated steel dowels are used, a lubrication bond breaker shall be used except when approved pullout tests indicate it is not necessary. Where butt-type joints with dowels are designated, the exposed end of the dowel shall be oiled.

h. Dowel bars at contraction joints may be placed in the full thickness of pavement by a mechanical

device approved by the COTR. The device shall be capable of installing dowel bars within the maximum permissible alignment tolerances. Dowel bars at longitudinal construction joints shall be bonded in drilled holes.

i. Installation. All devices used for the installation of expansion joints shall be approved by the

COTR.

j. The top of an assembled joint device shall be set at the proper distance below the pavement surface and the elevation shall be checked. Such devices shall be set to the required position and line and shall be securely held in place by stakes or other means to the maximum permissible tolerances during the pouring and finishing of the concrete. The premolded joint material shall be placed and held in a vertical position; if constructed in sections, there shall be no offsets between adjacent units.

k. Dowel bars and assemblies shall be checked for position and alignment. The maximum

permissible tolerances on dowel bar alignment shall be in accordance with paragraph 501-5.2.i.9. During the concrete placement operation, it is advisable to place plastic concrete directly on dowel assemblies immediately prior to passage of the paver to help maintain dowel position and alignment within maximum permissible tolerances.

l. When concrete is placed using slip-form pavers, dowels and tie bars shall be placed in

longitudinal construction joints by bonding the dowels or tie bars into holes drilled into the hardened concrete. Holes approximately 1/8-inch to 1/4-inch greater in diameter than the dowel or tie bar shall be drilled with rotary-type core drills that must be held securely in place to drill perpendicularly into the vertical face of the pavement slab. Rotary- type percussion drills may be used provided that spalling of concrete does not occur and the concrete has cured a minimum of 48 hours. The COTR may approve drilling operations sooner than 48 hours, if the contractor can provide evidence that there is no adverse affect on the concrete. Also, the COTR may extend the curing time requirement if the concrete exhibits adverse affect from drilling operations. Any damage to the concrete shall be repaired by the Contractor in a method approved by the COTR. Dowels or tie bars shall be bonded in the drilled holes using an epoxy resin material. Installation procedures shall be adequate to insure that the area around dowels is completely filled with epoxy grout. Resin and hardener shall be mixed in a mixing nozzle. Epoxy shall be injected into the back of the hole and displaced by the insertion of the dowel bar. Bars shall be completely



inserted into the hole and shall not be withdrawn and reinserted creating air pockets in the epoxy around the bar. The Contractor shall furnish a template for checking the position and alignment of the dowels. Dowel bars shall not be less than 12 inches from a transverse joint and shall not interfere with dowels in the transverse direction.

m. Sawing of Joints. Joints shall be cut as shown on the plans. Equipment shall be as described in

paragraph 501-4.1.f. The circular cutter shall be capable of cutting a groove in a straight line and shall produce a slot at least 1/8 inch wide and to the depth shown on the plans. The top portion of the slot shall be widened by sawing to provide adequate space for joint sealers as shown on the plans. Sawing shall commence as soon as the concrete has hardened sufficiently to permit cutting without chipping, spalling, or tearing and before uncontrolled shrinkage cracking of the pavement occurs. Sawing shall be carried on both during the day and night as required. The joints shall be sawed at the required spacing, consecutively in sequence of the concrete placement.

501-4.11 FINAL STRIKE-OFF, CONSOLIDATION, AND FINISHING

a. Sequence. The sequence of operations shall be the strike-off, floating and removal of laitance, straightedging, and final surface finish. The addition of superficial water to the surface of the concrete to assist in finishing operations will not be permitted.

b. Finishing at Joints. The concrete adjacent to joints shall be compacted or firmly placed without

voids or segregation against the joint material; it shall be firmly placed without voids or segregation under and around all load-transfer devices, joint assembly units, and other features designed to extend into the pavement. Concrete adjacent to joints shall be mechanically vibrated as required in paragraph 501-4.8.e.2. After the concrete has been placed and vibrated adjacent to the joints, the finishing machine shall be operated in a manner to avoid damage or misalignment of joints. If uninterrupted operations of the finishing machine, to, over, and beyond the joints, cause segregation of concrete, damage to, or misalignment of the joints, the finishing machine shall be stopped when the screed is approximately 8 inches from the joint. Segregated concrete shall be removed from the front of and off the joint; and the forward motion of the finishing machine shall be resumed. Thereafter, the finishing machine may be run over the joint without lifting the screed, provided there is no segregated concrete immediately between the joint and the screed or on top of the joint.

c. Machine Finishing. The concrete shall be spread as soon as it is placed, and it shall be struck off

and screeded by a finishing machine. The machine shall go over each area as many times and at such intervals as necessary to give to proper consolidation and to leave a surface of uniform texture. Excessive operation over a given area shall be avoided. When side forms are used, the tops of the forms shall be kept clean by an effective device attached to the machine, and the travel of the machine on the forms shall be maintained true without lift, wobbling, or other variation tending to affect the precision finish. During the first pass of the finishing machine, a uniform ridge of concrete shall be maintained ahead of the front screed for its entire length. When in operation, the screed shall be moved forward with a combined longitudinal and transverse shearing motion, always moving in the direction in which the work is progressing, and so manipulated that neither end is raised from the side forms during the striking-off process. If necessary, this shall be repeated until the surface is of uniform texture, true to grade and cross section, and free from porous areas.



d. Hand Finishing. Hand finishing methods will not be permitted, except under the following conditions: in the event of breakdown of the mechanical equipment, hand methods may be used to finish the concrete already deposited on the grade; in areas of narrow widths or of irregular dimensions where operation of the mechanical equipment is impractical. Concrete, as soon as placed, shall be struck off and screeded. An approved portable screed shall be used. A second screed shall be provided for striking off the bottom layer of concrete when reinforcement is used.

(1) The screed for the surface shall be a least 2 feet longer than the maximum width of the

slab to be struck off. It shall be of approved design, sufficiently rigid to retain its shape, and shall be constructed either of metal or of other suitable material covered with metal. Consolidation shall be attained by the use of suitable vibrators.

e. Floating. After the concrete has been struck off and consolidated, it shall be further smoothed

and trued by means of a longitudinal float using one of the following methods:

(1) Hand Method. Long-handled floats shall not be less than 12 feet in length and 6 inches in width, stiffened to prevent flexibility and warping. The float shall be operated from foot bridges spanning but not touching the concrete or from the edge of the pavement. Floating shall pass gradually from one side of the pavement to the other. Forward movement along the centerline of the pavement shall be in successive advances of not more than one-half the length of the float. Any excess water or laitance in excess of 1/8-inch thick shall be removed and wasted.

(2) Mechanical method. The Contractor may use a machine composed of a cutting and

smoothing float(s), suspended from and guided by a rigid frame and constantly in contact with, the side forms or underlying surface. If necessary, long-handled floats having blades not less than 5 feet in length and 6 inches in width may be used to smooth and fill in open-textured areas in the pavement. When the crown of the pavement will not permit the use of the mechanical float, the surface shall be floated transversely by means of a long-handled float. Care shall be taken not to work the crown out of the pavement during the operation. After floating, any excess water and laitance in excess of 1/8-inch thick shall be removed and wasted. Successive drags shall be lapped one-half the length of the blade.

f. Straight-edge Testing and Surface Correction. After the pavement has been struck off and while

the concrete is still plastic, it shall be tested for trueness with a Contractor furnished 16-foot straightedge swung from handles 3 feet longer than one-half the width of the slab. The straightedge shall be held in contact with the surface in successive positions parallel to the centerline and the whole area gone over from one side of the slab to the other, as necessary. Advancing shall be in successive stages of not more than one-half the length of the straightedge. Any excess water and laitance in excess of 1/8-inch thick shall be removed from the surface of the pavement and wasted. Any depressions shall be immediately filled with freshly mixed concrete, struck off, consolidated, and refinished. High areas shall be cut down and refinished. Special attention shall be given to assure that the surface across joints meets the smoothness requirements of paragraph 501-5.2.i.3. Straightedge testing and surface corrections shall continue until the entire surface is found to be free from observable departures from the straightedge and until the slab conforms to the required grade and cross section. The use of long-handled wood floats shall be confined to a minimum; they may be used only in emergencies and in areas not accessible to finishing equipment.



501-4.12 SURFACE TEXTURE

a. The surface of the pavement shall be finished with either a brush or broom, burlap drag, or artificial turf finish for all newly constructed concrete pavements.

b. Brush or Broom Finish. If the pavement surface texture is to be a type of brush or broom finish,

it shall be applied when the water sheen has practically disappeared. The equipment shall operate transversely across the pavement surface, providing corrugations that are uniform in appearance and approximately 1/16 of an inch in depth. It is important that the texturing equipment not tear or unduly roughen the pavement surface during the operation. Any imperfections resulting from the texturing operation shall be corrected.

c. Burlap Drag Finish. If a burlap drag is used to texture the pavement surface, it shall be at least

15 ounces per square yard. To obtain a textured surface, the transverse threads of the burlap shall be removed approximately 1 foot from the trailing edge. A heavy buildup of grout on the burlap threads produces the desired wide sweeping longitudinal striations on the pavement surface. The corrugations shall be uniform in appearance and approximately 1/16 of an inch in depth.

d. Artificial Turf Finish. If artificial turf is used to texture the surface, it shall be applied by

dragging the surface of the pavement in the direction of concrete placement with an approved full-width drag made with artificial turf. The leading transverse edge of the artificial turf drag will be securely fastened to a lightweight pole on a traveling bridge. At least 2 feet of the artificial turf shall be in contact with the concrete surface during dragging operations. A variety of different types of artificial turf are available and approval of any one type will be done only after it has been demonstrated by the Contractor to provide a satisfactory texture. One type that has provided satisfactory texture consists of 7,200 approximately 0.85-inches-long polyethylene turf blades per square foot. The corrugations shall be uniform in appearance and approximately 1/16 of an inch in depth.

501-4.13 NOT USED 501-4.14 CURING

a. Immediately after finishing operations are completed and marring of the concrete will not occur, the entire surface of the newly placed concrete shall be cured in accordance with the methods below. Failure to provide sufficient cover material, or lack of water to adequately take care of both curing and other requirements, shall be cause for immediate suspension of concreting operations. The concrete shall not be left exposed for more than 1/2 hour during the curing period.

b. Impervious Membrane Method. The entire surface of the pavement shall be sprayed uniformly

with white pigmented curing compound immediately after the finishing of the surface and before the set of the concrete has taken place. The curing compound shall not be applied during rainfall. Curing compound shall be applied by mechanical sprayers under pressure at the rate of 1 gallon to not more than 150 square feet. The spraying equipment shall be of the fully atomizing type equipped with a tank agitator. At the time of use, the compound shall be in a thoroughly mixed condition with the pigment uniformly dispersed throughout the vehicle. During application the compound shall be stirred continuously by mechanical means. Hand spraying of odd widths or shapes and concrete surfaces exposed by the removal of forms will be permitted. The curing compound shall be of such character that the film will harden within 30 minutes after application.



Should the film become damaged from any cause, including sawing operations, within the required curing period, the damaged portions shall be repaired immediately with additional compound or other approved means. Upon removal of side forms, the sides of the exposed slabs shall be protected immediately to provide a curing treatment equal to that provided for the surface.

c. Curing in Cold Weather. The concrete shall be maintained at a temperature of at least 50 degrees

F for a period of 72 hours after placing and at a temperature above freezing for the remainder of the curing time. The Contractor shall be responsible for the quality and strength of the concrete placed during cold weather, and any concrete injured by frost action shall be removed and replaced at the Contractor's expense.

501-4.15 REMOVING FORMS

a. Unless otherwise specified, forms shall not be removed from freshly placed concrete until it has hardened sufficiently to permit removal without chipping, spalling, or tearing. After the forms have been removed, the sides of the slab shall be cured as outlined in one of the methods indicated in paragraph 501-4.14. Major honeycombed areas shall be considered as defective work and shall be removed and replaced in accordance with paragraph 501-5.2.j.

501-4.16 SEALING JOINTS

a. The joints in the pavement shall be sealed in accordance with Item P-605. 501-4.17 PROTECTION OF PAVEMENT

a. The Contractor shall protect the pavement and its appurtenances against both public traffic and traffic caused by the Contractor's employees and agents. This shall include flagman to direct traffic and the erection and maintenance of warning signs, lights, pavement bridges, crossovers, and protection of unsealed joints from intrusion of foreign material, etc. Any damage to the pavement occurring prior to final acceptance shall be repaired or the pavement replaced at the Contractor's expense. The Contractor shall have available at all times, materials for the protection of the edges and surface of the unhardened concrete. Such protective materials shall consist of rolled polyethylene sheeting at least 4 mils thick of sufficient length and width to cover the plastic concrete slab and any edges. The sheeting may be mounted on either the paver or a separate movable bridge from which it can be unrolled without dragging over the plastic concrete surface. When rain appears imminent, all paving operations shall stop and all available personnel shall begin covering the surface of the unhardened concrete with the protective covering.

501-4.18 OPENING TO TRAFFIC

a. The COTR shall decide when the pavement shall be opened to traffic. The pavement shall not be opened to traffic until test specimens molded and cured in accordance with ASTM C 31 have attained a flexural strength of 550 pounds per square inch when tested in accordance with ASTM C 78. If such tests are not conducted, the pavement shall not be opened to traffic until 14 days after the concrete was placed. Prior to opening to traffic, the pavement shall be cleaned. Prior to opening the pavement to construction or aircraft traffic, all joints shall either be sealed or protected from damage by installation of, as a minimum, backer rod or tape subject to approval by the COTR.



501-4.19 REPAIR, REMOVAL, REPLACEMENT OF SLABS a. General. New pavement slabs that are broken, honeycombed or contain cracks shall be removed

and replaced or repaired, as specified hereinafter at no cost to the Authority. Spalls along joints shall be repaired as specified. Removal of partial slabs is not permitted. Removal and replacement shall be full depth, shall be full width of the paving lane, and the limit of removal shall be normal to the paving lane and to each original transverse joint. The COTR will determine whether cracks extend full depth of the pavement and may require cores to be drilled on the crack to determine depth of cracking. Such cores shall be 4-inch diameter, shall be drilled by the Contractor and shall be filled by the Contractor with a well consolidated concrete mixture bonded to the walls of the hole with epoxy resin, using approved procedures. Drilling of cores and refilling holes shall be at no expense to the Authority. All epoxy resin used in this work shall conform to ASTM C881, Type V.

Where cracks occur within an area 12 inches from another repair, the entire area around the cracks shall be removed and repaired as one. Where cracks occur within an area 12 inches from a joint, the area up to the joint shall be removed and repaired.

b. Slabs With Cracks Through Interior Areas. Interior area is defined as that area more than 5 feet

from either adjacent original transverse joint. Slabs with any cracks that extend into the interior area, regardless of direction, shall be replaced at no cost the Authority.

c. Cracks Close To and Parallel To Transverse Joints. All cracks essentially parallel to original

transverse joints and lying between 6 inches and 5 feet of either side of the joint shall be treated as specified hereinafter. Any crack extending more than 5 feet from the transverse joint shall be treated as specified above in subparagraph "Slabs With Cracks Through Interior Area." Any crack extending within 6 inches of the transverse joint shall be treated as specified below in subparagraph “Slabs With Cracks Within 6 Inches of the Original Transverse Joint”.

(1) Cracks Present: Slab shall be saw cut full depth on all sides; 5 feet from and parallel to the

original transverse joint, at the original transverse joint, and the two construction joints. The pavement shall be removed in a true vertical fashion by suitable equipment and approved safe lifting devices or shall be broken up and removed using light, hand-held jackhammers, 30 lb. or less, or other approved similar equipment. Care shall be taken to prevent damage to concrete to remain in place. Dowels shall be epoxy grouted into holes drilled into the existing concrete at the original transverse joint location. Dowels shall be of the size and spacing specified for other joints. Tie bars of equivalent size and spacing as dowels shall be drilled and epoxied into the existing concrete face of the new transverse joint 5’ parallel from the existing joint. The exposed construction joints shall be cleaned of all loose material and contaminants. The sawed face of the new transverse joint shall be coated with epoxy grout immediately prior to placing the new concrete. The original transverse joint shall be coated with a double layer of membrane forming curing compound as a bond breaker. Protruding portions of dowels shall be greased. The new slab shall be reinforced with #4 bars spaced in both directions as shown on the detail for reinforced slab construction. Care shall be taken to prevent curing compound from contacting dowels or tie bars. The resulting joints shall be prepared and sealed as specified for original construction

d. Slabs With Cracks Within 6 Inches of the Original Transverse Joint: If cracks occur within 6

inches of the original transverse joint, they shall be sawed in accordance with paragraph 501-4.10.m and sealed in accordance with Item P-605.



e. Removal and Replacement of Full Slabs. Where it is necessary to remove full slabs, the slab

edges shall be sawed full depth just beyond the end of the dowels or tie bars. All saw cuts shall be perpendicular to the slab surface. These joints shall then be carefully sawed full depth on the joint line. The main slab shall be further divided by sawing full depth, at appropriate locations, and each piece lifted out and removed. Suitable equipment shall be used to provide a truly vertical lift, and approved safe lifting devices used for attachment to the slabs. The narrow strips along doweled edges shall be carefully broken up and removed using light, hand-held jackhammers, 30 lb. or less, or other approved similar equipment. Care shall be taken to prevent damage to the dowels, tie bars, or to concrete to remain in place. The joint face below dowels shall be suitably trimmed so that there is no abrupt offset in any direction greater than ½ inch and no gradual offset greater than 1 inch when tested in a horizontal direction with a 12-foot straightedge. No mechanical impact breakers, other than the above hand-held equipment shall be used for any removal of slabs. If underbreak between 1-1/2 and 4 inches deep occurs at any point along any edge, the area shall be repaired as directed before replacing the removed slab. Procedures will be directed before replacing the removed slab. Procedures directed will be similar to those specified for surface spalls, modified as necessary. If underbreak over 4 inches deep occurs, the entire slab containing the underbreak shall be removed and replaced. Dowels of the size and spacing as specified for other joints in similar pavement shall be installed by epoxy grouting them into holes drilled into the existing concrete using procedures as specified. Protruding portions of dowels shall be painted and lightly oiled. All four edges of the new slab shall thus contain dowels. Placement of concrete shall be as specified for original construction. Prior to placement of new concrete, the underlying material (unless it is stabilized) shall be recompacted and shaped as specified in the appropriate Section of these specifications. The surfaces of all four joint faces shall be cleaned of all loose material and contaminants and coated with double application of membrane forming curing compound as bond breaker. Care shall be taken to prevent any curing compound from contacting dowels or tie bars. The resulting joints around the new slab shall be prepared and sealed as specified for original construction.

f. Repairing Spalls Along Joints. Where directed, spalls along joints of new slabs, and along

parallel cracks used as replacement joints, shall be repaired as illustrated on the plans.

g. Repairing joint overcuts into existing pavements. Where proposed joints do not match existing joints, the contractor shall not saw-cut into existing pavement more than two inches horizontally. This overcut shall be filled with a COTR approved epoxy material in accordance with the manufacturer’s instructions. Where proposed joints match existing joints, the contractor shall minimize the damage to the existing joint sealing materials. Damaged joint seal material shall be removed and replaced to the satisfaction of the COTR and Item P-605.

501-4.20 EXISTING CONCRETE PAVEMENT REMOVAL AND REPAIR

a. All operations shall be controlled to prevent damage to the concrete pavement and to the underlying material to remain in place. All saw cuts shall be made perpendicular to the slab surface.

(1) Removal of Existing Pavement Slab. When necessary to remove existing concrete

pavement and leave adjacent concrete in place, the removal shall be performed as illustrated on the drawings.



(2) Edge Repair. The edge of existing concrete pavement against which new pavement abuts shall be protected from damage at all times. Areas, which are damaged during construction, shall be repaired at no cost to the Authority; repair of previously existing damage areas will be considered a subsidiary part of concrete pavement construction.

A. Spall Repair. Spalls shall be repaired where directed by the COTR. Repair

shall be performed as indicated on the drawings.

B. Underbreak Repair. If bottom 1/3 (or less) of the slab needs repairs, the repair shall be considered an underbreak repair and shall be performed in accordance with this paragraph. All underbreak shall be repaired. First, all delaminated and loose material shall be removed. Next, the underlying material shall be recompacted, without addition of any new material. Finally, the void shall be completely filled with paving concrete, thoroughly consolidated. Care shall be taken to produce an even joint face from top to bottom. Prior to placing concrete, the underlying material shall be thoroughly moistened. After placement, the exposed surface shall be completely coated with curing compound.

C. Underlying Material. The underlying material adjacent to the edge of and under

the existing pavement which is to remain in place shall be protected from damage or disturbance during removal operations and until placement of new concrete, and shall be shaped as shown on the drawings or as directed. Sufficient underlying material shall be kept in place outside the joint line to completely prevent disturbance of material under the pavement, which is to remain in place. Any material under the portion of the concrete pavement which is to remain in place. Any material under the portion of the concrete pavement to remain in place which is disturbed or loses its compaction shall be carefully removed and replaced with concrete as specified in paragraph “Underbreak Repair.” The underlying material outside the joint line shall be thoroughly compacted and shall be moist when new concrete is place

MATERIAL ACCEPTANCE 501-5.1 ACCEPTANCE SAMPLING AND TESTING a. All acceptance sampling, making specimens, transportation of samples, initial and final curing and

coring for thickness necessary to determine conformance with the requirements specified in this section will be performed by the Contractor. All testing necessary to determine conformance with the requirements specified in this section will be performed by the COTR. Concrete shall be accepted for strength and thickness on a lot basis.

b. A lot shall consist of: (1) A day’s production not to exceed 4,500 square yards for 15 inch pavement. c. Testing organizations performing these tests shall meet the requirements of ASTM C 1077. The

Contractor shall bear the cost of sampling, making and transporting strength specimens to the COTR lab, for providing molds and sampling equipment, for providing curing facilities for the strength



specimens, for providing the testing equipment and for coring and filling operations. d. Flexural Strength

(1) Sampling. Each lot shall be divided into four equal sublots. One (1) sample shall be taken by the Contractor for each sublot from the plastic concrete delivered to the job site. Sampling locations shall be determined by the COTR in accordance with random sampling procedures contained in ASTM D 3665. The concrete shall be sampled in accordance with ASTM C 172.

(2) Making Specimens On-Site. Two (2) specimens shall be made by the Contractor on site,

in the presence of the COTR, from each sample for testing at 3, 7, 14, and 28 days age plus two reserve beams (a total of 10 beams per sample). Specimens shall be made in accordance with ASTM C 31.]

(3) Initial Curing, On-Site. The Contractor shall provide adequate facilities for the initial

curing of beams on site. During the 24 hours after molding, the temperature immediately adjacent to the specimens must be maintained in the range of 60 to 80 degrees F, and loss of moisture from the specimens must be prevented. The Contractor shall store the specimens on site during the 24 hours after molding in tightly constructed wooden boxes, damp sand pits, temporary buildings at construction sites, under wet burlap in favorable weather or in heavyweight closed plastic bags, or use other suitable methods, provided the temperature and moisture loss requirements are met. Initial curing shall be performed in accordance with ASTM C31.

(4) Final Curing. After initial cure, the Contractor shall provide facilities for protecting,

storing, and curing the beams until they are tested for flexural strength. The facilities shall be on site. The Contractor shall transport the specimens from the initial cure site to the final cure site, strip forms from the specimens, label, and place the specimens in the curing facilities. Storage conditions shall be in compliance with ASTM C31.

(5) Testing. The COTR shall test two specimens from each sample at 3, 7, 14, and 28 days

from the date of molding. Testing will be performed by the Quality Assurance (QA) firm selected by the COTR.

(6) Acceptance. Acceptance of pavement for flexural strength will be determined by the

COTR in accordance with paragraph 501-5.2.e. e. Pavement Thickness.

(1) Sampling. Each lot shall be divided into four equal sublots and one core shall be taken

by the Contractor for each sublot. Sampling locations shall be determined by the COTR in accordance with random sampling procedures contained in ASTM D 3665. Areas, such as thickened edges, with planned variable thickness, shall be excluded from sample locations.

A. Cores shall be cut with a core drill. The Contractor shall furnish all tools, labor,

and materials for cutting samples and filling the cored hole. Core holes shall be filled by the Contractor with a non-shrink grout approved by the COTR within one day after sampling.



(2) Testing. The thickness of the cores shall be determined by the COTR by the average

caliper measurement in accordance with ASTM C 174.

(3) Acceptance. Acceptance of pavement for thickness shall be determined by the COTR in accordance with paragraph 501-5.2.f.

f. Partial Lots. When operational conditions cause a lot to be terminated before the specified

number of tests have been made for the lot, or when the Contractor and COTR agree in writing to allow overages or minor placements to be considered as partial lots, the following procedure will be used to adjust the lot size and the number of tests for the lot.

g. Where three sublots have been produced, they shall constitute a lot. Where one or two sublots

have been produced, they shall be incorporated into the next lot or the previous lot and the total number of sublots shall be used in the acceptance criteria calculation, i.e., n=5 or n=6.

h. Outliers. All individual flexural strength tests within a lot shall be checked for an outlier in

accordance with ASTM E 178, at a significance level of 5 percent. Outliers shall be discarded, and the PWL shall be determined using the remaining test values.

501-5.2 ACCEPTANCE CRITERIA

a. General. Acceptance will be based on the following characteristics of the completed pavement:

(1) Flexural strength

(2) Thickness

(3) Smoothness

(4) Grade

(5) Edge slump

(6) Dowel bar alignment

b. Flexural strength will be evaluated for acceptance by the COTR in accordance with paragraph 501-5.2.e. Thickness will be evaluated for acceptance by the COTR in accordance with paragraph 501-5.2.f. Smoothness will be evaluated by the COTR in accordance with paragraph 501-5.2.i.3.

c. Acceptance for flexural strength will be based on the criteria contained in accordance with

paragraph 501-5.2.i.1. Acceptance for thickness will be based on the criteria contained in paragraph 501-5.2.i.2. Acceptance for smoothness will be based on the criteria contained in paragraph 501-5.2.i.3. Acceptance for grade will be based on the criteria contained in paragraph 501-5.2.i.5.

d. The COTR may at any time, not withstanding previous plant acceptance, reject and require the

Contractor to dispose of any batch of concrete mixture which is rendered unfit for use due to contamination, segregation, or improper slump. Such rejection may be based on only visual inspection. In the event of such rejection, the Contractor may take a representative sample of the rejected material in the presence of the COTR, and if it can be demonstrated in the laboratory, in the presence of the COTR, that such material was erroneously rejected, payment will be made for the material at the contract unit price.



e. Flexural Strength. Acceptance of each lot of in-place pavement for flexural strength shall be

based on the percentage of material within specification limits (PWL). The Contractor shall target production quality to achieve 90 PWL or higher.

f. Pavement Thickness. Acceptance of each lot of in-place pavement shall be based on the

percentage of material within specification limits. The Contractor shall target production quality to achieve 90 PWL or higher.

g. Percentage of Material Within Limits (PWL). The percentage of material within limits shall be

determined in accordance with procedures specified in Section 501-5.3.

h. The lower specification limit (L) for flexural strength and thickness shall be:

Lower Specification Limit (L)

Flexural Strength: 0.93 x strength specified in paragraph 3.01 Thickness: Lot Plan Thickness in inches – 0.50 inches

i. Acceptance Criteria.

(1) Flexural Strength. If the PWL of the lot equals or exceeds 90 percent for flexural strength, the lot shall be acceptable. Acceptance and payment for the lot shall be in accordance with Paragraph 501-8.1.

(2) Thickness. If the PWL of the lot equals or exceeds 90 percent for thickness, the lot

shall be acceptable. Acceptance and payment for the lot shall be in accordance with Paragraph 501-8.1.

(3) Smoothness. As soon as the concrete has hardened sufficiently, the pavement surface

shall be tested with a 16-foot straightedge or other specified device. Surface smoothness deviations shall not exceed 1/4 inch from a 16-foot straightedge placed in any direction, including placement along and spanning any pavement joint edge.

Areas in a slab showing high spots of more than 1/4 inch but not exceeding 1/2 inch in 16 feet shall be marked and immediately ground down with an approved grinding machine to an elevation that will fall within the tolerance of 1/4 inch or less. Where the departure from correct cross section exceeds 1/2 inch, the pavement shall be removed and replaced at the expense of the Contractor when so directed by the COTR.

(4) Grade. An evaluation of the surface grade shall be made by the COTR for compliance

to the tolerances contained below.

A. Lateral Deviation. Lateral deviation from established alignment of the pavement edge shall not exceed plus or minus 0.10 foot in any lane.

B. Vertical Deviation. Vertical deviation from established grade shall not

exceed plus or minus 0.04 foot at any point.



(5) Edge Slump. When slip-form paving is used, not more than 15 percent of the total free edge of each 500 feet of pavement, or fraction thereof, shall have an edge slump exceeding 1/4-inch, and none of the free edge of the pavement shall have an edge slump exceeding 3/8-inch. (The total free edge of 500 feet of pavement will be considered the cumulative total linear measurement of pavement edge originally constructed as nonadjacent to any existing pavement; i.e., 500 feet of paving lane originally constructed as a separate lane will have 1,000 feet of free edge, 500 feet of fill-in lane will have no free edge, etc.) The area affected by the downward movement of the concrete along the pavement edge shall be limited to not more than 18 inches from the edge. When excessive edge slump cannot be corrected before the concrete has hardened, the area with excessive edge slump shall be removed and replaced at the expense of the Contractor when so directed by the COTR.

(6) Dowel Bar Alignment. Dowel bars and assemblies shall be checked for position and

alignment. The maximum permissible tolerance on dowel bar alignment in each plane, horizontal and vertical, shall not exceed 2 percent or 1/4 inch per foot of a dowel bar.

j. Removal and Replacement of Concrete. Any area or section of concrete that is removed and

replaced shall be removed and replaced back to planned joints. The Contractor shall replace damaged dowels and the requirements for doweled longitudinal construction joints in paragraph 501-4.10 shall apply to all contraction joints exposed by concrete removal.

501-5.3 METHOD OF ESTIMATING PERCENTAGE OF MATERIAL WITHIN SPECIFICATION

LIMITS (PWL)

a. General. When the specifications provide for material to be sampled and tested on a statistical basis, the material will be evaluated for acceptance in accordance with this section. All test results for a lot will be analyzed statistically, using procedures to determine the total estimated percent of the lot that is within specification limits. This concept, termed percent within limits (PWL), is a statistically based evaluation method, whereby the PWL is computed on a lot basis, using the average (X) and standard deviation (Sn) of the specified number (n) of sublot tests for the lot and the specification tolerance limits (L for lower and U for upper) for the particular acceptance parameter. From these values, the respective Quality index(s) (QL for Lower Quality Index and/or QU for Upper Quality Index) is computed and the PWL for the specified n is determined from Table 1.

501-5.4 METHOD FOR COMPUTING PWL The computational sequence for computing the PWL is as follows:

a. Divide the lot into n sublots in accordance with the acceptance requirements of the specification. b. Locate the sampling position within the sublot in accordance with the random sampling

requirements of the specification.

c. Make a measurement at each location, or take a test portion and make the measurement on the test portion in accordance with the testing requirements of the specification.

d. Average all sublot values within the lot to find X by using the following formula:



X = (x1 + x2 + x3 + . . .xn) / n

Where:

X = Average of all sublot values within a lot

x1, x2 = Individual sublot values

n = Number of sublots

e. Find the standard deviation Sn by use of the following formula:

Sn = [(d12 + d22 + d32 + . . .dn2) / (n-1)]1/2

Where:

Sn = standard deviation of the number of sublot values in the set

d1, d2 = deviations of the individual sublot values X1, X2 . . . from the average value X

that is: d1 = (x1 - X), d2 = (xn - X) . . dn = (xn - X)

n = number of sublots

f. For single sided specification limits (i.e., L only), compute the Lower Quality Index QL by use of the following formula:

QL = (X - L) / Sn

Where:

L = specification lower tolerance limit

Estimate the percentage of material within limits (PWL) by entering Table 1 with QL, using the column appropriate to the total number (n) of measurements. If the value of QL falls between values shown on the table, use the next higher value of PWL.

g. For double sided specification limits (i.e. L and U), compute the Quality Indexes QL and QU by

use of the following formulas:

QL = (X - L) / Sn and QU = (U - X) / Sn

Where:

L and U = specification lower and upper tolerance limits

Estimate the percentage of material between the lower (L) and upper (U) tolerance limits (PWL) by entering Table 1 separately with QL and QU, using the column appropriate to the total number (n) of measurements, and determining the percent of material above PL and percent of material below PU for each tolerance limit. If the values of QL fall between values shown on the



table, use the next higher value of PL or PU. Determine the PWL by use of the following formula:

PWL = (PU + PL) - 100

Where:

PL = percent within lower specification limit PU = percent within upper specification limit

EXAMPLE OF PWL CALCULATION Project: Example Project (Example is for Bituminous Pavement. Procedure for PCC pavement is identical but values for L are those shown in Paragraph 501-5.2.h.). Test Item: Item P-401, Lot A.

a. PWL Determination for Mat Density.

(1) Density of four random cores taken from Lot A:

A-1 96.60 A-2 97.55 A-3 99.30 A-4 98.35

n = 4

(2) Calculate average density for the lot.

X = (x1 + x2 + x3 + . . xn) / n X = (96.60 + 97.55 + 99.30 + 98.35) / 4 X = 97.95 percent density

(3) Calculate the standard deviation for the lot.

Sn = [((96.60 - 97.95)2 + (97.55 - 97.95)2 + (99.30 -97.95)2 + (98.35 -97.95)2)) /

(4 - 1)]1/2

Sn = [(1.82 + 0.16 + 1.82 + 0.16) / 3]1/2

Sn = 1.15

(4) Calculate the Lower Quality Index QL for the lot. (L=96.3)

QL = (X -L) / Sn QL = (97.95 - 96.30) / 1.15 QL = 1.4384



(5) Determine PWL by entering Table 3 with QL= 1.44 and n= 4.

PWL = 98

b. PWL Determination for Air Voids.

(1) Air Voids of four random samples taken from Lot A:

A-1 5.00 A-2 3.74 A-3 2.30 A-4 3.25

(2) Calculate the average air voids for the lot.

X = (x1 + x + x3 . . n) / n X = (5.00 + 3.74 + 2.30 + 3.25) / 4 X = 3.57 percent

(3) Calculate the standard deviation Sn for the lot.

Sn = [((3.57 - 5.00)2 + (3.57 - 3.74)2 + (3.57 - 2.30)2 + (3.57 -3.25)2) / (4 - 1)]1/2

Sn = [(2.04 + 0.03 + 1.62 + 0.10 ) / 3]1/2

Sn = 1.12

(4) Calculate the Lower Quality Index QL for the lot. (L= 2.0)

QL = (X - L) Sn QL = (3.57 - 2.00) / 1.12 QL = 1.3992

(5) Determine PL by entering Table 3 with QL = 1.40 and n = 4.

PL = 97

(6) Calculate the Upper Quality Index QU for the lot. (U= 5.0)

QU = (U - X) / Sn QU = (5.00 - 3.57) / 1.12 QU = 1.2702

(7) Determine PU by entering Table 3 with QU = 1.27 and n = 4.

PU = 93

(8) Calculate Air Voids PWL



PWL = (PL + PU) - 100 PWL = (97 + 93) - 100 = 90

TABLE 3. TABLE FOR ESTIMATING PERCENT OF LOT WITHIN LIMITS (PWL)

Percent Within Limits

Positive Values of Q (QL and QU)

(PL and PC)

n=3 n=4 n=5 n=6 n=7

n=8

99

1.1541 1.4700 1.6714 1.8008 1.8888

1.9520

98

1.1524 1.4400 1.6016 1.6982 1.7612

1.8053

97

1.1496 1.4100 1.5427 1.6181 1.6661

1.6993

96

1.1456 1.3800 1.4897 1.5497 1.5871

1.6127

95

1.1405 1.3500 1.4407 1.4887 1.5181

1.5381

94

1.1342 1.3200 1.3946 1.4329 1.4561

1.4716

93

1.1269 1.2900 1.3508 1.3810 1.3991

1.4112

92

1.1184 1.2600 1.3088 1.3323 1.3461

1.3554

91

1.1089 1.2300 1.2683 1.2860 1.2964

1.3032

90

1.0982 1.2000 1.2290 1.2419 1.2492

1.2541

89

1.0864 1.1700 1.1909 1.1995 1.2043

1.2075

88

1.0736 1.1400 1.1537 1.1587 1.1613

1.1630

87

1.0597 1.1100 1.1173 1.1191 1.1199

1.1204

85

1.0288 1.0500 1.0467 1.0435 1.0413

1.0399

84

1.0119 1.0200 1.0124 1.0071 1.0037

1.0015

83

0.9939 0.9900 0.9785 0.9715 0.9672

0.9643

82

0.9749 0.9600 0.9452 0.9367 0.9325

0.9281

81

0.9550 0.9300 0.9123 0.9025 0.8966

0.8928

80

0.9342 0.9000 0.8799 0.8690 0.8625

0.8583

79

0.9124 0.8700 0.8478 0.8360 0.8291

0.8245

78

0.8897 0.8400 0.8160 0.8036 0.7962

0.7915

77

0.8662 0.8100 0.7846 0.7716 0.7640

0.7590

76

0.8417 0.7800 0.7535 0.7401 0.7322

0.7271

75

0.8165 0.7500 0.7226 0.7089 0.7009

0.6958

74

0.7904 0.7200 0.6921 0.6781 0.6701

0.6649




Positive Values of Q (QL and QU)

(PL and PC)

n=3 n=4 n=5 n=6 n=7

n=8

73 0.7636 0.6900 0.6617 0.6477 0.6396 0.6344 72

0.7360 0.6600 0.6316 0.6176 0.6095

0.6044

71

0.7077 0.6300 0.6016 0.5878 0.5798

0.5747

70

0.6787 0.6000 0.5719 0.5583 0.5504

0.5454

69

0.6490 0.5700 0.5423 0.5290 0.5213

0.5164

68

0.6187 0.5400 0.5129 0.4999 0.4924

0.4877

67

0.5878 0.5100 0.4836 0.4710 0.4638

0.4592

66

0.5563 0.4800 0.4545 0.4424 0.4354

0.4310

65

0.5242 0.4500 0.4255 0.4139 0.4073

0.4031

64

0.4916 0.4200 0.3967 0.3856 0.3793

0.3753

63

0.4586 0.3900 0.3679 0.3575 0.3515

0.3477

62

0.4251 0.3600 0.3392 0.3295 0.3239

0.3203

61

0.3911 0.3300 0.3107 0.3016 0.2964

0.2931

60

0.3568 0.3000 0.2822 0.2738 0.2691

0.2660

59

0.3222 0.2700 0.2537 0.2461 0.2418

0.2391

58

0.2872 0.2400 0.2254 0.2186 0.2147

0.2122

57

0.2519 0.2100 0.1971 0.1911 0.1877

0.1855

56

0.2164 0.1800 0.1688 0.1636 0.1607

0.1592

55

0.1806 0.1500 0.1408 0.1363 0.1338

0.1322

54

0.1447 0.1200 0.1125 0.1090 0.1070

0.1057

53

0.1087 0.0900 0.0843 0.0817 0.0802

0.0792

52

0.0725 0.0600 0.0562 0.0544 0.0534

0.0528

51

0.0363 0.0300 0.0281 0.0272 0.0267

0.0264

50

0.0 0.0 0.0 0.0 0.0

0.0

TABLE 3. TABLE FOR ESTIMATING PERCENT OF LOT WITHIN LIMITS (PWL)


Negative Values of Q (QL and QU)

PL and PU)

n=3 n=4 n=5 n=6 n=7

n=8





PL and PU)

n=3 n=4 n=5 n=6 n=7

n=8

49 -0.0363 -0.0300 -0.0281 -0.0272 -0.0267 -0.0264 48

-0.0725 -0.0600 -0.0562 -0.0544 -0.0534

-0.0528

47

-0.1087 -0.0900 -0.0843 -0.0817 -0.0802

-0.0792

46

-0.1447 -0.1200 -0.1125 -0.1090 -0.1070

-0.1057

45

-0.1806 -0.1500 -0.1408 -0.1363 -0.1338

-0.1322

44

-0.2164 -0.1800 -0.1688 -0.1636 -0.1607

-0.1592

43

-0.2519 -0.2100 -0.1971 -0.1911 -0.1877

-0.1855

42

-0.2872 -0.2400 -0.2254 -0.2186 -0.2147

-0.2122

41

-0.3222 -0.2700 -0.2537 -0.2461 -0.2418

-0.2391

40

-0.3568 -0.3000 -0.2822 -0.2738 -0.2691

-0.2660

39

-0.3911 -0.3300 -0.3107 -0.3016 -0.2964

-0.2931

38

-0.4251 -0.3600 -0.3392 -0.3295 -0.3239

-0.3203

37

-0.4586 -0.3900 -0.3679 -0.3575 -0.3515

-0.3477

36

-0.4916 -0.4200 -0.3967 -0.3856 -0.3793

-0.3753

35

-0.5242 -0.4500 -0.4255 -0.4139 -0.4073

-0.4031

34

-0.5563 -0.4800 -0.4545 -0.4424 -0.4354

-0.4310

33

-0.5878 -0.5100 -0.4836 -0.4710 -0.4638

-0.4592

32

-0.6187 -0.5400 -0.5129 -0.4999 -0.4924

-0.4877

31

-0.6490 -0.5700 -0.5423 -0.5290 -0.5213

-0.5164

30

-0.6787 -0.6000 -0.5719 -0.5583 -0.5504

-0.5454

29

-0.7077 -0.6300 -0.6016 -0.5878 -0.5798

-0.5747

28

-0.7360 -0.6600 -0.6316 -0.6176 -0.6095

-0.6044

27

-0.7636 -0.6900 -0.6617 -0.6477 -0.6396

-0.6344

26

-0.7904 -0.7200 -0.6921 -0.6781 -0.6701

-0.6649

25

-0.8165 -0.7500 -0.7226 -0.7089 -0.7009

-0.6958

24

-0.8417 -0.7800 -0.7535 -0.7401 -0.7322

-0.7271

23

-0.8662 -0.8100 -0.7846 -0.7716 -0.7640

-0.7590

22

-0.8897 -0.8400 -0.8160 -0.8036 -0.7962

-0.7915

21

-0.9124 -0.8700 -0.8478 -0.8360 -0.8291

-0.8245





PL and PU)

n=3 n=4 n=5 n=6 n=7

n=8

20 -0.9342 -0.9000 -0.8799 -0.8690 -0.8625 -0.8583 19

-0.9550 -0.9300 -0.9123 -0.9025 -0.8966

-0.8928

18

-0.9749 -0.9600 -0.9452 -0.9367 -0.9325

-0.9281

17

-0.9939 -0.9900 -0.9785 -0.9715 -0.9672

-0.9643

16

-1.0119 -1.0200 -1.0124 -1.0071 -1.0037

-1.0015

15

-1.0288 -1.0500 -1.0467 -1.0435 -1.0413

-1.0399

14

-1.0448 -1.0800 -1.0817 -1.0808 -1.0800

-1.0794

13

-1.0597 -1.1100 -1.1173 -1.1191 -1.1199

-1.1204

12

-1.0736 -1.1400 -1.1537 -1.1587 -1.1613

-1.1630

11

-1.0864 -1.1700 -1.1909 -1.1995 -1.2043

-1.2075

10

-1.0982 -1.2000 -1.2290 -1.2419 -1.2492

-1.2541

9

-1.1089 -1.2300 -1.2683 -1.2860 -1.2964

-1.3032

8

-1.1184 -1.2600 -1.3088 -1.3323 -1.3461

-1.3554

7

-1.1269 -1.2900 -1.3508 -1.3810 -1.3991

-1.4112

6

-1.1342 -1.3200 -1.3946 -1.4329 -1.4561

-1.4716

5

-1.1405 -1.3500 -1.4407 -1.4887 -1.5181

-1.5381

4

-1.1456 -1.3800 -1.4897 -1.5497 -1.5871

-1.6127

3

-1.1496 -1.4100 -1.5427 -1.6181 -1.6661

-1.6993

2

-1.1524 -1.4400 -1.6016 -1.6982 -1.7612

-1.8053

1

-1.1541 -1.4700 -1.6714 -1.8008 -1.8888

-1.9520

CONTRACTOR QUALITY CONTROL 501-6.1 QUALITY CONTROL PROGRAM

a. The Contractor shall develop a Quality Control Program in accordance with Section 1400 of the General Provisions. The program shall address all elements which affect the quality of the pavement including, but not limited to:

(1) Mix Design

(2) Aggregate Gradation

(3) Quality of Materials



(4) Stockpile Management

(5) Proportioning

(6) Mixing and Transportation

(7) Placing and Consolidation

(8) Joints

(9) Dowel Placement and Alignment

(l0) Flexural or Compressive Strength

(11) Finishing and Curing

(12) Surface Smoothness 501-6.2 QUALITY CONTROL TESTING

a. The Contractor shall perform all quality control tests necessary to control the production and construction processes applicable to this specification and as set forth in the Quality Control Program. The testing program shall include, but not necessarily be limited to, tests for aggregate gradation, aggregate moisture content, slump, and air content.

b. A Quality Control Testing Plan shall be developed as part of the Quality Control Program.

c. Fine Aggregate

(1) Gradation. A sieve analysis shall be made at least twice daily in accordance with

ASTM C 136 from randomly sampled material taken from the discharge gate of storage bins or from the conveyor belt.

(2) Moisture Content. If an electric moisture meter is used, at least two direct

measurements of moisture content shall be made per week to check the calibration. If direct measurements are made in lieu of using an electric meter, two (2) tests shall be made per day. Tests shall be made in accordance with ASTM C 70 or ASTM C 566.

d. Coarse Aggregate

(1) Gradation. A sieve analysis shall be made at least twice daily for each size of

aggregate. Tests shall be made in accordance with ASTM C 136 from randomly sampled material taken from the discharge gate of storage bins or from the conveyor belt.

(2) Moisture Content. If an electric moisture meter is used, at least two direct measurements

of moisture content shall be made per week to check the calibration. If direct measurements are made in lieu of using an electric meter, two tests shall be made per day. Tests shall be made in accordance with ASTM C 566.

e. Slump. Four (4) slump tests shall be performed for each lot of material produced in accordance

with the lot size defined in Section 501-5.1. One test shall be made for each sublot. Slump tests shall be performed in accordance with ASTM C 143 from material randomly sampled from material discharged from trucks at the paving site. Material samples shall be taken in accordance with ASTM C 172.



f. Air Content. Four (4) air content tests shall be performed for each lot of material produced in

accordance with the lot size defined in Section 501-5.1. One test shall be made for each sublot. Air content tests shall be performed in accordance with ASTM C 231 for gravel and stone coarse aggregate and ASTM C 173 for slag or other porous coarse aggregate, from material randomly sampled from trucks at the plant site. Material samples shall be taken in accordance with ASTM C 172.

501-6.3 CONTROL CHARTS

a. The Contractor shall maintain linear control charts for fine and course aggregate gradation, slump, and air content.

b. Control charts shall be posted in a location satisfactory to the COTR and shall be kept up to date

at all times. As a minimum, the control charts shall identify the project number, the contract item number, the test number, each test parameter, the Action and suspension Limits, or Specification limits, applicable to each test parameter, and the Contractor's test results. The Contractor shall use the control charts as part of a process control system for identifying potential problems and assignable causes before they occur. If the Contractor's projected data during production indicates a potential problem and the Contractor is not taking satisfactory corrective action, the COTR may halt production or acceptance of the material.

c. Fine and Coarse Aggregate Gradation. The Contractor shall record the running average of the

last five gradation tests for each control sieve on linear control charts. Specification limits contained in Tables 1 and 2 shall be superimposed on the Control Chart for job control.

d. Slump and Air Content. The Contractor shall maintain linear control charts both for individual

measurements and range (i.e. difference between highest and lowest measurements) for slump and air content in accordance with the following Action and Suspension Limits.

CONTROL CHART LIMITS

Based on Sample Size n=4

Control Parameter

Individual Measurements Range Suspension Limit Action Limit Suspension Limit

Slump Air Content

+/- 1 inch +/- 1.2%

+/- 1.5 inch +/- 1.8%

+/- 2.4 inch +/- 2.8%

The individual measurement control charts shall use the mix design target values as indicators of central tendency.

501-6.4 CORRECTIVE ACTION

a. The Quality Control Plan shall indicate that appropriate action shall be taken when the process is believed to be out of control. The Quality Control Plan shall detail what action will be taken to bring the process into control and shall contain sets of rules to gauge when a process is out of control. As a minimum, a process shall be deemed out of control and corrective action taken if any one of the following conditions exists.



b. Fine and Coarse Aggregate Gradation. When two consecutive averages of five tests are outside of the Tables 1 or 2 specification limits, immediate steps, including a halt to production, shall be taken to correct the grading.

c. Fine and Coarse Aggregate Moisture Content. Whenever the moisture content of the fine or

coarse aggregate changes by more than 0.5 percent, the scale settings for the aggregate batcher(s) and water batcher shall be adjusted.

d. Slump. The Contractor shall halt production and make appropriate adjustments whenever:

(1) one (1) point falls outside the Suspension Limit line for individual measurements or

range; or

(2) two (2) points in a row fall outside the Action Limit line for individual measurements.

e. Air Content. The Contractor shall halt production and adjust the amount of air-entraining admixture whenever:

(1) one (1) point falls outside the Suspension Limit line for individual measurements or

range; or

(2) two (2) points in a row fall outside the Action Limit line for individual measurements.

f. Whenever a point falls outside the Action Limits line, the air-entraining admixture dispenser shall be calibrated to ensure that it is operating correctly and with good reproducibility.

TESTING REQUIREMENTS ASTM C 31 Making and Curing Concrete Test Specimens in the Field ASTM C 39 Compressive Strength of Cylindrical Concrete Specimens ASTM C 70 Surface Moisture in Fine Aggregate ASTM C 78 Test for Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading) ASTM C 131 Test for Resistance to Abrasion of Small Size Coarse Aggregate by Use of the Los

Angeles Machine ASTM C 136 Sieve Analysis of Fine and Coarse Aggregates ASTM C 138 Test for Unit Weight, Yield, and Air Content (Gravimetric) of Concrete ASTM C 143 Test for Slump of Portland Cement Concrete ASTM C 172 Sampling Freshly Mixed Concrete ASTM C 173 Test for Air Content of Freshly Mixed Concrete by the Volumetric Method



ASTM C 174 Measuring Length of Drilled Concrete Cores ASTM C 227 Potential Alkali Reactivity of Cement-Aggregate Combinations (Mortar-Bar Method) ASTM C 231 Test for Air Content of Freshly Mixed Concrete by the Pressure Method ASTM C 289 Potential Reactivity of Aggregates (Chemical Method) ASTM C 295 Petrographic Examination of Aggregates for Concrete ASTM C 311 Sampling and Testing Fly Ash for Use as an Admixture in Portland Cement Concrete ASTM C 535 Test for Resistance to Abrasion of Large Size Coarse Aggregate by Use of the Los

Angeles Machine ASTM C 566 Total Moisture Content of Aggregates by Drying ASTM C 1077 Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in

Construction and Criteria for Laboratory Evaluation ASTM D 3665 Random Sampling of Construction Materials ASTM D 4791 Test Method for Flat or Elongated Particles in Coarse Aggregate AASHTO T 26 Quality of Water to be Used in Concrete MATERIAL REQUIREMENTS ASTM A 184 Specification for Fabricated Deformed Steel Bar Mats for Concrete Reinforcement ASTM A 185 Specification for Welded Steel Wire Fabric for Concrete Reinforcement ASTM A 497 Specification for Welded Deformed Steel Wire Fabric for Concrete Pavement ASTM A 615 Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement ASTM A 616 Specification for Rail-Steel Deformed and Plain Bars for Concrete Reinforcement ASTM A 617 Specification for Axle-Steel Deformed and Plain Bars for Concrete Reinforcement ASTM A 704 Specification for Welded Steel Plain Bar or Rod Mats for Concrete Reinforcement ASTM A 714 Specification for High-Strength Low-Alloy Welded and Seamless Steel Pipe ASTM C 33 Specification for Concrete Aggregates ASTM C 94 Specification for Ready-Mixed Concrete ASTM C 150 Specification for Portland Cement



ASTM C 171 Specification for Sheet Materials for Curing Concrete ASTM C 260 Specification for Air-Entraining Admixtures for Concrete ASTM C 309 Specification for Liquid Membrane-Forming Compounds ASTM C 494 Specification for Chemical Admixtures for Concrete ASTM C 595 Specification for Blended Hydraulic Cements ASTM C 618 Specification for Fly Ash and Raw or Calcined Natural Pozzolan for Use as a Mineral

Admixture in Portland Cement Concrete ASTM C 881 Specification for Epoxy-Resin_Base Bonding System for Concrete ASTM C 989 Specification for Ground Granulated Blast-Furnace Slag for Use in Concrete and

Mortars ASTM D 1751 Specification for Preformed Expansion Joint Fillers for Concrete Paving and Structural

Construction (Nonextruding and Resilient Bituminous Types) ASTM D 1752 Specification for Preformed Sponge Rubber and Cork Expansion Joint Fillers for

Concrete Paving and Structural Construction AASHTO M 254 Specification for Coated Dowel Bars ACI 305R Hot Weather Concreting ACI 306R Cold Weather Concreting. TT-P-644 Federal Specification for Primer Coating, (Rev. D) Alkyd, Corrosion-Inhibiting, Lead

and Chromate Free, VOC-Compliant END OF SECTION P-501



BITUMINOUS TACK COAT P-603-1

ITEM P-603 BITUMINOUS TACK COAT

DESCRIPTION

603-1.1 This item shall consist of preparing and treating a bituminous or concrete surface with bituminous material in accordance with these specifications and in reasonably close conformity to the lines shown on the plans.

MATERIALS

603-2.1 BITUMINOUS MATERIALS. The bituminous material shall be emulsified asphalt and shall conform to the requirements of Table 1. The type, grade, controlling specification, and application temperature of bituminous material to be used shall be specified by the COTR.

Table 1 Bituminous Material

Type and Grade Specification Application Temperature

Deg. F

Emulsified Asphalt

SS-1, SS-1h ASTM D 977 75-130

CSS-1, CSS-1h ASTM D 2397 75-130


603-3.1 WEATHER LIMITATIONS. The tack coat shall be applied only when the existing surface is dry and the atmospheric temperature is above 60 degrees F. The temperature requirements may be waived, but only when so directed by the COTR.

603-3.2 EQUIPMENT. The Contractor shall provide equipment for heating and applying the bituminous material.

The distributor shall be designed, equipped, maintained, and operated so that bituminous material at even heat may be applied uniformly on variable widths of surface at the specified rate. The allowable variation from the specified rate shall not exceed 10 percent. Distributor equipment shall include a tachometer, pressure gauges, volume-measuring devices or a calibrated tank, and a thermometer for measuring temperatures of tank contents. The distributor shall be self-powered and shall be equipped with a power unit for the pump and full circulation spray bars adjustable laterally and vertically.

If the distributor is not equipped with an operable quick shut off valve, the tack operations shall be started and stopped on building paper. The Contractor shall remove blotting sand prior to asphalt concrete lay down operations at no additional expense to the owner.

A power broom and/or blower shall be provided for any required cleaning of the surface to be treated.



603-3.3 APPLICATION OF BITUMINOUS MATERIAL. Immediately before applying the tack coat, the full width of surface to be treated shall be swept with a power broom and/or air blast to remove all loose dirt and other objectionable material.

Emulsified asphalt shall be diluted by the addition of water when directed by the COTR and shall be applied a sufficient time in advance of the paver to ensure that all water has evaporated before any of the overlying mixture is placed on the tacked surface.

The bituminous material including vehicle or solvent shall be uniformly applied with a bituminous distributor at the rate of 0.05 to 0.15 gallons per square yard depending on the condition of the existing surface. The type of bituminous material and application rate shall be approved by the COTR prior to application.

Following the application, the surface shall be allowed to cure without being disturbed for such period of time as may be necessary to permit drying out and setting of the tack coat. This period shall be determined by the COTR. The surface shall then be maintained by the Contractor until the next course has been placed. Suitable precautions shall be taken by the Contractor to protect the surface against damage during this interval.

603-3.4 BITUMINOUS MATERIAL CONTRACTOR’S RESPONSIBILITY. Samples of the bituminous material that the Contractor proposes to use, together with a statement as to its source and character, must be submitted and approved before use of such material begins. The Contractor shall require the manufacturer or producer of the bituminous material to furnish material subject to this and all other pertinent requirements of the contract. Only satisfactory materials so demonstrated by service tests, shall be acceptable.

The Contractor shall furnish the vendor’s certified test reports for each carload, or equivalent, of bituminous material shipped to the project. The tests reports shall contain all the data required by the applicable specification. If the Contractor applies the material prior to receipt of the tests reports, payment for the material shall be withheld until they are received. If the material does not pass the specifications it shall be replaced at the contractor’s expense. The report shall be delivered to the COTR before permission is granted for use of the material. The furnishing of the vendor’s certified test report for the bituminous material shall not be interpreted as a basis for final acceptance. All such test reports shall be subject to verification by testing samples of material received for use on the project.

603-3.5 FREIGHT AND WEIGH BILLS. Before the final estimate is allowed, the Contractor shall file with the COTR receipted bills when railroad shipments are made, and certified weigh bills when materials are received in any other manner, of the bituminous materials actually used in the construction covered by the contract. The Contractor shall not remove bituminous material from the tank car or storage tank until the initial outage and temperature measurements have been taken by the COTR, nor shall the car or tank be released until the final outage has been taken by the COTR. Copies of freight bills and weigh bills shall be furnished to the COTR during the progress of the work.


603-4.1 QUALITY CONTROL PROGRAM. The Contractor shall develop a Quality Control Program in accordance with Section 014000 “Quality Requirements”. The program shall address all elements which affect the quality of the work including, but not limited to:



1. Quality of Materials

2. Equipment

3. Application


ASTM D 977 Emulsified Asphalt

ASTM D 2397 Cationic Emulsified Asphalt

Asphalt Institute Manual MS-6 Table IV-3

Asphalt Pocketbook of Useful Information (Temperature-Volume Corrections for Emulsified Asphalts)

END ITEM P-603



JOINT SEALING FILLER P-605-1

ITEM P-605 JOINT SEALING FILLER

DESCRIPTION

605-1.1 This item shall consist of providing and installing a resilient and adhesive joint sealing filler capable of effectively sealing joints and cracks in pavements.

MATERIALS

605-2.1 JOINT SEALERS. Joint sealing materials shall meet the following requirements:

ASTM D 2628 Preformed Polychloroprene Elastomeric Joint Seals for Concrete Pavements

ASTM D 5893 Standard Specifications for Cold Applied, Single Component, Chemically Curing Silicone Joint Sealant for Portland Cement Concrete Pavements.

Each lot or batch of sealing compound shall be delivered to the jobsite in the manufacturer’s original sealed container. Each container shall be marked with the manufacturer’s name, batch or lot number, the safe heating temperature, and shall be accompanied by the manufacturer’s certification stating that the compound meets the requirements of this specification.

The manufacturer shall certify that the preformed seal will exert a minimum pressure of 3 pounds per square inch when compressed to 80 percent of nominal width and a maximum of 25 pounds per square inch when compressed to 50 percent of nominal width.

605-2.2 LUBRICANT. Lubricant for installation of preformed joint seal shall conform to the requirements of ASTM D 2835. It shall be a one (1) component polychloroprene compound containing only soluble phenolic resins blended together with antioxidants and acid acceptors in aromatic hydrocarbon solvent mixture and shall meet the following requirements:

Requirements ASTM

Average weight per gallon, pounds 7.8

Solids content, percent by weight 22 - 28 D1644, Method A

Film strength, psi 2,300 min. D412

Elongation, percent 750 min. D412

Each shipment of lubricant shall be delivered to the job site in the manufacturer's original sealed container. Each container shall be marked with the manufacturer's name, batch or lot number, and the date of manufacture and shall be accompanied by the manufacturer's certification stating that the lubricant meets the requirements of the specification.



This lubricant shall be stored at a temperature between 50 degrees F and 80 degrees F and shall be used within 270 days of its manufacture.

605-2.3 PRIMER. Primer shall be as recommended by the manufacturer of the proposed sealant material.


605-3.1 MANUFACTURER’S RECOMMENDATIONS.

A. Cold-applied sealants shall be stored, prepared, mixed, and placed strictly in accordance with approved manufacturer’s written instructions. While the width of the reservoir to receive the sealant shall be per the plans, the depth of the reservoir shall be in accordance with approved manufacturer’s written instructions. A certified copy of the manufacturer’s instructions shall be furnished prior to commencement of this work.

B. Preformed compression joint seals shall be stored, prepared, and placed strictly in accordance with approved manufacturer’s written instructions. The width and depth of the reservoir to receive the preformed compression joint seal shall be in accordance with approved manufacturer’s written instructions. A certified copy of the manufacturer’s instructions shall be furnished prior to commencement of this work.

605-3.2 TIME OF APPLICATION. Joints shall be sealed as soon after completion of the curing period as feasible and before the pavement is opened to traffic, including construction equipment. The pavement temperature shall be above 40 degrees F at the time of installation of the preformed joint seal and 50 degrees F at the time of installation of the poured joint sealing material.

If the pavement must be opened to traffic prior to placement of the sealant, the Contractor shall temporarily fill the joint with a jute or nylon rope immediately after the joint is sawed. The rope should be slightly larger than the joint and should be forced into the joint so that the top of the rope is 1/8 inch below the pavement surface. The rope shall be removed immediately prior to cleaning.

605-3.3 TEST SECTION. Prior to the cleaning and sealing of joints for the entire project, a test section at least 200 feet long for each type of sealant and joint shall be prepared using the specified materials and approved equipment. Before any other joint is sealed, the test section shall be inspected to determine that the material preparation and installation meet the requirements specified. A representative from the manufacturer of each type of sealant material shall be present to train the Contractor’s personnel on the correct procedures for preparation and installation of the sealant. The representative shall be on-site to observe the preparation and installation of the test section, and shall certify in writing that the sealant material is installed in conformance with the recommended installation instructions. If it is determined that the material or installation do not meet the requirements, the materials shall be removed, and the joints shall be recleaned and resealed at no cost to the Authority. All other joints shall be prepared and sealed in the manner approved for sealing the test section.



605-3.2 PREPARATION OF JOINTS.

a. Sawing. All joints shall be sawed in accordance with specifications and plan details. Immediately after sawing the joint, the resulting slurry shall be completely removed from joint and adjacent area by flushing with a jet of water, and by use of other tools as necessary.

b. Sealing. Immediately before sealing, the joints shall be thoroughly cleaned of all remaining laitance, curing compound, and other foreign material. Cleaning shall be accomplished by high pressure waterblasting. Upon completion of cleaning, the joints shall be blown out with compressed air free of oil and water. Only air compressors with operable oil and water traps shall be used to prepare the joints for sealing. The joint faces shall be surface dry when the seal is applied.

605-3.3 INSTALLATION OF SEALANTS. Joints shall be inspected for proper width, depth, alignment, and preparation, and shall be approved by the COTR before sealing is allowed. Sealants shall be installed in accordance with the following requirements:

Cold Applied Sealants. Cold applied joint sealing compound shall be applied by means of pressure equipment that will force the sealing material to the bottom of the joint and completely fill the joint without spilling the material on the surface of the pavement. A backing material shall be placed as shown on the plans and shall be nonadhesive to the concrete or the sealant material. Sealant that does not bond to the concrete surface of the joint walls, contains voids, or fails to set to a tack-free condition will be rejected and replaced by the Contractor at no additional cost to the Authority. Before sealing the joints, the Contractor shall demonstrate that the equipment and procedures for preparing, mixing, and placing the sealant will produce a satisfactory joint seal. This shall include the preparation of two small batches and the application of the resulting material. Any sealant spilled on the surface of the pavement, structures and/or lighting fixtures, shall be removed immediately.

Preformed Elastomeric Joint Seals. Preformed joint sealer shall be placed using equipment capable of installing the sealer in the upright position, without cutting, nicking, distorting, or otherwise damaging the seal. Lubricant shall be applied to the concrete or the preformed seal, or both, and the seal shall be installed in a substantially compressed condition and at the depth below the surface of the pavement as shown in the plans. The method of installation shall be such that the joint sealer will not be stretched more than 5 percent of the minimum theoretical length, or compressed more than 2 percent. The method of installation shall be checked for stretching or compression, using transverse joint sealer. The check shall consist of installing sealer in five (5) joints of at least 25 feet in length, removing the sealer immediately after installation, and checking the length. This check may be modified by premarking or precutting the sealer to length prior to installation if this is compatible with the equipment being used. If the measured length of any of these five (5) sealers indicated that the sealer is stretched or compressed beyond these limits, the installation shall be modified to correct the situation. Once satisfactory sealing operations have started, one (1) joint length per every hundred shall be removed and checked. If the limits are exceeded, the joint sealers on either side should be removed until the condition disappears. The affected joints shall be resealed in a satisfactory manner at no cost to the Authority, and the method of installation shall be checked again for satisfactory procedure. The seal shall be installed in the longest practicable lengths in longitudinal joints and shall be cut at the joint intersections for continuous installation of the seal in the transverse joints.






2. Preparation and Installation

3. Field Test


ASTM D 412 Test Methods for Vulcanized Rubber and Thermoplastic Elastomers – Tension

ASTM D 1644 Test Methods for Nonvolatile Content of Varnishes


ASTM D 2683 Preformed Polychloroprene Elastomeric Joint Seals for Concrete Pavements

ASTM D 2835 Lubricant for Installation of Preformed Compression Seals in Concrete Pavements

ASTM D 5893 Standard Specifications for Cold Applied, Single Component, Chemically Curing Silicone Joint Sealant for Portland Cement Concrete Pavements

COE CRD-C 548 Jet-fuel and Heat Resistant Preformed Polychloroprene Elastomeric Joint Seals for Rigid Pavements

END ITEM P-605


STRUCTURAL PORTLAND CEMENT CONCRETE P-610-1

ITEM P-610 STRUCTURAL PORTLAND CEMENT CONCRETE

DESCRIPTION

610-1.1 This item shall consist of plain and reinforced structural Portland Cement Concrete (PCC), prepared and constructed in accordance with these specifications, at the locations and of the form and dimensions shown on the plans.

MATERIALS

610-2.1 GENERAL. Only approved materials, conforming to the requirements of these specifications, shall be used in the work. They may be subjected to inspection and tests at any time during the progress of their preparation or use. The source of supply of each of the materials shall be approved by the COTR before delivery or use is started. Representative preliminary samples of the materials shall be submitted by the Contractor, when required, for examination and test. Materials shall be scored and handled to insure the preservation of their quality and fitness for use and shall be located to facilitate prompt inspection. All equipment for handling and transporting materials and concrete must be clean before any material or concrete is placed therein.

In no case shall the use of pit-run or naturally mixed aggregates be permitted. Naturally mixed aggregate shall be screened and washed, and all fine and coarse aggregates shall be stored separately and kept clean. The mixing of different kinds of aggregates from different sources in one storage pile or alternating batches of different aggregates will not be permitted.

610-2.2 COARSE AGGREGATE. The coarse aggregate for concrete shall meet the requirements of ASTM C 33.

Coarse aggregate shall be well graded from coarse to fine and shall meet one of the gradations shown in Table 1, using ASTM C 136.

610-2.3 FINE AGGREGATE. The fine aggregate for concrete shall meet the requirements of ASTM C 33.

The fine aggregate shall be well graded from fine to coarse and shall meet the requirements of Table 2 when tested in accordance with ASTM C 136:

Table 1. Gradation For Coarse Aggregate

Sieve Designation (square openings)


2” 1-1/2” 1” 3/4” 1/2” 3/8” No.4

No. 4 to 3/4 in. 100 90-100 20-55 0-10

No. 4 to 1 in. 100 90-100 25-60 0-10

No. 4 to 1-1/2 in. 100 95-100 35-70 10-30 0-5



Table 2. Gradation For Fine Aggregate

Sieve Designation (square openings)


3/8 in No. 4 No. 16 No. 30 No. 50 No. 100

100 95-100 45-80 25-55 10-30 2-10

Blending will be permitted, if necessary, in order to meet the gradation requirements for fine aggregate. Fine aggregate deficient in the percentage of material passing the No. 50 mesh sieve may be accepted, provided that such deficiency does not exceed 5 percent and is remedied by the addition of pozzolanic or cementitious materials other than Portland cement, as specified in 610-2.6 on admixtures, in sufficient quantity to produce the required workability as approved by the COTR.

610-2.4 CEMENT. Cement shall conform to the requirements of ASTM C 150 - Type I or Type II.

The Contractor shall furnish vendors’ certified test reports for each carload, or equivalent, of cement shipped to the project. The report shall be delivered to the COTR before permission to use the cement is granted. All such test reports shall be subject to verification by testing sample materials received for use on the project.

610-2.5 WATER. The water used in concrete shall be free from sewage, oil, acid, strong alkalis, vegetable matter, and clay and loam. If the water is of questionable quality, it shall be tested in accordance with AASHTO T 26.

610-2.6 ADMIXTURES. The use of any material added to the concrete mix shall be approved by the COTR. Before approval of any material, the Contractor shall be required to submit the results of complete physical and chemical analyses made by an acceptable testing laboratory. Subsequent tests shall be made of samples taken by the COTR from the supply of the material being furnished or proposed for use on the work to determine whether the admixture is uniform in quality with that approved.

Pozzolanic admixtures shall be flyash or raw or calcined natural pozzolans meeting the requirements of ASTM C 618.

Air-entraining admixtures shall meet the requirements of ASTM C 260. Air-entraining admixtures shall be added at the mixer in the amount necessary to produce the specified air content.

Water-reducing, set-controlling admixtures shall meet the requirements of ASTM C 494, Type A, water-reducing or Type D, water-reducing and retarding. Water-reducing admixtures shall be added at the mixer separately from air-entraining admixtures in accordance with the manufacturer’s printed instructions.

610-2.7 PREMOLDED JOINT MATERIAL. Premolded joint material for expansion joints shall meet the requirements of ASTM D 1751.

610-2.8 JOINT FILLER. The filler for joints shall meet the requirements of Item P-605, unless otherwise specified in the proposal.



610-2.9 STEEL REINFORCEMENT. Reinforcing shall consist of welded steel wire fabric conforming to the requirements of ASTM A 185 and Grade 60 billet steel conforming to the requirements of ASTM A 615.

610-2.10 COVER MATERIALS FOR CURING. Curing materials shall conform to one of the following specifications:

Waterproof paper for curing concrete ASTM C 171

Polyethylene Sheeting for Curing Concrete ASTM C 171

Liquid Membrane-Forming Compounds for Curing Concrete ASTM C 309, Type 2

610-2.11 CHEMICALLY RESISTANT FLEXIBLE WATERSTOPS: Thermoplastic elastomer rubber waterstops for embedding in concrete to prevent passage of fluids through joints; resistant to oils, solvents, and chemicals. Factory fabricate corners, intersections, and directional changes.

1. PRODUCTS: Subject to compliance with requirements, provide one of the following or approved equal:

A. JP SPECIALTIES, INC.; EARTH SHIELD TPE-RUBBER

B. VINYLEX CORP.; PETROSTOP.

C. WESTEC BARRIER TECHNOLOGIES, INC.; 600 SERIES TPE-R.

2. PROFILE: Ribbed without center bulb

3. DIMENSIONS: 4 inches by 3/16 inch; non-tapered.


610-3.1 GENERAL. The Contractor shall furnish all labor, materials, and services necessary for, and incidental to, the completion of all work as shown on the drawings and specified herein. All machinery and equipment owned or controlled by the Contractor, which he proposes to use on the work, shall be of sufficient size to meet the requirements of the work, and shall be such as to produce satisfactory work; all work shall be subject to the inspection and approval of the COTR.

610-3.2 CONCRETE COMPOSITION. The concrete shall develop a compressive strength of 5,000 psi in 28 days as determined by test cylinders made in accordance with ASTM C 31 and tested in accordance with ASTM C 39. The concrete shall contain not less than 470 pounds of cement per cubic yard. The concrete shall contain 5 percent of entrained air, plus or minus 1 percent, as determined by ASTM C 231 and shall have a slump of not more than 4 inches as determined by ASTM C 143.

610-3.3 ACCEPTANCE SAMPLING AND TESTING. Concrete for each structure will be accepted on the basis of the compressive strength specified in paragraph 3.2. The concrete shall be sampled in accordance with ASTM C 172. Compressive strength specimens shall be made in accordance with ASTM C 31 and tested in accordance with ASTM C 39.

Concrete cylindrical test specimens shall be made in accordance with ASTM C 31 and tested in accordance with ASTM C 39. The Contractor shall cure and store the test specimens under such



conditions as directed. The COTR will make the actual tests on the specimens at no expense to the Contractor.

610-3.4 PROPORTIONING AND MEASURING DEVICES. When package cement is used, the quantity for each batch shall be equal to one or more whole sacks of cement. The aggregates shall be measured separately by weight. If aggregates are delivered to the mixer in batch trucks, the exact amount for each mixer charge shall be contained in each batch compartment. Weighing boxes or hoppers shall be approved by the COTR and shall provide means of regulating the flow of aggregates into the batch box so that the required and exact weight of aggregates can be readily obtained.

610-3.5 CONSISTENCY. The consistency of the concrete shall be checked by the slump test specified in ASTM C 143.

610-3.6 MIXING. Concrete may be mixed at a central point or wholly or in part in truck mixers. The concrete shall be mixed and delivered in accordance with the requirements of ASTM C 94.

610-3.7 MIXING CONDITIONS. The concrete shall be mixed only in quantities required for immediate use. Concrete shall not be mixed while the air temperature is below 40 degrees F without permission of the COTR. If permission is granted for mixing under such conditions, aggregates or water, or both, shall be heated and the concrete shall be placed at a temperature not less than 50 degrees F nor more than 100 degrees F. The Contractor shall be held responsible for any defective work, resulting from freezing or injury in any manner during placing and curing, and shall replace such work at his/her expense.

Retempering of concrete by adding water or any other material shall not be permitted.

The delivery of concrete to the job shall be in such a manner that batches of concrete will be deposited at uninterrupted intervals.

610-3.8 FORMS. Concrete shall not be placed until all the forms and reinforcements have been inspected and approved by the COTR. Forms shall be of suitable material and shall be of the type, size, shape, quality, and strength to build the structure as designed on the plans. The forms shall be true to line and grade and shall be mortar-tight and sufficiently rigid to prevent displacement and sagging between supports. The Contractor shall bear responsibility for their adequacy. The surfaces of forms shall be smooth and free from irregularities, dents, sags, and holes.

The internal ties shall be arranged so that, when the forms are removed, no metal will show in the concrete surface or discolor the surface when exposed to weathering. All forms shall be wetted with water or with a non-staining mineral oil, which shall be applied shortly before the concrete is placed. If mineral oil is used, application to forms shall be done such that no oil touches or is inadvertently applied to the reinforcing steel. Forms shall be constructed so that they can be removed without injuring the concrete or concrete surface. The forms shall not be removed before the expiration of at least 30 hours from vertical faces, walls, slender columns, and similar structures; forms supported by falsework under slabs, beams, girders, arches, and similar construction shall not be removed until tests indicate that at least 60 percent of the design strength of the concrete has developed.

610-3.9 PLACING REINFORCEMENT. All reinforcement shall be accurately placed, as shown on the plans, and shall be firmly held in position during concreting. Bars shall be fastened together at intersections. The reinforcement shall be supported by approved metal chairs. Shop drawings, lists, and bending details shall be supplied by the Contractor when required.

610-3.10 EMBEDDED ITEMS. Before placing concrete, any items that are to be embedded shall be firmly and securely fastened in place as indicated. All such items shall be clean and free from coating,



rust, scale, oil, or any foreign matter. The embedding of wood shall be avoided. The concrete shall be spaded and consolidated around and against embedded items.

610-3.11 PLACING CONCRETE. All concrete shall be placed during daylight, unless otherwise approved. The concrete shall not be placed until the depth and character of foundation, the adequacy of forms and falsework, and the placing of the steel reinforcing have been approved. Concrete shall be placed as soon as practical after mixing and in no case later than 1 hour after water has been added to the mix. The method and manner of placing shall be such to avoid segregation and displacement of the reinforcement. Troughs, pipes, and chutes shall be used as an aid in placing concrete when necessary. Dropping the concrete a distance of more than 5 feet, or depositing a large quantity at one point, will not be permitted. Concrete shall be placed upon clean, damp surfaces, free from running water, or upon properly consolidated soil.

The concrete shall be consolidated with suitable mechanical vibrators operating within the concrete. When necessary, vibrating shall be supplemented by hand spading with suitable tools to assure proper and adequate compaction. Vibrators shall be manipulated so as to work the concrete thoroughly around the reinforcement and embedded fixtures and into corners and angles of the forms. The vibration at any joint shall be of sufficient duration to accomplish compaction but shall not be prolonged to the point where segregation occurs. Concrete deposited under water shall be carefully placed in a compact mass in its final position by means of a tremie, a closed bottom dump bucket, or other approved method and shall not be disturbed after being deposited.

610-3.12 CONSTRUCTION JOINTS. When the placing of concrete is suspended, necessary provisions shall be made for joining future work before the placed concrete takes its initial set. For the proper bonding of old and new concrete, such provisions shall be made for grooves, steps, keys, dovetails, reinforcing bars or other devices as may be prescribed. The work shall be arranged so that a section begun on any day shall be finished during daylight of the same day. Before depositing new concrete on or against concrete that has hardened, the surface of the hardened concrete shall be cleaned by a heavy steel broom, roughened slightly, wetted, and covered with a neat coating of cement paste or grout.

610-3.13 EXPANSION JOINTS. Expansion joints shall be constructed at such points and of such dimensions as may be indicated on the drawings. The premolded filler shall be cut to the same shape as that of the surfaces being joined. The filler shall be fixed firmly against the surface of the concrete already in place in such manner that it will not be displaced when concrete is deposited against it.

610-3.14 DEFECTIVE WORK. Any defective work discovered after the forms have been removed shall be immediately removed and replaced. If any dimensions are deficient, or if the surface of the concrete is bulged, uneven, or shows honeycomb, which in the opinion of the COTR cannot be repaired satisfactorily, the entire section shall be removed and replaced at the expense of the Contractor.

610-3.15 SURFACE FINISH. All exposed concrete surfaces shall be true, smooth, and free from open or rough spaces, depressions, or projections. The concrete in horizontal plane surfaces shall be brought flush with the finished top surface at the proper elevation and shall be struck-off with a straightedge and floated. Mortar finishing shall not be permitted, nor shall dry cement or sand-cement mortar be spread over the concrete during the finishing of horizontal plane surfaces.

When directed, the surface finish of exposed concrete shall be a rubbed finish. If forms can be removed while the concrete is still green, the surface shall be pointed and wetted and then rubbed with a wooden float until all irregularities are removed. If the concrete has hardened before being rubbed, a carborundum stone shall be used to finish the surface. When approved, the finishing can be done with a rubbing machine.



610-3.16 CURING AND PROTECTION. All concrete shall be properly cured and protected by the Contractor. The work shall be protected from the elements, flowing water, and from defacement of any nature during the building operations. The concrete shall be cured as soon as it has sufficiently hardened by covering with an approved material. Water-absorptive coverings shall be thoroughly saturated when placed and kept saturated for a period of at least 3 days. All curing mats or blankets shall be sufficiently weighted or tied down to keep the concrete surface covered and to prevent the surface from being exposed to currents of air. Where wooden forms are used, they shall be kept wet at all times until removed to prevent the opening of joints and drying out of the concrete. Traffic shall not be allowed on concrete surfaces for 7 days after the concrete has been placed.

610-3.17 DRAINS OR DUCTS. Drainage pipes, conduits, and ducts that are to be encased in concrete shall be installed by the Contractor before the concrete is placed. The pipe shall be held rigidly so that it will not be displaced or moved during the placing of the concrete.

610-3.18 COLD WEATHER PROTECTION. When concrete is placed at temperatures below 40 degrees F, the Contractor shall provide satisfactory methods and means to protect the mix from injury by freezing. The aggregates, or water, or both, shall be heated in order to place the concrete at temperatures between 50 degrees F and 100 degrees F.

Calcium chloride may be incorporated in the mixing water when directed by the COTR. Not more than 2 pounds of Type 1 nor more than 1.6 pounds of Type 2 shall be added per bag of cement. After the concrete has been placed, the Contractor shall provide sufficient protection such as cover, canvas, framework, heating apparatus, etc., to enclose and protect the structure and maintain the temperature of the mix at not less than 50 degrees F until at least 60 percent of the designed strength has been attained.

610-3.19 FILLING JOINTS. All joints that require filling shall be thoroughly cleaned, and any excess mortar or concrete shall be cut out with proper tools. Joint filling shall not be started until after final curing and shall be done only when the concrete is completely dry. The cleaning and filling shall be carefully done with proper equipment and in a manner to obtain a neat looking joint free from excess filler.


610-4.1 QUALITY CONTROL PROGRAM. The Contractor shall develop a Quality Control Program in accordance with Section 014000, ”Quality Requirements.” The program shall address all elements which affect the quality of the work including, but not limited to:

1. Mix Design 2. Aggregate Gradation 3. Quality of Materials 4. Sampling and Testing 5. Proportioning 6. Mixing and Transportation 7. Placing and Consolidation 8. Joints 9. Reinforcement Placement and Alignment 10. Compressive Strength 11. Finishing and Curing 12. Surface Smoothness




ASTM C 31 Making and Curing Test Specimens in the Field

ASTM C 39 Compressive Strength of Cylindrical Concrete Specimens

ASTM C 136 Sieve Analysis of Fine and Coarse Aggregates

ASTM C 138 Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete

ASTM C 143 Slump of Hydraulic Cement Concrete

ASTM C 231 Air Content of Freshly Mixed Concrete by the Pressure Method

ASTM C 666 Resistance of Concrete to Rapid Freezing and Thawing

ASTM C 1077 Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation


ASTM A 185 Steel Welded Wire Fabric, Plain, for Concrete Reinforcement

ASTM A 615 Deformed and Plain Billet-Steel Bars for Concrete Reinforcement

ASTM C 33 Concrete Aggregates

ASTM C 94 Ready-Mixed Concrete

ASTM C 150 Portland Cement

ASTM C 171 Sheet Materials for Curing Concrete

ASTM C 172 Sampling Freshly Mixed Concrete

ASTM C 260 Air-Entraining Admixtures for Concrete

ASTM C 309 Liquid Membrane-Forming Compounds for Curing Concrete

ASTM C 494 Chemical Admixtures for Concrete

ASTM D 1751 Specification for Preformed Expansion Joint Fillers for Concrete Paving and Structural Construction (Non-extruding and Resilient Bituminous Types)

AASHTO T 26 Quality of Water to be Used in Concrete



END OF ITEM P-610


RUNWAY AND TAXIWAY PAINTING P-620-1

ITEM P-620 RUNWAY AND TAXIWAY PAINTING

DESCRIPTION

620-1.1 This item shall consist of the painting of temporary and permanent markings and stripes on the pavement surfaces in accordance with these specifications and at the locations shown on the plans, or as directed by the COTR. The contractor shall be responsible for maintaining any existing pavement markings to remain and for removal of any temporary pavement markings. This item shall also consists of the removal of existing pavement markings from the existing Portland cement concrete (PCC) and bituminous pavement surfaces, where required.

MATERIALS

620-2.1 MATERIALS ACCEPTANCE. The Contractor shall furnish manufacturer’s certified test reports for materials shipped to the project. The certified test reports shall include a statement that the materials meet the specification requirements. The reports can be used for material acceptance or the COTR may perform verification testing. The reports shall not be interpreted as a basis for payment. The Contractor shall notify the COTR upon arrival of a shipment of materials to the site.

620-2.2 PAINT. Paint shall be waterborne in accordance with the requirements of Federal Specification TT-P-1952E, Type II. Paint shall be furnished in White-37925, Yellow-33538 or 33655 and Black-37038 in accordance with Federal Standard No. 595.

620-2.3 REFLECTIVE MEDIA. Glass beads shall meet the requirements for Federal Specification. TT-B-1325D, Type I, Gradation A. Glass beads shall be treated with all compatible coupling agents recommended by the manufacturers of the paint and reflective media to ensure adhesion and embedment.


620-3.1 WEATHER LIMITATIONS. The painting shall be performed only when the surface is dry and when the surface temperature is at least 45 degrees F and rising and the pavement surface temperature is at least 5 degrees F above the dew point. Painting operations shall be discontinued when the surface temperature exceeds the paint manufacturer’s recommendations.

620-3.2 EQUIPMENT. Equipment shall include the apparatus necessary to properly clean the existing surface, a mechanical marking machine, a bead dispensing machine, and such auxiliary hand-painting equipment as may be necessary to satisfactorily complete the job.

The mechanical marker shall be an atomizing spray-type or airless-type marking machine suitable for application of traffic paint. It shall produce an even and uniform film thickness at the required coverage and shall apply markings of uniform cross-sections and clear-cut edges without running or spattering and without over spray.

620-3.3 PREPARATION OF SURFACE. Immediately before application of the paint, the surface shall be dry and free from dirt, grease, oil, laitance, or other foreign material that would reduce the bond between the paint and the pavement. The area to be painted shall be cleaned by sweeping and blowing



or by other methods as required to remove all dirt, laitance, and loose materials without damage to the pavement surface. Use of any chemicals or impact abrasives during surface preparation shall be approved in advance by the COTR. Paint shall not be applied to Portland cement concrete pavement until the areas to be painted are clean of curing material. High-pressure water shall be used to remove curing materials.

620-3.4 LAYOUT OF MARKINGS. The proposed markings shall be laid out in advance of the paint application. Any temporary markings necessary to open areas to traffic are shown on the Construction Phasing Plans.

620-3.5 APPLICATION. Paint shall be applied at the locations and to the dimensions and spacing shown on the plans. Paint shall not be applied until the layout and condition of the surface has been approved by the COTR. The edges of the markings shall not vary from a straight line more than 1/2 inch in 50 feet and marking dimensions and spacings shall be within the following tolerances:

Dimension and Spacing Tolerance

36 inches or less ±1/2 in

greater than 36 inches to 6 feet ± 1 in

greater than 6 feet to 60 feet ± 2 in

greater than 60 feet ± 3 in

The paint shall be mixed in accordance with the manufacturer’s instructions and applied to the pavement with a marking machine at the rate shown in Table 1. The addition of thinner will not be permitted. A period of 24 days shall elapse between placement of a PCC pavement and bituminous surface course and application of pavement markings.

Table 1. Application Rates For Paint And Glass Beads

Paint Type

Paint

Square feet per gallon, ft2/gal.

Glass Beads, Type I, Gradation A

Pounds per gallon of paint - lb./gal.

Permanent 115 12

Temporary 230 N/A

Glass beads shall be distributed upon the marked areas at the locations shown on the plans to receive glass beads immediately after application of the paint. A dispenser shall be furnished that is properly designed for attachment to the marking machine and suitable for dispensing glass beads. Glass beads shall be applied at the rate shown in Table 1. Glass beads shall not be applied to black paint or temporary marking. Glass beads shall adhere to the cured paint or all marking operations shall cease until corrections are made.

All emptied containers shall be returned to the paint storage area for checking by the COTR. The containers shall not be removed from the airport or destroyed until authorized by the COTR.



620-3.7 PROTECTION AND CLEANUP. After application of the markings, all markings shall be protected from damage until dry. All surfaces shall be protected from excess moisture and/or rain and from disfiguration by spatter, splashes, spillage, or drippings. The Contractor shall remove from the work area all debris, waste, loose or unadhered reflective media, and by-products generated by the surface preparation and application operations to the satisfaction of the COTR. The Contractor shall dispose of these wastes in strict compliance with all applicable state, local, and Federal environmental statutes and regulations.

620-3.8 PAVEMENT MARKING REMOVAL. Pavement markings shall be removed by the use of high pressure water blasting. Prior to beginning full-scale removal, the Contractor shall demonstrate to the COTR the method and effectiveness of the removal process on a section of paint no less than 50 square feet. To be considered acceptable, the process employed must remove the paint without leaving an objectionable shadow, as determined by the COTR, and without damage to the underlying pavement. Once the COTR has accepted the method of removal, the Contractor shall remove the paint on the designated areas. Any residue from the removal operation shall be removed from the area via a vacuum truck or other means acceptable to the COTR.



1. Surface Preparation


3. Layout of Marking

4. Application

5. Protection


FED SPEC TT-B-1325D Beads (Glass Spheres) Retroreflective

FED SPEC TT-P-1952E Paint, Traffic and Airfield Marking, Waterborne

FED STD 595 Colors used in Government Procurement

END OF ITEM P-620



ELECTRICAL SERVICE, LOW-VOLTAGE ELECTRICAL POWER CONDUCTORS AND CABLES

260519 - 1

SECTION 260519 - ELECTRICAL SERVICE, LOW-VOLTAGE ELECTRICAL POWER CONDUCTORS AND CABLES

PART 1 - GENERAL



B. This section of the specification defines requirements for the new feeder from the power center to the cart stand.

1.2 SUMMARY

A. Section Includes:

1. Building wires and cables rated 600 V and less. 2. Connectors, splices, and terminations rated 600 V and less.


A. Product Data: For each type of product.


A. Qualification Data: For testing agency.

B. Field quality-control reports.


A. Testing Agency Qualifications: Member company of NETA or an NRTL.

1. Testing Agency's Field Supervisor: Certified by NETA to supervise on-site testing.

PART 2 - PRODUCTS

2.1 CONDUCTORS AND CABLES

A. Products: Subject to compliance with requirements, provide one of the following, or approved equal:



260519 - 2

1. Alpha Wire Company. 2. American Insulated Wire Corp. 3. General Cable; General Cable Corporation. 4. Southwire Company.

B. Copper Conductors: Comply with NEMA WC 70/ICEA S-95-658.

C. Conductor Insulation: Comply with NEMA WC 70/ICEA S-95-658 for Type XHHW-2 .

2.2 CONNECTORS AND SPLICES

A. Products: Subject to compliance with requirements, provide one of the following, or approved equal:

1. 3M. 2. Ideal Industries, Inc. 3. ILSCO. 4. O-Z/Gedney; an EGS Electrical Group brand; an Emerson Industrial Automation

business. 5. Tyco Electronics Corp.

B. Description: Factory-fabricated connectors and splices of size, ampacity rating, material, type, and class for application and service indicated.

C. Use compression type connector for conductor size #6 and larger.

2.3 SYSTEM DESCRIPTION

A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.

B. Comply with NFPA 70.

PART 3 - EXECUTION

3.1 CONDUCTOR MATERIAL APPLICATIONS

A. Feeders: Copper . Solid for No. 10 AWG and smaller; stranded for No. 8 AWG and larger.

3.2 CONDUCTOR INSULATION AND MULTICONDUCTOR CABLE APPLICATIONS AND WIRING METHODS

A. Service: Type XHHW-2, single conductors in raceway .

B. Exposed Feeders: Type XHHW-2, single conductors in raceway .



260519 - 3

C. Feeders Concealed in Concrete, below Slabs-on-Grade, and Underground: Type XHHW-2, single conductors in raceway .

3.3 INSTALLATION OF CONDUCTORS AND CABLES

A. Complete raceway installation between conductor and cable termination points according to Section 260533 "Electrical Service, Raceways and Boxes for Electrical Systems" prior to pulling conductors and cables.

B. Use manufacturer-approved pulling compound or lubricant where necessary; compound used must not deteriorate conductor or insulation. Do not exceed manufacturer's recommended maximum pulling tensions and sidewall pressure values.

C. Use pulling means, including fish tape, cable, rope, and basket-weave wire/cable grips, that will not damage cables or raceway.

3.4 CONNECTIONS

A. Tighten electrical connectors and terminals according to manufacturer's published torque-tightening values. If manufacturer's torque values are not indicated, use those specified in UL 486A-486B.

B. Make splices, terminations, and taps that are compatible with conductor material.

3.5 IDENTIFICATION

A. Identify and color-code conductors and cables according to Section 260553 "Electrical Service, Identification for Electrical Systems."

B. Identify each spare conductor at each end with identity number and location of other end of conductor, and identify as spare conductor.

3.6 METERING

A. Existing current transformers shall be salvaged and turned over to the Authority. Refer to drawings for additional requirements.

3.7 FIELD QUALITY CONTROL

A. Testing Agency: Engage a qualified testing agency to perform tests and inspections.

B. Perform the following tests and inspections:

1. After installing conductors and cables and before electrical circuitry has been energized, test service entrance and feeder conductors for compliance with requirements.



260519 - 4

2. Perform each visual and mechanical inspection and electrical test stated in NETA Acceptance Testing Specification. Certify compliance with test parameters.

3. Infrared Scanning: After Substantial Completion, but not more than 60 days after Final Acceptance, perform an infrared scan of each splice in conductors No. 3 AWG and larger. Remove box and equipment covers so splices are accessible to portable scanner. Correct deficiencies determined during the scan.

a. Follow-up Infrared Scanning: Perform an additional follow-up infrared scan of each splice 11 months after date of Substantial Completion.

b. Instrument: Use an infrared scanning device designed to measure temperature or to detect significant deviations from normal values. Provide calibration record for device.

c. Record of Infrared Scanning: Prepare a certified report that identifies splices checked and that describes scanning results. Include notation of deficiencies detected, remedial action taken, and observations after remedial action.

C. Test and Inspection Reports: Prepare a written report to record the following:

1. Procedures used. 2. Results that comply with requirements. 3. Results that do not comply with requirements and corrective action taken to achieve

compliance with requirements.

D. Cables will be considered defective if they do not pass tests and inspections.


4.1 Conform to all applicable provisions of Section 014000 - Quality Requirements and the requirements of this Section. Be responsible for periodic inspections for conformance with the approved SPPP. The results of the periodic inspections shall be submitted to the COTR upon completion.



ELECTRICAL SERVICE, GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS

260526 - 1

SECTION 260526 – ELECTRICAL SERVICE, GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS

PART 1 - GENERAL



1.2 SUMMARY

A. Section includes grounding and bonding systems and equipment.

1. Underground distribution grounding.


A. Product Data: For each type of product indicated.


A. As-Built Data: Plans showing dimensioned as-built locations of grounding features specified in "Field Quality Control" Article, including the following:

1. Ground rods.

B. Field quality-control reports.


A. Comply with UL 467 for grounding and bonding materials and equipment.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Products: Subject to compliance with requirements, provide one of the following or approved equal:

1. Burndy; Part of Hubbell Electrical Systems. 2. ERICO International Corporation.



260526 - 2

3. O-Z/Gedney; an EGS Electrical Group brand; an Emerson Industrial Automation business.

2.2 SYSTEM DESCRIPTION

A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.

B. Comply with UL 467 for grounding and bonding materials and equipment.

2.3 CONDUCTORS

A. Insulated Conductors: Copper wire or cable insulated for 600 V unless otherwise required by applicable Code or authorities having jurisdiction.

B. Bare Copper Conductors:

1. Solid Conductors: ASTM B 3. 2. Stranded Conductors: ASTM B 8. 3. Tinned Conductors: ASTM B 33.

2.4 CONNECTORS

A. Listed and labeled by an NRTL acceptable to authorities having jurisdiction for applications in which used and for specific types, sizes, and combinations of conductors and other items connected.

B. Welded Connectors: Exothermic-welding kits of types recommended by kit manufacturer for materials being joined and installation conditions.

C. Bus-Bar Connectors: Mechanical type, cast silicon bronze, solderless compression -type wire terminals, and long-barrel, two-bolt connection to ground bus bar.

2.5 GROUNDING ELECTRODES

A. Ground Rods: Copper-clad steel; 3/4 inch by 10 feet (19 mm by 3 m) .

PART 3 - EXECUTION

3.1 APPLICATIONS

A. Conductors: Install solid conductor for No. 8 AWG and smaller, and stranded conductors for No. 6 AWG and larger unless otherwise indicated.

B. Underground Grounding Conductors: Install bare tinned-copper conductor, size as indicated on drawings. .



260526 - 3

1. Bury at least 24 inches (600 mm) below grade.

C. Conductor Terminations and Connections:

1. Pipe and Equipment Grounding Conductor Terminations: Bolted connectors. 2. Underground Connections: Welded connectors.

3.2 GROUNDING UNDERGROUND DISTRIBUTION SYSTEM COMPONENTS

A. Comply with IEEE C2 grounding requirements.

3.3 EQUIPMENT GROUNDING

A. Install insulated equipment grounding conductors with all feeders.

3.4 INSTALLATION

A. Grounding Conductors: Route along shortest and straightest paths possible unless otherwise indicated or required by Code. Avoid obstructing access or placing conductors where they may be subjected to strain, impact, or damage.

B. Ground Rods: Drive rods until tops are 2 inches (50 mm) below finished floor or final grade unless otherwise indicated.

1. Interconnect ground rods with grounding electrode conductor below grade and as otherwise indicated. Make connections without exposing steel or damaging coating if any.


A. Tests and Inspections:

1. After installing grounding system but before permanent electrical circuits have been energized, test for compliance with requirements.

2. Inspect physical and mechanical condition. Verify tightness of accessible, bolted, electrical connections with a calibrated torque wrench according to manufacturer's written instructions.

3. Prepare dimensioned Drawings locating each ground rod. Identify each by letter in alphabetical order, and key to the record of tests and observations. Include the number of rods driven and their depth at each location, and include observations of weather and other phenomena that may affect test results. Describe measures taken to improve test results.

B. Grounding system will be considered defective if it does not pass tests and inspections.

C. Prepare test and inspection reports.



260526 - 4





ELECTRICAL SERVICE, UNDERGROUND DUCTS AND RACEWAYS FOR ELECTRICAL SYSTEMS

260543 - 1

SECTION 260543 – ELECTRICAL SERVICE, UNDERGROUND DUCTS AND RACEWAYS FOR ELECTRICAL SYSTEMS

PART 1 - GENERAL




1.2 SUMMARY


1. Conduit, ducts, and duct accessories for concrete-encased duct banks.

1.3 DEFINITION

A. RNC: Rigid nonmetallic conduit.


A. Product Data: For the following:

1. Duct-bank materials, including separators and miscellaneous components. 2. Ducts and conduits and their accessories, including elbows, end bells, bends, fittings, and

solvent cement. 3. Accessories for manholes. 4. Warning tape.


A. Source quality-control test reports.

B. Field quality-control test reports.


A. Testing Agency Qualifications: Qualified according to ASTM E 329 for testing indicated.



260543 - 2

B. Comply with ANSI C2.

C. Comply with NFPA 70.

1.7 DELIVERY, STORAGE, AND HANDLING

A. Deliver ducts to Project site with ends capped. Store nonmetallic ducts with supports to prevent bending, warping, and deforming.

1.8 COORDINATION

A. Coordinate layout and installation of ducts with final arrangement of other utilities, site grading, and surface features as determined in the field.

B. Coordinate elevations of ducts with final locations and profiles of ducts and duct banks as determined by coordination with other utilities, underground obstructions, and surface features. Revise locations and elevations from as required to suit field conditions and to ensure that duct runs drain to manholes and handholes, and as approved by Architect.

PART 2 - PRODUCTS

2.1 CONDUIT

A. Rigid Steel Conduit: Galvanized. Comply with ANSI C80.1.

B. RNC: NEMA TC 2, Type EPC-40-PVC, UL 651, with matching fittings by same manufacturer as the conduit, complying with NEMA TC 3 and UL 514B.

2.2 NONMETALLIC DUCTS AND DUCT ACCESSORIES

A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following: 1. Cantex, Inc. 2. CertainTeed Corp.; Pipe & Plastics Group. 3. Condux International, Inc. 4. IPEX Inc. 5. Lamson & Sessions; Carlon Electrical Products.

B. Duct Accessories:

1. Duct Separators: Factory-fabricated rigid PVC interlocking spacers, sized for type and sizes of ducts with which used, and selected to provide minimum duct spacings indicated while supporting ducts during concreting or backfilling.

2. Warning Tape: Underground-line warning tape .



260543 - 3

2.3 UTILITY STRUCTURE ACCESSORIES

A. Manufacturers: Subject to compliance with requirements, provide products by one of the following: 1. Campbell Foundry Company. 2. East Jordan Iron Works, Inc. 3. Elmhurst-Chicago Stone Co. 4. McKinley Iron Works, Inc. 5. Neenah Foundry Company. 6. Oldcastle Precast Group. 7. Pennsylvania Insert Corporation. 8. Riverton Concrete Products; a division of Cretex Companies, Inc.. 9. Strongwell Corporation; Lenoir City Division. 10. Underground Devices, Inc. 11. Utility Concrete Products, LLC. 12. Utility Vault Co.

B. Expansion Anchors for Installation after Concrete Is Cast: Zinc-plated, carbon-steel-wedge type with stainless-steel expander clip with 1/2-inch (13-mm) bolt, 5300-lbf (24-kN) rated pullout strength, and minimum 6800-lbf (30-kN) rated shear strength.

C. Cable Rack Assembly: Nonmetallic. Components fabricated from nonconductive, fiberglass-reinforced polymer.

1. Stanchions: Nominal 36 inches (900 mm) high by 4 inches (100 mm) wide, with minimum of 9 holes for arm attachment.

D. Duct-Sealing Compound: Nonhardening, safe for contact with human skin, not deleterious to cable insulation, and workable at temperatures as low as 35 deg F (2 deg C). Capable of withstanding temperature of 300 deg F (150 deg C) without slump and adhering to clean surfaces of plastic ducts, metallic conduits, conduit coatings, concrete, masonry, lead, cable sheaths, cable jackets, insulation materials, and common metals.

PART 3 - EXECUTION

3.1 UNDERGROUND DUCT APPLICATION

A. Ducts for Electrical Feeders 600 V and Less: RNC, NEMA Type EPC-40 -PVC, in concrete-encased duct bank, unless otherwise indicated.

3.2 EARTHWORK

A. Excavation and Backfill: Comply with specification P-152, but do not use heavy-duty, hydraulic-operated, compaction equipment.

B. Restore surface features at areas disturbed by excavation and reestablish original grades, unless otherwise indicated.



260543 - 4

C. Restore areas disturbed by trenching, storing of dirt, cable laying, and other work. Restore vegetation and include necessary topsoiling, fertilizing, liming, seeding, sodding, sprigging, and mulching. Refer to specification section 329200 for requirements.

D. Cut and patch existing pavement in the path of underground ducts according to specification section 017329.

3.3 DUCT INSTALLATION

A. Slope: Pitch ducts a minimum slope of 1:300 down toward manholes and handholes and away from buildings and equipment. Slope ducts from a high point in runs between two manholes to drain in both directions.

B. Curves and Bends: Use 5-degree angle couplings for small changes in direction. Use manufactured long sweep bends with a minimum radius of 48 inches (1220 mm) , both horizontally and vertically, at other locations, unless otherwise indicated.

C. Joints: Use solvent-cemented joints in ducts and fittings and make watertight according to manufacturer's written instructions. Stagger couplings so those of adjacent ducts do not lie in same plane.

D. Duct Entrances to Manholes and Concrete and Polymer Concrete Handholes: Use end bells, spaced approximately 10 inches (250 mm) o.c. for 5-inch (125-mm) ducts, and vary proportionately for other duct sizes.

1. Begin change from regular spacing to end-bell spacing 10 feet (3 m) from the end bell without reducing duct line slope and without forming a trap in the line.

2. Grout end bells into structure walls from both sides to provide watertight entrances.

E. Sealing: Provide temporary closure at terminations of ducts that have cables pulled. Seal spare ducts at terminations. Use sealing compound and plugs to withstand at least 15-psig (1.03-MPa) hydrostatic pressure.

F. Pulling Cord: Install 100-lbf- (445-N-) test nylon cord in ducts, including spares.

G. Concrete-Encased Ducts: Support ducts on duct separators.

1. Separator Installation: Space separators close enough to prevent sagging and deforming of ducts, with not less than 5 spacers per 20 feet (6 m) of duct. Secure separators to earth and to ducts to prevent floating during concreting. Stagger separators approximately 6 inches (150 mm) between tiers. Tie entire assembly together using fabric straps; do not use tie wires or reinforcing steel that may form conductive or magnetic loops around ducts or duct groups.

2. Concreting Sequence: Pour each run of envelope between manholes or other terminations in one continuous operation.

a. Start at one end and finish at the other, allowing for expansion and contraction of ducts as their temperature changes during and after the pour. Use expansion



260543 - 5

fittings installed according to manufacturer's written recommendations, or use other specific measures to prevent expansion-contraction damage.

b. If more than one pour is necessary, terminate each pour in a vertical plane and install 3/4-inch (19-mm) reinforcing rod dowels extending 18 inches (450 mm) into concrete on both sides of joint near corners of envelope.

3. Pouring Concrete: Spade concrete carefully during pours to prevent voids under and between conduits and at exterior surface of envelope. Do not allow a heavy mass of concrete to fall directly onto ducts. Use a plank to direct concrete down sides of bank assembly to trench bottom. Allow concrete to flow to center of bank and rise up in middle, uniformly filling all open spaces. Do not use power-driven agitating equipment unless specifically designed for duct-bank application.

4. Reinforcement: Reinforce concrete-encased duct banks where they cross disturbed earth and where indicated. Arrange reinforcing rods and ties without forming conductive or magnetic loops around ducts or duct groups.

5. Forms: Use walls of trench to form side walls of duct bank where soil is self-supporting and concrete envelope can be poured without soil inclusions; otherwise, use forms.

6. Minimum Space between Ducts: as indicated on drawings. 7. Depth: Install top of duct bank as shown on drawings.. 8. Stub-Ups: Use manufactured rigid steel conduit elbows for stub-ups at equipment.

a. Couple steel conduits to ducts with adapters designed for this purpose, and encase coupling with 3 inches (75 mm) of concrete.

b. Stub-Ups to Equipment: For equipment mounted on outdoor concrete bases, extend steel conduit horizontally a minimum of 60 inches (1500 mm) from edge of base. Install insulated grounding bushings on terminations at equipment.

9. Warning Tape: Bury 4” wide detectable warning tape approximately 12 inches (300 mm) above all concrete-encased ducts and duct banks. Align tape parallel to and within 3 inches (75 mm) of the centerline of duct bank. Provide an additional warning tape for each 12-inch (300-mm) increment of duct-bank width over a nominal 18 inches (450 mm). Space additional tapes 12 inches (300 mm) apart, horizontally.


A. Perform the following tests and inspections and prepare test reports: 1. Pull aluminum or wood test mandrel through duct to prove joint integrity and test for out-

of-round duct. Provide mandrel equal to 80 percent fill of duct. If obstructions are indicated, remove obstructions and retest.

B. Correct deficiencies and retest as specified above to demonstrate compliance.

3.5 CLEANING

A. Pull leather-washer-type duct cleaner, with graduated washer sizes, through full length of ducts (both new and existing). Follow with rubber duct swab for final cleaning and to assist in spreading lubricant throughout ducts.



260543 - 6





ELECTRICAL SERVICE, IDENTIFICATION FOR ELECTRICAL SYSTEMS 260553- 1

SECTION 260553 – ELECTRICAL SERVICE, IDENTIFICATION FOR ELECTRICAL SYSTEMS

PART 1 - GENERAL


A. Drawings and general provisions of Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This section applies to work associated with the new Hydrant Cart Test Stand Electrical Service. This section does not apply to other electrical work associated with the Stand; refer to other sections of this specification.

B. This Section specifies electrical identification materials and includes requirements for electrical identification including but not limited to the following:

1. Identification labeling for raceways, cables, and conductors. 2. Operational instruction signs. 3. Warning and caution signs. 4. Equipment labels and signs.

C. Related Sections: The following Sections contain requirements that relate to this Section:

1. Refer to other Division 26 sections for additional specific electrical identification associated with specific items.

1.3 SUBMITTALS

A. Product Data for each type of product specified.

B. Schedule of all tags, markers, nameplates, signs, etc.


A. Electrical Component Standard: Components and installation shall comply with NFPA 70 "National Electrical Code."

B. Comply with manufacturers instructions.



PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, provide products by the following:

1. American Engraving Co. 2. Seton Name Plate Co. 3. Standard Signs, Inc. 4. W.H. Brady, Co. 5. Almetek Industries 6. Tech Products, Inc. 7. William Frick & Company 8. Thomas & Betts

2.2 ELECTRICAL IDENTIFICATION PRODUCTS

A. Engraved, Plastic Laminated Labels, Signs, and Instruction Plates: Engraving stock melamine plastic laminate, 1/16-inch minimum thick for signs up to 20 square inches, or 8 inches in length; 1/8-inch thick for larger sizes. Drill holes for mechanical fasteners when mounted indoors.

B. Baked Enamel Warning and Caution Signs for Interior Use: Preprinted aluminum signs, punched for fasteners, with colors, legend, and size appropriate to the location.

C. Exterior Metal Backed Butyrate Warning and Caution Signs: Weather resistant, nonfading, preprinted cellulose acetate butyrate signs with 20-gage galvanized steel backing, with colors, legend, and size appropriate to the location. Provide 1/4-inch grommets in corners for mounting.

D. Fasteners for Plastic Laminated and Metal Signs: Self tapping stainless steel screws or number 10/32 stainless steel machine screws with nuts and flat and lock washers.

E. Cable Ties: Fungus inert, self extinguishing, one piece, self locking nylon cable ties, 0.18-inch minimum width, 50-lb minimum tensile strength, and suitable for a temperature range from minus 50 deg F to 350 deg F.

F. Cable Markers: Provide "E-Z Tag" as manufactured by Almetek Industries Inc., or "Everlast" tags as manufactured by Tech Products Inc. Tags shall consist of 1.0 inch high numerals or letters placed in a tag holder. Tags and holder shall be manufactured from U.V. stabilized non-conductive, non-corrosive polyethylene or equal. Tag holder shall be black and numerals and letters shall be black on yellow background. Numerals and letters shall be oriented either horizontally or vertically depending on orientation of cable.

G. Pressure Sensitive Markers for Outdoor Equipment: Provide markers as manufactured by Almetek Industries or William Frick & Company or equal. Provide minimum 1.0 inch high numerals or letters. On low voltage equipment provide markers which are black on reflective silver background. Markers shall be resistent to U.V. light.



PART 3 - EXECUTION

3.1 INSTALLATION

A. Lettering and Graphics: Coordinate names, abbreviations, colors, and other designations with corresponding designations specified or indicated. Install numbers, lettering, and colors as approved in submittals and as required by code.

B. Install identification products in accordance with manufacturer's written instructions and requirements of NEC.

C. Sequence of Work: Where identification is to be applied to surfaces that require finish, install identification after completion of finish work.

D. Low Voltage Conductor Color-Coding: Provide color coding for as follows:

208/120 Volts Phase 480/277 Volts Black A Yellow Red B Brown Blue C Orange White Neutral Gray Green Ground Green

E. Use low voltage conductors with color factory-applied the entire length of the conductors except as follows:

1. The following color-coding methods may be used in lieu of factory color-coded wire for sizes No. 4 AWG and Larger.

a. Apply colored, pressure-sensitive plastic tape in half lapped turns for a distance of 6 inches from terminal points and in boxes where splices or taps are made. Apply the last two laps of tape with no tension to prevent possible unwinding.

F. Provide warning, caution, and instruction signs as follows:

1. Install warning, caution, or instruction signs where required by NEC, where indicated, or where required for safe operation and maintenance of electrical systems. Install engraved plastic laminated instruction signs where instructions or explanations are needed for system or equipment operation. Install butyrate signs with metal backing for outdoor items. Attach signs to outdoor equipment using two-part epoxy cement.

G. Provide equipment/system, circuit/device identification as follows:

1. Provide engraved plastic laminate identification markers on electrical equipment. For 240V systems and below provide white lettering on black background. For 480/277V systems, use black lettering on yellow background. Text shall match terminology and numbering of the Contract Documents and shop drawings. Apply markers on all of the following:



a. Panelboards, electrical cabinets, and enclosures. b. Electrical switchgear and switchboards. c. Disconnect switches. d. Circuit breakers

H. Circuit Schedules: For panelboards provide typed circuit schedules with identification of items controlled by each breaker.

I. Install labels, tags and markers at locations for best convenience of viewing without interference with operation and maintenance of equipment.

J. Pad Mounted Equipment: Place 1.0-inch high, black on reflective yellow marker indicating voltage and circuit number in upper left corner of exterior of door securing feeder compartment. Where two feeders enter a compartment, place marker on exterior of door along top edge opposite respective feeder.

K. Raceway: Identify with pressure sensitive markers purpose of circuit ( i.e., lighting, power, alarm, signal, PA, etc.). Place marker on junction boxes and along raceway on 150-foot centers. Markers shall be black on white background.



END OF SECTION 26 05 53


ELECTRICAL SERVICE, PANELBOARDS 262416- 1

SECTION 262416 – ELECTRICAL SERVICE, PANELBOARDS

PART 1 - GENERAL




1.2 SUMMARY

A. Section Includes:

1. New Breakers in existing panelboards.


A. Product Data: For each type of overcurrent protective device, accessory, and component indicated. Include dimensions and manufacturers' technical data on features, performance, electrical characteristics, ratings, and finishes.


A. Field Quality-Control Reports:

1. Test procedures used. 2. Test results that comply with requirements. 3. Results of failed tests and corrective action taken to achieve test results that comply with

requirements.


A. Source Limitations: Obtain overcurrent protective devices, components, and accessories from single source from single manufacturer – match existing panelboard manufacturer.

B. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.

C. Comply with NEMA PB 1.

D. Comply with NFPA 70.



1.6 DELIVERY, STORAGE, AND HANDLING

A. Handle and prepare circuit breakers for installation according to NEMA PB 1.


A. Interruption of Existing Electric Service: Refer to plans for requirements.

1.8 COORDINATION

A. New circuit breakers in existing panelboards: Breakers shall be the standard product of the original equipment manufacturer and compatible with the existing panelboard. Short circuit interrupting ratings shall be equal to or greater than the highest rated existing breaker in the panel. Contractor shall verify type and all requirements in field prior to releasing equipment.

PART 2 - PRODUCTS

2.1 GENERAL REQUIREMENTS FOR PANELBOARDS

A. New circuit breakers in existing panelboards: Breakers shall be the standard product of the original equipment manufacturer and compatible with the existing panelboard.

2.2 OVERCURRENT PROTECTIVE DEVICES

A. Manufacturers: New circuit breakers in existing panelboards: Breakers shall be the standard product of the original equipment manufacturer and compatible with the existing panelboard.

B. Molded-Case Circuit Breaker (MCCB): Comply with UL 489, with fully rated interrupting capacity equal to or greater than the rating of the highest rated device in the panelboard.

1. Thermal-Magnetic Circuit Breakers: Inverse time-current element for low-level overloads, and instantaneous magnetic trip element for short circuits. Adjustable magnetic trip setting for circuit-breaker frame sizes 250 A and larger.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Receive, inspect, handle, and store circuit breakers according to NEMA PB 1.1.

B. Examine breakers before installation. Reject breakers that are damaged or rusted or have been subjected to water saturation.



C. Examine elements and surfaces to receive breakers for compliance with installation tolerances and other conditions affecting performance of the Work.

D. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 INSTALLATION

A. Install breakers in accordance with manufacturer’s installation instructions.

B. Install filler plates in unused spaces.

C. Arrange conductors in gutters into groups and bundle and wrap with wire ties.

D. Comply with NECA 1.

3.3 IDENTIFICATION

A. Identify field-installed conductors, interconnecting wiring, and components; provide warning signs complying with Section 260553 "Electrical Service, Identification for Electrical Systems."

B. Create a directory to indicate installed circuit loads; incorporate Owner's final room designations. Obtain approval before installing. Use a computer or typewriter to create directory; handwritten directories are not acceptable.


A. Perform tests and inspections.

B. Acceptance Testing Preparation: 1. Test continuity of each circuit.

C. Tests and Inspections:

1. Perform each visual and mechanical inspection and electrical test stated in NETA Acceptance Testing Specification. Certify compliance with test parameters.

2. Correct malfunctioning units on-site, where possible, and retest to demonstrate compliance; otherwise, replace with new units and retest.

3.5 ADJUSTING

A. Adjust moving parts and operable component to function smoothly, and lubricate as recommended by manufacturer.




FUEL SYSTEM ELECTRICAL 260500.10 10-1

SECTION 260500.10 10 - FUEL SYSTEM ELECTRICAL

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. Work of this section includes furnishing all labor, materials, tools, equipment, services and facilities required for the complete and proper installation of the electrical work shown on the drawings in conjunction with the Fuel System work. Fuel System work to include providing a new Emergency Fuel Shutoff (EFSO) System for the Signature Load Rack, provide electrical distribution work, instrumentation and controls for the new Hydrant Cart Test Stand (HCTS) provided by this Project, including all new components indicated. The work provided shall include the completion and coordination of the work between the various sections of these specifications.

1.2 QUALITY CONTROL

A. Building Codes - All electrical work shall be in accordance with the following building codes:

B. The latest edition of the code at the time of bid shall apply, unless the local authority enforces an earlier version.

1. The National Electrical Code (N.F.P.A. 70).

2. The National Electrical Safety Code (ANSI C-2)

3. The Life Safety Code (N.F.P.A. 101).

4. Municipal ordinances governing electrical work.

5. The International Building Code.

6. Aircraft Fuel Servicing (N.F.P.A. 407)

7. Material Standards - All material shall be new and shall conform to the standards where such have been established for that particular material or product. Publications and Standards of the organization listed below are applicable to materials specified herein.

8. American society for Testing and Materials (A.S.T.M.)

9. Underwriter’s Laboratories, Inc. (U.L.)

10. National Electrical Manufacturer Association (N.E.M.A.)

11. Insulated Cable Engineers Association (I.C.E.A.)

12. Institute of Electrical and Electronic Engineers (I.E.E.E.)



13. National Fire Protection Association (N.F.P.A.)

14. American National Standards Institute (A.N.S.I.)

15. Shop Drawings/Product Data - Contractor shall submit for approval data of materials and equipment to be incorporated in the work in accordance with Section 335243.10 10, Fuel System General Provisions. Submittals shall include complete descriptive material and electrical characteristics. Provide shop drawings/product data on the following:

C. Cable (each type)

1. Conduit and fittings (each type)

2. Disconnect Switches

3. Pullboxes, Junction Boxes and Outlets

4. Cable Test Report format to be used per 3.2.B

5. The drawings are diagrammatic and indicate the general arrangement of electrical equipment. Do not scale drawings. Obtain dimensions for layout of equipment in the field.

D. Obtain all permits and inspections for the installation of this work and pay all charges incident thereto. Deliver to COTR all certificates of said inspection issued by authorities having jurisdiction.

E. Refer to the General and Special Conditions of the contract for warranty requirements.

F. Review all Specification sections and drawings for equipment requiring electrical service. Provide service to and make connections to all such equipment furnished on the project.

G. Contractor shall submit for approval and then furnish Operation and Maintenance manuals in accordance with Section 335243.10 10. Fuel System General Provisions. Provide O&M materials for Liquid Level Switches and EFSO System.

H. Install, test and commission all electrical components provided in Division 335243.


A. Approved Control System Suppliers include: See Section 335243.10 10.

B. For the EFSO system and motor operated valves (see Section 335243.15 10) provide the services of competent and effective manufacturer’s field services as recommended by the manufacturer and as necessary to commission and turn-over the system to the Authority. No additions to the contract for these services shall be considered.

C. Provide performance tests of all hardware supplied as part of the control equipment in accordance with manufacturer recommendations.



PART 2 - PRODUCTS

2.1 GENERAL

A. All materials shall be new, unless specifically indicated to be reused.

B. All materials shall be U.L. listed and bear the U.L. label.

C. Materials of the same type shall be the product of one manufacturer.

D. All materials installed in areas classified as hazardous locations shall be U.L. labeled for appropriate, Class 1, Group D, applications.

2.2 BASIC MATERIALS

A. Power Circuit Conductors

1. Conductors for power circuits No. 12 AWG and smaller shall be solid copper, 90 degrees C THHN/THWN 600 volt insulation.

2. Conductors No. 10 AWG and larger shall be stranded copper, 90 degrees C THHN/THWN 600 volt insulation.

3. Where multiple conductor power cables are indicated, provide 600 V Power tray cable with ground conductor, Type TC, UL 1277. Internal conductors shall be 90 degrees C THHN/THWN 600 volt insulated stranded copper. Overall jacket shall be PVC and suitable for direct bury use.

4. Where multiconductor power cable is shown routed exposed in hazardous areas, it shall be UL Type MC-HL. Cable shall be UL listed for cable tray use, sun light resistance and for direct burial. Cable shall have stranded copper conductors per ASTM B-8 with color coded 600V, 90 degrees C, XHHW-2 insulation, with stranded copper grounding conductor meeting requirements of NEC Table 250-122. Cable shall be surrounded by an impervious, continuous, welded, corrugated, aluminum C-L-X sheath with an overall black (sunlight resistant) PVC jacket. Provide Okonite Type C-L-X or approved equal by General Cable, Houston Wire & Cable or Rockbestos Surprenant Cable Corporation.

B. Control, signal and instrumentation conductors: 1. Low voltage control conductors for use on 120 volt wiring systems shall be No. 12 AWG

(minimum) stranded type copper, THHN/THWN, unless indicated otherwise on the drawings.

2. Remote control and signal circuits: a. Fuel System Controls: No. 14 AWG (minimum size), standard copper conductors, 600

volt, type THHN/THWN 90oC insulation for 120 VAC circuits. Use of # 16 AWG solid copper THHN/THWN shall be used on 24 VDC systems and where indicated on the drawings.

b. EFSO System: c. Where multiple conductor control cables are indicated, provide 600 V control tray

cable, Type TC, UL 1277. Internal conductors shall be 90 degrees C



TFN/THHN/THWN 600 volt insulated stranded copper. Overall jacket shall be PVC and suitable for direct bury use.

C. Grounding System:

1. Equipment grounding conductors in conduit shall be green insulated type THW, THWN, or XHHW conductors sized as indicated on the drawings. Where size is not indicated on the drawings, conductor size shall be determined from the National Electrical Code table on sizes of equipment grounding conductors.

2. Bonding jumpers shall be flexible copper bonding jumpers sized in accordance with the National Electrical Code tables for grounding electrode conductors.

3. Ground rods shall be ¾” x 10’-0” copper clad steel.

4. Ground receptacle assembly shall be Dabico DAB-GRA-C10, Crouse-Hinds Type GCR or approved equal by Appleton or Killark. Omit cap and chain.

5. Grounding electrode conductors shall be bare copper unless indicated to be insulated in which case they shall be green insulated copper conductor. All grounding electrode conductors shall be sized as indicated on the drawings. Bare copper grounding cable shall be ASTEM B 8 soft-drawn unless otherwise indicated.

6. Use a chemical anchoring system where indicated for anchoring ground bar in concrete. System shall be a fast curing injection system. Provide HILTI HIT-HY 150 system or equal by Kelken Construction Systems, Superior Industries Inc. or Simpson-Liebig.

D. Pullwire:

1. Leave a nylon pull rope in each spare conduit. Pull rope shall have a minimum tensile strength of 2000 pounds and shall be 3/16-inch in diameter. Leave a minimum 24 inches spare rope at each end.

2. Where shown, leave a metallic location wire in an empty conduit. Wire to be a minimum #10 AWG, copper conductor with THWH or XHHW insulation.

E. Raceway System: refer to section 260533.11 10, “Fuel System Conduit.”

F. Connectors:

1. Pressure Type: UL 486A

2. Splice: UL 486C.

3. Insulating Tape: UL 510.

2.3 DISTRIBUTION EQUIPMENT

A. Acceptable manufacturers: Square D, Crouse-Hinds, OZ Gedney, Killark, Appleton.



B. Disconnect switches shall be a minimum of 20 amp, 600V rated, as appropriate for voltage level of system, heavy duty type, 3 pole with ability to lock in “off” position. Switch enclosure shall be NEMA 3/7 and suitable for use in Class I, Group D hazardous locations. Crouse-Hinds Series EFD manual motor starting switch or approved equal by Appleton or Killark.

2.4 EXTERIOR TERMINATION/PULL BOXES

A. Exterior termination/pull boxes shall be NEMA 4 in non-classified areas and shall be rated both Nema 7 and Nema 3 in hazardous areas. Mount boxes on C-Channel electrical equipment racks. Nominal dimensions shall be as shown on the drawings or where not indicated, as required by the National Electrical Code.

B. Enclosure doors shall be gasketed with screw secured cover.

C. Provide back mounting plate(s) for terminal blocks, relays, and other equipment.

D. All wiring shall be terminated on labeled terminal blocks, Square D #GR-6 Series or equal. Terminate conductors with crimp type ring terminations and mark wire ends with tube type wire markers.

E. Provide ground bar mounted to the interior of the enclosure for termination of grounding conductors and shields. Bond to entering raceways with bonding bushings.

F. All conduits shall be connected to enclosure with conduit hubs. Seal conduit interiors after conductor installation to prevent the entrance of moisture. Conduits shall be sealed in accordance with the N.E.C. Art. 500, when exiting hazardous areas.

2.5 FIBER OPTIC SYSTEM – INSIDE PLANT

A. Patch Cords

1. 8/150 um single mode.

2. Type SC connectors.

3. Cords shall meet or exceed the minimum mechanical and optical characteristics for optical fiber patch cords as specified in ANSI/TIA/EIA-568-B.3.

4. 2-strand “zip cord” construction.

5. Acceptable Manufacturers:

a. Lucent.

b. Avaya.

c. Amp.

B. Optical Fiber Termination Panels



1. Description: 24-position, wall-mounted optical fiber patch panel.

2. Specifications:

a. Metal construction with bottom tray for storage and excess fiber coils.

b. Hinged front panel for access to rear of fiber connectors.

c. Front panel with facility for color coding each termination

3. Acceptable manufacturers:

a. Lucent.

b. Hubbell.

c. AMP.

2.6 COPPER COMMUNICATION SYSTEM

A. Cabling:

1. Provide high performance 4 pair Category 6 unshielded twisted pair (UTP) cable.

2. Specifications: Cable shall meet or exceed the minimum mechanical and electrical characteristics for Cat 6 horizontal cable as specified by TIA.

3. Configuration:

a. All data cables shall be light blue in color.

b. Terminate ends with 8-pin modular connector with TIA T568B configuration, orange in color to designate data.

4. Acceptable manufacturers:

a. Lucent.

b. Avaya.

c. AMP.

d. Belden.

5. Cable selection: As part of the cable selection process, cable manufacturers/vendors shall submit, in writing, their minimum guaranteed specifications for cable attenuation, NEXT, and structural return loss.

2.7 LEAK DETECTION SYSTEM



A. Refer to section 335800.10 10 for components requiring electric connection.

PART 3 - EXECUTION

3.1 RACEWAY SYSTEM

A. General: refer to Section 260533.11 10, “Fuel System Conduit.”

3.2 CONDUCTORS

A. Do not install more conductors in a raceway than indicated on the drawings. A maximum of three branch circuits are to be installed in any one conduit, on 3-phase 4-wire system, unless specifically indicated on the drawings. No two branch circuits of the same phase are to be installed in the same conduit, unless specifically indicated on the drawings.

B. Conductors shall be tested to be continuous and free of short circuits and grounds prior to any terminations, or splicing to tested cables. Contractor shall provide the Engineer a spreadsheet listing each conductor in each conduit and its resistance to adjacent conductors in the same conduit as well as the conduit itself. The same spreadsheet shall list the results of each conductors Megometer test. The Megger test shall be conducted based on cable manufactures settings, or a maximum of 750V, whichever is less. The Engineer shall then approve the wiring at which point the contractor shall be approved to terminate, splice or seal the conduit and install the re-enterable compound (if applicable). If the Engineer does not approve the conductor test, the contractor shall replace the conductor at no additional cost to the project. If the contractor seals the conduit prior to approval and it is shown that there is an issue in the cabling, the contractor shall replace the cabling, and reimburse for any project costs expended by the Engineer in site visits, or inspections and any other delayed contractors with no additional cost to the project. Insuring that the wire is properly installed and tested is critical to the project operation.

1. Shorts shall be defined as any two points with approximately 250 ohms or less resistance between them.

2. Opens on any one conductor shall be defined as having more than approximately 100 ohms resistance between the two test points.

3. Megometer readings shall be considered failed if the readings do not read approximately 750 megaohms or greater.

C. Identification:

1. Conductors within pull boxes shall be grounded and identified with nylon tie straps with circuit identification tag.

2. Identify each control conductor at its terminal points with wrap around tape wire markers. I.D. to indicate terminal block and point designation, or other appropriate identifying indication.

3. Refer to section 260553.12 10, “Identification”.



D. Color code all secondary service, feeder and branch circuit conductors. Control and signal system conductors need not be color coded.

E. Terminate conductors No. 10 AWG and smaller specified in the Fueling System Specifications to be stranded, with crimp type lug or stud. Direct termination of stranded conductors with crimp terminator to terminal screws, lugs, or other points is not permitted even if terminal is rated for stranded conductors. Crimp terminal shall be the configuration type suitable for terminal point and applied using a ratcheting, hydraulic or controlled cycling, crimper to ensure uniform crimps.

F. Control, communications or signal conductors shall be installed in separate raceway systems from branch circuit or feeder raceway, unless indicated otherwise on the drawings.

G. Conductors connected on the ‘safe’ side of intrinsically safe barriers shall be installed in separate raceway from all other conductors. Conductors shall be isolated from other circuits by appropriate barriers where installed in a common enclosure.

H. Where existing conductors are to be terminated, connected to or used in any manner, CONTRACTOR shall test existing conductors to be continuous and free from shorts or grounds, CONTRACTOR shall trace existing conductors to source, verify circuit labeling, re-label if found to be mislabeled and shall terminate existing conductors as required.

3.3 GROUNDING

A. Branch circuit equipment grounding conductors may not be shown on the drawings; however, an equipment grounding conductor shall be installed in all raceways and cables.

3.4 DEVICE AND EQUIPMENT INSTALLATION

A. Provide equipment identification labels of laminated plastic on each motor controller, panelboard, disconnect means and other distribution equipment. Indicate equipment designation, voltage and power source.

3.5 EQUIPMENT CONNECTIONS

A. Connect all equipment requiring electrical connections under the Fuel System specifications. Where electrical connections to equipment require specific locations, obtain location from shop drawings. Do not scale drawings for location of conduit stud-ups or boxes mounted in wall or floor to serve specific equipment.

B. Electrical circuits to equipment furnished under other divisions of these specifications are based on design loads. If actual equipment furnished has loads others than design loads, revise electrical circuits and protective devices to be compatible with equipment furnished and in compliance with the National Electrical Code at no additional cost to Authority.

C. Contractor’s attention is directed to other divisions of these specifications, where equipment requiring electrical service is specified, to become aware of the scope of work under this division of these specifications requiring electrical service and connections to equipment specified elsewhere.



3.6 CLEANING AND PAINTING

A. Remove, oil, dirt, grease and foreign materials from all raceways, fittings, boxes, panelboards and cabinets to provide a clean surface for painting. Touchup scratched or marred surfaces of lighting fixtures, panelboards, control panels, or equipment enclosure with paint furnished by the equipment manufacturers specifically for that purpose. Paint all exposed electrical equipment, including conduits and fittings, as directed by COTR.

B. Stainless Steel boxes, racks and components shall be cleaned of all oil, dirt, grease and foreign materials. Care shall be taken to insure that strong acid solutions are not used for cleaning. Scratches shall be polished out using a non-iron product such as Stainless Steel Wool or Scotchbrite scouring pads with either water or paste designed specifically for Stainless Steel use.

3.7 LEAK DETECTION SYSTEM

A. Refer to section 335800.10 10

3.8 HORIZONTAL COPPER CABLNG ACCEPTANCE TESTING

A. All pairs shall be terminated to modular 8-pin jacks and tested for opens, mis-wires, splits, pairs, crossed pairs and end-to-end connectivity. Also, Contractor shall submit testing report/results to the COTR.

B. Contractor shall employ the services of a certified telecommunications installer to install and test horizontal copper cabling and equipment. Contractor shall provide all necessary test equipment and shall confirm that all cabling is properly installed by testing each pair and ensure each end is properly labeled. Contractor shall label all pairs and jacks. Contractor shall report to the COTR any pairs that are not continuous.

3.9 TRAINING

A. Training shall be provided to Authority (including the Fuel Operator’s personnel) on all aspects of the electrical systems including the EFSO valves, the HCTS and the EFSO system. Training shall be conducted on the site with the system as installed. Training shall include systems maintenance and calibration. The training shall be provided during the first two months of the guarantee period as scheduled by Authority. Allow twelve hours for training. Coordinate with Authority to insure that multiple shifts are covered for all training activities.

B. A training plan shall be provided to Authority for review and approval prior to scheduling the sessions.

C. Training shall be scheduled with Authority.

D. The operating and maintenance manuals shall be available for use during the training.

E. Provide additional training as may be required or requested by Authority at additional cost. This training may be at the job site or at Contractor facilities as appropriate.




4.1 Conform to all applicable provisions of Division 01 Section “Quality Requirements" and the requirements of this Section. Be responsible for periodic inspections for conformance with the approved SPPP. The results of the periodic inspections shall be submitted to the COTR upon completion.



FUEL SYSTEM CONDUIT 260533.11 10-1

SECTION 260533.11 10 - FUEL SYSTEM CONDUIT

PART 1 - GENERAL

1.1 DESCRIPTION

A. This section covers the complete conduit system for the jet fuel system.

B. Definition: The term conduit, as used in this Specification, shall mean any or all of the raceway types specified.

C. Submittals and General Requirements: See 335243.10 10

1.2 QUALITY CONTROL

A. Referenced Industry Standard: The following specifications and standards are incorporated into and become a part of this Specification by reference. Except where a specific date is given, the issue in effect, including amendments, addenda, revisions, supplements and errata on the date of invitation for bids, shall apply. In text, such specifications and standards are referenced to by basic designation only.

1. Underwriter’s Laboratories, Inc. (U.L.) Publications:

a. No. 1: Flexible Metal Electrical Conduit

b. No. 6: Rigid Galvanized Conduit

c. No. 467: Electrical Grounding and Bonding

d. No. 651: Rigid Nonmetallic Electrical Conduit

e. No. 797: Electrical Metallic Tubing

f. No. 1242: Intermediate Metal Conduit

2. American National Standards Institute (ANSI):

a. C-80.1: Rigid Galvanized Conduit

b. C-80.3: Electrical Metallic Tubing

3. National Fire Protection Association (NFPA):

a. No. 70: National Electrical Code (NEC)

B. Acceptable Manufacturers: Products of the following manufacturers, which comply with these specifications, are acceptable.



1. Metallic Conduit Fittings:

a. Appleton, Crouse Hinds, ETP

b. Thomas and Betts, Steel City, OZ/Gedney

c. RACO, Efcor

2. Support Channel:

a. Unistrut, Midland-Ross Company

b. Kindorf

c. Powers

3. Non-Metallic Conduit and Fittings:

a. Carlon

b. Certainteed

c. Adalet – PLM

C. Coordination

1. Coordinate conduit installation with electrical equipment furnished.

2. Coordinate conduit installation with contract documents and other Contractors. Adjust installation to eliminate conflicts. Review all shop drawings submitted under this and other sections to insure coordination with all equipment requiring electrical service and to avoid conflict interference’s. Coordinate installation sequence with other Contractors to avoid conflicts including equipment access and provide the fastest overall installation schedule.

1.3 STORAGE AND HANDLING

A. Refer to the electrical general section of the Specifications for storage and handling requirements.

B. Non-metallic conduits stored on site prior to installation shall be stored on a flat surface off of the ground and shall be protected from the direct rays of the sun and debris.

C. Damaged, oxidized, warped, improperly stored material or with excessive amount of foreign debris will be removed from the project and replaced with new materials.

PART 2 - PRODUCTS

2.1 GENERAL MATERIALS REQUIREMENTS



A. Furnish all materials specified herein.

B. All conduit and fittings shall be listed and bear a label by underwriter’s laboratories (U.L.) for use as raceway system for electrical conductors.

C. Raceway is required for all wiring, unless specifically indicated or specified otherwise.

D. Size: The minimum size of conduit shall be ½ inch except exterior installations and except when installed in concrete slabs when the minimum size shall be ¾ inch. The size of all conduits shall be in accordance with the NEC, but not less than indicated on the drawings.

2.2 CONDUIT

A. Intermediate Metal Conduit (IMC) – UL 1242.

B. Galvanized Rigid Metal Conduit (GRS) – UL 6 and ANSI C80.1.

C. Schedule 40 PVC Conduit – UL 651.

D. Liquid-tight flexible metal conduit – UL 360 and UL 1660.

E. Explosion proof (liquid-tight) flexible metal conduit – Nema 7, UL 886

F. PVC-coated GRS – Nema RN 1. Provide a 40 mil, bonded, exterior, PVC factory coating and a 2 mil, urethane interior coating. Threads shall be urethane coated.

2.3 RIGID AND IMC CONDUIT FITTINGS

A. Fittings for rigid steel and IMC shall be standard threaded couplings, locknuts, bushings and elbows. All materials shall be galvanized steel type. Where galvanized steel is not commercially available for a given type or size of fitting, aluminum or cast iron alloy shall be allowed as long as the fitting material is compatible with conduit material and is listed for use with the particular conduit type. Malleable iron fittings are not allowed. Set screw or non-thread fittings are not permitted. Bushings shall be metallic insulating type consisting of insulating insert molded or locked into the metallic body or the fitting. Erickson-type couplings may be used to complete a conduit run.

B. PVC –coated GRS shall utilize PVC coated conduit fittings by the conduit manufacturer. Fitting, where applicable, shall be internally and externally coated.

C. In-line conduit sealing fittings or conduit seals shall be cast alloy with conduit hubs as appropriate for the raceway installation. Conduit sealing fittings shall be sized for the conduit fill indicated or shall be expanded fill type fittings where required to be in compliance with Article 501.15(C)(6) of the NEC. Where expanded fill type fittings are used, conduit seal bodies shall have expanded fill area, UL listed for 40% conductor fill. Install drain and inspection fittings in seals which are at a low point in the conduit run and in all seals installed vertically. Seal fittings shall be Crouse Hinds EYS Series or equal for horizontal conduit seals. Crouse Hinds Series EZD or equal for vertical conduit seals requiring drains. Crouse Hinds EYSX or equal for expanded fill conduit seal applications not requiring drains and Crouse Hinds EYDX or equal fitting for expanded fill conduit seal applications requiring drains.



2.4 NON-METALLIC CONDUIT AND FITTINGS

A. Non-metallic conduit shall be heavy wall, Schedule 40 PVC and as indicated on the drawings.

B. Non-metallic conduit fittings shall be of the same material as the conduit furnished and be the product of the same manufacturer.

2.5 CONDUIT SUPPORTS

A. All part and hardware shall be zinc-coated or have equivalent corrosion protection.

B. Conduit straps shall be single hole cast metal type or two hole galvanized metal type. Conduit clamps shall be spring steel type for use with exposed structural steel.

C. Conduit support channels shall be 1 ½” x 1 ½” x 14 gauge galvanized or with equivalent treatment channel. Channel suspension shall be 3/8” threaded steel rods. Use swivel type connector to attach suspension rods to structure. Spring steel clips are not acceptable. Conduit straps shall be spring steel conduit straps compatible with channel. Wire or chain is not acceptable for conduit hangers.

D. Individual conduit hangers shall be galvanized spring steel specifically designed for the purposes, sized appropriately for the conduit type and diameter, and have pre-assembled closure bolt and nut and provisions for receiving threaded hanger rod. Support with ¼” threaded steel rod for individuals conduits 1.5 inch and smaller and 3/8 inch rod individual conduits 2.0 inch and larger.

E. Individual conduit straps on metal studs shall be spring steel and should wrap around entire face of stud securely biting into both edges and have provisions for screwing into stud. Size straps for conduit to be supported. Tie warps are not acceptable.

F. Support multiple conduits from metal studs using pre-assembled bar hangar assembly consisting of hangar bar, retaining clips and conduit straps.

2.6 FLEXIBLE CONDUIT AND FITTINGS

A. Flexible conduit shall be steel metallic type. Where specified herein, indicated on the drawings, when used in damp or wet locations, or in Class 1, Division 2 hazardous locations, as classified by the National Electrical Code, flexible conduit shall be liquid tight.

B. All flexible conduit shall be classified as suitable for system grounding.

C. Connectors for flexible conduit shall be insulated throat type rated as suitable for system ground continuity. Connectors for liquid tight conduit shall be screw-in ground cone type.

D. Flexible conduit shall not be less than ½-inch trade size and in no case shall flexible conduit size be less than permitted by the National Electrical Code for the number and size of conductors to be installed herein.

E. Flexible conduits installed in Class 1, hazardous locations shall be U.L. listed for the application, liquid tight for wet locations, bronze brand covering and flexible brass core.



2.7 MISCELLANEOUS CONDUIT FITTINGS AND ACCESSORIES

A. Vinyl all weather electrical tape for corrosion protection shall be Scotch #88, Tomic #85, Permacel #295.

B. Expansion and deflection couplings shall be in accordance with U.L. 467 and U.L. 514. They shall accommodate ¾-inch deflection, expansion, or contraction in any direction and shall allow 30 degrees angular deflections. Couplings shall contain an internal flexible metal braid to maintain raceway system ground continuity.

C. Fire and smoke stop materials shall be, rock wool fiber, silicone foam, or silicone sealant, U.L. rated to maintain the fire floor and fire wall partition rating

D. Provide expanded fill type conduit sealing fittings where required by NEC cable fill requirements. Provide breather-type conduit seals for vertical conduit runs and at low points in conduit systems to prevent accumulation of condensate above seal.

E. Provide watertight, malleable iron thruwall seals where indicated and for all conduit penetrations through concrete vault walls. Provide O.Z. Gedney series FSK series, Spring City Electrical Manufacturing Company Type WEP or approved equal.

F. Provide re-enterable, watertight, cable gel/encapsulant where indicated to stop water egress into vault equipment enclosures. Provide 3M Scotchcast, AmcorrSTOPAQ 3000, or approved equal.

G. Provide electrical grade insulating spray on for all terminals in IVV and IVP vaults. Provide 3M Scotch Brand 1602 or approved equal by Caig or TechSpray.

2.8 MICRODUCT/INNERDUCT

A. Microduct, innerduct, tube cable, refer to the pathways that shall be provided for the installation of the air blown fiber optics.

B. Tube cable and Tube Distribution Units (TDU).

1. Tube cable shall be 7-cell, Sumitomo Part Number TC07TOX and, where indicated, 2-Cell Sumitomo Part Number TC02TOX. Tubing and the ABF distribution boxes supplied for this work shall be compatible with existing tubing and boxes. The tubing material shall conform to all required fire safety codes for the areas within which it will be installed. Listed type unit ratings OFNP, OFNR, OFCR, and/or OFCP (as required in the NEC).

2. Inside plant tube distribution boxes (TDU’s) shall be appropriately sized for the amount of tubing to be used but in no case smaller than “20x20x7” and shall meet with the COTR’s approval. Provide Sumitomo Electric Model DE12IDU.

3. Outside plant TDU’s installed below grade in pullboxes shall be Nema 6P rated enclosures with the number and quantity of tube clips and tube clip organizers as required. Enclosure shall be approximately 18” x 16” x 10” d, with hinges mounted such that hinges are on the bottom of enclosure. Provide Integra Premium HT 6P or approved Hoffman or FIBOX USA equal.



PART 3 - EXECUTION

3.1 INSTALLATION

A. General

1. Conceal all conduits, except in unfinished spaces such as equipment rooms or where indicated by symbol on the drawings.

2. Leave all empty conduits with a 2000 pound 3/16 inch diameter nylon pull rope.

3. Install as complete raceway runs prior to installation of cables or wires.

4. Flattened, dented, or deformed conduits are not permitted, and shall be removed and replaced.

5. Secure rigid conduit i.e. rigid galvanized conduit and intermediate metal conduit, to sheet metal enclosures with two (2) locknuts and insulated bushing.

6. Fasten conduit support device to structure with wood screws on wood, toggle bolts on hollow masonry, anchors as specified on sold masonry or concrete, and machine bolts, clamps, or spring steel clips, on steel. Nails are not acceptable.

7. Protect conduits against dirt, plaster, and foreign debris with conduit plugs. Plugs shall remain in place until all masonry is complete. Protect conduit stub-ups during construction from damage; any damaged conduits shall not be used.

8. Seal all conduits entering buildings from below grade and all conduits entering exterior mounted electrical equipment with insulating electrical putty to prevent entrance of moisture.

9. Install conduit with wiring, including homeruns as indicated on the drawings. Any change resulting in a savings in labor or materials is to be made only in accordance with a contract change. Deviations shall be made only where necessary to avoid interference’s and when approved by the COTR by written authorization.

10. Conduits which penetrate roof membranes shall be installed in accordance with manufacturer’s recommendations and architectural specifications.

11. Use flexible conduit for connection to vibrating equipment and rotating machinery and for connection from junction box to flush mounted lighting fixtures.

12. Separate raceway systems are to be installed for power systems and for control, signal and communications systems. Do not install control, signal or communications cables in the same raceways as branch circuit or feeders cables, unless indicated otherwise on the drawings.

13. Install re-enterable, watertight, cable gel/encapsulant in cast junction boxes, where indicated, to stop water egress into vault equipment enclosures. Install per manufacturer’s directions after commissioning of control system is complete.



14. Apply electrical grade insulating spray on for all exposed wire terminals located within cast junction boxes and equipment enclosures located underground in fuel vaults. Apply per manufacturer’s directions in the presence of the COTR.

15. Provide identification markings on all EFSO System conduit routed exposed. Markings shall be at a minimum every 25 feet and within 5 feet of wall penetrations on each side. Markings shall consist of any one of the following:

a. Self adhesive, colored, vinyl tape not less than 3 mils thick (Brady, Panduit, 3M): red with minimum ½” inch high white letters “EFSO.”

b. Self-adhesive vinyl labels with letters overlaminated with a clear, weather-resistant and chemical-resistant coating (Brady, Panduit, 3M): ¾” wide minimum with ½” high (minimum) white letters “EFSO.”

B. Uses Permitted.

1. Conduits installed within concrete slabs, concrete pads and concrete floor slabs which are in direct contact with grade shall be PVC-coated, galvanized rigid steel (G.R.S.).

2. Conduits installed in direct contact with earth shall be PVC-coated, GRS. Conduits installed in exterior locations shall be galvanized rigid steel.

3. Conduit types shall not be mixed indiscriminately with other types in the same run, unless specified herein.

4. Use flexible conduit for connections to motors, dry type transformers, electrical duct heaters, unit heaters, valves, meters, filter/separators, vibrating fueling equipment and flush mounted lighting fixtures.

a. Flexible conduit used for connection of motors, valves, and vibrating fueling equipment shall not exceed 18-inches in length.

b. Maintain ground continuity through flexible conduit with green equipment grounding conductor; do not use flexible conduit for ground continuity.

c. Liquid tight flexible conduit shall be used to connect equipment in exterior, damp or wet locations and electrical equipment rooms.

5. All conduits installed within fuel vaults or pits shall be galvanized rigid steel (G.R.S.) or intermediate metallic conduit (IMC).

6. Where hazardous locations, as classified by the National Electrical Code, exist, all conduits and fittings and the installation of these materials shall comply with Article 500 of the National Electrical Code.

7. All conduits for interior wiring system whose voltage is above 240 volts shall be galvanized rigid steel.

8. Concrete encased underground duct banks shall be installed where indicated on the drawings. Duct bank conduits shall be non-metallic Schedule 40, heavy wall PVC for concrete encasement.



C. Below Grade Raceway Installations

1. Direct Burial Conduit:

a. Install top of conduits 24 inches minimum below finished grade.

b. Install top of conduits 6 inches minimum below bottom of building slabs.

c. Install top of conduits 30-inches minimum below grade, below roads and any other paved surfaces where indicated.

d. Where transition is made from below grade PVC installation to a metallic conduit system above grade or slab, make transition with PCV-coated, galvanized, rigid steel conduit. For corrosion protection, where the elbow penetrates surface, provide PVC-coated conduit. Corrosion protection shall extend for 6 inches above and below concrete surface.

e. For excavation and backfilling, refer to earthwork specification section.

f. Conduit shall be run following the most direct route between points.

2. Duct Bank:

a. Duct bank configuration shall be in accordance with the details indicated on the drawings and contained in the Specifications. Conduit size shall be as indicated on the drawings.

b. Duct banks shall be installed with top of concrete not less than thirty inches below finished grade or pavement unless position of existing underground utilities prevents installation at this depth. Under such conditions, depth may be reduced in accordance with the National Electrical Code. Refer to earthwork section of the Specification for excavation bedding and backfill. The bottom of the conduit trench shall be flat and level.

c. Conduits shall be anchored to and supported in the trench with fiber or plastic conduit spacers, designed and provided by the manufacturer for the purpose, and installed not more than 5 foot on center. Stagger conduit couplings a minimum of 12 inches.

d. Change in direction exceeding 10 degrees shall be made with long sweep bends with minimum radius of curvature of twenty five feet unless indicated otherwise on plan. In absence of radius being indicated on drawings and in all cases the minimum radius of curvature of long sweep bends shall be 4 feet. Manufactured bends may be used at the ends of run. All 90 degree elbows shall be factory made and shall be long sweep type (24 inches minimum radius) unless indicated otherwise on the drawings.

e. Conduit joints shall be watertight and shall be made by the application of PVC solvent, furnished by the manufacturer of the conduit. Solvent shall be applied to interior of coupling and exterior of conduit, in accordance with manufacturer’s recommendations.



f. Concrete for use with duct bank shall be 2,500 lb. 28-day concrete. Refer to cast P-610 Structural Portland Cement Concrete for additional requirements for concrete.

g. Concrete cover for duct banks shall be not less than 3 inches from edge of duct or five inches from center of largest duct, whichever is greater. Spacing between ducts shall be no less than 3inches spacing between ducts from as measured from duct edges.

h. All open conduit ends shall be plugged during construction to prevent water, mud, concrete and debris from entering duct banks and manholes. Prior to the installation of cables, each conduit shall be cleaned by pulling a standard, flexible mandrel not less than twelve inches long, with diameter approximately ¼” less than inside diameter of conduit, through the conduit. In addition, a brush with soft bristles and diameter approximately equal to inside diameter of conduit shall be pulled through conduit.

i. Conduits terminating underground to fuel vaults shall be PVC-coated GRS. Transition from ductbank (concrete-encased schedule 40 PVC) to PVC-coated GRS within ductbank a minimum of 6 inches from end of ductbank.

D. Raceway Installations Within Concrete:

1. Conduit shall be run following the most direct route between points.

2. Conduit shall not be installed in concrete which is less than 3-inches thick or where the outside diameter is larger than 1/3 of the slab thickness.

3. Conduits installed in concrete slabs shall be buried in the concrete slab. Wire low conduits to upper side of the bottom reinforcing steel, and upper conduits to the lower side of the top reinforcing steel. Separate parallel runs of conduits within slab by at least one inch.

4. Conduits shall not be installed within sheet walls unless specifically indicated on the drawings. Conduits shall not be run directly below and parallel with load bearing walls.

5. Conduit shall be PVC-coated GRS.

6. The maximum project of conduit stub-up and bushing above slab shall be three inches.

7. Protect all conduits entering and leaving concrete floor slabs from physical damage during construction.

E. Exposed Raceway Installation:

1. Conduit shall be run parallel or at right angles to existing walls, ceiling, and structural members.

2. Support branch circuit conduits at intervals not exceeding ten feet and within three feet of each outlet, junction box, panelboard, enclosure or cabinet.

3. Attach feeder conduits larger than one inch trade diameter to or from structure on intervals not exceeding twelve feet with conduit beam clamps, one hold conduit straps or



trapeze type support in accordance with support systems described from branch circuit conduits.

4. Exposed conduits, fittings, boxes and supports shall be painted, see painting section of Specifications.

5. Where conduits must pass through structural members, obtain approval of the COTR with respect to location and size of hole prior to drilling.

6. Install conduit sleeves in slabs where conduits 2.0 inch and larger pass through or where indicated. Sleeves shall extend 1-inch minimum above finished slab. Seal all spare sleeves and between conduits and sleeves to maintain fire rating and to make watertight and smoke-tight.

7. Conduits rigidly secured to building construction on opposite sides of a building expansion joint shall be provided with an expansion and deflection coupling. In lieu of an expansion coupling, conduits 2-1/2 inches and smaller may be provided with junction boxes on both sides of the expansion joint connected by 15-inches of slack flexible conduit with bonding jumper.

F. Raceway Seals in Hazardous Locations:

1. Install raceway sealing fittings according to the manufacturer’s written instructions. Locate fittings at suitable, approved, accessible locations and fill them with UL-listed sealing compound. For concealed raceways, install each fitting in a flush steel box with a blank cover plate having a finish similar to that of adjacent plates or surfaces. Install raceway sealing fittings at the following points:

a. Where conduits enter or leave hazardous locations.

b. Where otherwise required by NEC.

c. At each entrance of arcing devices in hazardous locations.

d. Where indicated on drawings.

2. Raceway seals shall be cast alloy with conduit hubs as appropriate for the raceway installation.

3. Install drain and inspection fittings in seals which are at a low point in the conduit run and in all seals installed vertically to prevent accumulation of condensate above seal.

4. Provide expanded fill type conduit sealing fittings where required by NEC cable fill requirements.

G. Innerduct

1. Shall be provided and installed by Contractor.

2. Contractor shall follow the manufacturer’s instructions for installation of innerduct and not exceed the manufacturer’s recommended maximum allowable tension.



3. When pulling into a conduit, a guide should be used to prevent damage when passing over manhole edges, past other cables, and racking in a manhole.

4. Lubrication shall be used to reduce friction and ease installation.

5. The innerducts shall be as specified on the drawings.

6. The maximum tension to be applied to innerducts should be as recommended by the manufacturer.

7. Pull Lines, shall be provided and installed for all innerducts

3.2 ADJUSTMENT, CLEANING AND PROTECTION

A. Clean: Upon completion, clean all installed materials of paint, dirt, construction debris. All conduit systems shall be cleaned of water and debris prior to the installation of any conductors.

3.3 REUSE OF EXISTING CONDITIONS

A. Where existing conduits are specified to be reused, each conduit shall be cleaned prior to installation of conductors or cables. A standard flexible mandrel with a diameter approximately ¼ inch less than that inside diameter of the conduit shall be pulled through and then a brush with soft bristles which has a diameter equal to the inside diameter of the conduit.

B. Where a ductbank connection is made to a previously poured encasement, the new encasement shall be well bonded or doweled to the existing encasement.

C. All conduit fittings shall be checked for tightness and retightened, it necessary, and all supports verified and adjusted.






FUEL SYSTEM IDENTIFICATION FOR ELECTRICAL SYSTEMS 260553.12 10-1

SECTION 260553.12 10 – FUEL SYSTEM INDENTIFICATION FOR ELECTRICAL SYSTEMS

PART 1 - GENERAL

1.1 DESCRIPTION

A. The work required under this section of the specification consists of the installation of identification devices for electrical equipment, including outlet boxes, pull boxes, junction boxes, raceways and conduits, cables, enclosures, and panelboards as required to comply with ANSI C2, NFPA 70, OSHA standards, and authorities having jurisdiction.


A. Reference Industry Standards: The following specifications and standards are incorporated into and become a part of this specification by reference. Except where a specific date is given, the issue in effect (including amendments, addenda, revisions, supplements and errata) on the date of invitation bids, shall apply. In text, such specifications and standards are referenced to by basic designation only.

1. Comply with ANSI C2.

2. Comply with NFPA 70 National Electric Code (N.E.C.)

3. Comply with OSHA 29 CFR 1910.145

B. Acceptable Manufacturer’s

1. Brady ID

2. Panduit

3. Engineer approved equal

PART 2 - PRODUCTS

2.1 GENERAL MATERIAL REQUIREMENTS


B. All material shall be new and provided with all means and methods of installation.

C. Nameplates shall be laminated plastic of high quality laminated ABS, laminated impact acrylic or acrylic cap with ABS core.

D. Adhesive labels shall be self adhesive vinyl or polyester. Labels shall be a minimum of 3 mils thick and be over laminated with a clear, weather and chemical resistant coating.



E. Wraparound, pre-tensioned plastic sleeves shall be flexible, preprinted, color coded, acrylic band sized to suit the diameter of the conduit it identifies and arranged to stay in place by pretensioned gripping action or heavy duty mounting clips.

2.2 SIZE AND COLOR REQUIREMENTS

A. Size and color of identification devices shall be per industry standards and authorities having jurisdiction. Where such standards are not defined, contractor shall use this section.

B. Feeders, buses, branch circuit conductors and medium voltage cables shall be properly phased and identified throughout the project. Individual conductors shall be color coded as noted below.

1. 120/208V and medium voltage conductors

a. Phase A – Black

b. Phase B – Red

c. Phase C – Blue

d. Neutral – White

e. Ground – Green

f. Isolated Ground – Green with yellow stripe

2. 277/480V

a. Phase A – Brown

b. Phase B – Orange

c. Phase C – Yellow

d. Neutral – Grey

e. Ground – Green

f. Isolated Ground – Green with yellow stripe

C. Labels on outlet boxes for switches, receptacles and wall mounted junction boxes shall be labeled with ½”, white adhesive labels with 3/8” black lettering. Outdoor labels shall be rated as such.

D. Equipment nameplates shall be engraved laminate with contrasting sub layer. Unless shown on drawings or specified elsewhere, nameplates shall meet the following.

1. Panelboards – 1” laminate with ½” lettering on line 1 and 1/8” letter on line 2



2. Control panels – 1-1/2” laminate with 1” lettering if single line or 7/8” on line 1 and ½” on remaining lines for multi line texts

3. Motor Controllers – ½” laminate with ¼” lettering

E. Cable tray shall be labeled with 1” high black letters on yellow adhesive stock. Outdoor cable tray shall use engraved laminate stock with yellow surface and white sub layer.

F. Conduits and raceway shall be labeled with black letters on yellow adhesive stock. Conduits and raceway under 3” shall be labeled with ¾” letters and over 3” shall be labeled with 1” letters.

G. Cables and conductors shall be labeled with heat shrink or adhesive backed wire wrap. Size of lettering shall be proportional to the size of the label and should be easily readable.

2.3 JUNCTION AND PULL BOXES

A. Junction and pull boxes shall be marked in a similar fashion as conduit and raceway.

B. If shown on drawings, names of boxes shall be the same. If not shown, boxes shall be labeled as to function or corresponding conduit junction.

2.4 RACEWAYS

A. Label raceways every thirty (30) feet and within twenty-four (24) inches of any wall penetration or termination point.

PART 3 - EXECUTION

3.1 INSTALLATION

A. All surfaces to be labeled shall be free of dirt, dust, oil or other foreign bodies prior to applying the appropriate marking device.

B. All marking devices shall be applied in a professional, workman like manner and per manufactures recommendations.

C. Contractor shall remove any debris created during the marking operations including but not limited to drill shavings, tape backing and packing materials.




FUEL SYSTEM INSTRUMENTATION 260900.10 10-1

SECTION 260900.10 10 – FUEL SYSTEM INSTRUMENTATION

PART 1 - GENERAL

1.1 SCOPE OF WORK

A. The work of this Section includes the furnishing and installing of controls and instrumentation for the new hydrant cart test stand at Dulles International Airport, complete with equipment provided under other Sections, as shown on the drawings and as specified. Equipment shall include, but not be limited to:

1. Selector Switches

2. Push Button Stations

3. Field Mounted Control Stations

4. Test Stand Control Panel (TSCP)

5. Automatic Tank Gauging System – Tank ST-1

6. Flow Switches

7. External mounted alarm horns

B. Provide all labor, equipment and material necessary to integrate new equipment into a new, complete and fully operational control system as indicated on the Drawings and as specified in the Contract Documents.

C. Contractor shall hire a qualified manufacturer’s integrator for reprogramming of the existing Fuel Master (FMU-1) to allow for activation of Refueler Loading Mode or Hydrant Cart Test Stand Mode based on what key is used.

D. Contractor shall hire a qualified manufacturer’s integrator for reprogramming of the existing Veeder Root tank level gauging system (TLS-350). Reprogramming is to include integrating new tank ST-1 level/temperature information, pump run signal input and high/high-high level outputs to the new PLC.

E. Provide final system performance verification to ensure that the system functions as intended. The system shall be capable of being run in 1) a manual mode or 2) in an automatic mode supplemented by manual operations.

F. The control system shall include all control devices, sensors, actuators, valves, transmitters, control panels, color coded control wiring, meters, gauges, and tubing as specified and as required to fulfill the intent of these specifications. Coordinate all this work with the mechanical, electrical and fueling system specifications.



G. Raceway requirements, supports, and other applicable requirements governing the installation of control conductors shall conform to Division 16 unless expressly modified and specified in this Section. All internal wiring shall be supplied ready for field connections at terminal blocks.

H. Nameplates shall be provided for all devices mounted on or inside the Test Stand Control Panel (TSCP). Nameplates shall be black phenolic with white engraving with minimum 1/4-inch lettering unless otherwise indicated. Refer to Section 260553.12 10 - Fuel System Identification for Electrical Systems for additional details.

I. All control and instrumentation work, control panels and programmable controllers provided under this Division shall be accomplished, to the fullest extent, under the responsible direction of the qualified control system subcontractor as described in Section 335243.10 10 – General Provisions.

1.2 RELATED SECTIONS

A. Section 335243.10 10 “Fuel System General Provisions”

B. Section 335243.16 10 “Fuel System Control Valves”

C. Section 335643.13 10 “Fuel System Aboveground Horizontal Tanks”

D. Section 335809.93 10 “Fuel System Description of Operation” - Work of this section shall be by the control system supplier.

1.3 APPLICABLE STANDARDS

A. Comply with the requirements of the referenced standards identified herein. Should more stringent requirements be demanded by the local authorities having jurisdiction - or the Airport Authority - including the Fire Chief - the requirements of these authorities shall take precedence provided they exceed the requirements of code.

B. INSTRUMENT SOCIETY OF AMERICA: Comply with the Instrumentation symbols and Identification standard ISA-S5.1

C. UNDERWRITER LABORATORIES: Provide electrical components and assemblies - whenever possible - which have been UL listed and shall be labeled.

D. ANSI/NFPA 70: National Electric Code (NEC)

E. NEMA: Comply with the National Electrical Manufacturer’s Association’s “Industrial Controls and Systems” standard.

F. Comply with all standards which are applicable to the work of this Section, those listed in these specifications.




A. See Section 335243.10 10 “Fuel System General Provisions.” The control system supplier shall have a complete engineering, sales, installation and service organization with demonstrated success in the design, application programming, installation, gabrication and start-up of four automated aircraft fueling control systems of similar size to this project within the last five years. Acceptable suppliers/manufacturers for the overall system include:

1. Custom Controls Mfr – Merriam, KS

2. Telemetry and Process Controls, Inc. – Lake Elmo, MN

1.5 PROJECT RECORD DOCUMENTATION

A. The Controls System Supplier shall, at system turnover, provide revised shop drawings of the TSCP, and other equipment supplied under this Division. The Supplier’s drawings and shop drawings/cut sheets shall reflect the actual installation and shall represent operating sequences that are a part of the control systems functions at the completion and acceptance of the project by the COTR.

B. Submit number of copies per Division 1 of the revised documents and each shall be stamped.

C. “As-Built” with a date assigned to the stamp. Documents shall include drawings, shop drawings, catalog cuts and programming complete with programming notes. All the materials shall be indexed and organized in electronic format on DVDs.

D. Submit a comprehensive report of the check-out and debugging of the completed system at turnover.

E. At the completion of the project, submit a recommended spare parts list for the overall project and submit a corresponding unit cost breakdown.

1.6 SUBMITTALS

A. The Contractor shall submit, with the Bid, a statement of qualifications including: Documentation of the Bonding capacity of the Control System Supplier and applicable Bond rate.

B. Submit comprehensive and complete controls submittals in a bound format (which can be submitted separate from the balance of the submittals made to the Engineer by the Contractor). The controls submittal shall be submitted to the Engineer within forty days following the date on the Notice to Commence Work on Site. The submittal shall satisfactorily identify the following elements forming the control system.

1. All fabrication and erection drawings used for assembly and installation.

2. General outline drawings of the Test Stand Control Panel.

3. Detailed equipment installation drawings showing the proposed mounting and fastening details to structure.



4. Complete internal wiring diagrams for all control panels and electronic distributed control elements. Also provide all wiring schematics provided by the manufacturer.

5. External connection diagrams showing terminal block designations for all field wiring connections.

6. Provide a separate and comprehensive Bill of Material for the controls.

7. Nameplate list which conforms to the names used throughout the balance of the submittal.

8. Programs: Provide copies with complete labeling including the drives on the computer.

9. Provide Programmable Logic Controller ladder diagrams with programming notes.

10. Color copies of proposed revised Tank Farm graphics screens with the first submittal of all equipment and color copies of final screen graphics at the completion of the project.

11. Provide schematic diagrams for electrical items showing external connections, terminal block numbers, internal wiring diagrams, one-line diagrams and point to point wiring diagrams including wire identification numbers for all in-panel wire.

12. Detailed cut sheets on discrete and distributed instrumentation.

13. Software documentation including written description of the program, editors, compilers, utilities, source code, memory maps, written description of subroutines, interrupts and listing of database information.

1.7 OPERATION AND MAINTENANCE DATA

A. The finished manual to be provided by the Contractor at the completion of the project shall be in a single or matched set of three D-ring binders with clear labeling along the spine to indicate the nature of the document and to allow the document to be stored in a standard bookcase. The data within the binder shall be segregated according to the material provided and shall be tabbed and labeled accordingly. Binders shall not exceed 3” in capacity. The data shall be comprehensive and shall provide the Authority with enough information to provide a foundation for operating the system and for maintaining the system’s operation in the long term

B. Submit in accordance with Division 1.

C. Submit the following specific documents and diagrams - these are minimum requirements - the Contractor shall provide comprehensive documentation as noted in these specifications.

1. A written document of the programs provided as part of the system for the operator use in learning and operating the system. Include keyboard and final graphic screen illustrations to help orient the user to the operation of the system. Provide set-by-step procedures for daily and regular operator functions corresponding to operation of the fuel system.



2. Comprehensive operation and maintenance manuals for the system and elements which make up the system

3. Recommended spare parts list.

4. Copies of drawings showing internal and external wiring for the system.

5. Copies of the original Bill of Material.

6. Provide copies of the final PLC program, fully commented, with full components for the system (in color if required).

PART 2 - MATERIALS

2.1 GENERAL

A. Provide products suitable in the application intended - that is, a fuel system for combustible and flammable fluids in a critical application where failure of the control system could seriously compromise the use of the overall system. Provide a system which is reliable and complimentary to the nature of the application.

B. Provide transient protection for all outdoor control circuits. Provide wire markers on all control circuit wiring. Markers shall be as provided by Panduit Corporation, Brady, or accepted alternate. Markers shall comply with Section 260553.12 10 - Fuel System Identification For Electrical Systems.

C. Provide wire markers on all control circuit wiring. Markers shall be as provided by Panduit Corporation, Brady, or accepted alternate. Wire markers shall be mechanically printed; hand written wire markers are not acceptable. Markers shall comply with Section 260553.12 10 - Fuel System Identification For Electrical Systems.

D. Provide control transformers for electric operated valves, and electric operated devices as necessary to integrate the control system into the overall fuel system.

2.2 TEST STAND CONTROL PANEL (TSCP)

A. Custom fabricated, NEMA 4X panel red “High Jet-A Temp” light , red “High Motor Winding Temp” light, red “EFSO Activated” light, green “AC Power On” light and green “DC Power On” light. Panel assembly shall be rated for, and panel enclosure listed for the hazard rating in which installed. Panel shall be mounted on HCTS Rack as shown on drawings. Panel shall be large enough to house all devices necessary for operation of the system including relays, terminals, etc.

B. Programmable Logic Controller (PLC)

1. Install the programs, software and hardware as required to meet the intent of the design documents, including the sequence of operation as defined by Section 335809.93 10 “Fuel System Description of Operation”.



2. Provide complete Input/Output (I/O) Systems as required for specified system operation. The I/O station shall be complete including all required power supplies, backplane and I/O modules. Provide the indicated number of input and output points of each type for the station, plus a minimum of 20 percent (but not less than two) spare I/O points of each type:

a. Each input shall be separately fused. Isolation shall also be provided between all internal logic and external power circuit meeting the minimum specification of 1500 VRMS.

b. The I/O system shall be isolated and current limited or fused from the internal circuitry so that shorting, grounding or opening the circuit at the receiving or transmitting equipment will not affect control system performance. Provide surge suppression devices for solid-state devices.

c. All I/O points shall utilize interposing relays to isolate I/O modules from field equipment.

d. Each I/O module shall contain visual indication of ON/OFF status of individual input and output points.

e. Each I/O module shall contain built-in wire duct and shall be of dead-front construction. The module shall have a mechanical keying scheme to prevent improper module placement in the rack.

f. Point configuration shall be as follows:

1) Each analog circuit will have a dedicated analog to digital converter (A/D) of a minimum 16 bits.

2) 4-20 mA dc analog output signals shall be two-wire.

3) Output contacts shall be rated 120 volts ac, 2 amps or 24 volts dc, 0.2 amps (inductive).

3. PLC power supplies shall operate from 120 volts ac, 60 hertz, single-phase power. Power for the PLC shall be by Panel LFS-1. Provide all equipment required to transform and/or condition the power for use by the PLC. The power supply shall be sized based on the load of all devices in the panel.

4. PLC’s shall be Modicon Momentum, I/O and bases or approved equal.

C. Electrical System:

1. Wiring:

a. Provide all wiring necessary for equipment specified for installation.

b. Terminal blocks for all external connections except shielded cables.



c. NEC type THHJN/MTW wire, rated 105 degrees at 600 volts. Dc signal wiring shall be as specified in Sections 16121 and 16122.

d. Wire shall be sized for load being serviced, No. 14 AWG minimum unless otherwise indicated.

2. Wiring shall be color coded.

3. Wire Markers:

a. Hot stamped type, Brady Ty-grip, Electrovert slip on Type Z, or Floy Tag FT200C wire markers sized for snug fit for wire size.

b. Identify both ends of wire with the same unique wire number.

c. Wire numbers shall be assigned where specific designations are not indicated.

4. Wiring Methods:

a. Main groups of wires routed in plastic non-flammable wiring duct with removable covers.

b. Smaller groups of wire cabled and secured with nylon cable clamps and ties or plastic spiral wraps.

c. Instrument dc signal wiring shall be routed in separate ducts or groups from ac power and control wiring.

d. Wire with no splices and all connections made on equipment studs or terminal blocks. Except for shielded cables, bring all wiring requiring field connections out to terminal blocks conveniently grouped to receive the external cables. Wire all space contacts on switches and relays to terminal blocks.

e. Provide extra flexible hinge wire in areas subject to flexing such as hinged panels, doors, etc.

f. Equipment Connections:

1) All connections made with insulated locking spade lug terminals except where devices specified are available only with solder-type terminals.

2) Terminals installed as recommended by manufacturer.

g. Solder Connections: Soldering iron used not to exceed 100W.

h. Provide terminal blocks for all external connections.

i. Provide copper internal ground bus. Connect all internal grounds required to the bus.

5. Terminal Blocks:



a. Terminal blocks shall be as follows:

1) All field wiring terminals.

a) Modular type, Entrelec Series 5000 or Weidmuller type SAKC 10. Submit sample of any other type for approval by the COTR.

b) Provide terminal marking strips.

c) Spacing: Provide the following clear space between terminal strips for field cabling.

Minimum: 6 inches

Normal: 1.5 inches for each 15 terminals high.

b. Mount terminal blocks in one or more rows on the mounting panel within the board. Provide means for cleating external control cables which enter from the bottom. Location of terminal blocks and arrangements of external circuits shall be subject to approval by the COTR.

c. Identify each terminal on each block by stamping or marking the terminal designation permanently on the block.

d. Provide 15 percent extra terminals with identification as required by the COTR.

6. AC Bus:

a. Provide terminations in panel for incoming 120 volt ac power supply.

7. Push Buttons:

a. Heavy duty oil-tight units with contacts rated 10-A continuous at 120 V ac. Provide explosion-proof switches for panels mounted in hazardous areas.

b. Provide the number of contacts and contact development as indicated.

c. Start or ON push buttons shall have a black operator.

d. Stop or OFF push buttons shall have a red operator.

8. Indicator Lights:

a. Oil-tight indicating lights as indicated for each control diagram, with integral push-to-test feature.

b. Suitable for indoor or outdoor flush panel mounting. Provide explosion-proof lights for panels mounted in hazardous areas.

c. Transformer type for ac applications

d. Minimum 10,000 hr. lamp life



9. General Purpose Control Relays:

a. Potter & Brumfield Series KRP, Struthers-Dunn Series 219, or Square D.

b. Provide with coil voltage as indicated with a neon coil energization indicator on 120 volt ac coils.

c. Number of contacts required rated at 10-A at 120V ac.

d. Provide plug in relay with socket.

10. Dc Power Supply:

a. Unit shall operate from a 120-volt ac, 60 hertz power source.

b. Output shall be ±24 volts dc.

11. Mounting of Relays and Control Devices:

a. Complete accessibility to all terminals, relay sockets, and other devices without dismantling of panel equipment.

b. Do not block access to any instruments or control devices mounted on face sheet.

2.3 DISTRIBUTED INSTRUMENTS

A. Control Transformers shall have adequate capacity for all connected controls. Input and output voltages shall be as required for the control power voltage available, and the voltages required by the control components.

1. Provide control transformers for electric operated control valves and distributed instruments as required for a complete and fully operational control system.

B. Temperature Switches (Pump P-1 Motor Windings): See Section 335243.23 10 - Fuel System Pumps.

2.4 TIMING RELAYS

1. Where software is not used to time out events forming a portion of the control system, timing relays shall be provided and mounted in the Main Control Panel. Relays shall be plug-in type with coil voltage and number of contacts as necessary to provide the intended function. Contacts shall be rated for a minimum of 10 amps at 120VAC.

2.5 AUTOMATIC TANK GAUGING SYSTEM

A. Provide an automatic tank gauging (ATG) system for Tank ST-1. Provide all hardware, software, programming and field services necessary.



B. Level Gauge/Probe: The level gauging system must use a self contained probe and transmitter to send level and temperature information to an existing Veeder Root TLS-350. The level indicating system must require no periodic calibration after installation is complete. The level indicating system must be approved for installation in a Class I, Division 1, Group D hazardous area and certified intrinsically safe by an approved agency and shall provide lightning protection integral to unit. The level gauge shall have to ability to provide product, interface and temperature and have the ability to store upto 100 points of a strapping table. Unit shall operate on 120 VAC, 60 Hz power supply. Provide a Veeder Root 846391-3XX or approved equal. Unit shall have a 3-inch S.S. mounting flange. Coordinate installation requirements with Section 335643.13 10 - Fuel System Aboveground Horizontal Tanks.

C. Tank Interstitial Sensor: An interstitial sensor shall be provided to detect leaks in the double-walled steel tank. The presence of liquid in the interstitial space shall trigger an alarm and must be compatible with the Veeder Root TLS-350. Provide Veeder Root 794390-420 or approved equal.

D. Integrator shall coordinate and program strapping table provided by tank manufacturer into the gauge and provide for Volume, Level, Interface and temperature to the HMI at the Tank Farm.

2.6 CONTROL RELAYS

A. Plug-in type general purpose control relays with coil voltage and number of contacts as required to re-establish automatic operation of the existing controls and as indicated on Drawings. Where the number of contacts required exceeds the number available on a single relay, provide cascaded relays. Provide with plug-in relay socket with numbered wire terminals corresponding to the relay pin numbers. Contacts shall be rated for a minimum 10 amps at 125 VAC.

B. Approved Manufacturers:

1. Square D

2. Potter-Brunfield

3. Struthers-Dunn

2.7 EXTERIOR ALARM HORNS

A. Weather resistant.

B. Sound output adjustable at horn enclosure.

C. Construction: Copper-free (less than 0.3 of 1% copper) aluminum.

D. Single projection type

E. Loudness rating at 10 feet, 100 decibels minimum

F. Nominal voltage: 120Vac.



G. Federal or approved equal

H. Mount to HCTS Rack as shown. Mount as indicated but 8’ high minimum.

I. Horn shall be controlled from the control system to alert the operator to critical alarms and EFSO activation.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install a complete control system as specified, indicated, or required for proper and safe operation of the new facility. All materials and workmanship shall comply with these specifications as a minimum. However, the Contractor shall conform to manufacturer’s recommendations. Should a conflict arise between the specifications and the manufacturer’s recommendations, the Contractor shall identify same as soon as the conflict arises and notify the COTR in writing.

B. The Contractor shall provide all openings in floors, walls, roofs, and other structures that are necessary but not necessarily shown on the drawings for complete equipment installation.

C. All floor-mounted equipment shall be installed level utilizing shims, and anchors adjoining floors or structures with bolts or cinch anchors.

D. All internal and external connections that are necessary to allow the system to function as specified shall be provided, tested and turned over to the Authority by the Contractor.

E. Securely anchor TSCP to rack in a minimum (4) places.


A. The Contractor shall provide the services of an experienced service engineer to verify proper installation, calibrate instrumentation, assist in start-up and testing and instruct the Operator of the new fueling system. Provide a minimum of (1) week (5 days, 1 trip) on site, but provide all reasonable increases in this minimum framework should the COTR and Operator feel that, in their judgment, that the training associated with this system of controls has been incomplete or ineffective. The Contractor is responsible for training the individuals effectively - not just being on-site. Provide a plan for training, a schedule and a recommended list of attendees.

B. The Contractor shall also provide the on-site attendance of representatives from the Controls System Supplier when judged necessary by the COTR, for the purposes of coordination, schedule and other such requirements. Costs associated with attendance on-site shall not increase the contract sum.

C. All trips to the site shall be coordinated with the COTR.

D. Provide four copies of all individual video recordings (DVD format) of all training sessions.



3.3 EXAMINATION

A. The Contractor shall review all owner furnished equipment submittals relating to the control of the fuel system.

B. The Contractor shall verify that all necessary, specified and provided systems are ready to be turned over to the Authority PRIOR to requesting that the Engineer perform final system evaluations. The Contractor is responsible for providing completed systems without dependence upon the Engineer or COTR.

3.4 DELIVERY, HANDLING AND STORAGE

A. The Contractor shall provide factory shipping cartons for each piece of equipment and control device. Provide factory applied plastic end caps on each length of tubing. Maintain cartons and end caps through shipping, storage and handling as required to prevent equipment and tubing damage, and to eliminate dirt and moisture from entering equipment and lodging inside of tubing. Store equipment and materials inside an enclosure provided by Contractor and protected from weather.

3.5 CONTROL WIRING

A. Install all electric wiring in accordance with ANSI/NFPA 70, this specification and Division 26 (as applicable).

B. Install control wiring, without splices between terminal points, using an assigned color-code and numbered on both ends. Install in neat, workmanlike manner, securely fastened. Install in accordance with this specification and Section 260553.12 10 - Fuel System Identification For Electrical Systems (as applicable).

1. Install circuits over 25-volt with color-coded 90°F, 600 volt insulation, minimum No. 14 AWG wire, in conduit.

2. Install circuits under 25-volt with color-coded minimum No. 16 wire in conduit with high temperature (105°F (41°C) plastic insulation on each conductor and plastic sheath over all. Provide shielded cables where indicated on plans or where required by the instrument provided.

3. Provide surge protection on all control and control power circuits routed outside of Panel TSCP. Surge protection shall consist of surge suppressers, transient, protectors and optical isolated relays as applicable.

3.6 CONTROL PANELS

A. Mount control panels adjacent to associated equipment on vibration-free walls or free-standing angle iron supports. Provide engraved plastic nameplates for instrument and controls inside cabinet and engraved lamicoid nameplates on cabinet face.



3.7 DATA CABLES

A. General: Install all signal transmission components in accordance with ANSI C2, Form 511A, and Division 26 requirements as applicable.

B. Keep cable runs as short as possible, allowing extra length for connections to terminal boards. In particular, do not bend flexible coaxial cables in a radius less than ten times the cable outside diameter. Use sleeves or grommets to protect cables from vibration at points where they pass around sharp corners or through penetrations.

C. Grounding shall be in accordance with ANSI C2. All ground wire shall be copper.

D. Provide transient protection for all non-fiber optic data cables exiting the control panel. Transient protection devices shall be compatible with the type of data cable and the communication baud rate.

3.8 TESTING

A. Field Test: When installation of the system is complete, calibrate equipment and verify operation before the system is placed on-line. All testing, calibrating, adjusting and final field tests shall be completed by the installer and witnessed by the COTR. Provide a detailed cross-check of each sensor within the system by making a comparison between the reading at the sensor and a standard traceable to the National Bureau of Standards.

B. Check all control and signal wiring from TSCP to field devices. As applicable, check all wiring for continuity and that they are free of shorts.

C. Provide a cross-check of each control point within the system by making a comparison between the control command and the field controlled device. Verify that all systems are operable from local controls in the specified failure mode upon PLC failure or loss of power. Submit the results of functional and diagnostic tests and calibrations to the COTR for final system acceptance.

D. At necessary points during construction and upon completion of the work, demonstrate system operation to COTR, for verification of proper operation.




This page intentionally left blank.


FUEL SYSTEM MOTOR STARTERS 262913.11 10-1

SECTION 262913.11 10 - FUEL SYSTEM MOTOR STARTERS

PART 1 - GENERAL

1.1 DESCRIPTION:

A. The work required under this section of the Specifications consists of the installation of manual or magnetic starters for use on systems 600 Volts and below for all integral or fractional horsepower motors not controlled by starters in a motor control center or by starters provided as an integral component of a specific piece of equipment.

B. Definition: The words motor control units, starters, and motor controllers are used synonymously in these contract documents.


A. The following Specifications and standards are incorporated into and become a part of this Specification by reference. Except where a specific date is given, the issue in effect (including amendments, addenda, revisions, supplements and errata) on the date of invitation for bids, shall apply. In text, such Specifications and standards are referenced by basic designation only.

1. Federal Specifications (Fed. Spec.)

a. W-C-375: Circuit Breakers, Molded Case

b. W-F-1814: Fuse, Cartridge, High Interrupting Capacity

2. National Electrical Manufacturers Association (NEMA) Standards:

a. ICS-1: General Standards for Industrial Control and Systems

b. ICS-2: Industrial Control Devices, Controllers and Assemblies.

c. ICS-3: Industrial Systems

d. ICS-4: Terminal Blocks for Industrial Control Equipment and Systems

e. ICS-6: Enclosures for Industrial Controls and Systems

3. Underwriter's Laboratories, Inc. (U.L.) Publications:

a. UL 198.2: High Interrupting Capacity Fuses, Current Limiting Type

b. UL 198.4: Class R Fuses

c. UL 508: Industrial Control Equipment

4. National Fire Protection Association (NFPA):



a. NFPA 70: National Electrical Code

5. American National Standards Institute (A.N.S.I.):

a. C97.1: Low Voltage Cartridge Fuses, 600 Volts or Less

B. Acceptable Manufacturers: Products of the following manufacture's, which comply with these Specifications, are acceptable.

1. Motor control centers and controllers:

a. Cutler Hammer

b. Square D

c. General Electric

d. Allen-Bradley

e. Siemens (I.T.E.)

C. Coordination:

1. Review shop drawings submitted under this and other sections, as well as other divisions, to ensure coordination between work required among different trades. Coordinate the installation sequence with other contractors to avoid conflicts and to provide the fastest overall installation schedule.

2. Coordinate installation with architectural and structural features, equipment installed under other sections of the Specifications and electrical equipment to insure access and so that clearance minimums are provided.

3. Related Sections

a. Section 330950.11 10 – Fuel System Emergency Fuel Shutoff System

b. Section 335243.23 10 – Fuel System Pumps

c. Section 335809.93 10 – Fuel System Description of Operation

PART 2 - PRODUCTS

2.1 GENERAL:

A. Furnish all materials specified herein. Provide a starter for each motor furnished on the project, except where controllers are specified to be furnished as integral with the motor/equipment.

B. Motor starter units, circuit breakers, and fused devices shall be U.L. listed and bear the U.L. label.



C. Enclosure shall be NEMA Type 4X weatherproof in all damp, wet, or exterior locations, unless other type is indicated on the drawings or specified herein.

D. The motor starters shall be rated for the system voltage in which they are installed.

E. Magnetic motor starters shall be soft start reduced voltage type unless otherwise indicated on the drawings or specified herein. Reduced voltage magnetic starters shall be combination starters with solid state, soft starters Soft starters shall be sized for “standard duty” and shall include pump controller modules, circuit breaker/HMCP and overload relays. Solid State soft-start starters shall be three phase SCR controlled for stepless reduced voltage starting of induction motors. Current transformers shall provide feedback signal to regulate torque during start up and to prevent overload conditions while motor is running. Starter shall have starting current of 300 percent of full load amps for thirty seconds, bypass/isolation contactor (integral or separate), and three phase thermal overload relay.

F. All combination starters shall have provisions for padlocking unit handle in the open de-energized position.

G. Furnish an equipment grounding conductor lug, bonded to the started enclosure.

2.2 PRODUCT/MATERIAL DESCRIPTION:

A. Magnetic starters shall be minimum NEMA Size O, the combination type, motor circuit protectors unless otherwise indicated on the drawings or specified herein. U.L. listed interrupting rating of motor circuit protectors shall not be less than indicated on the drawings at system voltage.

B. Each magnetic starter shall have three overload relays. Control voltage shall be 120 volts provided from a control power transformer built into starter. Provide fuse for control coil in the primary circuit for each phase connection.

C. Manual motor starters shall be manually operated, trip free, quick make quick break switching device with motor running protection overload heaters elements in each underground conductor of the motor circuit. Provide red neon "running" pilot lamp in cover of starter.

D. Magnetic starter doors shall be interlocked to prevent door from being opened until switch is in the "OFF" position. However, a "cheater screw" or other inconspicuous means shall be provided to permit access to energized starter, by authorized personnel. An interlock contact shall be provided within the starter to open control circuit to magnetic starter when device handle is in the open position. A door activated interlock switch is not acceptable.

E. Each magnetic starter shall be provided with H.O.A. switch, on-off switch, start-stop push bottom or provisions for remote mounted control device as indicated on the drawings . Where not indicated on the drawings, provide an H.O.A. switch for any motors automatically controlled or an ON-OFF switch for those specified to be manually controlled. Provide each magnetic starter with a "RUN" and "OVERLOAD" pilot lamp. Control devices shall be of oil-tie construction. Identify each control and pilot device with a metal tag or plastic laminated label.



F. Overload heaters shall be non-adjustable and manually reset melting alloy or bi-metallic type shall be selected in accordance with full load rating of motors actually furnished. A heater schedule applicable to starter size shall be provided on inside of door of each magnetic starter. Relay switching mechanism in magnetic starters shall be single pole, double throw normally open position connected to operate a door mounted, oil-tie blue pilot lamp to indicate starter has tripped on overload.

G. Provide contracts in magnetic starters to provide interlocking control sequence of operation specified under Division 26 or 33. Provide one N.O. and one N.C. spare auxiliary contact in each starter.

H. Starter sizes are based on design conditions using horsepower ratings of motors indicated on drawings. If motors actually furnished have horsepower ratings other than those indicated, motor starters and feeders shall be adjusted in accordance with the rated horsepower at no additional cost to the Authority.

I. Nameplates

1. Each magnetic and manual motor starter shall be provided with an engraved plastic nameplate approximately 1" x 3" permanently attached to the unit exterior door of magnetic starters or to the wall above or below manual motor starters.

2. Refer to the electrical general section of these Specifications for nameplate requirements.

PART 3 - EXECUTION

3.1 INSTALLATION:

A. Locate motor starters to provide working clearance and fully accessibility as required by the National Electrical Code.

B. Lace and group conductors installed in starter with nylon tie straps. Only one conductor shall be installed under terminals. Form and train conductors in enclosure neatly parallel and at right angles to sides of box. Uninsulated conductor shall not extend beyond one-eighths inch from terminal lug.

C. Mounting and Support:

1. Mounting

a. Enclosure shall be secured to structure by a minimum of four (4) fastening devices. A 1.5 inch minimum diameter round washer shall be used between head of screw or bolt and enclosure.

b. Enclosures shall be mounted where indicated on the drawings or specified herein. Support form the structure with fastening device specified. Mount with operating handle at 60" AFF, unless other height is indicated.

c. Attach enclosure directly to masonry, concrete, or wood surfaces.



d. Mounted enclosure on metal channel (strut), which is connected to structure with fastening device.

e. Where enclosure is not indicated on a wall or structure, construct a metal channel (strut) free standing frame secured to floor, pad, or other appropriate building structure. Refer to the detail on the drawing for frame installation and construction information.

f. Mount starter with control devices between 48" and 60" above floor or grade, unless otherwise indicated on the drawings.

D. Do not splice conductors in enclosure. Where required install junction box or wireway adjacent to disconnect and splice or tap conductors in box. Refer to number of conductors in a conduit limitation defined in the conductors and cables section of the Specifications and do not exceed.

E. Conductors not terminating in starter shall not exceed through or enter starter enclosure.

F. Provide on-site startup services of manufacturer’s representative for commissioning and training of Authority’s personnel. Services shall include a minimum of one 2-day trip on site.

G. Install push-in knock-out closure plugs in any unused knock-out openings.

3.2 CLEANING AND ADJUSTMENT:

A. After completion, clean the interior and exterior or dirt, paint, and construction debris.

B. Touch up paint all scratched or marred surfaces with factory furnished touch up paint of the same color as the factory applied paint.

C. Select and install overload heaters based on the full load current of the motor actually installed. All heaters which nuisance trip with the next larger size only.

D. Adjust motor circuit protector settings in accordance with the manufacturer’s recommendations to sustain motor locked rotor current.






FUEL SYSTEM DISCONNECT SWITCHES 262921.10 10-1

SECTION 262921.10 10 – FUEL SYSTEM DISCONNECT SWITCHES

PART 1 - GENERAL

1.1 DESCRIPTION:

A. This section covers disconnect switches for electrical equipment, 600V and below, and fuses mounted in the disconnect devices.

B. Furnish and install disconnect switches for any of the following conditions:

1. Where indicated on the drawings.

2. For all motor controllers unless installation conforms to exceptions in the National Electrical Code.

3. For all motors located out-of-sight of its motor controller.

4. Where required by the National Electrical Code.


A. Referenced Industry Standard: The following Specifications and Standards are incorporated into and become a part of the Specification by reference. Except where a specific date is given, the issue in effect (including amendments, addenda, revisions, supplements and errata) on the date of invitation for bids, shall apply. In text, such specifications and standards are referenced to by basic designation only.

1. Underwriter’s Laboratories, Inc. (U.L.) Publications:

a. No. 98: Enclosed Switches

b. No. 198.2: High-Interrupting Capacity Fuses, Current Limiting Type

c. No. 198.4: Class R fuses

2. National Fire Protection Association (NFPA) Publications:

a. No. 70: National Electrical Code (N.E.C.)

3. National Electrical Manufacturers Association (NEMA) Publications:

a. No. KS 1: Enclosed Switches

4. Federal Specification (Fed. Spec.):

a. No. WS-865-C



B. Acceptable Manufacturers: Products of the following manufacturers, which comply with these Specifications, are acceptable:

1. General Electric

2. Cutler-Hammer

3. Westinghouse

4. Square D

C. Coordination: Coordinate installations with architectural and structural features, equipment installed under other sections of the Specifications and electrical equipment to insure disconnect switch access and so that clearance minimums are provided.

PART 2 - PRODUCTS

2.1 GENERAL MATERIAL REQUIREMENTS:


B. All disconnects and fused shall be U.L. listed and bear a U.L. label.

C. Switches shall be heavy duty, type, minimum 30 amp rated, unless larger size is indicated, and type HD horsepower rated as required when motor load is served.

D. Switches shall be 600 volt rated, except for use in system below 240 volt, when they may be 250 volt rated.

E. Furnish a solid neutral bus or lug for each switch being installed in a circuit which include a neutral conductor.

F. Furnish an equipment grounding conductor lug bonded to the switch enclosure.

G. Disconnect switches shall be non-fusible safety switch, unless fused type is specified or indicated on the drawings, with the number of poles required to disconnect all ungrounded conductors serving equipment.

H. Enclosure shall be industrial oil tight, NEMA 12 gasketed in all interior locations, unless other type is indicated on the drawings or specified herein. Enclosures located in exterior, unclassified (non-hazardous) locations shall be corrosion resistant -metallic, NEMA 4X stainless steel, NEMA 4X. Enclosures in exterior classified (hazardous) locations shall be NEMA 7 and NEMA 3R.

2.2 PRODUCT/MATERIAL DESCRIPTION:

A. Switching mechanism shall be quick-made, quick-break type.



B. Where non-fused disconnect switches are indicated on the drawings or specified for use as disconnects, they shall be the non-fused type.

C. Switches shall have the following features:

1. Provide line terminal shields in all switches.

2. Each switch shall have provisions for padlocking in the “OFF” position.

3. Each switch shall have door interlocks to prevent door from being opened when switch is in closed position. Provide inconspicuous means to defeat interlock mechanism.

4. Provide permanent nameplate indicating switch rating in voltage, amperes and horsepower.

5. ARC chute for each pole.

D. Disconnect switches for three phase motors rated two horsepower and above shall be three pole nonfusible type rated as indicated on the drawings. Disconnect switches for three phase motors rated below two horsepower shall be three pole manual motor starter switches without overload protection. Disconnect for single phase motors shall be single or two horsepower rated switches without protection.

E. Fusible switches through 600 amp shall be provided with rejection clips to accept RK1 or RK5 fuses only. Fusible switches larger than 500 amp shall be suitable for class L fuses. Furnish and install a complete set of fuses in each disconnect sized as indicated on the drawings. Fuses serving predominately motor or transformer load shall be dual-element, time delay type, otherwise non-time delay fast acting type is required. Fuses shall be current limiting with 200,000 A.I.C. Furnish one complete set of fuses for each type and size installed in the project and turn over to the Authority at the time of the final inspection.

PART 3 - EXECUTION

3.1 INSTALLATION:

A. Locate disconnect switches to provide working clearance and full accessibility as required by the National Electrical Code.

B. Unless indicated otherwise on the drawings, locate disconnects adjacent to equipment served.

C. Lace and group conductors installed in disconnect with nylon tie straps. Only one conductor shall be installed under terminals. Form and train conductors in enclosure neatly parallel and at right angles to sides of box. Uninsulated conductor shall not extend beyond one-eighths inch from the terminal lug.

D. Mounting and Support

1. Enclosure shall be secured to structure by a minimum of four (4) fastening devices. Disconnect switches 600 amp and larger shall be secured by a minimum of eight (8)



devices. A 1.5 inch minimum diameter round washer shall be used between head of screw or bolt and enclosure.

2. Mounting

a. Enclosures shall be mounted where indicated on the drawings or specified herein. Support from the structure with fastening device specified.

b. Attach enclosure directly to masonry, concrete, or wood surface.

c. Attach enclosure on metal channel (strut), which is connected to structure with fastening device specified, for installations on steel structure, sheet metal equipment enclosure, or sheet rock walls.

d. Where enclosure is not indicated on a wall or structure, construct a metal channel (strut) free standing frame secured to floor, pad, or other appropriate building structure. Construct racks in similar fashion to the details on the drawings shown for frame installation and construction information.

e. Mount switch with handle between 36” and 60” above floor or grade, unless otherwise indicated on the drawings.

E. Do not splice conductors in enclosure. Where required, install junction box or wireway adjacent to disconnect and splice or tap conductors in box. Refer to number of conductors in a conduit limitation defined in the conductors and cables section of the Specifications and do not exceed.

F. Conductors not terminating in disconnect shall not exceed through or enter disconnect enclosure.

G. Install push-in knock-out closure plugs in any unused knock-out openings.

H. Identification

1. Disconnect switches shall be identified with a 1” x 3” laminated engraved plastic nameplate.

2. Refer to the electrical general section of the Specifications for identification requirements.

3.2 CLEANING AND ADJUSTMENT:

A. After completion, clean the interior and exterior of dirt, paint and construction debris.

B. Touch up paint all scratched or marred surfaces with factory furnished touch up paint of the same color as the factory applied paint.








DEWATERING 312319-1

SECTION 312319 - DEWATERING PART 1 - GENERAL 1.1 RELATED DOCUMENTS


1.2 SUMMARY

A. This Section includes construction dewatering that may be required in the event that uncontaminated or petroleum impacted groundwater is encountered within excavations and existing utility manholes. Dewatering of contaminated groundwater may be required in the event a sheen, odor, or discoloration is evident.

1.3 PERFORMANCE REQUIREMENTS

A. Dewatering Performance: Design, provide, test, operate, monitor, and maintain a dewatering system of sufficient scope, size, and capacity to control ground-water flow into, and removal from, excavations and impacted utility manholes, and permit work to proceed on dry, stable subgrades.

1. Work includes removing dewatering system when no longer needed.

2. Accomplish dewatering without damaging adjacent buildings/structures. 1.4 SUBMITTALS

A. Shop Drawings:

1. Show arrangement, locations, and details of dewatering equipment, treatment system, and storage tanks including proposed discharge points (if applicable).

2. Describe how water will be collected, stored and treated before discharging to storm sewer. Provide sizes, dimensions, locations, and capacities of collection, storage and treatment facilities. Also describe procedures to be implemented in the event that free product is encountered.

3. Include Shop Drawings signed and sealed by the qualified professional engineer responsible for their preparation.

B. Qualification Data: For firms and persons specified in “Quality Assurance” Article to demonstrate their capabilities and experience. Include lists of competed projects with project names and addresses, names and addresses of architects and owners, and other information specified.

1. Submit qualifications of specialist(s) responsible for groundwater control and treatment (if applicable).


DEWATERING 312319-2

2. Submit qualifications of laboratory to be used in testing environmental samples (if applicable)

3. If applicable, include a sampling plan to ensure discharges from on-site treatment facilities are meeting the Authority’s non-detect requirement.


A. Installer Qualifications: Engage an experienced environmental professional/firm responsible for the treatment, storage and disposal of contaminated groundwater required for this Project.

B. Operator Qualifications: The Contractor shall have a qualified environmental professional to monitor the water treatment operation during all discharges. The environmental professional shall have a minimum of 5 years of environmental experience, and have experience in the operation of portable treatment systems.

1. Engineering Responsibility: Engage a qualified professional engineer to prepare to supervise the preparation of date for the dewatering system including drawings, testing program, testing result interpretation, and comprehensive engineering analysis that show the system’s compliance with specified requirements.

C. Regulatory Requirements: Comply with water disposal requirements of authorities having jurisdiction. The Authority requires contaminated groundwater be treated before being discharged to the storm sewer.


A. Existing Utilities: Do not interrupt utilities serving facilities occupied by the Owner or others unless permitted in writing by the COTR and then only after arranging to provide temporary utility services according to requirements indicated.

B. Water Collection and Treatment:

1. Petroleum contaminated water will be encountered during construction. Petroleum impacted water ranges from free product to 1 ppm. The Contractor shall provide training for personnel in accordance with OSHA regulations, in order to work in these conditions.

2. The Contractor can discharge uncontaminated manhole water to the storm system. If the manhole water contains a petroleum sheen, odor, or discoloration, the Contractor shall treat and discharge contaminated water in accordance with the requirements of paragraph 3 below.

3. Petroleum contaminated water shall be directed at the manufacturer’s recommended rate through portable oil/water separator (minimum capacity 45 gpm) with carbon filter unit before being discharged to the storm sewer. Effluent from the oil/water separator must be maintained at “none detect” levels of Total Petroleum Hydrocarbon (TPH) in accordance with Authority requirements. Alternatively, water collected from the dewatering operation may be temporarily stored in tanks for off-site treatment and disposal at an approved recycling facility.


DEWATERING 312319-3

During dewatering, collect a minimum of three (3) environmental samples (grab samples) during each eight-hour shift. Each sample must be collected under standard chain-of-custody procedures by a qualified environmental professional. Samples shall be submitted to a qualified laboratory for analysis of Total Petroleum Hydrocarbon (TPH). Results of analysis shall be reported to COTR within 24 hours of sample collection. TPH concentrations of treated water shall be “none detect.” The Authority may collect random samples of treated and untreated groundwater.

4. The Contractor shall be responsible for mitigating any releases of untreated water into the environment in accordance with the regulations of the Virginia Department of Environmental Quality.

PART 2 - PRODUCTS 2.1 PORTABLE OIL/WATER SEPARATOR

A. Minimum capacity: 45 gallons per minute

B. Carbon unit: coordinated with oil/water separator capacity to meet Authority’s TPH discharge requirement of “none detect.”

PART 3 - EXECUTION 3.1 PREPARATION

A. Install dewatering system to ensure minimum interference with active areas of the AOA and other adjacent occupied and used facilities.

1. Do not close or obstruct taxiway, taxilanes, service roads, or other adjacent occupied or used facilities without permission from Owner and authorities having jurisdiction. Provide alternate routes around closed or obstructed traffic ways if required by governing regulations.

2. Stage the treatment system and storage tanks in the pre-approved location (if applicable). 3.2 DEWATERING

A. Prior to initiating dewatering activities, the Contractor shall visibly inspect the water for the presence of contamination. The Contractor shall maintain a log detailing existing conditions (i.e. odor, sheen, color, estimated water volume, etc.). If the Contractor suspects contamination (sheen, odor, discoloration, etc.), the COTR shall immediately be notified, and the Contractor shall make preparations for the removal, storage, treatment, and proper disposal of the contaminated water.

B. Provide adequate equipment to dewater, store, treat/dispose, and control ground water from entering the impacted manholes or excavation.

C. Dispose of water in a manner to avoid endangering public health, property, and portions of work under construction or completed. Dispose of water in a manner to avoid inconvenience to others.


DEWATERING 312319-4

Provide sumps, sedimentation tanks, and other flow-control devices as required to complete the work. Contaminated water shall be treated in accordance with 1.6 of this Section.

D. Provide standby equipment on-site, installed and available for immediate operation, to maintain dewatering on a continuous basis if any part of system becomes inadequate or fails. If dewatering requirements are not satisfied due to inadequacy or failure of dewatering system, restore damaged structures and foundation soils at not additional expense.

1. Remove dewatering system from Project site on completion of dewatering.

E. Damages: promptly repair damages to adjacent facilities caused by dewatering operations. 3.3 DOCUMENTATION

A. Provide all field logs and manifests for the offsite disposal of contaminated water.

PART 4 - CONTRACTOR’S QUALITY CONTROL


A. Conform to all applicable provisions of Division 01 Section “Quality Requirements". Be responsible for periodic inspections for conformance with the approved Dewatering plan. The results of the periodic inspections shall be submitted to the COTR upon completion.



FUEL SYSTEM EXCAVATION, BEDDING & BACKFILL 312323.13 10-1

SECTION 312323.13 10 - FUEL SYSTEM EXCAVATION, BEDDING AND BACKFILL

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes the following.

1. Excavating and backfilling for underground fuel system utilities and appurtenances. This section shall be considered a supplement to Item P-152 and applies specifically to work associated with the fuel system. Refer to Item P-152 for general excavation and backfilling provisions.

2. Fuel pipe bedding

B. Related Work Specified Elsewhere:

1. Excavation and Embankment: Item P-152

2. Dewatering: Section 312319

3. Drawings and General Provisions of Contract, including General and Supplementary Conditions and DIVISION 1 Specifications Section.

4. Fuel System General Provisions: Section 335243.10 10

1.2 REFERENCES

A. American Society for Testing and Materials (ASTM):

1. C33-13 – Concrete Aggregates

2. C144-11 – Aggregate for Masonry Mortar

3. C150-12 – Portland Cement

4. C618-12a – Coal Fly Ash and Raw or Calcined Natural Pozzolans for Use in Concrete

5. D4832-10 – Preparation and Testing of Controlled Low Strength Material (CLSM) Test Cylinders

B. Federal Aviation Administration (FAA)

1. AC 150/5370-10F-11 – P-153 Controlled Low Strength Materials

C. C. Occupational Safety and Health Administration (OSHA):

1. 29 CFR Part 1926-07 – Safety and Health Regulations for Construction.



1.3 SUBMITTALS

A. Submit as specified in 335243.10 10, Fuel System General Provisions

B. Includes, but not limited to, the following:

1. Warning tape data and sample.

2. Pipe bedding and aggregate materials data and tests.

3. Flowable fill.

C. Where selecting an option for excavation, trenching, and shoring, design from “OSHA Part 1926,” submit (For information only and not for COTR approval) copies of design calculations and notes for sloping, benching, support systems, shield systems, and other protective systems approved by the Responsible Person or Contractors Registered Professional Engineer. Provide excavation designs by a Professional Engineer where required by OSHA.

D. Provide one set of photographs to the COTR of existing structures and site improvements on and adjacent to site prior to start of work.


A. Tests of all Contractor-secured materials and products being submitted for approval to determine conformance with all requirements of these specifications shall be performed by an independent testing laboratory retained and compensated by the Contractor.

B. As materials are incorporated into the Project, on-site and off-site quality control tests will be performed during construction to determine conformance with Drawings and Specifications. Testing shall be performed by an independent testing laboratory as referenced in Item P-152. Frequency of on-site and off-site testing is specified in PART 3.

1.5 PROJECT/SITE CONDITIONS

A. Lines and grades shall be as indicated. Authority will furnish reference points as necessary to permit the Contractor to layout and construct the Work properly.

B. Carefully maintain all reference points and replace as directed by the COTR if disturbed or destroyed.

C. Disposition of Utilities:

1. Adequately protect from damage all active utilities and remove or relocate only as indicated, specified, or directed. Contractor shall submit proposed procedures for protecting existing utilities that cross the fuel line excavation.

2. Report inactive and abandoned utilities encountered in excavating and grading operations to the COTR. Remove, plug, or cap as directed by the COTR.



3. Provide a minimum 48-hours’notice to COTR and receive written notice to proceed before interrupting any utility.

D. New spot and contour elevations shown on the contract drawings are finish grade in unpaved areas and top of pavement in paved areas.

E. Geotechnical information is available for this project and can be obtained from the Authority. Rock is anticipated. Dewatering may be required for the project.

F. Stockpiling of topsoil and other excavated materials will be permitted at the location indicated on the construction documents.

PART 2 - PRODUCTS

2.1 GRANULAR MATERIAL

A. Pipe Bedding Material for exterior coated steel pipe shall be clean, natural sand conforming to ASTM C144 (masonry aggregate), or ASTM C33 (fine concrete aggregate) with 100% passing the No. 4 sieve. Neither shall have more than 5% by weight passing the No. 200 sieve.

ASTM C33 ASTM C144 Sieve Percent Passing Percent Passing3/8-in. --- --- No. 4 95-100 100 No. 8 80 to 100 95 to 100 No. 16 50 to 85 70 to 100 No. 30 25 to 60 40 to 75 No. 50 10 to 30 10 to 35 No. 100 2 to 10 2 to 15 No. 200 --- 0 to 5

2.2 FLOWABLE FILL

A. Flowable fill, also known as Controlled Low Strength Materials (CLSM), may be used in place of other pipe bedding materials with COTR’s approval.

B. A flowable fill design mix shall be developed by an independent testing laboratory retained and paid by the Contractor. Mix shall consist of sand conforming to ASTM C33 or C144, fly ash conforming to ASTM C618, Portland cement conforming to ASTM C150 or other materials approved by the COTR and have a 28 day compressive strength of not less than 25 psi or more than 150 psi. The objective of this material is to provide a flowable material that will completely fill spaces around pipe and structures and develop adequate strength to support loads while remaining easily excavatable. Mixes that produce 28 day compressive strengths consistently above 150 psi are unacceptable. Slump at time of placement shall not exceed 7 inch. In general, the water content in the mix should not be so high that it hydraulically inhibits consolidation of the material.

C. Flowable fill material conforming to FAA P-153 Class 1 (50-150 psi) is acceptable in lieu of developing and producing a mix under this specification section, except that no aggregate



material may be used that exceeds the gradations for sand and fine aggregate specified in the preceding paragraph.

2.3 WARNING TAPES FOR UNDERGROUND UTILITIES

A. For the purposes of early warning and identification of buried pipes during future trenching or excavation.

B. Tape shall be plastic, acid- and alkali-resistant polyethylene film, at least 6 inches in width and 4 mils thick, of the color indicated, and continuously inscribed with at least 1-inch-high, black lettering, indicating type of buried line installed:

C. “CAUTION BURIED JET FUEL LINE BELOW,” yellow tape.

D. “CAUTION BURIED ELECTRIC LINE BELOW,” red tape.

E. “CAUTION BURIED TELEPHONE/COMMUNICATIONS LINE BELOW”, orange tape.

F. Use detectable warning tape above all nonmetallic piping. Tape shall be manufactured with protected integral wire, foil backing, or other means of enabling detection to 36” depths. Provide a minimum 12 gage copper detection wire.

PART 3 - EXECUTION

3.1 EXCAVATION AND TRENCHING

A. Sheeting, Shoring and Sloping:

1. Use when required for slope stability and where resulting slopes from excavation or trenching might endanger people or in-place or proposed structures or utilities.

2. Provide materials on site prior to start of excavation. Adjust spacing and arrangement as required by conditions encountered.

3. Remove sheeting and bracing as backfill progresses. Fill voids left after withdrawal with sand or other approved fill material.

4. The Contractor is entirely responsible for excavation means, methods and safety, including compliance with OSHA 29 CFR Part 1926 – Safety and Health Regulations for Construction. Excavation and trench details shown on the drawings have been provided for the sole purpose of addressing design issues related to the intended short and long term performance of the respective structures and utilities and conveying these requirements to the Contractor. The presence of these details shall not be construed to mean or imply that site soils have been classified in accordance with OSHA safety requirements or that the Engineer has designed or taken responsibility for design of systems related to excavation safety.

5. Existing infrastructure, ongoing Authority or tenant operations and project work limits may preclude some traditional trenching methods such as sloped sides and require others



such as sheeting, shoring, trench boxes or others. The Contractor is free to select and use any method or combination of methods that facilitate the work, and adequately protects workers and existing infrastructure to remain in service.

B. Explosives: Blasting will not be permitted.

C. Trenching for Underground Utilities:

1. Side Walls:

a. Make vertical or sloped within specified trench width limits below a plane 12 inches above top of pipe.

b. Make vertical, sloped or stepped as required for stability, above a plane 12 inches above top of pipe.

c. Excavate without undercutting.

2. Trench Depth:

a. Excavate to depth indicated on plans and sufficient to provide the minimum bedding requirements for the pipe being placed. If utility depth is not indicated on plans or profiles, the following depths shall be used as typical minimums from top-of-pipe to finish grade. If local codes require greater cover depths, the local code depth for the specific utility shall be used. Shallower depths may be used when required to match existing utilities at tie-ins or special conditions approved by the COTR.

1) Fuel Lines, 48 inches

2) Electric conduits and ductbanks, 30 inches

b. Do not exceed depth indicated where conditions of bottom are satisfactory.

c. Increase depth as necessary to remove unsuitable supporting materials as directed.

3. Trench Bottom:

a. Protect and maintain when suitable natural materials are encountered.

b. Remove rock fragments and materials when overexcavated. Payment shall be negotiated with Authority for authorized replacement of unsuitable materials. Correct at no additional cost to Authority when trench is overexcavated without authority or to stabilize bottom rendered unsuitable through negligence or improper operations.

4. Trench Width:

a. Excavate trench to a width, which will permit satisfactory jointing of the pipe and thorough tamping of bedding.

b. Unless indicated otherwise, do not exceed following trench widths:



1) Below a plane 12 inches above top of pipe.

Nominal Pipe Size

Trench Width Minimum

Maximum

Less than 24 inches Pipe OD + 1 foot Pipe OD + 2 feet

24 inches and larger Pipe OD + 2 feet Pipe OD + 3 feet

2) Above plane defined in (1), as determined by Contractor means and methods.

3) Maximum trench width limitations shall apply in all areas more than 5 feet from manhole or structure walls.

4) Maximum width shall be as near the minimum specified as can be controlled by construction equipment and methods utilized.

5. Fill Areas: Perform trenching only after compacted fill has reached an elevation of not less than one foot above the top of the pipe.

6. Limit maximum length of open trench to 100 feet in advance and to 100 feet behind pipe installation unless approved by the COTR.

D. Dewatering:

1. Control grading around excavations to prevent surface water from flowing into excavations.

2. Drain or pump as required to continuously maintain all excavations and trenches free of water or mud from any source and discharge to approved locations. Commence when water first appears and continue until work is complete to the extent that no damage will result from hydrostatic pressure, flotation, or other causes.

3. Remove subgrade material rendered unsuitable by excessive wetting or siltation and replace with approved backfill material.

3.2 SUBGRADE PREPARATION

A. General:

1. Excavate or backfill as required to construct subgrades to the elevations and grades indicated.

2. Remove all unsuitable material and replace with acceptable fill material. Perform all wetting, drying, shaping, and compacting required to prepare subgrade.

B. Subgrade for Fills: Roughen by discing or scarifying and wet or dry top 6 inches as required to bond with fill.



3.3 FILL AND BACKFILL

A. General Fill and Backfill: Refer to Item P-152

B. Pipe Bedding Material:

1. Place pipe bedding as indicated using bedding material specified.

2. Consolidation or compaction by flooding or jetting methods will not be permitted.

3. Place pipe bedding material as follows:

a. With level bottom layer at proper grade to receive and uniformly support pipe barrel throughout its length.

b. Add second layer simultaneously to both sides of the pipe with care to avoid displacement.

c. Complete promptly after placement of pipe.

4. Compact Pipe Bedding Material as follows:

a. In lifts not exceeding 12 inches of loose material.

b. Rod, spade, or use pneumatic or vibratory equipment. Throughout depth of embedment.

c. Pipe bedding adjacent to coated steel pipe shall be compacted using sound mechanical methods acceptable to the COTR that thoroughly compact the bedding material to a condition that is firm and tight without damaging pipe coatings. Compaction acceptance will be based on visual observation of the bedding placement and compaction operation, and the ability of the procedure to provide in-place bedding that is tight and does not show signs of additional consolidation when walked on. Density testing will not be performed on pipe bedding adjacent to coated piping.

C. Flowable Fill:

1. Place in trench after pipe or structure is installed and approved for backfill.

2. Place in manner that prevents lateral or vertical displacement of pipe or structures. Pipelines with exterior protective coating or which are protected by a cathodic protection system shall not be restrained by straps or wires which will damage coatings or concentrate corrosion.

3. Material shall be placed within 2 hours of mixing with water. Placement shall conform to ACI and other typical procedures and practices used to place concrete, including Cold and Hot weather practices.

4. Backfill may proceed on top of flowable fill after it is sufficiently set to support foot traffic without deformation.



3.4 SITE GRADING, SURFACE TOLERANCE – Refer to Item P-152

3.5 WASTE MATERIALS

A. Remove unsuitable materials from Work area as excavated.

B. Demolished or excavated materials such as asphalt, concrete, and others which are unsuitable for reuse in the Project shall become property of Contractor and be disposed of off-site at locations arranged for and paid for by the Contractor.

3.6 ON-SITE TESTING Refer to Item P-152

A. Flowable Fill:

1. Make and test one set of four cylinder specimens in accordance with ASTM D4832 for every 100 cubic yards of material placed but not less than one set for each day’s pour.

3.7 MAINTENANCE AND CLEANUP Refer to Item P-152





STORM WATER POLLUTION PREVENTION PLAN 312514-1

SECTION 312514 - STORM WATER POLLUTION PREVENTION

PART 1 - GENERAL


A. Drawings, Contract and Special Provisions, Supplementary Conditions, latest version of Virginia Erosion and Sediment Control Handbook and other Division 01 Specifications apply to this Section.

1.2 SUMMARY

A. This Section includes preparation for and submitting for approval for a Stormwater Pollution Prevention Plan (SPPP).

1. Provisions for furnishing, installing and removal of silt fence, filter boxes, storm drain inlet protection, straw bale barriers, construction entrances, sediment traps, diversion berm, dust control and other erosion control measures during construction, and temporary and permanent soil stabilization measures, as noted on the contract plans and in the approved SPPP. All measures and practices shall be in accordance with the latest version of the Virginia Erosion and Sediment Control Handbook and for preventing contamination of stormwater from construction activities in accordance with the Commonwealth Of Virginia Regulation 9VAC 25-180 (i.e., temporary fuel storage, fueling operations, equipment maintenance, hazardous material and waste handling, good housekeeping practices, etc.).

B. Related Sections

1. Division 01 Section “Quality Requirements” for quality issues.

1.3 DEFINITIONS

A. CWA- Clean Water Act means the law passed by the Congress of the United States in 1972 controlling the Discharge of Pollutants into the Nation's waterways.

B. BMP- Best Management Practices are defined as any one or group of management practices, activities, policies, equipment, and structures that will: prevent pollutants from entering the environment, minimize pollutants from entering the environment, and mitigate, reduce, and treat prior to the pollutant entering the environment.



C. NPDES- National Pollutant Discharge Elimination System is the national program for issuing, modifying, revoking, reissuing, terminating, monitoring and enforcing permits pursuant to sections 402, 318, and 405 of the CWA.

D. VDEQ- Virginia Department of Environmental Quality is the agency of the Commonwealth of Virginia that manages the Commonwealth of Virginia's environmental regulations.

E. VPDES- Virginia Pollutant Discharge Elimination System is the Commonwealth of Virginia program and regulations that describe the proper management of discharges of pollutants into the waters of the Commonwealth

F. DCR- The Commonwealth of Virginia Department of Conservation and Recreation, Division of Soil and Water Conservation, regulates land disturbing activities and erosion and sedimentation compliance.

1.4 SUBMITTALS

A. Stormwater Pollution Prevention Plan (SPPP) - Prepare and submit for written approval by the Authority in accordance with the information provided below. Do not initiate ground-disturbing activities until the Authority has approved the SPPP. In addition, the SPPP will serve as the Soil Erosion and Sediment Control Plan required as a condition of the Authority's issuance of a Construction Permit by the Authority's Building Codes Department. Issuance of this Construction Permit is required prior to initiation of any project construction.

B. The SPPP may utilize plans, details, notes and other information provided in the construction documents, however, such information shall not, in itself, be construed to meet the requirements of this Section. Provide additional details to ensure that the SPPP accurately reflects means and methods for construction.

C. Prepare the SPPP on regular 8 ½ X 11 inch paper. Include attachments of the plans showing locations of erosion and sediment control devices and BMPs. Submit four (4) bound copies to the COTR for review and approval.

D. Plan Certification with Virginia Pollution Discharge Elimination System Regulation (9VAC 25-180) and DCR (4VAC50-30).

1. Submit with Plan Certification the following certification statement signed by an officer of the company of Contractor and signed by all its subcontractors:

"I certify under penalty of law that I understand the terms and conditions of the General Permit for Discharges from Construction Activities that authorizes the storm water discharges from construction activities associated with the site identified by the permit."



2. The above certification shall be executed on the Contractor's letterhead. Include the name, title, address, and telephone number of contractor and all subcontractors, and the date the certification is made. The Certification shall be attached to the SPPP and submitted to the COTR.

E. Once the SPPP has been approved by the COTR, submit a Virginia Storm Water Management Program (VSMP) permit application to the Virginia Department of Conservation and Recreation (DCR) to obtain the VSMP permit. Submit payment of $500 with the permit application. The Contractor shall include the cost of the VSMP in his proposal

F. Be responsible for submitting the Notice of Project Termination (NPT) shown in Appendix II for all construction activities within this particular construction project. Contractor shall notify the Authority and provide a copy to the COTR upon completion of this construction project.

G. Submit the name, and a copy of the certificate of competence issued by the Department of Conservation and Recreation for the person in charge of and responsible for carrying out the land-disturbing activity prior to conducting any land-disturbing activities.

H. Prepare the SPPP narrative and associated drawings in accordance with the following outline:

1. Site Description: A detailed description of the construction activities, physical features of the site, and other pertinent information shall be included in this Section.

a. A description of the nature of the construction activities;

b. A description of the intended sequence of major activities which disturb soils for major portions of the site (e.g. grubbing, excavation, grading);

c. Estimate of the total area of land disturbing activities. Land disturbing areas greater than 2,500 square feet require the implementation and enforcement of a SPPP.

d. Describe the quality of any discharge water from the site;

e. A description of the existing vegetative cover at the site, include an estimate of the total buffer area that is covered by the vegetation before construction activities commence.

f. The name of the receiving water(s), their tributaries, and the ultimate receiving water(s). A description of the aerial extent of wetlands present at the site and other sensitive habitats present on site describe measures that will be used to protect wetlands.



g. Include in the plan a schedule of the planned start and completion of construction activities, major grading activities, and other activities that may require stabilization measures to be initiated at the site.

2. Potential Pollution Sources:

a. Describe potential pollution sources. Description should include, but not be limited to, the following:

1) Vehicle Fueling: A description of the location and number of all above ground storage tanks (ASTs) and any storage containers that will be used for the purpose of fueling vehicles or storing any materials used during construction activities (indicate location on the site map).

2) Storage Tanks: ASTs storing regulated substances and greater than 660 gallons shall be registered with the Department of Environmental Quality. All ASTs shall be properly equipped and follow the AST requirements. For example, requirements include that ASTs be double walled or have 110% secondary containment devices that will not collect rainwater. Tanks shall have spill containment buckets and be properly labeled, etc. Earthen berms shall not be permitted.

3) Materials Storage: A description of the storage location and a minimum quantity of all hazardous and non-hazardous materials that might pollute storm water. Pollutants such as, but not limited to, paints, solvents, hydraulic fluids, engine oil, form oil, etc. that will be used during the course of construction activities. All containers of materials of any size that are used on site and their associated secondary containment shall be covered to prevent rainwater from coming in contact with the containers. Earthen berms shall not be permitted. All drums and containers shall be removed from the site as they become empty.

4) Sanitary Waste Facility: A description of the location and the number of sanitary waste facilities (e.g. portable chemical toilets) and method of disposal for the subject waste during the course of construction activities on site.

5) Equipment Maintenance: A detailed description of how and where equipment will be maintained. This shall include fluid changes, servicing, breakdowns, etc. The plan shall provide a standard operating procedure that shall be used for the protection of the environment while maintaining the equipment.

6) The SPPP shall include a drum and container management plan. The plan shall describe the methods and location for the containment, protection, and storage of all solvents, chemicals, petroleum products, and all toxic material as defined by the EPA brought on site. All drums and containers shall be



stored within a secondary containment system and shall be covered to prevent rainwater from entering the secondary containment.

3. Best Management Practices (BMPs) And Control Measures. The purpose of this Section is to identify all appropriate BMPs and control measures that shall be implemented at the construction site. This Section of the plan shall clearly describe the construction activities in sequence and their associated BMPS, control measures, and Erosion and Sediment (E&S) controls that are applicable. This Section shall indicate the timing to achieve the above-referenced sequencing relative to the installation of BMPs, E&S, and the control measures.

a. The components of this Section of the plan shall, at a minimum, include but not be limited to the following:

1) Stabilization Practices: All stabilization practices, including interim and permanent stabilization measures as well as specific scheduling of the Implementation of the practices, shall be included in this Section. Where possible, this portion of the plan shall describe all existing vegetation that is preserved for the purpose of site stabilization. Stabilization measures include, but are not limited to the following:

a) Sod stabilization

b) Geotextile

c) Mulching

d) Temporary Seeding

e) Permanent Seeding

f) Preservation of mature vegetation

g) Other measures/stabilization practices

2) Structural BMPS: This Section shall adequately describe the structural BMPs and practices that will divert and mitigate storm water runoff from soils, sediments, exposed materials, ASTs, and containers of hazardous/non-hazardous materials. Structural BMPs include, but are not limited to the following list:

a) Silt fences

b) Sediment traps



c) Subsurface drains

d) Secondary containment for ASTs and containers

e) Coverage for ASTs and containers

f) Storm drain inlet protection

g) Construction rock entrance

h) Temporary or permanent sediment basins

i) Portable Sediment Tanks

j) Other BMPs and structural controls.

3) The installation of these structural BMPs may be subject to the CWA Section 404 "Permitting Requirements". Be responsible for determination whether the above-permitting requirements apply to any of the structural BMPs.

4) Provide wheel washers and construction rock entrances for all projects where constructions traffic enters or exits paved surfaces. Be responsible for ensuring that all wheel washers and construction rock entrances are designed and constructed to adequately meet the expected construction traffic demand.

5) Temporary or Permanent Sediment Basins

a) If the project site involves common drainage areas that serve 3 acres or more of disturbed area(s), a temporary or permanent sediment basin is required. Such a basin shall provide 134 cubic feet of storage per acre drained. Where 134 cubic feet of storage per acre drained or equivalent is not attainable due to site constraints, smaller sediment basins and sediment traps shall be used as approved by the COTR on a case-by-case basis.

b) To prevent the movement and erosion of soils, structural measures should be placed on all upland areas.

4. Operational Practices (Good Housekeeping Practices). This Section shall include measures and BMPs including good housekeeping practices that address the following sources of pollution:

a. The plan shall contain measures that prevent trash, innocuous solid materials, building materials, garbage, and debris from entering the Authority's storm sewer system or directly into a stream or waterway.



b. Provide a daily program of vacuum or hand sweeping or other acceptable means of cleaning sediments that are tracked or transported onto the public roads from the construction sites shall be implemented. The roads may be washed only after the sediments have been removed.

5. Inspection And Maintenance of BMPs

a. Provide a schedule of inspection of all structural BMPs, the necessary maintenance and corrective action to correct all discrepancies found on site. Designate qualified personnel that have adequate knowledge of E&S requirements and storm water management and pollution prevention requirements, to inspect all structural control measures and BMPs at "least every seven calendar days and within 24 hours of the end of a storm event that is .5 inches or greater."

b. At a minimum develop a checklist for these inspections that conforms to the inspection checklist of Appendix I. Areas where final stabilization has been established need only be inspected once every month. Provide the completed inspection checklist and a report summarizing the corrective actions taken by the contractor to the COTR according to the following schedule of frequencies:

1) Every seven (7) calendar days: Under the normal circumstances.

2) Every 24 hours: After a rainfall of 0.5 inches or greater, of intensity.

3) Every 30 days: for the areas where final stabilization has been accomplished.

c. Correct any and all discrepancies immediately upon discovery. The SPPP shall be revised as necessary to reflect any modifications to strengthen the BMPs and other structural controls in order to address the discrepancies. The above inspections and findings shall be subject to Authority field verification. Be responsible for responding to all regulatory inquiries from the Virginia Department of Environmental Quality-Water Division (VDEQ-Water), Virginia Department of Conservation and Recreation (DCR), and the Environmental Protection Agency (EPA) Region III. Be responsible for addressing the outcome of all compliance monitoring inspections conducted by the above regulatory agencies. Take all corrective actions as required by VDEQ-Water, DCR or EPA Region III.

6. Non-Storm water Discharge. This SPPP is for the sole purpose of preventing pollution associated with storm water runoff (Act of God: rain, snow, etc.). Plan shall identify all non-storm water components, process waste water discharges, and any other non-storm water influent that may exist in this particular construction site. Plan shall ensure that all of the above non-storm water discharges are appropriately eliminated, permitted or addressed through other acceptable regulatory permitting mechanisms.

7. Detailed Composite SPPP Map. Prepare the following:



a. Drainage pattern and approximate slopes anticipated after completing major grading activities on site.

b. Soil disturbance areas.

c. Location of all Best Management Practices (BMPs), structural controls, non-structural controls, good housekeeping practices (GHP) and other erosion and sediment (E&S) control measures to be used during the course of construction activities.

d. Locations where stabilization is expected to be used, including the types of vegetative cover which will be employed on site.

e. Location of all receiving waters, including their tributaries and the ultimate receiving waters (including wetlands/sensitive habitats).

f. Location of all points of discharge to existing storm sewers and outfalls.

g. Existing and planned paved areas, impervious surfaces, and buildings.

h. Location of all post-construction BMPs and Storm water management practices that will address the long-term water quality improvement needs for the site, if applicable.

i. Location of any fuel storage, materials storage and sanitary waste and other potential pollution sources and their associated BMPs. shall be reflected on the site map.

j. Two site maps shall be developed, one indicating pre-construction and during construction site conditions and the second indicating final site conditions. Maps shall be to the same scale.


A. Prepare and submit the SPPP with input from each subcontractor.

PART 2 - PRODUCTS

2.1 GENERAL

A. Provide erosion and sediment control devices and products as indicated, in accordance with the SPPP and in accordance with the latest updated version of the Virginia Erosion and Sediment Control Handbook.



PART 3 - EXECUTION

3.1 IMPLEMENTATION

A. Implement and maintain the approved SPPP throughout the life of the contract in accordance with provisions of the Virginia Erosion and Sediment Control Handbook and applicable contract documents.

B. Exercise every reasonable precaution, including temporary and permanent measures, throughout the duration of the project to control erosion and prevent or minimize pollution of rivers, streams, lakes and other receiving waters. Apply siltation and stabilization control measures to material, subject to erosion, exposed by any activity associated with construction including but not limited to local material sources, stockpiles, disposal areas, and haul roads.

C. Initiate stabilization measures as soon as practicable in portions of the site where construction activities have temporarily or permanently ceased but no later than 14 days after the construction activities have temporarily or permanently ceased. Except as provided in the following paragraphs:

1. If snow cover and or severe weather conditions preclude initiation of the stabilization measures by the 14th day after construction activities have ceased, either temporarily or permanently, the stabilization practices shall be initiated as soon as practicable.

2. If construction activities resume on a portion of the site within 21 days from the date that construction activities have temporarily ceased, then stabilization practices need not be initiated on that particular portion of the site by the 14th day after construction activities have temporarily ceased.

D. Be solely responsible for complying with the soil erosion, sedimentation control and good housekeeping requirements of this Contract, and for otherwise preventing contamination of storm water from construction activities. Be solely responsible for any and all fines, penalties or damage that result from the Contractor’s failure to comply.

3.2 EROSION AND SILTATION CONTROL:

A. Control erosion and siltation through the use of the devices and measures specified herein, in the approved SPPP or as is otherwise necessary. The Authority reserves the right to require other temporary measures not specifically described herein to correct an erosion or siltation condition.

B. Maintenance: Maintain erosion and siltation control devices and measures in a functional condition at all times. Inspect temporary and permanent erosion and sedimentation control measures after each rainfall and at least daily during periods of prolonged rainfall. Correct



deficiencies immediately. Make a daily review of the location of erosion and sediment control devices to ensure that they are properly located for effectiveness. Where deficiencies exist, make corrections immediately as approved or directed by the COTR.

PART 4 - CONTRACTOR’S QUALITY CONTROL


A. Conform to all applicable provisions of Division 01 Section “Quality Requirements". Be responsible for periodic inspections for conformance with the approved SPPP. The results of the periodic inspections shall be submitted to the COTR upon completion.



APPENDIX I



SPPP INSPECTION CHECKLIST

BMP

Proper

Installation

Yes, No. or NA

Proper

Operation

Yes or No

Housekeeping

Practices

Good-Poor

Potential

Hazard

Yes or No

Discharge:

Storm water

Non-storm water

Effectiveness

of BMP

Observations

Comments

1. Drainage Swale

2. Gabion

3. Silt Fence

4. Dry Pond

5. Cattle Grate

6. Earth Dike

7. Sediment Trap

8. Hay Bale

9. Subsurface Drains

10. Pipe Slope Drains

11. Level Spreaders



BMP

Proper

Installation

Yes, No. or NA

Proper

Operation

Yes or No

Housekeeping

Practices

Good-Poor

Potential

Hazard

Yes or No

Discharge:

Storm water

Non-storm water

Effectiveness

of BMP

Observations

Comments

12. Storm Drain Inlet Protection

13. Reinforced Soil Retaining Basins



SPPP INSPECTION CHECKLIST

BMP

Proper

Installation

Yes, No. or NA

Proper

Operation

Yes or No

Housekeeping

Practices

Good-Poor

Potential

Hazard

Yes or No

Discharge:

Storm water

Non-storm water

Effectiveness

of BMP

Observations

Comments

14. Temporary or Permanent Sediment Basins

15. Construction Rock Entrance

16. Rock Outlet Protection

17. Secondary Containment for all ASTs

18. Evidence of oil, fuel or other material spills or releases on site

19. Other BMPs



BMP

Proper

Installation

Yes, No. or NA

Proper

Operation

Yes or No

Housekeeping

Practices

Good-Poor

Potential

Hazard

Yes or No

Discharge:

Storm water

Non-storm water

Effectiveness

of BMP

Observations

Comments

20. Other BMPs



Please list any discrepancies or items that are not in compliance in the space provided below.

Please list the corrective actions necessary to abate the above-listed discrepancies.

Note: All corrective actions must take place within 7 days of the discovery of the above discrepancies and non-compliance item(s).

Inspector:

Signature: Date: ________________



APPENDIX II



Metropolitan Washington Airports Authority

Notice of Project Termination

For

Storm water Discharges from Construction Activities

Note: This form shall be completed by the construction contractors upon final stabilization of the site, upon elimination of all storm water, or when the construction contractor has changed within the same construction project. The contractor shall submit a completed copy of this form to the Authority, at the address provided below and a copy to PMC's Resident Engineer within 30 days after final stabilization has been achieved or when it is no longer the construction contractor for this project. (An officer of the company shall sign this certification)

Completed form shall be submitted to:

Manager, Building Codes/Environmental Branch

Engineering Division

Ronald Reagan Washington National Airport

Washington, D.C. 20001

Copy to: Parsons Management Consultants

For DCA Projects

Hangar 6 Construction Management Program

Ronald Reagan Washington National Airport

Washington, D.C. 20001

Attn: Project's Resident Engineer

For IAD Projects

Parsons Management Consultants

45045 Aviation Drive

Dulles, VA 20166

Attn: Project’s Resident Engineer



Contract Number:

Contractor Information:

Contractor's name and mailing address:

Subcontractor(s) name and mailing address:

Location of Construction Site:

Project Name

Address

City State Zip Code ____________

Latitude Longitude ______________________

If there is a change in the contractor(s) please provide the new contractor's information here:

Certification:

"I certify under penalty of law that disturbed soils at the identified project have been finally stabilized and temporary erosion and sediment control measures have been removed or will be removed at an appropriate time and that all storm water discharges associated with construction activities in this project have been eliminated, or that I am no longer the contractor for this construction site."

Print name:

Title:

Signature:

Date:

(This certification shall be signed by an officer of the company)



APPENDIX III



METROPOLITAN WASHINGTON AIRPORTS AUTHORITY

RONALD REAGAN WASHINGTON NATIONAL AIRPORT

HAZARDOUS MATERIALS SPILL NOTIFICATION CHECKLIST

Note: This checklist shall be completed by all tenants of Ronald Reagan Washington National Airport (DCA) in the event of a hazardous material spill (under CERCLA, CWA, CAA, TSCA and/or a release of hazardous waste under RCRA). It is the responsibility of the tenants to notify all pertinent regulatory agencies within the time frame prescribed under the respective statutes and regulations.

1. Tenant Name:

2. Facility location within DCA where spill occurred:

3. Facility Environmental Manager, Foreman, or person in charge:

4. Time and date of release:

5. Amount of release material:

6. Description of how the release occurred and whether material reached a floor drain (if the situation occurred, describe amount of material that entered drain):

7. Type of material released (include common and chemical name; attach MSDS and/or Waste Manifest):

a. In the event of a release, verbal notification to DCA Fire Department and DCA

b. Environmental Coordinator must be made immediately as follows:

Fire Department:

(703) 417-8250

DCA Operations:

(703) 417-8050

Government Programs Engineer

(703) 417-8071



(703) 417-8099 (fax)

Manager, Resource Support Division

(703) 417-8072

(703) 417-8099 (fax)

8. Provide details of immediate actions taken to stop spill/release and subsequent clean-up:

9. The checklist and written copies of all notifications to the regulatory agencies shall be submitted to the following person within six (6) hours of the incident (on weekends, note time of submittal):

Government Programs Engineer

Engineering and Maintenance Division

East Building

Washington, DC 20001

Fax: (703) 417-8099

Submitted

Not submitted

10. A report describing how the incident occurred, if it entered storm or sanitary drain, emergency response me covered from the clean-up actions, and follow up activities shall be submitted to the person in question assures taken, post-emergency clean up actions, the storage and disposition of any materials re 9 within 48 hours of the emergency.

Submitted

Not submitted

Any questions regarding the use, completion, and scope of this checklist should be directed to the Authority’s Building Codes/Environmental Department.

FOR DCA USE ONLY

Please explain below the follow-up actions required with respect to this incident.




STORM WATER POLLUTION PREVENTION 312514 - 24

METROPOLITAN WASHINGTON AIRPORTS AUTHORITY

WASHINGTON DULLES INTERNATIONAL AIRPORT

HAZARDOUS MATERIALS SPILL NOTIFICATION CHECKLIST

Note: This checklist shall be completed by all tenants of Washington Dulles International Airport (IAD) in the event of a hazardous material spill (under CERCLA, CWA, CAA, TSCA and/or a release of hazardous waste under RCRA). It is the responsibility of the tenants to notify all pertinent regulatory agencies within the time frame prescribed under the respective statutes and regulations.

11. Tenant Name:

12. Facility location within IAD where spill occurred:

13. Facility Environmental Manager, Foreman, or person in charge:

14. Time and date of release:

15. Amount of release material:

16. Description of how the release occurred and whether material reached a floor drain (if this situation occurred, describe amount of material that entered drain):

17. Type of material released (include common and chemical name; attach MSDS and/or Waste Manifest):

18. In the event of a release, verbal notification to IAD Fire Department and IAD Environmental Coordinator must be made immediately as follows:

Fire Department:

(703) 572-2970

IAD Government

Programs Engineer

(703) 572-0210



EXCAVATION SUPPORT AND PROTECTION 315000-1

SECTION 315000 - EXCAVATION SUPPORT AND PROTECTION 1.1 DESCRIPTION.

A. The work covered by this item shall consist of support of excavation for utility trenches and utility structure excavations by means of sheet piling, bracing, trench boxes, water control, maintenance of shoring and bracing, and removal of shoring and bracing as required.

1.2 PRODUCTS

A. Provide adequate shoring and bracing material that will support loads imposed. Materials need not be new, but shall be in serviceable condition.

B. Steel Sheet Piling: Continuous interlocking type ASTM A328.

C. Fabricated Connections and other steel: ASTM A36, unless otherwise indicated.

D. Trench Boxes: Designed or as approved for use by the Shoring Engineer. 1.3 APPLICATIONS

A. All utility and foundation excavations 5 feet or greater below existing grade shall be supported by sheeting and shoring or by trench boxing.

B. A positive dewatering system shall be operated to maintain the elevation of groundwater at not less than 2 feet below the floor of the excavation in accordance with Section 312319 “Dewatering.” Dewatering methods should result in minimal lowering of water table outside excavation limits.

1.4 SUBMITTALS. Submit the following in accordance with the conditions of the contract.

A. Support of Excavation Working Drawings: Submit professionally signed and sealed working drawings showing proposed excavation support systems. Include details, arrangement, and method of construction for proposed system and details illustrating the method for preloading the bracing. Show level of adjacent pavements, struts, shores, and tiebacks as applicable, and permissible depth to which excavation may be carried before such supports are installed and preloaded. Show full excavation depth load to be carried by various members of the support system; and, if required, the preloads. Submit appropriate design calculations including maximum theoretical deflections of support members. Show proposed method of installing sheet piling, sequence of driving, template and driving equipment description.

B. Surface Water Control: Submit a water control plan for information only prior to beginning the work.

C. Field Conditions: Working drawings shall show the actual locations of utilities in relation to the proposed design. Show design and methods to overcome interferences with such existing utilities.



D. Removal: Show the proposed sequence of removal of temporary equipment, strut and shore removal as applicable, and as related to structure, and utility placement and backfilling operations.


A. Engineer Qualifications: A registered professional engineer legally authorized to practice in the Commonwealth of Virginia and having at least 5 years experience in providing successful engineering services for excavation support systems similar in extent required for this project.

B. Supervision: Engage and assign supervision of excavation support system to a qualified professional engineer foundation consultant having at least 5 years experience in the supervision of similar work. Submit name of engaged consultant and qualifying technical experience.

C. Regulations: The contractor shall comply with all codes, ordinances and requirements of the Authority, the Commonwealth of Virginia, and the Federal Occupational Safety and Health Act of 1970.

3.1 DESIGN CRITERIA GENERAL:

A. The Contractor shall make his own assessment of existing conditions including adjacent activities, the possible effects of his proposed temporary works and construction methods, and shall select and design such support systems, methods and details as will assure safety to the public, adjacent activities, and the completed work.

B. The design and construction of the support system, the surface water control system, and the adequacy thereof, shall be the responsibility of the Contractor and shall be designed by the Contractor’s registered professional engineer. Construction procedure description and sequence of installation of the system shall also be included. System design and calculations must be acceptable to the local authorities having jurisdiction and shall be approved by the COTR. The review and approval by the COTR of the drawings for any systems will not relieve the Contractor of his responsibility for the adequacy of the excavation support system nor for providing safe working conditions.

C. Design the excavation support system and all components to support the maximum loads that can occur during construction, including earth pressure, utility loads, equipment, traffic and construction loads, and other surcharge loads to allow the safe and expeditious completion of the work without movement or settlement of the ground, to prevent laterals and vertical movement of the support system during excavation activities, and to prevent damage to or movement of adjacent utilities and taxiways. For excavation in the vicinity of aircraft operations, aircraft wheel loading shall be included in the design. The design aircraft for Washington Dulles International Airport is a fully loaded Boeing 747 for taxiways and gateway access.

D. Striping for temporary lead-in lines and Sheeting and Shoring plans shall maintain a minimum distance of 30’ from the outermost point of aircraft main gear wheels to the edge of the excavation.

E. Support system components will not be allowed outside of the Contractor’s limit of work.

F. When the slope of excavation face exceeds the angle of repose, design the support system to



prevent material from sliding into the excavation.

G. In running sand and silt, provide a positive means of securing the support system. Provide a positive means of containing materials behind the support system.

H. Surface Water Control: Control grading around excavations to prevent surface water from flowing into excavation areas.

I. All excavations shall be kept continually free of water or mud from any source, including leaking utilities. When water is found in the excavation, remove unsuitable excessively wet subgrade materials and replace with approved compacted fill material as directed by the COTR and at no additional cost to the Authority.

J. Leaking Utilities: Dewatering system shall accommodate all inflows of water into the excavation from whatever source, including any existing underground piping or utilities which may be leaking. If contractor notes leaking utilities, contact COTR immediately defining type and extent of leaking utility.

K. Contractor shall be responsible for, and repair without cost to the Authority, damage due to piping, stability, subsidence, or other phenomenon to work in place, the other Contractors’ equipment, and the excavation including damage to the bottom due to heave. The Contractor shall also be responsible for the removal of material and pumping out of the excavated area that may result from Contractor’s negligence, inadequate or improper design and operation of the shoring system, the water control system or the dewatering system.

CONSTRUCTION METHODS 4.1 GENERAL

A. Before starting work, verify governing dimensions and elevations.

B. Survey adjacent pavements and improvements, employing qualified professional surveyor, establishing exact elevations at fixed points to act as bench marks. Clearly identify bench marks and record existing elevations.

C. During excavation, resurvey bench marks weekly, maintaining accurate log of surveyed elevations for comparison with original elevations. Promptly notify the COTR if changes in elevations occur, or if cracks, sags, or other damage is noted.

D. Perform installation, maintenance and removal of sheeting, shoring and bracing for trench excavation in accordance with the design plans which have been approved by the COTR.

E. Monitor paved areas for settlement or subsidence at excavations on a daily basis. Notify the COTR immediately if any settlement or subsidence is noted. Repairs shall be made immediately after notification to the COTR.

F. Monitor support system daily for damage or voids behind support system and if noted, make repairs and fill voids immediately.

G. Prior to excavation below groundwater level, place system into operation to lower water levels as



required and then operate it continuously 24 hours a day, 7 days a week until the structures have been constructed, including placement of fill materials, and until dewatering is no longer needed.

H. Provide standby equipment on site, installed and available, for immediate operation if required to maintain dewatering on a continuous basis in the event any part of system becomes inadequate or fails.

CONTRACTOR’S QUALITY CONTROL


A. Conform to all applicable provisions of Division 01 Section “Quality Requirements". Be responsible for periodic inspections for conformance with the approved Excavation Support and Protection plans. The results of the periodic inspections shall be submitted to the COTR upon completion.

END OF ITEM 315000


TURF AND GRASSES 329200-1

SECTION 329200 – TURF AND GRASSES

PART 1 - GENERAL



1.2 SUMMARY

A. This Section specifies subsoil scarification, topsoil placement, application of soil amendments, final grading, fertilizing, turf seeding, mulching, and initial irrigation for the areas indicated on Drawings.

B. This Section also includes removing of topsoil from designated stockpiles, areas to be stripped on the site or from approved sources off the site and subsequent transporting of topsoil to area of placement on site.

C. Related Sections:

1. Item P-152 “Excavation and Embankment.”

D. Topsoil has been (or will be) stockpiled for reuse in turf and grass areas. If quantity of stockpiled topsoil is insufficient, provide additional topsoil to complete turf and grass areas.

1.3 SUBMITTALS

A. Submit the following to COTR in accordance with requirements of Division 01 Section, "Submittals."

B. Certification of Grass Seed: Seed vendor's signed statement of turf seed analysis, certifying that each lot of seed has been tested in accordance with requirements of the Commonwealth of Virginia within the previous 6 months by a recognized independent seed testing laboratory. This statement shall include:

1. Name and address of laboratory.

2. Date of analysis.

3. Origin and lot number for each type of seed variety.

4. Results of analysis, including, for each seed variety:

a. Botanical and common name (species and variety).

b. Percentage by weight of variety in overall mixture.

c. Percentage of purity.

d. Percentage of germination.



e. Percentage by weight of weed content.

f. Percentage by weight of inert content.

C. Topsoil Analysis Report: Report of analysis by a Authority approved soil testing laboratory stating percentages of silt, clay, sand and organic matter, soil pH, and the mineral and plant nutrient content of soil. Report shall indicate suitability of topsoil for healthy, vigorous growth of turf grasses. If not suitable, include recommended quantities for nitrogen, phosphorus, potash, limestone, aluminum sulphate, or other soil amendments that shall be added to make topsoil suitable.

D. Sod Analysis: Notify COTR of sod source, including name and telephone number of supplier, and provide certification of seed mix of sod in accordance with sod certification requirements of the Commonwealth of Virginia.


A. Planting time: Sow permanent seed in all areas of project in periods between March 15 to May 15, or between August 15 and October 1 unless otherwise approved in writing by the COTR.

B. Maintenance period: Correlate planting with specified maintenance periods to provide required maintenance from date of substantial completion.

1.5 SPECIAL PROJECT WARRANTY

A. Warranty turf areas through specified maintenance period and until final acceptance.

PART 2 - PRODUCTS

2.1 NEW TOPSOIL

A. Fertile, friable, naturally loamy, surface soil; free of subsoil, clay lumps, brush, weeds, and other litter; and free of roots, stumps, stones larger than 2 inches in any dimension, and other extraneous or toxic matter harmful to plant growth.

B. When tested in accordance with the methods of testing as recommended by the Association of Official Agricultural Chemists topsoil shall have a pH range of 5.5 to 7.6. Organic content shall not be less than 3 percent or more than 20 percent as determined by the wet-combustion method (chromic acid reduction). Not less than 20 percent or more than 80 percent of the topsoil material shall pass the 200 - mesh sieve, as determined by the wash test in accordance with ASTM C 117.

1. Natural topsoil may be amended by the Contractor with approved materials and methods to meet above requirements.



C. Obtain topsoil from local sources or from areas having similar soil characteristics to that found at site of work. Obtain topsoil from naturally well-drained sites where topsoil occurs at least 4 inches deep. Obtaining topsoil from bogs or marshes is prohibited.

2.2 SOIL AMENDMENTS

A. Lime: Natural limestone, conforming to requirements of ASTM C 602, and containing at least 85 percent of total carbonates ground to such fineness that at least 90 percent passes a 10-mesh sieve and at least 50 percent passes a 100-mesh sieve.

1. Provide lime in form of dolomitic limestone.

B. Peat Humus: Finely divided or granular texture and with pH of 6.0 to 7.5 composed of moss peat (other than sphagnum), peat humus, or reed-sedge peat.

2.3 FERTILIZER

A. Complete, 10-20-10 commercial fertilizer of neutral character, with some elements derived from organic sources, conforming to requirements of Federal Specification O-F-241d and applicable laws of the Commonwealth of Virginia. Fertilizer to provide nitrogen in a form that will be available during initial period of turf growth.

2.4 GRASS SEED MIXTURE

A. Grass Seed: Provide fresh, clean, new-crop seed complying with tolerance for purity and germination established by Official Seed Analysts of North America for lawn grasses. Seeds included in the mix shall be listed in the most current version of the Virginia Turfgrass Variety Recommendations. Seed mixtures shall be a blend of three standard varieties with no dwarf and shall consist of the following (by weight):

10 % Kentucky Bluegrass

80 % Tall Fescue

10 % Perennial Rye

2.5 SOD

A. Machine-cut, strongly rooted, certified turfgrass sod, at least 2 years old and free of weeds and undesirable native grasses. Provide sod capable of vigorous growth and development when planted (viable, not dormant) and complying with the following requirements:

1. Type: Kentucky Bluegrass (Poa pratensis).

B. Sod Pad Size: Uniform thickness of 5/8 inch, plus or minus 1/4 inch, measured at time of cutting and excluding top growth and thatch. Provide in supplier's standard size of uniform length and width with maximum 5 percent allowable deviation in either length or width. Broken or torn pads or pads with uneven ends are not acceptable.



C. Sod Strength: Provide sod pads capable of supporting their own weight and retaining size and shape when supplier's standard size pad is suspended vertically from a firm grasp on upper 10 percent of the pad.

2.6 MULCH

A. Anti-Erosion Mulch: Clean, salt hay or threshed straw of wheat, rye, oats or barley. Mulch to be air-dry and free of mold and seeds of noxious grasses or weeds.

B. Seed Mulch: Peat moss in natural, shredded, or granulated form, of fine texture, with a pH of 4.0 to 6.0 and a water absorbing capacity of 1,100 to 2,000 percent.

PART 3 - EXECUTION

3.1 SOIL PREPARATION

A. Limit preparation to areas that will be planted within 72 hours.

B. Till subgrade to a minimum depth of 6 inches. Remove stones exceeding 2 inches in any dimension and sticks, roots, rubbish, and other extraneous matter including gravel or other inorganic deposits in excess of four (4) stones per square foot (average).

1. Immediately after initial tilling, remove existing grass clumps, vegetation, and turf. Dispose of such material outside of Owner's property; do not turn over into soil being prepared for turfs.

2. Maintain grades in a true and even condition where grades to be provided with topsoil have been established by others.

3. Where grades have not yet been established, smooth-grade the areas to the prescribed elevations indicated and leave in a condition that is properly compacted and evenly graded to prevent formation of low areas where water may pond.

C. Spread topsoil mixture to depth required meeting thickness, grades, and elevations shown, after light rolling and natural settlement.

1. Provide minimum depth of 2 inches after compaction, unless otherwise indicated. Do not spread if either topsoil material or sub grade is frozen.

2. Clean topsoil of roots, plants, sods, stones, clay lumps, and other extraneous materials harmful or toxic to plant growth.

3. Allow for sod thickness in areas to be sodded.

D. Add soil amendments to top surface of topsoil at rates specified and spread initial fertilizers at rate of 1,500 lbs. per acre of topsoil.

1. Mix lime with dry soil before mixing in fertilizer.

2. Mix thoroughly into top 4 inches of topsoil prior to fine-grading.



3. Do not mix fertilizer with topsoil more than 72 hours in advance of seeding or sodding operations.

4. Till soil to a homogenous mixture of fine texture, free of lumps, clods, stones, roots, and other extraneous matter.

E. Fine-grade to a smooth, even surface with loose, uniformly fine texture. Roll and rake, remove ridges, and fill depressions to meet finish grades. After compaction rolling, leave surfaces at prescribed grades with uniform slope to drain and free from low areas where water might pond. Limit fine-grading to areas that can be planted within 72 hours. Remove trash, debris, stones larger than 2 inches in diameter, and other objects that may interfere with planting or maintenance operations.

F. Promptly remove topsoil or other materials falling on pavement as result of hauling or spreading of topsoil.

3.2 SEEDING

A. Restore prepared turf areas to specified condition if eroded or otherwise disturbed after fine-grading and before planting.

B. Moisten prepared turf areas before planting if soil is dry. Water thoroughly and allow surface to dry off before seeding operations. Do not create muddy soil.

C. Sow seed with a spreader or a seeding machine. Do not seed when wind velocity exceeds 5 miles per hour. Distribute seed evenly over entire area by sowing equal quantity in 2 directions at right angles to each other.

1. Do not use wet seed or seed that is moldy or otherwise damaged in transit or storage.

2. Sow no less than the quantity of seed specified.

D. Rake seed lightly into top 1/8 inch of soil, roll lightly, and water with fine spray.

3.3 HYDROSEEDING

A. Mix specified seed, fertilizer, and pulverized mulch in water, using equipment specifically designed for hydroseed application. Continue mixing until uniformly blended into homogenous slurry suitable for hydraulic application.

B. Apply slurry uniformly to all areas to be seeded. Rate of application as required obtaining seed application rate equivalent to 6 pounds per 1,000 sq. ft. (260 lbs. per acre).

3.4 SODDING

A. Lay sod within 24 hours of stripping. Do not lay dormant sod or if ground is frozen.

B. Lay sod to form solid mass with tightly fitted joints. Butt ends and sides of sod strips; do not overlap. Stagger strips to offset joints in adjacent courses. Work from boards to avoid damage to sub grade or sod.



C. Tamp or roll lightly to ensure contact with sub grade. Work sifted soil into minor cracks between pieces of sod; remove excess to avoid smothering adjacent grass.

D. Anchor sod on slopes with wood pegs as required to prevent slippage.

E. Water sod with fine spray immediately after planting. During first week, water daily or more frequently as necessary to maintain moist soil to depth of 4 inches.

F. The contractor shall secure sod from movement by water and jet blast. As a minimum, all sod shall be stapled as indicated. The gauge of the staple shall be sized to accommodate soil conditions and staple length. The staples shall be driven flush with the surface of the sod.

3.5 MULCHING

A. Protect seeded slopes against erosion with jute mesh erosion netting or other similar coverings acceptable to COTR.

B. Protect seeded areas against hot, dry weather or drying winds by applying specified mulch within 24 hours after completion of seeding operations. Presoak and scatter evenly to a depth of 1/8 inches to 3/16 inches thick and roll to a smooth surface. Do not mound.

3.6 RECONDITIONING EXISTING TURF AREAS

A. Recondition turf areas where settlement or washouts occur or where minor re-grading is required.

B. Recondition existing turf areas damaged by Contractor's operations including storage of materials or equipment and movement of vehicles.

C. Recondition other existing turf areas as indicated.

D. Provide fertilizer, seed or sod, and soil amendments same as specified for new turf areas and as required to provide healthy stand of grass in reconditioned areas. Provide new topsoil as required to fill low spots and meet required finish grades.

E. Remove diseased or unsatisfactory grass clumps; do not bury into soil. Remove topsoil containing foreign materials resulting from Contractor's operations including oil drippings, stone, gravel, and other construction materials; replace with new topsoil.

F. Where substantial turf remains (but is thin), mow, rake, aerate if compacted, fill low spots, remove humps, cultivate soil, apply lime, fertilizer, and sow specified seed at rate indicated. Remove weeds before seeding. If weeds are extensive, apply selective chemical weed killers as required. Apply seedbed mulch, if required, to maintain moist condition.

G. Water newly planted areas and keep moist until new grass is established.



3.7 PROTECTION

A. Erect barricades and warning signs as required to protect newly planted areas from traffic. Maintain barricades throughout the maintenance period. Maintain barricades until a substantial and healthy stand of grass is established.

B. Take necessary precautions as required to avoid damage to existing plants, turf, and structures.

3.8 MAINTENANCE

A. Obtain the services of a professional lawn and landscape firm to provide the required maintenance services of this Article. Do not use Contractor’s own forces to accomplish this maintenance.

B. Begin maintenance of grass areas immediately after each area is planted and continue for the periods required to establish acceptable stand of turf grass, but no less than the following:

1. Seeded areas, at least 60 days, after date of Substantial Completion.

a. If seeded in fall after September 1, provide minimum of 30 days maintenance in fall, and provide a minimum of 45 additional days continuing maintenance during following spring until acceptable turf is established.

2. Sodded areas, at least 30 days after date of Substantial Completion.

C. Maintain turf areas by watering, fertilizing, weeding, mowing, trimming, and other operations such as rolling, re-grading, and replanting as required to establish a smooth, acceptable turf, free of eroded or bare areas.

D. Re-mulch with new mulch in areas where mulch has been disturbed by wind or maintenance operations sufficiently to nullify its purpose. Anchor as required preventing displacement.

E. Replant bare areas with same materials specified for new turf.

F. Watering: Provide and maintain temporary piping, hoses and watering equipment to convey water from Authority's water source(s) location indicated and to keep turf areas uniformly moist as required for proper growth. Design temporary watering system to provide a minimum of 3/4 inch of water per day.

1. Lay out temporary watering system and arrange watering schedule to prevent puddling, water erosion, and displacement of seed or mulch. Lay out temporary watering system to avoid necessity of walking over muddy or newly seeded areas.

2. Begin watering immediately. Water on a daily basis for the following 10 days. Apply water uniformly, providing coverage over entire site nominally equivalent to 3/4 inches of rainfall per day. Reduce rate to nominal 1/2 inch of water per day after 5 days.

3. At end of initial 10-day period, remove temporary irrigation system. Continue watering with conventional sprinkler watering system on an as-needed basis.

4. Watering of areas within Taxiway/Taxilane Safety Zones shall be coordinated with COTR and Airport Operations. Watering of these areas shall be done during hours of restricted aircraft activity.



G. Mow grass as soon as there is 3 - 4 inches of top growth, cut grass with the mower blades set at 1-1/2" to 2" height. Repeat mowing as required to maintain specified height.

1. Remove no more than 40 percent of grass leaf growth in initial or subsequent mowings. Do not delay mowing until grass blades bend over and become matted. Do not mow when grass is wet. Time initial and subsequent mowings to maintain following grass heights.

a. Mow grass from 1-1/2 inches to 2 inches high. Do not mow to less than 1-1/2 inches.

2. Apply second fertilizer application after first mowing and when grass is dry. Use fertilizer that will provide at least 1.0 lb. of actual nitrogen per 1,000 sq. ft. of turf area.

3.9 ACCEPTANCE

A. When work is substantially completed, including maintenance, COTR will, upon request, make an inspection to determine acceptability.

B. Turf work may be inspected for acceptance in parts agreeable to the COTR, provided work offered for inspection is complete, including maintenance.

C. Replant rejected work and continue specified maintenance until re-inspected by COTR and found to be acceptable.

D. Seeded areas will be acceptable provided requirements, including maintenance, have been met and healthy, uniform close stand of specified grass has been established with an average of one healthy grass plant per square inch, free of weeds, with no bare spots in excess of 5 inches in diameter, and free of surface irregularities.

E. Sodded areas will be acceptable provided requirements, including maintenance, have been met and healthy, well-rooted, even-colored, viable turf has been established, free of weeds, open joints, bare areas, and surface irregularities.

3.10 CLEANUP

A. Promptly remove soil and debris created by turf work from paved areas. Clean wheels of vehicles before leaving site to avoid tracking soil onto surface of paved areas.

B. Maintain all areas neat and clean during seeding operations. On a daily basis, remove excess materials and debris to site location designated by COTR. At completion of Work, remove all such materials from site and dispose of in a legal manner.

C. Restore any damage caused by seeding operations to original condition.

D. Remove all staples form sodded areas, upon acceptance.


A. Conform to all applicable provisions of Section 01 40 00 “Quality Requirements".



B. Address all the elements which affect the quality of work including but not limited to:

1. Certification of Grass Seed

2. Topsoil Analysis

3. Sod Analysis

4. Application and Protection



WASHINGTON DULLES INTERNATIONAL AIRPORT IA1302 HYDRANT FUEL LINE IMPROVEMENTS FEBURARY 24, 2014

FUEL SYSTEM INSPECTION, TESTING AND FLUSHING 330850.10 10-1

SECTION 330850.10 10 - FUEL SYSTEM INSPECTION, TESTING AND FLUSHING

PART 1 - GENERAL

1.1 DESCRIPTION

A. Inspection of all fabrication, assembly and installation performed to construct the new aircraft fueling system.

B. Test all fuel system controls, operations, equipment and systems.

C. Flush all piping and equipment within the system.


A. Laboratory listing services for specific methods of construction, fabrication and assemblies shall be as specified in Section 335243.13 10, Fuel System Pipe, Fittings and Installation.


C. American Petroleum Institute (API)

D. Joint Inspection Group (JIG), Bulletin 35

E. American Society for Testing and Materials (ASTM), D1655-13


A. All tests shall be performed in accordance with the applicable Related Documents.

B. All Work, as specified herein, shall be observed by the COTR.

1.4 SUBMITTALS

A. Submit as specified in Section 335243.10 10, Fuel System General Provisions

B. The Contractor shall develop, submit for review and approval, written plans for each phase of testing and flushing.

C. The testing and flushing plans shall include but, not be limited to the following:

1. Identification of system or component to be tested or flushed

2. Date and time to be performed

3. Method and Description of Event



4. Coordination of approvals

5. Event results (when completed)

6. Conclusions and recommendations

7. Spill prevention procedures

D. The Contractor shall submit for examination by the COTR, qualifications of the personnel to be utilized in testing and flushing prior to proceeding.

E. All inspections, testing and flushing tasks shall be recorded and certified by the Contractor and shall include the signatures of the personnel involved.

PART 2 - MATERIALS

2.1 EQUIPMENT

A. The Contractor shall provide all necessary devices to test and flush the complete system. Items shall include but, not be limited to the following:

1. Electronic holiday detectors

2. Air compressors

3. Pumps

4. Pressure and temperature recorders

5. Flow rate indicators and recorders

6. Millipore sample devices and media

The Contractor shall provide any temporary piping, connectors, hoses, pumps, filters, Baker tanks, tanker vehicles and operators to test and flush all segments of the system.

2.2 JET A

A. Obtain Jet-A from the Authority for inspection, testing and flushing operations. Fuel shall meet the specifications of ASTM D1655-13. Coordinate fuel usage with the COTR. The color of fuel provided shall be a maximum of A2, B2, or G2 with a particulate contamination not exceeding the B scale on the shell particle assessment guide. There shall be less than 15 ppm of water and Water Separation (Microsep) Rating of at least 85 WSIM.

PART 3 - EXECUTION

3.1 GENERAL



A. The Contractor shall be responsible for the operation of all permanent and temporary equipment and systems and conduct all performance tests in a safe and effective manner. The Contractor shall provide all the necessary equipment, tools, media and labor required for the proper performance of the tests.

B. The Authority will provide the fuels required for testing and flushing. The fuels to be provided shall be Jet-A per ASTM D1655. Water shall not be used for the testing and flushing of any fuel piping or components unless specifically called for on the plans. (Water may be used to flush existing piping that is to be abandoned, removed or decommissioned.)

C. The Fuel Removal and Draining requirements of Section 026500.01 10 shall apply to flushing activities. Fuel that is determined acceptable for use shall be retained in storage. In the event the fuel is unacceptable for use, it must be removed from the site and replaced at the Contractor’s expense.

3.2 INSPECTION OF PIPE WELDING

A. Ten percent of the aboveground fuel piping 2 1/2-inch and larger shall be selected for radiographing.

B. It will be the responsibility of the Contractor to coordinate and arrange for radiographic testing by an approved testing laboratory service.

C. Piping where factory welds have been performed must also be radiographed by an approved testing laboratory with results provided to the Contractor upon delivery and receipt of the piping.

D. All radiographing and testing reports shall be in accordance with ANSI B31.3. Each weld must be stamped and numbered for future identification and shall appear on final (“As-Built”) fabrication layout drawings.

E. All welds shall be left exposed until radiographed, processed and certified. Welds which do not meet the standards of B31.3 shall be repaired, cut out, rewelded and re-radiographed by the Contractor at no additional cost to the Authority.

3.3 INSPECTION OF PIPE COATINGS

A. The Contractor shall inspect all exterior pipe and joint coatings with a Holiday Tester to locate any damage to the protective coatings during the course of construction.

B. This element of testing shall take place after all welding and radiographing has been completed, but before the section of piping is lowered into the trench.

C. The inspection shall be performed by using an approved tester at a voltage recommended by the coating manufacturer.

D. All damaged sections shall be repaired by using the procedures and materials specified in Section 335243.13.



3.4 TESTING OF FUEL PIPING

A. Pneumatic and hydrostatic testing shall be performed on fuel piping as described in specification 335243.13 - Fuel System Pipe, Fittings and Installation.

B. Complete a soak test on the new hydrant system piping per JIG Bulletin 35. Prior to installation, completely fill the new pipe with fuel for a period of 7 days. A retention sample shall be collected at the beginning of the test. Following the test period, a fuel sample shall be taken and sent to an approved laboratory and the following tests performed:

Test Method Jet Fuels ASTM IP Appearance ● D4176 Gum ● D381 540 Water Reaction D1094 289 MSEP ● D3948 Conductivity ● D2624 274 Saybolt Colour ● D156 Thermal Stability (JFTOT)

● D3241 323

Distillation ● D86 123 Flash Point ● D56 170

A successful result requires that all tested properties are within specified limits. If any test results do not comply with the applicable specification, the fuel shall be resampled and retested. If the fuel is still not in compliance, the piping shall be refilled and the soak test repeated until a satisfactory result is obtained.

3.5 SYSTEM FLUSHING

A. It will be the Contractor’s responsibility to provide the Authority with a complete and functional system. One important aspect of this accomplishment is the interior cleanliness of the piping system. Therefore, this becomes a critical part of the Contractor’s responsibility.

B. Prior to starting the flushing process, the Contractor shall develop a detailed procedure, sequence and schedule for approval by the COTR. Contractor shall also prepare a simple Spill Prevention Control and Countermeasures Plan (SPCC) in accordance with 40 CFR 112 documenting measures put in place during the flushing process.

C. The Contractor shall be responsible for providing and installing all temporary manifolds, high point vents, low point drains, valves, connections and devices to facilitate the flushing process.

D. When possible, temporary piping assemblies will be used to form a closed loop piping system for recirculation. When a closed loop piping system is not possible, fuel will be flushed into Baker tanks or tank trucks provided by the Contractor. If used, Baker tanks will require secondary containment such as lined earthen berms to be temporarily installed that are capable of containing at least the volume of the largest Baker tank used to store fuel. If left with fuel overnight, the Baker tanks must be attended by at least one Contractor personnel.



E. Components such as control valves, strainer baskets, hydrant valves and control devices shall not be in place during flushing.

F. The desired velocity rate for flushing is 10 feet per second to satisfy Airline QA Standards With a three volume minimum prior to testing.

G. A two-test minimum is required to ensure piping cleanliness. The system being flushed must be displaced with clean fuel prior to taking second test.

H. Acceptance Specifications:

1. Visual - All fuel samples must be clear and bright. Other visual clues must be observed and acted upon accordingly, i.e.; feel, color, odor, etc. This test shall be performed with a minimum of 1 gallon of jet fuel.

2. Perform a membrane test per ASTM D3830. A minimum of 1 gallon of jet fuel shall be used for this test. Visually assess the membrane and compare it with a color rating booklet. The color shall be a maximum of A2, B2, or G2 with a particulate contamination not exceeding the B scale on the shell particle assessment guide. Flushing shall continue and the membrane test repeated, until a sample is obtained which meets these requirements. Note: If color rating exceeds the above limits or is in dispute, a matched weight gravimetric rating not to exceed 0.5 mg/gal shall govern.

3. Water - 15 ppm maximum.

4. Water Separation (Microsep) Rating - 85 WSIM minimum.

I. Final Acceptance:

1. It shall be the responsibility of the Fuel System Operator, or his designee, to have final decision on system cleanliness and acceptance before aircraft fuel servicing is permitted.

J. After flushing has been completed and approved, the Contractor shall remove all temporary cross connections, spool pieces, etc., and install control valves, metering elements, strainer baskets, etc. The Contractor shall also be responsible for replacing all filter media used during the flushing operation and cleaning the interior of any aboveground fuel storage tanks and filter vessels used during the flushing operation so that the entire Tank Farm facility may be received in a new and clean condition.

3.6 SYSTEM TESTING

A. After all individual devices and components have been tested and after the piping system has been tested and flushed, the Contractor shall perform overall operational system tests. It shall be the responsibility of the Contractor to debug, test and verify operation of the installed systems in complete conformance to itemized functions of each system as identified throughout Division 33.

B. The Contractor shall be responsible for establishing all testing procedures and shall demonstrate operation of each completed “system” to the COTR, Operator and the Authority. Each demonstration may be videotaped by the Authority at his discretion. At a minimum, the following tests must be completed before commissioning any new fuel piping:



1. Leak Detection

a. After each phase of the fuel system modifications are complete, the leak detection system will be modified to reflect the changes as discussed in Section 335800.10 10.





FUEL SYSTEM EMERGENCY SHUTOFF SYSTEM 330950.11 10-1

SECTION 330950.11 10 - FUEL SYSTEM EMERGENCY SHUTOFF SYSTEM

PART 1 - GENERAL

1.1 SUMMARY

A. Work of this section includes furnishing all labor, materials, tools, equipment and services required to properly complete the modification of the Emergency Fuel Shutoff (EFSO) System at the Signature Load Rack and integration with the Tank Farm at Washington Dulles International Airport.

B. Related work specified elsewhere:

1. Drawings and General Provisions of Contract, including General and Supplementary Conditions and DIVISION 1 Specifications Section

a. 260500.10 10 - Fuel System Electrical

b. 260533.11 10 - Fuel System Conduit

c. 260553.12 10 - Fuel System Identification for Electrical Systems

C. Work provided under this Section includes, but is not limited to, the following:

1. Signature Emergency Fuel Shutoff Control Panel (Panel EFSO-S) and Components

2. Fiber Optic Patch Panel

3. EFSO Manual Pull Stations

4. EFSO Strobes and Beacons

D. General Layout:

1. The system is composed of EFSO control panel, two manual pull stations, alarm strobe lights, location lights and an existing motor-operated valve (MOV).

2. The EFSO panel is located in the Signature Electrical Building west of the Load Rack.

3. The EFSO panels do not currently communicate with the Tank Farm. This contract will provide all necessary equipment, materials and labor to integrate the Signature EFSO system into the airport wide EFSO system and Tank Farm HMI, EXCEPT fiber optic cabling, terminations and patch-through. All fiber optic cabling, terminations and patch-through is work of the Authority.

4. The (2) EFSO pull stations are individually wired back to Panel EFSO-S for addressability.



5. EFSO addressable system wiring shall be Class B two-wire circuiting. Underground initiating and control circuit wiring shall be PVC jacketed.

1.2 SUBMITTALS

A. Submit as specified in Division 1 and 260500.10 10.

B. Additional submittals required by this section include the following:

1. Control System Logic Equipment drawing (Block Diagram) showing all input/output devices, communications interfaces, the controller cabinets, operator interface devices, and prefabricated cables. Provide additional detail for all interfaces between the system and Tank Farm EFSO system.

2. Provide a comprehensive description of all failure modes for hardware devices that make up the EFSO system - in particular, the hardware interface, and UPS, in addition to the PLC’s. Identify how each element is restored to operative conditions.

3. Panel Components

4. Fiber Optic Patch Panel

5. EFSO Manual Pull Stations

6. EFSO Strobes

7. EFSO Location Lights

8. Interconnecting diagrams for associated hardware including the EFSO pull stations and MOV.

C. EFSO System shop drawings and calculations shall be prepared by a designer possessing as a minimum NICET (National Institute for Certification in Engineering Technologies) Level III certification in system design. All EFSO system Contractor provided shop drawings and calculations shall be sealed and signed by a licensed Professional Engineer registered in the Commonwealth of Virginia.

1.3 INSTALLATION

A. The installation of control hardware and the satisfactory operation of same shall be performed by those experienced in the installation and use of the equipment.


A. Provide the services of competent and effective manufacturer’s field services as recommended by the manufacturer and as necessary to commission and turn-over the system to the Authority. No additions to the contract for these services shall be considered.



B. Provide performance tests of all hardware supplied as part of the control system in accordance with manufacturer recommendations.


A. Acceptable suppliers/manufacturers for the overall EFSO system include:

1. Siemens Cerberus

PART 2 - MATERIALS

2.1 SIGNATURE EFSO CONTROL PANEL (PANEL EFSO-S) AND COMPONENTS

A. Per the Authorities Engineer Design Manual, the EFSO control panel shall be a Siemens Cerberus Pyrotronics MXL with blue enclosure. The EFSO control panel shall provide power, annunciation, supervision and control for the complete fuel detection, alarm, and monitoring system. The EFSO control panel shall be configured to provide interconnection to the EFSO control panel at the Tower Control Cab (DCA) or Ramp Tower Control Cab (IAD), the Fuel Farm EFSO control panel (DCA/IAD) and the airport Central Station: NCC WAN (Network Command Center Wide Area Network) at Fire Station 301 (DCA), NCC WAN at Fire Station 302 (IAD). The EFSO control panel shall operate from a 3 wire 120 volt power supply and be provided with internal 24 volt DC uninterrupted power supply (UPS) and back-up battery. EFSO (MXL) control panel configuration as required shall consist of the following components:

MPS-6 power supply MKB-2 display annunciator module MMB-2 central processing module ALD-2I addressable input module Interface module for communication to NCC WAN MOM-4 modules BT-34 battery CRM-4 Output module MID-16 Input module Contractor is to provide all control modules, mounting cages, enclosures, back boxes and

other ancillary items as required to provide a complete and working system

B. Fabricate name plates using laminated phenolic sheeting. Nameplate attachments shall be by rivet or a nut/bolt combination. The use of adhesives is not permitted. Attachment devices shall be stainless steel.

C. Contractor shall have the option of proposing a smaller, compatible Siemen’s MXL extension panel in lieu of the full Pyrotronics MXL panel if approved by the COTR.

D. All MXL initiating and alarming circuits shall be protected against power surges per manufacturer’s recommendations.

E. Electrical System:

1. Wiring:



a. Provide all wiring necessary for equipment specified for installation, including internal wiring for all space equipment and all future connections as required.

b. Terminal blocks for all external connections except shielded cables.

c. NEC type THHN/MTW wire, rated 105 degrees at 600 volts.

d. Provide #14 AWG (minimum) for 120 Vac control circuits, #12 AWG (minimum for 120Vac power circuits and #14 AWG (minimum) for 24VDC circuits unless otherwise indicated.

e. EFSO addressable system wiring shall be Class B two-wire circuiting. Underground initiating and control circuit wiring shall be PVC jacketed Type TC per UL 277, stranded copper, Class B with color coded THHN/THWN conductor insulation. Multiple T-tapping is allowed and end-of-line devices are not required. ALD initiating circuit wiring shall be TSP minimum #16 awg. Indicating and control circuit wiring shall be minimum #14. Line voltage circuit wiring shall be minimum #12 awg. Battery circuit wiring shall be minimum #10 awg.

2. Wiring shall be color coded.

3. Wire Markers:

a. Wire Identifications shall comply with provisions of 260553.12 10.

b. Identify both ends of wire with the same unique wire number.

c. Wire numbers shall be assigned where specific designations are not indicated.

4. Wiring Methods:

a. Groups of wire cabled and secured with nylon cable clamps and ties or plastic spiral wraps.

b. Wire with no splices and all connections made on equipment studs or terminal blocks. Except for shielded cables, bring all wiring requiring field connections out to terminal blocks conveniently grouped to receive the external cables. Wire all space contacts on switches and relays to terminal blocks.

c. Provide extra flexible hinge wire in areas subject to flexing such as hinged panels, doors, etc.

d. Connect all internal grounds required to the ground bus.

F. Provide all necessary relays for supplied equipment and as shown on the drawings. Relays shall be by Potter & Brumfield, “Series KRP” or by Struthers-Dunn “Series 219” unless indicated otherwise on drawings. Coil voltage shall be as indicated with a neon coil energized indicator on 120Vac coils. The relays shall be plug-in type with matching sockets. Contacts shall be rated at 10A at 120 volts AC unless otherwise indicated on drawings.



G. Panel shall be mounted in Signature Electrical Building to plywood backboard as shown on drawings.

2.2 FIBER OPTIC PATCH PANEL

A. Fiber Patch panel shall be small footprint and wall-mountable. Patch Panel shall be mounted to plywood backboard next to Panel EFSO-S in the Signature Electrical Building. Provide minimum 12 ports. Fiber terminations shall be ST style ceramic or bronze adapters. Used ports shall be labeled. Panels shall be Belden FiberExpress, Corning (CSS) WCH-02P or approved equal.

2.3 EFSO MANUAL PULL STATIONS

A. EFSO manual pull boxes shall be located per the requirements of NFPA 407. The manual pull box shall be mounted to a new free-standing rack as detailed on the drawings with a mounting height of 54" from box centerline above finished grade. Pull station shall be weatherproof and rated for use outdoors, or should otherwise be mounted in an easily accessible, clear weatherproof pull-station enclosure. Pull stations shall be Siemens or approved equal by Honeywell or EST.

B. Each station shall be supplied with signage. Signage shall meet the requirements of NFPA 407 except that signs shall be bronze aluminum mounting frame, red with white border, with white letters 3" high and ½" strokes; EFSO signage shall be designed to be mounted at a minimum height of 7 feet above the finish grade to bottom of sign. Final sign mounting height shall be approved by Fire Marshal prior to installation. Sign shall read “EMERGENCY FUEL SHUTOFF – PULL.”

2.4 EFSO STROBE LIGHTS

A. Each EFSO manual pull station location shall incorporate an EFSO strobe light. The strobe light shall be mounted to a mast with nominal mounting height of 8' above finished grade. The final installation height shall be coordinated and approved by the Fire Marshal. The EFSO strobe light shall incorporate a blue lens with long life light element and shall be activated when the EFSO pull station is activated and be flashing until the system is reset. Provide Siemens Outdoor rated strobe light with addressable module.

2.5 EFSO LOCATOR LIGHTS

A. Each EFSO manual pull station location shall incorporate an EFSO locator light. The locator light shall be mounted to a mast with nominal mounting height between 12' and 20’ above finished grade. The final installation height shall be coordinated and approved by the Fire Marshal. The EFSO locator light shall incorporate a blue lens with long life light (75W min.) element and shall be maintained on at all times. Provide Federal Signal StreamLine Low Profile Steady Burning LED Light or approved equal.

PART 3 - EXECUTION



3.1 EMERGENCY SHUTOFF SYSTEM (EFSO)

A. Upon completion of all work, each new station shall be manually operated and it shall be verified that the correct indicator is illuminated, strobe activated and that the fuel tank farm is correctly notified and all audio/visual alarms are working properly. Test results shall be recorded and submitted for record.

3.2 EFSO SYSTEM SEQUENCE OF OPERATION

A. Activation of any station shall cause the following to occur:

1. Alarm Panel EFSO-S that an EFSO event has occurred at a specific station. If multiple stations are activated, communicate alarms in sequential, first received format.

2. Panel EFSO-S will alarm the Tank Farm (via fiber optics) that there has been an EFSO event at the Signature Load Rack. This will be indicated on the Tank Farm HMI screen. This signal will be treated the same as any other terminal hydrant EFSO signal and shall be programmed as such.

3. The existing MOV at the Signature Load Rack will close. This MOV shall maintain the ability to be controlled and monitored at the Tank Farm.

4. Panel EFSO-S will open a contact that disallows the MOV from opening, even if the EFSO station itself is reset.

B. Resetting the EFSO System:

1. Determine and correct the problem at the activated station.

2. Reset the manual pull station.

3. Reset the system at Panel EFSO-S or from the HMI at the Tank Farm in order to open the MOV.

3.3 MODIFICATION OF EXISTING CONTROLS

A. The existing control system consisting of the Human Machine Interface (HMI) computer and EFSO Panel at the Tank Farm shall be modified to accommodate the new EFSO control system as specified herein.

1. Add status of both EFSO pull stations to the EFSO screen. A new screen may be used if necessary.

2. Add the status of the existing MOV and provide the ability to open/close the valve.

3. A new screen shall be developed that depicts the network layout and communication status of each device. Failure to communicate shall be an alarm on the HMI.



B. Modification of the existing PLC shall be fully documented and incorporated in the existing O&M manuals. In the absence of existing PLC Logic printout, the Contractor shall supply a full program printout as specified for the new PLC Processors.

C. Contractor shall coordinate with the Operator for an investigative trip of (3) days to obtain a copy of each existing program, O&M manuals and HMI screens.

D. Contractor shall provide screen shots of modified or new screens for Authority and Operator approval at least 3 months prior to startup. Authority and Operator shall then review and send back comments within 4 weeks. If modifications are necessary, the contractor shall then resubmit screens for approval. All submissions shall be in color. Animated links and data points shall be labeled and described so that the Authority and Operator can get a fuller picture of how the screens will look.






FUEL SYSTEM MICROTUNNELING, BORING AND UTILITY CASINGS 335243.08 10-1

SECTION 335243.08 10 – FUEL SYSTEM MICROTUNNELING, BORING AND UTILITY CASINGS

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes pipe insulators, end seals and casing pipe, installed by boring and jacking, microtunneling, or directional drilling methods.

B. Related Work specified elsewhere.

1. Drawings and general provisions of the Contract, including General and Supplementary Conditions and DIVISION 1 Specification Sections, apply to this Section.

2. Item P-152 – Excavation and Embankment

3. Section 335243.10 10 – Fuel System General Provisions

4. Section 312323.13 10 – Fuel System Excavation Bedding and Backfill

5. Section 335343.91 10 – Fuel System Cathodic Protection System

1.2 REFERENCES

A. American Petroleum Institute (API)

1. API RP1102 – Recommended Practice for Liquid Petroleum Pipelines Crossing Railroads and Highways

2. API 1104 – Standard for Welding Pipelines and Related Facilities

3. API 5L – Specification – Line Pipe

4. Section 335243.13 10 – Fuel System Pipe, Fitting and Installation

1.3 SUBMITTALS

A. Submit as specified in Section 335243.10 10, Fuel System General Provisions.

B. Submit the following for acceptance prior to shipment:

1. Casing pipe

2. Pipe insulators

3. Link seals and shrink sleeves



4. Casing Filler

5. Boring methodology

6. A written submittal shall be provided for the excavation plans for bore pits including shoring, trench protection, and other safety measures provided. In accordance with OSHA requirements, the submittal shall be signed and sealed by a licensed professional engineer where depths exceed 20 feet.

7. Casing pipe material and certification.

8. Pressure test results

9. Continuity test results

10. Survey results documenting casing start and end elevations

PART 2 - PRODUCTS

2.1 MATERIALS

A. Welded Casing Pipe

1. New, smooth wall, welded steel pipe conforming to API-5L, Grade B (35ksi minimum yield strength steel) or Grade X42 (42 ksi minimum yield strength steel). New pipe manufactured using salvaged steel is unacceptable.

2. Minimum Casing Thicknesses: Minimum Wall Thickness

*Casing Diameter For Aircraft mm In. mm in.

Under 350 Under 14 6.35 0.250 350 and 400 14 and 16 7.14 0.281 450 18 7.92 0.312 500 20 8.37 0.344 550 22 9.53 0.375 600 24 10.31 0.406 650 26 11.13 0.438 700 and 750 28 and 30 11.91 0.469 800 32 12.70 0.500 350 34 13.49 0.531 900 36 13.49 0.531 950, 1000, and 1050

38, 40 and 42

14.3 0.563

3. Wall thickness shown in the above table is the calculated minimum wall thickness required for the indicated pipe size and service condition and may not be a standard wall



thickness manufactured or normally available. Provide casing wall greater or equal to value shown in table.

4. In single carrier pipe casings, minimum casing inside diameter shall exceed outside diameter of carrier pipe joints or couplings by 4 inches (100 mm).

5. With approval of the COTR, Contractor may use a larger casing pipe and/or eliminate the intermediate receiving pit to accommodate their proposed boring equipment. Any design (including Owner’s Engineer), installation or material change costs required to accommodate a larger casing pipe shall be borne by the Contractor.

B. Joints:

1. All casing pipe field joints and closure plates shall be welded in accordance with API 1104.

C. Pipe Insulators:

1. Segmented high density polyethylene insulators with runners shall be Thinsulator Model M-2 as manufactured by T.D. Williamson Company, Model PE as manufactured by PSI (Pipeline, Seal and Insulator Inc.) or COTR approved equivalent for use with pipe and casing sizes specified or indicated.

2. Place at locations and spacing indicated on the plans. Where not specifically called for on the plans, insulators shall be installed not more than 6 feet apart.

3. Leg lengths shall be sized to keep carrier pipe positioned within limits of end seal adjustment. When segmented mechanical end seals are indicated on plans (with or without rubber boot seals) pipe insulators must center the carrier pipe in the casing.

4. The casing insulators shall be spaced at the minimum intervals as recommended by the manufacturer for the particular pipe size and service conditions.

D. Link Seals:

1. Use one link seal unit at each end of the casing pipe to keep the carrier pipe centered in the casing and seal the ends of the casing pipe. The seal shall ensure complete electrical isolation of carriers from casing. Link seals shall be manufactured by Pipeline Seal and Insulator Thunderline Link Seal Model OS-316 with Nitrile sealing elements, 316 stainless steel fasteners and non-metallic pressure plate or approved equivalent.

E. Heat Shrink Sleeve:

1. Provide heat shrink sleeve as shown on the drawings at each end of the casing pipe to protect the link seal. The heat shrink sleeve shall be an oil, jet fuel and water resistant unit approved by COTR.

F. Casing Filler

1. The interstitial space between the casing pipe and carrier pipe shall be filled with an approved casing filler. Fill material shall be:



a. Petroleum wax-based filler such as “Trenton Fill-Coat No. 1 – Hot Installed Casing Filler” or “Trenton Fill-Coat No. 2”

b. Low strength concrete fill material such as “Elastizell PS” with the following mix and properties: 1) Expansion material shall be Elastizell JLE. 2) Use Portland cement complying with ASTM C150. 3) Elastizell PS 120 shall have a cast density of 38 pcf +/- 2 pcf and a

minimum compressive strength of 100 psi at 28 days. c. COTR approved substitute.

2. The applicator shall be certified by the manufacturer of the filler material as technically qualified to perform this work and shall demonstrate a reasonable level of satisfactory experience in pipeline fill installations. The specialized batching, mixing, and placing equipment shall be approved by the manufacturer.

G. Cathodic Protection Test Station

1. Install per Section 335343.91 10, Fuel System Cathodic Protection System.

2. Confirm electrical isolation of carrier and casing pipe prior to backfill in accordance with Part 3.

PART 3 - EXECUTION

3.1 GENERAL INSTALLATION

A. Contractor shall obtain all permits and/or authorizations from appropriate agencies prior to start of construction. Construction shall be coordinated so as not to interfere with ongoing operations or other construction activities.

B. All Work shall, as a minimum, meet the requirements of API RP1102 and the authorities having jurisdiction, and shall be subject to their inspection and approval.

3.2 CASING PIPE INSTALLATION AND EQUIPMENT

A. Installation of Casing Pipes by Conventional Boring and Jacking, Directional Drilling or Microtunneling:

1. At locations where Drawings indicate or Contractor elects, with approval of the COTR, to install casing pipes by trenchless methods, the Contractor shall thoroughly review available subsurface information and perform additional investigations necessary to select equipment and techniques which will assure installation of the casing pipe(s) to the lines indicated and within tolerances specified without damage to new or existing facilities. Contractor shall be responsible for verifying the location of all existing underground utilities and structures prior to beginning work and will be responsible for repairing damages to utilities resulting from Contractor’s work.

2. Geotechnical data in the vicinity of the casings is available for Contractor review.



3. Casing pipes installed with less than two pipe diameters of cover shall utilize methods and monitoring to assure no uplift of yard areas, pavement, or structures occur above the casing.

4. Contractor shall evaluate stability and nature of soil, including cohesive properties and groundwater to the extent necessary to assure that cave-in and associated short- or long-term subsidence over the pipe will not occur. In soils subject to liquefaction or cave-in, the Contractor shall use equipment with recessed cutters, pressure balanced cutting faces, or other equipment which is capable of restraining soil adjacent to the casing while excavating material necessary for installation.

5. In firm materials not subject to cave-in, cutting heads and casing pipe shall be constructed with reinforcing bands and wing cutters set to provide the minimum overcut necessary for the installation of the casing pipe.

a. Overcut for casings 24 inches (600 mm) or less shall not exceed 0.5-inch (12.5 mm).

b. Overcut for casing pipe greater than 24 inches (600 mm) and up to 48 inches (1200 mm) shall not exceed 0.75-inch (19 mm).

6. Jacking equipment shall be sized to provide adequate thrust to install the indicated casing pipe. Contractor may utilize casing lubrication, or other techniques to reduce jacking loads and facilitate installation of the casing pipe. Thrust blocks shall be sized and ultimate jacking loads selected which will not damage existing or proposed facilities. Contractor’s use of intermediate receiving pits will be subject to the review and approval of the COTR.

7. Equipment shall include measures for controlling line and grade within 15% of the indicated pipe slope. The casing invert elevation shall not exceed 0.10 foot above or below the plan elevation at the beginning point. Casing installer shall maintain a daily log indicating casing elevations at the cutting head. A licensed surveyor shall be retained to document the final invert elevations at the beginning and ending point of the casing. The daily log and final survey data shall be submitted to the COTR.

8. Boring equipment head shall be designed to make directional changes when monitoring indicates the casing is drifting off line or grade. A laser guidance system or other reliable method shall be used to monitor and maintain a constant grade setting across the proposed bore path. Any horizontal or vertical variation shall be immediately brought to the attention of the COTR.

9. Pits shall not exceed limits indicated and be excavated, shored, and braced adequately to provide safe working conditions and protect adjacent facilities. Contractor shall provide barriers, signs, and other devices necessary to protect traffic and pedestrians. All work shall be conducted in accordance with the requirements of 29 CFR 1926.

10. Casings rejected due to misalignment or other failures to conform to Specifications shall be abandoned in place and filled with concrete grout. Rejected casing pipe shall not be recovered for reuse.

3.3 Carrier Pipe



A. Carrier pipe conforming to the requirements of Section 335243.13 10, Fuel System Pipe, Fittings and Installation shall be welded and installed in the casing pipe before backfilling bore pits. The carrier pipe within the casing shall be pneumatically tested by welding end caps on the line prior to tying into the mainline piping. Pneumatic testing shall comply with the provisions of Section 335243.13 10, Fuel System Pipe, Fittings and Installation.

B. Contractor shall confirm the casing and carrier pipe are electrically isolated by completing a continuity test. A dc resistance of 200 ohms or greater is required. If the resistance is less than this value, the pipe shall be pulled out of the casing and the cause for the low resistance determined and corrected. Continuity test results shall be observed by the COTR and documented including date of test, resistance observed, and testing entity.

3.4 INSULATORS AND END SEALS

A. Install according to manufacturer’s recommendations and as indicated.

3.5 Casing Filler

A. The interstitial space between the casing pipe and carrier pipe shall be filled with an approved casing fill material. Filler shall completely fill the interstitial space and be installed in accordance with manufacturers recommendations.

3.6 Excavation and Backfilling

A. Excavation and backfilling of bore pits shall be completed in accordance with the provisions of Section 312323.13 10, Fuel System Site Excavation, Bedding and Backfill and Item P-152.





FUEL SYSTEM GENERAL PROVISIONS 335243.10 10-1

SECTION 335243.10 10 - FUEL SYSTEM GENERAL PROVISIONS

PART 1 - GENERAL

1.1 SUMMARY

A. Work in this section includes furnishing all materials, labor and supervision necessary for the construction of miscellaneous fuel system improvements at Washington Dulles International Airport. The work shall include all pipe, fittings, valves, appurtenances and activities as specified herein and shown on the drawings. All testing, inspection and flushing shall be provided as specified to provide a complete and operational system.

B. The General Provisions described herein, together with the conditions of the contract and Section 013300 apply to the work in the Fuel System Work specifications denoted by specification numbers XXXXXX.XX 10. This Section is hereby made a part of all other Sections of Fuel System work, as if repeated in each.

C. All permits and licenses that are required by governing authorities for the performance of work shall be procured and paid for by the Contractor.

D. The work will be completed during normal operating hours and conditions unless otherwise specified. Staging of construction activities is required. Connection of the new fuel system piping to the existing fuel system piping will be performed at night and shall be coordinated with the fuel system operator to assure the continued operation of the existing fuel system. Contractor shall comply with all provisions of the Authorities - Orders and Instructions – Fuel System Work Coordination at Washington Dulles International Airport (IAD 6-2-2).

1.2 GENERAL SCOPE OF WORK

A. GENERAL

1. Fuel system improvements will include complete abandonment of the existing hydrant piping, new fuel piping, modifications to the existing hydrant cart test stand, installation of an isolation vault, and modifications to the emergency fuel shutoff system. The fuel system work will be completed in phases.

1.3 QUALIFICATIONS OF BIDDERS

A. The Aviation Fuel Distribution System work shall be completed by a Contractor who conforms to the following requirements: 1. Contractor must have been involved in the construction of commercial aviation fueling

industry projects for a minimum of ten (10) years. 2. Contactor must have successfully completed three (3) projects similar in complexity and

scope within the last five (5) years. The projects shall include installing internally coated steel piping above and belowground, the installation of isolation valve vaults, installation of horizontal fuel tanks, and construction of concrete vaults. The Contractor shall



provide a description of the referenced projects and client references to include contact name, phone number and organization.

3. Contractor must have developed and implemented an aviation fuel system flushing plan, using a method that utilizes flushing into mobile tankage. The flushing plan must have incorporated the fuel quality requirements of ATA 103. Provide a list of projects with appropriate descriptions where flushing plans have been developed and implemented by the Contractor.

4. Contractor has as a member of his team, a tunneling subcontractor who has successfully completed a minimum of three tunneling projects of similar length and diameter in the past ten (10) years. The tunneling subcontractor shall provide a description of the referenced projects and client references to include contact name, phone number and organization.

5. Contractor has as a member of his team, a controls subcontractor who has successfully completed three (3) PLC based Emergency Fuel Shutoff Systems (EFSO) projects requiring the integration and transmission of data for viewing at a remote location (e.g. Tank Farm) for airport terminals with hydrant fueling systems. The controls subcontractor shall provide a description of the referenced projects and client references to include contact name, phone number and organization.

1.4 REFERENCES

A. Refer to each individual section in this division for a list of applicable references from each of the following organizations:

1. Air Transport Association (ATA)

2. American Petroleum Institute (API)

3. National Fire Protection Association (NFPA)

4. Underwriters Laboratories (UL)

5. American Society of Mechanical Engineers (ASME)

6. American Society for Testing and Materials (ASTM)

7. Environmental Protection Agency (EPA)

8. Factory Mutual Engineering Division (FM)

9. Industrial Risk Insurance (IRI)

10. Military Specifications (Mil)

11. Occupational Safety & Health Administration (OSHA)

12. Petroleum Equipment Industry (PEI)

13. Federal Aviation Administration (FAA)

14. Virginia Department of Environmental Quality (DEQ)



15. Joint Inspection Group (JIG)

1.5 DEFINITIONS

A. “Piping” includes in addition to pipe, all fittings, valves, sleeves, hangers, and other supports and accessories related to such piping.

B. The words “furnish and install”, “provide”, “furnish”, and “install” are used to mean the Contractor shall furnish and completely install the system, service, equipment, or material named along with other associated devices, equipment, material, wiring, piping, etc. as required. System shall be a complete operating installation, and shall conform to the codes, standards and guidelines applicable to this type of project.

C. It is the intent of the specifications and drawings to call for finished work, tested and ready for operation.

1. All apparatus, appliances, materials, or work not shown on drawings but mentioned in specifications, or vice versa, and/or all incidental accessories necessary to make work complete and ready for operation, even though not specified or shown on drawings, shall be furnished and installed without increase in contract price.

2. Should there be discrepancies or questions of intent, refer matter to the COTR in writing for a decision before ordering any equipment or materials or before starting any related work.

1.6 COMPLIANCE SUBMITTALS

A. Submittals are required for all material specified in Divisions XX XX XX.XX 10. If material or equipment is shown on the drawings to be included in this project but is not specified, the Contractor shall bring this to the immediate attention of the COTR. Submittals are required for all material and equipment incorporated into this project whether specified or not.

B. Submittals are required for the proposed subcontractors primarily responsible for tunneling/micro-tunneling, fuel pipe installation, EFSO controls and leak detection.

C. The Contractor’s attention is called to the COTR’s review of Compliance Submittals. This review shall be completed and the submittal returned to the Contractor before starting procurement, installation or fabrication.

D. The Contractor’s submission of a compliance submittal constitutes that he has both verified and coordinated all dimensional data, quantities, field conditions, catalog data, and compliance with the specification or he assumes full responsibility for doing so.

E. Compliance Submittals shall include all components and units associated with decommissioning the existing fuel hydrant system and fabrication of the new hydrant fueling system as specified in the following Fuel System Work sections:

1. Fuel System Piping Abandonment and Removal 026500.01 10

2. Fuel System Electrical 260500.10 10



3. Fuel System Conduit 260533.11 10

4. Fuel System Identification for Electrical Systems 260553.12 10

5. Fuel System Instrumentation 260900.10 10

6. Fuel System Motor Starters 262913.11 10

7. Fuel System Disconnect Switches 262921.10 10

8. Fuel System Excavation, Bedding and Backfill 312323.13 10

9. Fuel System Inspection, Testing and Flushing 330850.10 10

10. Fuel System Emergency Fuel Shutoff System 330950.11 10

11. Fuel System Microtunneling, Boring and Utility Casings 335243.08 10

12. Fuel System General Provisions 335243.10 10

13. Fuel System Piping Specialties 335243.11 10

14. Fuel System Pipe, Fittings and Installation 335243.13 10

15. Fuel System General Valves 335243.15 10

16. Fuel System Control Valves 33523.16 10

17. Fuel System Metering Equipment 335243.17 10

18. Fuel System Service Pits and Valve Vault Covers 335243.20 10

19. Fuel System Pumps 335243.23 10

20. Fuel System Coating 335280.10 10

21. Fuel System Cathodic Protection System 335343.91 10

22. Fuel System Cathodic Protection System Testing 335343.92 10

23. Fuel System Aboveground Horizontal Tanks 335643.13 10

24. Fuel System Leak Detection System 335800.10 10

25. Fuel System Description of Operation 335809.93 10

F. Submittal Formats are as follows:

1. Product Information: Submit manufacturer’s data sheets identifying equipment size, descriptions, materials, ratings, etc.



2. Drawings: Submit drawings which graphically show relationship of various components of the work, schematic diagrams of systems, details of fabrication, layouts of particular elements, connections and other relational aspects of the work.

3. Instructions: Preprinted material describing installation of a product, system or material, including special notices and material safety data sheet, if any, concerning impedance, hazards and safety precautions.

4. Statements: A document required of the Contractor, or through the Contractor, from a supplier, installer, manufacture, or other lower tier Contractor. The purpose of which is to confirm the quality or orderly progression of a portion of the work by documenting procedures, acceptability of methods or personnel, qualifications or other verifications of quality.

5. Reports: Reports of inspections or tests, including analysis and interpretation of test results. Each report shall be properly identified. Test methods used shall be identified and test results shall be recorded.

6. Certificates: Statement signed by an official authorized to certify on behalf of the manufacturer of a product, system or material, attesting that the product, system or material meets specified requirements. The statement must be dated after the award of this contract, must state the Contractor’s name and address, must name the project and location, and must list the specific requirements that are being certified.

7. Records: Documentation to record compliance with technical or administrative requirements.

8. Submittal Review Action:

a. A – Approved: Indicates information is sufficient in detail and adequately organized for performance of the review. Material conforms to the intended functional requirements of the contract documents and is approved for fabrication, procurement and incorporation into the project as submitted.

b. B – Approved as Noted/No Resubmittal Required: Indicates information submitted is sufficient in detail and adequately organized for performance of the review. Material conforms to the intended functional requirements of the contract documents and is approved for fabrication, procurement and incorporation into the project as noted. Submitted item is not considered by the reviewer to be a critical element of the project and/or noted comments are minimal in quantity and complexity so that no additional review is necessary. Copies with limited marks are acceptable to all parties as permanent record documents.

c. C – Approved as Noted/Resubmit: Indicates information submitted is sufficient in detail and adequately organized for performance of the review. Item generally conforms to the intended functional requirements of the contract documents and is approved for fabrication, procurement and incorporation into the project as noted. Submitted item is not considered by the reviewer to be a critical element of the project but noted comments are sufficient in quantity or complexity so that resubmission is appropriate to assure responsive action, or copies with marks are not acceptable to all parties as permanent record documents. Item must be resubmitted responsive to the reviewers’ comments.



d. D – Revise/Resubmit: Indicates information submitted may not be sufficient in detail or adequately organized for performance of the review. Item may appear to conform to the intended functional requirements of the contract documents but certain elements do not or lack sufficient information to be evaluated. Item is not approved for fabrication, procurement or incorporation into the project. Submitted item is considered by the reviewer to be a critical element of the project and/or noted comments are sufficient in quantity or complexity so that resubmission is necessary to assure acceptable responsive action and conformance with the contract documents. Item must be resubmitted responsive to the reviewers’ comments.

e. E – Rejected/Resubmit: Indicates information submitted is not sufficient in detail, is not adequately organized for performance of the review, or does not conform to the intended functional requirements of the contract documents. Item is not approved for fabrication, procurement or incorporation into the project. Item must be resubmitted responsive to the contract documents and reviewers comments.

f. F – No Action Required: Indicates item has been submitted for informational purposes only and no action response or comments are needed by the reviewer. Item should be retained in project files.

g. G – Not Subject to Review: Indicates submission of item was not required by the contract documents and is not part of the reviewers’ contractual project scope. Item is being returned without review or comment.


A. Materials and equipment shall be new, unused, and shall bear manufacture’s name, model number, and other identification marking.

B. Materials and equipment shall be standard product of manufacturer regularly engaged in the production of required type of material or equipment for at least 5 years (unless specifically exempted by COTR) and shall be manufacturer’s latest design having published properties.

C. If more than one unit of the same type of equipment is required, (i.e., control valves, manual valves, etc.) they shall be products of a single manufacturer.

D. All equipment, materials, components, coatings, and accessories provided shall be suitable for use with the specific product. The following table is provided to indicate the basic design conditions of the components:

SERVICE PRESSURE TEMPERATURE SPECIFIC GRAVITY Jet Fuel 275 psig -20 to 110F 0.810.05

E. The Contractor is responsible for protecting all equipment and material from loss or damage until the system is completed and accepted by the COTR.

F. The Contractor shall be responsible for coordinating with the manufacturer for installation of the equipment furnished. The Contractor shall be responsible for warranty work required and shall coordinate with the manufacturer of the equipment to accomplish warranty work including any labor and additional cost for such warranty work. The equipment manufacturer shall



provide the Contractor with installation manuals and instructions. The Contractor shall receive and install this equipment for a complete furnished and installed installation including all accessories as specified within these specifications and as shown on drawings.

G. The Contractor shall check equipment delivered to job site by the equipment supplier against approved Compliance Submittals or other required documentation. The Contractor shall report all discrepancies, shortages, or lack of data to the COTR and equipment supplier for adjustments within one week after equipment is received. If such report is not made within one week, it shall be assumed no discrepancies, shortages or lack of data has been found.

H. Contractor shall provide the following for all equipment furnished:

1. All rough-ins for equipment and accessories

2. Installation of loose trim provided with equipment by the equipment supplier

3. Furnish and install all piping connections, valves, unions, control valves, drains and other accessories as indicated on the plans and as specified here within these documents.

I. The products of specific manufacturers have been used as the basis of design. Any changes to the structure, piping, controls and electrical connections that result from the use of other manufacturers shall be coordinated with all other trades by the Contractor and approved in writing on letterhead by the COTR before the ordering of the equipment from the manufacturer. Any resultant modifications required shall be performed without incurring additions to the contract price.

J. The bid shall be based only on products specified. The Contractor shall verify delivery dates for timeliness before submitting his bid. Desired product substitutions shall be brought to the COTR’s attention prior to bidding. No consideration shall be given to substitutions after bids are received.

K. Unless this Contractor states in writing at the time of pricing any and all exclusions to these specifications or drawings in his bid proposal, this Contractor shall furnish and install at the job site the equipment, material, labor and services as specified herein and shown on the drawings for the amount of his bid.

1.8 DRAWINGS

A. Drawings are diagrammatic and indicate the general arrangement of systems and work included in the contract. Drawings are not to be scaled. All drawings and details shall be examined and coordinated by the Contractor to establish exact location of piping and equipment. Where conflicts occur, the Contractor shall inform the COTR immediately.

B. The Contractor shall follow all contract drawings in laying out work and shall check shop drawings of other trades to verify spaces in which work will be installed.

1.9 MAINTENANCE MANUALS



A. In addition to the requirements specified in the General Conditions, at the project’s completion, the Contractor shall submit a complete system Operating and Maintenance Manual (O&M). The manual at a minimum shall include the following:

1. The manual shall be composed of typed instruction sheets with large drawing sheets (not reduced) folded in with reinforced margin. It shall have a post binder system so that the sheets can be easily substituted and shall have a hard cover.

2. The manual shall be organized into systems and shall contain the manufacturer’s complete detailed operating and maintenance instructions with data sheets for each piece of equipment furnished under this project.

3. Include a spare parts list for each major piece of equipment furnished for the project including but not limited to:

a. Manual Valves

b. Leak detection system

c. Service pits

d. EFSO system

e. Leak detection system

f. Hydrant Cart Test Stand

4. Provide a comprehensive list of maintenance procedures for preventative maintenance and troubleshooting; repair and reassembly, aligning and adjusting, and disassembly.

1.10 NAMEPLATES

A. All major equipment items shall have a permanent, stamped metal, nameplate. The nameplate shall be permanently attached to the equipment in a manner such that it does not hinder the operation of the equipment. All nameplates shall be protected from overspray during field painting operations. Nameplates shall generally include the applicable items in the following list:

1. Manufacturer’s Size and Type

2. Serial Number

3. Design Capacity

4. Design Pressure

5. Design Temperature

6. Code Conformance



1.11 CODE REQUIREMENTS AND PERMITS

A. All work indicated on the contract drawings and herein specified shall conform with all applicable codes or laws of the State of Virginia and any other governmental bodies having jurisdiction and shall be installed to the satisfaction of the inspecting authority.

B. Any deviations from the contract documents or specifications required for conformance with the applicable codes or laws shall be made without change in contract price, but not until such deviations have been brought to the attention of, and approved in writing, by the COTR.

C. The applicable codes and laws shall govern the minimum requirements only. Where the drawings or specifications call for materials, construction limitations, or other similar requirements in excess of the code requirements, the drawings and specifications shall be followed.

D. The Contractor shall obtain and pay for permits and licenses, and shall pay all fees and taxes and give all notices bearing on the conduct of the work as drawn and specified. Certificates of compliance, approval, or acceptance from all authorities having jurisdiction over the work shall be obtained and delivered to the COTR.

E. All work indicated on the drawings and herein specified shall conform with all applicable standards of the National Fire Protection Association, American Petroleum Institute, American National Standards Institute and American Society for Testing and Materials.

F. All work indicated on the drawings, and herein specified, or tasks required in the performance of the work but not specifically indicated in the drawing or specifications, shall conform to the applicable requirements of the Occupational Safety and Health Administration (OSHA) as provided in 29 CFR. Applicable requirements include, but are not limited to, Part 1910 – Occupational Safety and Health Standards and Part 1926 – Safety and Health Regulations for Construction.

G. All equipment, materials, and specialties shall be installed and connected in accordance with the best engineering practice and standards for this type of work. Unless otherwise specified or shown on the drawings, the recommendations and instructions of the manufacturer shall be followed for installing the work.

H. The Contractor shall promptly notify the COTR in writing, of any instances in the specifications or on the drawings that are in conflict with any of the aforementioned authorities so that any required changes shall be adjusted before the contract is awarded. If the Contractor performs any work contrary to such laws, rules, regulations or recommendations, without notice, he shall bear all cost arising therefrom.

PART 2 - PRODUCTS - Not Applicable

PART 3 - EXECUTION

3.1 GENERAL INSTALLATION



A. Contractor shall be responsible for the safety and protection from loss or damage of all equipment and material received until all the work under this contract is complete and the Contractor has received final acceptance. Protect all equipment and material during storage and prior to start-up, which shall include the coverings of all openings, protection against water intrusion or accumulation, protection against rust and other damage, etc.

B. Contractor shall ensure that all equipment installed as part of this contract shall be properly aligned, adjusted and lubricated before final acceptance.

C. Contractor shall spot paint all equipment where the shop paint has been damaged or flaked off.

D. Furnish all bolts, studs, nuts and gaskets for makeup of all connections to the equipment and replace all gaskets, bolts and fasteners damaged or as directed during the flushing process.

E. All connections to equipment shall be made with socket welds, unions or flanges.

3.2 REQUIREMENTS

A. Mechanical and electrical designs are based on the requirements for the specified manufacturers listed in the equipment specification. Conduit sizes are selected on the basis of specified equipment. Increased manufacturers requirements necessitating piping changes, additional power conductors, controls, foundations, etc., or any changes required to accommodate any alternate or substitute manufacturer’s equipment, other than as shown on drawings shall be provided without any increase in contract price by Contractor.

B. Manufacturers, where specifically called for, must provide factory tests, unit installation observations, unit start-up and tests, etc., as specified. Signed reports shall be submitted to the COTR upon completion of these services. Subletting of these services will not be permitted. Compliance Submittals shall be accompanied with a letter of certification by the manufacturer that the specified services shall be provided. Failure to do so shall be cause to reject the Compliance Submittals.

C. The contract drawings are in part schematic, intended to convey the scope of work and indicate the general layout, design, and arrangement. The Contractor shall follow these drawings in the layout of his work and shall consult general construction drawings, electrical drawings, and all other drawings for this project. Contractor shall verify all existing site conditions to determine all conditions affecting the work shown or specified. The contract drawings are not to be scaled and the Contractor shall verify areas in which the work is to be installed.

D. Follow drawings in laying out work, check drawings of other trades to verify spaces in which work will be installed, and maintain maximum space conditions at all points. Where space conditions appear inadequate, COTR shall be notified before proceeding with installation.

E. All work shall be performed by trained personnel of the particular trade involved and shall be done in neat and workmanlike manner as approved by the COTR.

1. Work shall be performed in cooperation with other trades and scheduled to allow timely and efficient completion of project.



2. Furnish other trades advance information on locations and sizes of frames, boxes, sleeves and openings needed for work. Also furnish information and shop drawings necessary to permit other trades affected to install their work properly without delay.

3. Where there is evidence that work of one trade will interfere with work of other trades, all trades shall assist in working out space conditions to make satisfactory adjustments.

F. Work installed before coordinating with other trades causing interference with work of such other trades shall be changed to correct such condition without increase in contract price and as directed by COTR.

G. Where specific details and dimensions are not shown on the drawings, the Contractor shall take measurements and make layouts as required for the proper installation of the work and for coordination with all other work on the project. In case of any discrepancies between the drawings and the specifications, it shall be assumed by the signing of the Contract that the higher cost (if any difference in costs) is included in the contract price. The Contractor shall perform the work in accordance with the drawings or with the specifications, as determined and approved by the COTR.

H. The Contractor shall be responsible for a scheduled sequence in performing the work so that it will not interfere with the Authority’s operation. Before any work is started, the Contractor shall consult with the Contracting Officer’s Technical Representative (COTR) and arrange a satisfactory schedule.

1. Make temporary alterations as required to execute work so that all operations and services are maintained with the minimum possible interruption.

2. Temporary shut-downs shall be segregated and shall be of the shortest possible duration. All facilities shall be kept in continuous operation unless Authority grants specific written permission to the contrary.

I. It is the responsibility of the Contractor to monitor the construction area for the presence of flammable vapors and to assure the proper construction methods and equipment is used if hazardous conditions exist.

3.3 EXISTING CONDITIONS

A. Each bidder shall inspect the site as required for knowledge of existing conditions. Failure to obtain such knowledge shall not relieve the successful bidder of the responsibility to meet existing conditions in performing the work under the contract.

B. Where new work cannot be installed without changes in existing plant, facility, or systems or where it is indicated on drawings to re-work an existing installation, this contract shall include alterations to existing work as required to install new work. Additions to the contract cost will not be allowed because of the Contractor’s failure to inspect existing conditions.

C. Existing conditions indicated on the drawings are taken from the best information available on previous contract drawings and from visual site inspection. They are not to be construed as “As Built” conditions, but are to indicate the intent of this work. It shall be the responsibility of the Contractor to verify all existing conditions at the project site and to perform the work as required to meet the existing conditions and the intent of this work indicated.



D. Unless specified otherwise, all existing material and equipment shown or required to be removed from existing construction and not shown to be reused or turned over to the Authority shall become the property of the Contractor and shall be promptly removed from the site.

E. Any existing material or equipment which is to be reused or is to remain in place and which is damaged by this Contractor in performing the contract work shall be repaired to the satisfaction of the Authority or shall be replaced with new equipment and material.

3.4 STORING MATERIALS

A. Unless otherwise arranged for by the Contractor, buildings of the Authority shall not be used for Contractor storage or job office purposes. Open or exposed space for storage of material and location of temporary job facilities will be allocated to the Contractor. The Contractor, at his own expense, shall provide any temporary structures such as trailers and sheds, as may be required for this purpose.

3.5 CUTTING AND PATCHING

A. The responsibility for the cutting of existing masonry and concrete which is required for the installation of new work shall be by the Contractor. The Contractor shall coordinate with the Authority before any cutting and obtain approval from the Contracting Officer’s Technical Representative (COTR) prior to any cutting.

B. Cutting shall be done with extreme care and in such a manner that the strength of the structure will not be endangered. Wherever possible, openings in concrete or masonry construction shall be by concrete saw or rotary core drill. Openings in any construction shall be cut the minimum size required for the installation of the work.

C. Where openings or holes are cut in existing construction and the cutting breaks existing electrical circuitry, control circuitry, communications, conduit, or wiring, then it shall be the responsibility of the Contractor to have the circuitry, conduit, and rewiring re-routed as required and as approved by the COTR. Temporary completion shall be provided where necessary before the permanent re-routing and completion work is finished. All costs for this work shall be the responsibility of the Contractor and no additions will be allowed to the contract price.

D. Where existing work is removed from openings in existing construction and the opening is not to be reused for new work, the opening shall be filled and patched to match existing adjacent construction.

3.6 BASES, FOUNDATIONS, SUPPORTS AND ATTACHMENTS

A. The Contractor shall provide all structural steel, concrete, and materials necessary to properly support and anchor equipment and lines provided under this contract.

B. All equipment and materials shall be securely attached in an approved manner. Attachments shall be of a strong and durable nature and suitable for the service required.

C. Concrete bases shall be provided where shown on the drawings. Equipment which is to be grouted in place shall be grouted with non-shrink grout.



D. All equipment shall be mounted, aligned, adjusted, and serviced in accordance with manufacturer’s recommendations before system testing and final acceptance of the system.

3.7 ELECTRICAL COORDINATION

A. All electrical products and their installation shall conform unless otherwise specifically noted, to applicable standards of the National Electrical Manufacturers Association, NFPA 70, Division 33 of these specifications, and shall also be listed by Underwriter’s Laboratories, Inc. and/or other agencies, as required.

3.8 TESTING LABORATORY SERVICES

A. The Contractor shall secure the services of an independent testing laboratory approved by the COTR to perform all testing, witnessing and certification of materials. This applies to coating integrity, fuel acceptability, pressure tests and weld examinations.

B. The cost for all laboratory services will be the responsibility of the Contractor.

C. The laboratory shall:

1. Cooperate with the Contracting Officer’s Technical Representative (COTR), Authority and Contractor; and provide qualified personnel promptly on notice.

2. Perform specified inspections, sampling and testing of materials and methods of construction:

a. Comply with specified standards; ASTM, other recognized authorities and as specified.

b. Ascertain compliance with requirements of contract documents.

3. Promptly notify the Contracting Officer’s Technical Representative (COTR), Authority and Contractor of irregularities or deficiencies of work, which are observed during performance of services.

4. Promptly submit 2 copies of reports of inspections and test to the COTR including:

a. Date Issued

b. Project Title and Number

c. Testing Laboratory Name and Address

d. Name and Signature of Inspector

e. Date of Inspection or Sampling

f. Record of Temperature and Weather

g. Date of Test



h. Identification of Product and Specification Section

i. Location in Project

j. Type of Inspection or Test

k. Observations Regarding Compliance with Contract Documents

5. Perform additional pre-approved services as required by the Contracting Officer’s Technical Representative (COTR), Authority and Contractor.

6. The laboratory is not authorized to:

a. Release, revoke, alter, or enlarge on, requirements of contract documents

b. Approve or accept any portion of work

c. Perform any duties of the Contractor

D. The Contractor shall:

1. Coordinate laboratory services, cooperate with laboratory personnel, provide access to project and to manufacturer’s operations.

2. Furnish to laboratory preliminary representative samples of materials to be tested, in required quantities.

3. Furnish labor and facilities:

a. To provide access to work to be tested

b. To obtain and handle samples at the site

c. To facilitate inspections and tests

d. For laboratory’s use for storage of test samples

4. Arrange with laboratory and pay for pre-approved additional samples and tests required for Contractor’s convenience.

5. The Authority shall reserve the right to request the Contractor to obtain the services of a separate, equally qualified independent testing laboratory, to perform additional inspections, sampling and testing required when initial test indicate work does not comply with contract documents. The Contractor shall pay the costs of such retesting.

3.9 WARRANTY BY CONTRACTOR

A. Warrant all systems, equipment, materials and components installed under these specifications for a period of not less than one (1) year from time of beneficial use of the facility and systems by the Authority.








FUEL SYSTEM PIPING SPECIALTIES 335243.11 10-1

SECTION 335243.11 10 - FUEL SYSTEM PIPING SPECIALTIES

PART 1 - GENERAL

1.1 DESCRIPTION

A. The work and components specified in this section are directly related to, but not limited to, Section 335243.13 10 - “Pipe, Fittings and Installation.”

B. This section of the specification includes piping specialty items that are not considered general piping materials, but are contiguous to the overall piping system.

C. The Contractor shall provide the necessary labor and materials to install the items specified herein, and as indicated on the Contract Drawings.

D. All materials shall be of a domestic manufacturing process and shall be certified as such in the Compliance Submittals.

E. All components shall be suitable for use in aviation fuel systems with the fuel characteristics specified in Section 335243.10 10 – “General Provisions”.


A. Section 335243.10 10 – Fuel System General Provisions

B. Section 335243.13 10 – Fuel System Pipe, Fittings & Installation

C. Section 335280.10 10 – Fuel System Coatings

D. Section 330850.10 10 – Fuel System Inspection, Testing and Flushing

1.3 SUBMITTALS

A. Submit Compliance Submittals in accordance with Section 33 52 43.00 Fuel System General Provisions.

B. Product Information: Submit manufacturer’s data sheets identifying the make, model, type, material, size, pressure rating, etc.

1.4 QUALITY CONTROL

A. All piping specialties shall be in compliance with the applicable codes and standards such as ASTM, ANSI, API, etc. as specified in Section 335243.10 10 – “General Provisions”.

B. The Contractor shall prepare and provide compliance submittals for all piping specialties including the manufacturer, type, materials, and certifications required.



C. For the purpose of standardization and conformance, components will be specified using a manufacturer name and model number. It should be noted, the term “or approved equal”, will be added so as not to limit the manufacturers listed.

PART 2 - MATERIALS

2.1 LOADING HOSE

A. For the loading of aviation fuel the equipment shall include a 3-inch hose for Jet-A. Hose shall be capable of 150 psi working pressure

B. The hose shall be 10 ft in length

C. Tube shall be nitrile with single ply, high-tensile nylon cord reinforcement interwoven hard wall construction with a black neoprene cover and meet the requirements of API 1529 Grade 2 Type C and NFPA 407.

D. Provide commercial hose trough as detailed for the loading hose.

E. Provide hose certification.

2.2 JET-A LOADING HOSE NOZZLE

A. To interface with aircraft refueling vehicles, provide a single point commercial refueling nozzle. The refueling nozzle shall be a Cla-Val Model 347GF or approved equal.

B. The 2-1/2-inch-diameter aluminum and stainless coupler with CRES wire races shall include a 60 mesh strainer and swivel with a 2-1/2-inch female NPT inlet. The coupler shall be compatible with a standard 3-lug adapter. The nozzle shall be provided with a 35 psi pressure regulator. The nozzle shall include a male quick disconnect adapter.

2.3 JET-A REFUELER SINGLE POINT RECEPTACLE

A. Provide a 2 ½” aircraft standard bayonet refueling single point adapter to allow the connection of the hydrant carts and refueler trucks to connect to the test stand connections. The adapter shall be a have a 4” ANSI 150 flat face flange connection. Provide no product selection, provide plastic dust cap, and provide pressure relief valve. Shall be Eaton Model 60373BDF or approved equal. The refueling nozzle shall be a Cla-Val Model 347GF or approved equal.

2.4 AUTOMATIC AIR VENT

A. The filter vessels shall have a 1-inch air vent with an either an internally epoxy coated ASTM A105 Forged Steel Body and Cap or 316SS body and cap. Valve, seat, float, and internals shall be stainless steel. Provide spiral wound gasket between body and cap as specified in Section 33 52 43.13 10 or approved equal. Inlet and outlet shall have 1" ANSI 150 raised face flanges. Air vent shall be Armstrong Model 33-AV or approved equal.



2.5 STRAINER

A. The housing and flanges shall be carbon steel with a 304 stainless basket. Seals shall be Teflon and base seal shall be Buna-N. Maximum working pressure shall be 285 psi at 100 degrees F. Strainer shall be 40 mesh. Strainer shall be FMC Technologies Smith Meter 2” – 8” In-Line Series Strainer or approved equal.

B. Body shall have a bolted cover for easy removal of the basket.

C. Body shall be include a ¾” NPT drain connection with ball valve and cam and groove connection with dust cap.

D. Piping connections shall be in-line ANSI 150-pound raised-face flanged.

2.6 FUEL SAMPLING CONNECTIONS

A. To determine the quality of fuel within the piping system, fuel sample (Millipore) connections will be required. The assembly or kit shall be Gammon #7 or approved equal.

B. To determine the quality of fuel within the filter vessels, fuel sample connections will be required. The assembly or kit will be Gammon #7T or approved equal.

C. Fuel sample connections shall be provided as indicated. Contractor shall provide additional temporary fuel sampling connections as required for flushing operations.

D. The kit shall include stainless steel probe, ball valve and dry break quick coupler with chain - affixed dust plug of aluminum suitable for sampling aviation jet fuel or aviation gasoline from piping systems or equipment. Sampling connection shall be installed on side of pipe, (not top or bottom) or as noted on sample station and shall extend to the centerline of the fuel pipe.

2.7 SIGHT FLOW INDICATORS

A. Sight flow indicators shall be propeller style with two viewing windows of high strength tempered windows and viton window gaskets. The sight flow indicator shall be VISI-FLO 1500 Series or approved equal.

B. Stainless-steel body shall be suitable for 275 psi working pressure.

C. End connections shall be 150-pound ANSI raised-faced flanged.

2.8 JET-A LOADING HOSE SWIVEL JOINT

A. To provide operational flexibility, the loading hose units shall be equipped with style #30 swivel joint. Swivel Joint shall be Emco Wheaton D2000 Swivel Joint or approved equal.

B. The swivel joint shall have a 3-inch ductile iron flanged body with female threaded sleeve with a minimum operating range of 150 psi working pressure to full vacuum. Swivel joint shall be provided with 3-inch 150# ANSI inlet and outlet flanged connections. Provide threaded flange connection to transition to loading hose. The swivel joint shall be non-lubricated type.



2.9 INSTRUMENT TUBING AND FITTINGS

A. Tubing:

1. Material shall be ASTM A269 Type 304 annealed stainless steel.

2. Wall thickness shall be as required by the fittings, but not less than .049”.

B. Fittings:

1. Manufacturer shall be Parker-Hannifin “Ferulok” or Swagelok stainless steel bit-type tube fittings for flareless tubes.

2.10 INSTRUMENT VALVES:

A. Instrument valves shall be instrument grade block and bleed needle valve as manufactured by Wika Type 910.11.200 or approved equal.

B. Body shall be A316 stainless steel, with working pressure of 6,000 psi.

C. Packing shall be fire resistant and as recommended by the manufacturer for use with hydrocarbon fuels.

2.11 PRESSURE GAUGES AND ACCESSORIES

A. Pressure gauges shall be WIKA Model 233.53 or approved equal. Pressure gauges shall be graduated in pounds per square inch (PSI). Under normal operating conditions, all gauge pointers shall be approximately vertical and be located at mid-point of scale. Each gauge shall be equipped with a steel ½” instrument valve with bleed port. The gauge shall be silicone filled and have all internal parts immersed. Install gauges using pipe-fittings as shown on the drawings. Furnish all pressure gauges with bleeder to remove air from the bourdon tube. Pressure ranges shall be as indicated on the plans. Provide peak hold feature on gauge(s) where indicated.

B. Unless otherwise specified or indicated on the drawings, all indicating pressure gauges shall be 4 ½-inch dial size, shatter proof lens, with stainless steel case, having a +/- 1.0 percent accuracy over its full range. It shall also have a 316 stainless steel bourdon tube, bellows, diaphragm and a ½-inch rear NPT connection. Gauges shall be mounted as indicated on plans or in a panel as indicated with the differential pressure gauge and labeled as indicated on the flow diagram.

2.12 SPECTACLE FLANGE

A. To facilitate testing and flushing of the piping system, spectacle flanges may be required, if so, they shall be as manufactured by T.D. Williamson or approved equal.

B. The spectacle flange assembly shall be the blind and ring spacer style suitable for mounting between 150-pound ANSI raised-face flanges.



2.13 METER PROVER CONNECTION

A. To facilitate meter proving operations, the piping system shall have dedicated meter prover connections. The hose connections shall be OPW fittings #633-A and 634-B or approved equal.

B. The assembly shall include a 4-inch adapter and protective cap of aluminum.

2.14 INSULATING KITS

A. It is required to provide an insulation kit prior to transitioning underground at the Signature fillstand to separate electrical charges between aboveground and underground piping. Insulating kits shall also be used as indicated on the drawings to electrically isolate all hydrant pit valves and to electrically isolate the motor operated valves from the cathodic protection system. Insulating kits are also to be used where above grade piping transitions to below grade piping.

B. The gasket material is required to be fireproof and pass the requirements of the API 6FB, 3rd edition fire test. When required, the gasket material shall be manufactured by Pikotek Model VCFS or approved equal.

C. Joints shall consist of weldneck flanges or a weldneck flange with mating valve flange and a flange insulation gasket.

D. The insulation gasket assembly shall consist of a PTFE spring-energized primary sealing element and an E-ring secondary seal all seated in a metal core. The gasket assembly shall have 750-800 VPM dielectric strength and 65,000 PSI compressive strength. The gaskets have a thickness of .308-inches for pipe diameters sized 6-inches to 14-inches.

E. Insulating washers shall be G10 epoxy glass material, 1/8-inch thick (minimum). Dielectric strength shall be compatible with minimum insulating values of insulating sleeves and gaskets. Furnish double quantity of insulating and cadmium-plated steel washers for “full” insulation of flanges.

F. Insulating sleeves shall be of spiral wound Mylar, 1/32-inch wall thickness length as required to match thickness of two series 150 raised face flanges plus insulation. Gasket shall provide “full” insulation of studs, minimum dielectric strength shall be 4000 VPM.

G. Flange assemblies shall provide a minimum resistance of 1,000 ohms measured between each stud and both flanges (when dry).

2.15 PIPE SLEEVES

A. To center, support, insulate and protect piping as it passes the concrete walls and slabs, a pipe sleeve unit or series of components shall be used. Components shall be PSI Link-Seal Model WS or approved equal

B. Sleeve sizes through 10-inches shall be Schedule 40 steel pipe or standard wall thickness. Sleeve sizes 12-inches and larger shall have a 0.375-inch wall thickness or standard wall thickness.



C. Provide an anchor collar of the same type of steel as the sleeve. The collar shall be welded all around on both sides to the sleeve at the point on the sleeve that positions at the mid-point of the structural wall or pad when the sleeve is in place.

D. Sleeves shall be 2-inch nominal pipe sizes larger for pipes less than 4-inch diameter and two pipe sizes larger for pipes 4-inch nominal diameter and larger. Coordinate sleeve dimension with sleeve seal specified herein.

E. Sleeves through walls and pads shall be cast in place. Piping shall be installed centered in sleeve. Use one link seal unit at each end of the sleeve through walls to keep the containment pipe in proper alignment.

F. Firmly bolt a pipe insulator around the fuel pipe to prevent damage to the pipe coating. Shoe height of runners shall be as required to center the pipeline in the sleeve. Insulator shall be a segmented collar molded of high-density polyethylene with runners.

G. To protect the seals and insulators, install a boot to permit ample movement of the carrier pipe in a lengthwise, side, and vertical direction. The boot shall be oil, jet fuel, and water-resistant double-accordion bellows-type molded. The bands shall be 1/2-inch-wide stainless steel thumb-screw type with rounded edges which are easily tightened by hand or by pliers.

2.16 PIPE SLEEVE SEAL

A. Provide and install expanding seals at the end of all fuel piping buried in a casing and for pit penetrations. Seal shall be as manufactured by PSI Link-Seal Model OS-316 suitable for -40 to 210 degrees standard insulating type. The casing shall always be electrically isolated from the carrier. Casing shall be 2 pipe sizes larger than the carrier pipe.

B. Where sleeves are installed in dike walls, both sleeve and link seal shall be as fabricated by PSI. The sleeve shall be configured with minimum dimensions and characteristics shown on the drawings. Sleeves may be field fabricated or may be supplied by PSI. Regardless, dimensions called out on the drawings shall be maintained as a minimum.

C. Maintain electrical isolation from sleeve to rebar and from sleeve to piping.

2.17 PIPE SLEEVE INSULATORS

A. Insulator shall be a segmented collar molded of high-density polyethylene with runners. Components shall be manufactured by PSI or approved equal.

B. Shoe height of runners shall be as required to center the pipeline in the sleeve.

C. Insulator shall be bolted around the fuel pipe without damage to the coating.

2.18 SLEEVE BOOTS

A. Boots shall be oil, chemical, and water resistant double accordion bellows type molded. Components shall be manufactured by PSI or approved equal



B. Boot shall permit ample movement of the carrier pipe lengthwise, side, and vertical direction.

C. The boot shall be a minimum of 3/8" thick with circumferential ribs molded in the inner surface where bands are applied to increase the contact pressure for a tighter joint.

D. The bands shall be 1/2-inch wide stainless steel thumb screw type with rounded edges which are easily tightened by hand or pliers.

E. The boot shall have an extra thickness at the sleeve edge to protect the boot from damage during backfill.

F. The remainder of the boot shall be a minimum of 3/16-inch thick.

G. The boot shall be slipped on the fuel pipe before any tie-in weld is made.

2.19 15 GALLON SUMP SEPARATOR

A. Provide a Schultz 15-gallon, stainless steel sump separator or approved equal. Unit shall be self-contained designed to separate water and dirt from fuel. Mount unit so top is a maximum of 4-feet above ground to allow pouring of fuel samples into the separator and high enough to enable draining of water from the separator with a 5 gallon bucket under the drain valve piping.

B. Separator shall be piped to allow water to be drained by gravity by a ¾-inch ball valve with cam-lock and dust cap into bucket. A downstream hand pump shall draw off clean product and return it to the storage. The clean suction line shall be ¾” and shall have a flanged insert check valve and spring return closed ball valve. All valves shall be as specified in Section 335243.15 10. Hand pump shall be as specified in Section 335243.23 10.

2.20 HIGH POINT AND LOW POINT CONNECTIONS:

A. Contractor shall provide and install 2” dry break connections for each high point vent and low point drain. Material shall be aluminum with male NPT connection and Viton seals. Unit shall be Dixon model DDA200ALMNPT, or approved equal.

PART 3 - EXECUTION

3.1 INSTALLATION

A. All components shall be installed in the piping system as indicated on the Contract Drawings. Where exact dimensions are not indicated, the drawings may be scaled to determine an approximate location.

B. The Contractor shall be responsible for providing the necessary labor and materials to install the component.

C. The Contractor shall be responsible for providing the proper clearances of all components to assure adequate operational and maintenance clearances.



3.2 INSPECTION AND TESTING

A. The work will be inspected for approved manufacturer, component type and final installation.

B. The Contractor shall be responsible for the adjustments of all devices to assure proper function of the device is provided.


4.1 Conform to all applicable provisions of Division 01 Section “Quality Requirements", Section 33 52 43.10 10 and the requirements of this Section. Be responsible for periodic inspections for conformance with the approved SPPP. The results of the periodic inspections shall be submitted to the COTR upon completion.



FUEL SYSTEM PIPE, FITTINGS AND INSTALLATION 335243.13 10-1

SECTION 335243.13 10 - FUEL SYSTEM PIPE, FITTINGS AND INSTALLATION

PART 1 - GENERAL

1.1 SUMMARY

A. This Section of the specifications describes and provides for the furnishing, installing and testing of pipe and piping components for the aviation fueling system.

1.2 PRODUCTS INSTALLED BUT NOT SUPPLIED UNDER THIS SECTION

A. Not applicable


A. Section 312323.13 10 - Fuel System Site Excavation, Bedding & Backfill

B. Section 335243.08 10 – Fuel System Microtunneling, Boring and Utility Casings

C. Section 335280.10 10 – Fuel System Coatings

D. Section 330850.10 10 – Fuel System Inspection, Testing and Flushing

E. Section 335343.92 10 – Fuel System Cathodic Protection System

1.4 REFERENCES


1. A53 - Pipe, Steel, Black, and Hot Dipped, Zinc Coated Welded and Seamless

2. A105 - Forging, Carbon Steel, for Piping Components

3. A193 – Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service

4. A194 - Carbon and Alloy Steel Nuts for Bolts for High Pressure and High Temperature Service

5. A234 - Piping Fitting of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures

6. D1655 - Standard Specification for Aviation Turbine Fuels

B. American Society of Mechanical Engineers (ASME)

1. B1.20.1 – Pipe Threads, General Purpose



2. B16.5 - Pipe Flanges and Flanged Fittings

3. B16.9 – Factory Made Wrought Steel Butt Welding Fittings

4. B16.9 - Factory Made Wrought Steel Butt Welding Fittings

5. B16.11 - Forged Steel Fittings, Socket Welding and Threaded

6. B16.25 - Buttwelding Ends

7. B31.1 - Power Piping

8. B31.3 - Chemical Plant and Petroleum Refinery Piping

C. American Petroleum Institute (API):

1. RP 1110 – Pressure Testing of Liquid Petroleum Pipelines

2. Spec 5L - Line Pipe

3. Std. 601.21 - Metallic Gaskets for Piping, Double-Jacketed Corrugated and Spiral Wound

D. Federal Specifications (FS) QQ-P-416 - Plating, Cadmium

E. National Electrical Manufacturer’s Association (NEMA)

1.5 DEFINITIONS

A. Unless otherwise specified, the working pressure ratings as used in these specifications for valves, fittings, unions, and other piping specialties refer to pressure ratings in pounds per square inch above atmosphere (PSIG) in accordance with applicable ASME Standards.

B. The use of the word "piping" shall be interpreted to include all pipe, valves, fittings, flanges, supports, or accessories for any particular portion of the work, or system to which the word "piping" is applied.

1.6 SUBMITTALS

A. General: Compliance Submittals shall be in accordance with Section 335243.10 10, Fuel System General Provisions.

B. Product Information: Submit manufacturer’s data sheets identifying equipment size, materials, pressure ratings, etc.

1. Piping

2. Fittings (include specialty hot tap and line plug)

3. Flanges and Gaskets

4. Bolts, Nuts and Washers



C. Reports:

1. Radiograph Test Reports

D. Certificates:

1. Pipe

2. Fittings (include specialty hot tap and line plug)

3. Flanges and Gaskets

4. Bolts, Nuts and Washers

5. Welder Performance Qualification (WPQ)

6. Welding Procedure Specifications (WPS)

7. Piping System Installation

8. Test Equipment and Results

E. Records:

1. Procedure Qualification Records (PQR)


A. All pipe and piping materials shall be provided by a manufacturer and fabricator approved by the COTR.

B. Welding operations, qualification of welders and welding procedures shall comply with ASME B31.3 and the ASME Boiler and Pressure Vessel Code, Section I and Section IX. Certified copies of the welding procedure, the procedure qualification, and the welder, qualification certification must be submitted prior to beginning any welding operations.

C. Welders must be qualified to position 6G of ASME B31.3, tested on the type of pipe used in this project, and must have been qualified within the six months preceding this project or the welder shall be re-qualified.

D. Contractor is responsible for all costs associated with procedure and welder qualifications.

E. Certified copies of the quality control procedures and results of the internal pipe coating application shall be submitted.

F. No foreign materials or components, supplied as part of this Section, shall be utilized. The use of the words “domestic materials” or “no foreign materials” shall mean all materials shall be of U.S. origin. The Contractor shall certify this condition in the compliance submittals. If at any time, the COTR determines that any flanges, fittings, bolts or nuts are not of U.S. origin, the Authority shall be entitled to replace the components without need for individual testing for



conformance to technical specifications. Contractor shall be responsible for all costs associated with such replacement.

G. The installation shall include all necessary materials, coating, supports, controls, valves and fittings, hereinafter described or called for on the Contract Drawings accompanying these specifications, or as necessary to make the installation complete.

H. The drawings and specifications shall be considered complementary, one to the other, so that materials and labor indicated, or called for, or implied by the one and not the other, shall be supplied and installed as though specifically called for by both.

I. All materials and equipment provided under these specifications shall be new, unused products of manufacturers regularly engaged in production of such equipment for a minimum of 5 years. All products shall conform to the applicable code or standard for its manufacturing, fabricating and installation.

PART 2 - MATERIALS

2.1 PIPING MATERIALS

A. The piping system is a combination of above ground and below ground piping. All above ground piping shall be of single wall construction. Below ground piping is single wall construction; however, a casing system is required for the two taxiway crossings. These two casings require wax fill between the casing and carrier piping.

B. All direct buried piping connections shall be welded. Welded joints shall conform to the standards set forth in the ASME B31.3 Code for Petroleum Refinery Piping.

C. Threaded joints are only allowed for small bore piping that has no internal pressure such as vent or atmospheric drain piping. Threaded joints shall be American Standard for Pipe Threads, ASME B1.20.1. All burrs shall be removed. Pipe ends shall be reamed out to size of bore and all chips shall be removed. Teflon pipe thread sealant shall be used on the male threads only and shall not extend past the end of the pipe.

D. Furnish and install flanges where shown and at connections to all equipment. Flanged connections are only allowed above ground or within pits/vaults. Flanges shall not be direct buried except at temporary line plug (stopple) connections.

E. Unless otherwise specified herein or stipulated on the Drawings, all flanges shall be matched on piping, valve or equipment as to size, and shall be constructed from materials equivalent to the piping. Flanges shall be raised face.

F. Pipe fittings shall be of standard manufacture of materials, weight, and quality corresponding to the pipe with which they are used.

G. Fittings such as elbows, tees, reducers and caps shall be used for all changes in piping direction, intersections, size changes and end closures unless otherwise stipulated on the Drawings or specified herein.



H. The manufacturer or supplier of the piping materials shall provide a certificate of the inspection, stating origin of manufacture and that all material has been manufactured, sampled, tested and inspected in accordance with the specified ASTM, API and other identified specification and has found to meet those requirements.

I. All piping shall be stamped with specification and grade. Shop coated pipe shall have specification and grade stenciled on the coating.

J. Galvanized piping is not allowed in the aircraft fueling system.

2.2 PIPING SPECIFICATIONS

A. The following table is provided to indicate the basic design conditions of the components within this section of the specification:

SERVICE SYMBOL PRESSURE TEMPERATURE SPECIFIC GRAVITY Jet Fuel JF 275 psig -20 to 110F 0.810.05

Drain

D 15 psig -20 to 110F 0.810.05

Vent

V 0 psig -20 to 110F 0.810.05

B. The following table is provided to indicate the various materials of construction for the design service required by this specification.

ITEM 2” AND SMALLER 2 1/2” AND LARGER

Carrier Pipe: ASTM A53 Grade B ASTM A53 Grade B or API 5L

Schedule 80 Seamless Grade B, ERW or Seamless

2-1/2 to 10” - Sch. 40

12” and over - 0.375-inch

Note: Where applicable, use double random lengths to minimize the number of welds required


Joints: Socket Weld Butt – Weld



End preparation to ASME B16.25

Note: Atmospheric pressure small-bore piping may be threaded. Socket welded and threaded connections are only allowed above ground or within pits/vaults.


Flanges: 150lb ASME B16.5 150lb. ASME B16.5

Carbon Steel ASTM A105 Carbon Steel ASTM A105

Socket Weld Raised-Face Weld Neck Raised-Face

Note: Flange face and ASME rating to be compatible with corresponding component. ITEM 2” AND SMALLER 2 1/2” AND LARGER

Fittings: Socket Weld, Buttweld, ASME B16.9

ASTM A105, Grade 2 Carbon Steel per ASTM

3,000 lb. A234 Grade B, wall thickness

to match pipe

Note: Bushings shall not be used except as noted. ITEM 2” AND SMALLER 2 1/2” AND LARGER

Bolts: Carbon Steel, Teflon Carbon Steel, Teflon

Coated Machine Bolts Coated Machine Bolts



ASTM A193, Grade B7 ASTM A193, Grade B7

Note: Studs may be used for corresponding equipment. ITEM 2” AND SMALLER 2 1/2” AND LARGER

Nuts:

Nuts to be heavy hexagon ASTM A194, Grade 2H

Teflon Coated

ASTM A194, Grade 2H

Teflon Coated

Note: Nuts shall be properly torqued to manufacturer’s recommendations. ITEM 2” AND SMALLER 2 1/2” AND LARGER

Gaskets: Flexitallic Type CG Flexitallic Type CG

304 Stainless Steel Windings 304 Stainless Steel Windings

with Non-Asbestos Filler with Non-Asbestos Filler

Conform to A.P.I. 601.21 Conform to A.P.I. 601.21

Note: Gaskets to be 1/8” in thickness - ring style for R.F. flanges.

C. The interior and exterior coating for all pipe and piping materials shall be as specified in Section 335280.10 10, Fuel System Coating.

D. Welded elbows shall be long radius unless otherwise shown.

E. Changes in direction of pipe of other than 45 degrees or 90 degrees shall be made as follows:

1. With long radius welds cut to proper angle and shop beveled.



2. Or, at the option of the Contractor, with long radius pipe bends. Pipe roundness shall be maintained to factory tolerance for straight pipe lengths. Submit shop drawings of all bends and bending procedures for approval.

3. Bends of 10 degrees or less shall be miter joints.

F. Tee Connections:

1. Branch connections may be used in lieu of butt welding tees for sizes below 3" only, and only above ground or within pits/vaults. Branch connections shall not be used in direct buried piping unless otherwise indicated by the Contract Drawings.

2. Branch connections shall be weldolets, sockolets, socket-welded nipolets, or socket-welded elbolets, as manufactured by Bonney Forge or equal.

3. Material shall be ASTM A105, Grade 2, standard weight steel, and shall conform to ASME B16.11.

4. Use for all vent and instrument connections.

5. If approved by the COTR, the Contractor may use fabricated branch connections in lieu of butt welded tees for direct buried applications. Connections shall be sweepolets or insert-weldolets as manufactured by Bonney Forge or equal. All welds on these connections shall be full penetration butt welds and shall be radiographed.

G. Vault Sump Piping:

1. To facilitate pumping out of vault sumps, a drop pipe and quick coupling shall be used. The quick coupling assembly shall be Dixon Model DDA200ALMNPT or approved equal.

2. The assembly shall be a dry break coupling adapter and protective dust cap of aluminum construction.

3. Use aluminum Schedule 40, 2-inch threaded pipe and fittings for fabricating the drop pipe at the vault sump.

H. Fittings for Threaded Fuel Pipe:

1. Threads of threaded jointed piping shall be full, clean, sharp, and true.

2. Bushings shall not be used except as noted on the drawings.

3. 3,000 pound forged steel conforming to ASME B16.11.

2.3 TESTING EQUIPMENT

A. The Contractor shall provide all necessary devices to test the completed piping system. Items shall include but, not be limited to the following:

1. Air compressors:



a. Air compressors shall be equipped with condensate dryer system and filter capable of generating oil-free air at -20 F dew point.

b. Air compressors shall have sufficient capacity to bring the system pressure in a maximum of 60 minutes.

2. Pressure and temperature recorders:

a. Provide certified and calibrated test instruments capable of recording direct temperature, pressure and time in the same scale and chart.

b. Submit data for test instruments and certificates of calibration.

3. Temporary piping:

a. Provide all piping, fittings, valves, gauges and equipment required for inspection and testing.

2.4 FUELS

A. The Contractor shall perform hydrostatic testing of the new pipe. The Fuel System Operator will provide the Jet A fuel required for the hydrostatic testing. The fuel shall meet ASTM D1665, latest revision specification for Jet A Type Aviation Turbine Fuel.

PART 3 - EXECUTION

3.1 CLEAN PIPING REQUIREMENTS

A. The importance of keeping the interior of all piping systems clean during construction is critical. The Contractor is required to keep the interior of the carrier piping, and the annular space between carrier pipe and casing pipe, clean from all visible dirt or foreign matter at all times and under all conditions. If for any reason the inside of the piping contains dirt or foreign matter, the Contractor shall correct this condition to the COTR's satisfaction with all necessary material, labor and equipment for cleaning being furnished at the Contractor's expense. The following measures shall be taken to assure cleanliness of the system:

1. The pipe and fittings shall be delivered to the job site sealed. The seals are not to be removed until the pipe is installed. After each day's work, the open ends of all pipe being installed shall be sealed closed with an expansion type weatherproof and watertight seal manufactured for this purposes. At the Contractors option, weld caps or plate steel may be welded into place on the end of the pipe.

2. All fittings and valves shall be kept in a covered dry storage area until installation.

3. Pipe shall not be installed or stored in areas or ditches containing water or mud.

4. At openings for branches in piping, all material that falls into the pipe must be removed before welding in the branch fittings.



3.2 HANDLING PIPE

A. The shipment, delivery, and installation of all pipe and accessories shall be handled in such manner as to ensure a sound undamaged condition. Particular care shall be taken not to damage pipe coating when storing pipe. No other pipe or materials of any kind shall be placed inside a pipe or fitting after the coating has been applied.

B. Perform the hauling of pipe and other materials in such a manner as to prevent damage to pipe and material. If damage is sustained, Contractor shall be responsible for repair or replacement cost.

3.3 FABRICATION AND INSTALLATION

A. All piping materials, fabrication, installation and application shall be in compliance with the latest requirements of the code for Petroleum Refinery Piping ASME B31.3, and all state and local regulations when applicable.

B. All temporary piping required for construction, testing, flushing and start-up shall be furnished by the Contractor. Such piping shall remain the property of the Contractor; and it shall be his responsibility to dismantle and remove it from the premises when no longer required.

C. End Preparation: The base metals for all butt-welding pipe joints shall be prepared to provide for proper "fit-up" in accordance with ASME B16.25. Ends shall be prepared by machining or flame cutting. Hand flame cutting is only allowed subject to approval by the COTR and only where the use of machine or automatic machine flame cutting is impractical. Hand flame cuttings shall be ground smooth. No welded joint shall be made where either flame cut or machine cut ends provide a spacing between the pipe so large that more than one stringer bead is required to completely close the pipe. Where flame cutting by hand is employed, the included angle or bevel at the end of the pipe shall be not less than plus or minus 5 degrees from that which is required elsewhere in these specifications for machine cut beveled ends. Pipe end for socket welding shall be reamed for the full inside diameter to remove all burrs and obstructions.

D. All pipe shall follow the routes shown on the drawings and shall be placed accurately to measurements indicated or established from the work. Pipe shall be placed clear of equipment, and other work. Changes in direction shall be made by use of fittings for standard angles and by trimmed fittings for angles other than standard. Reference earlier paragraphs in this section.

E. Any damage to the internal or external pipe coatings by bending or handling, including lineup of pipe joints, shall be the responsibility of the Contractor and shall be repaired to equal the original coating. Repair of the internal coating damaged by field welding of pipe joints is not required.

F. Proper pipe joint alignment and separation shall be accomplished without the use of backing rings.

G. Weld spatter shall be removed around welds leaving a smooth clean surface.

H. Pipe shall be fabricated to measurements established on the job and shall be carefully worked into place without springing or forcing.



I. Flanges and unions shall not be placed in a location that will be inaccessible after completion of the work.

J. All piping and equipment shall be properly supported and guided. Anchors shall be provided where shown and where required to absorb or transmit thrust and eliminate vibration or pulsation.

K. Changes in pipe size shall be made with reducing fittings. The Contractor shall pay special attention to the type of reducer, and its orientation, shown on the Contract Drawings. Bushings shall not be used unless otherwise shown.

L. Flanged joints shall be accurately centered and aligned prior to installation of bolts so as to prevent mechanical pre-stressing of the flanges, pipe and equipment.

M. For Buried Piping refer Section 332323.13 10 Fuel System Site Excavation, Bedding & Backfill for trench excavation, backfill and compaction requirements.

N. Install pipe so as to be clear of contacts with other pipes, pipe sleeves, casings, reinforcing steel, conduits, cables, or other metallic structures. Minimum separation from non-metallic utilities is 12” and from metallic utilities is 24”. Should uncovered field conditions result in clearances less than this, bring to the attention of the COTR for resolution prior to installing the new piping.

O. Verify all measurements before commencing work. Submit discrepancies for clarification before proceeding.

P. Arrange all piping with proper slopes, without sags, traps, or pockets.

Q. Provide high point vents, pump outs, and low point drains as required and indicated on the drawings.

3.4 WELDING

A. Qualifications of welders shall be done by Contractor in accordance with ASME B31.3, Petroleum Refinery Piping, on the project site, witnessed by the COTR and before being allowed to make construction welds. Certified test results for each welder employed by the Contractor shall be kept in the contractor's field office for inspection by the COTR. Performance test records of welders issued by a previous employer, in lieu of qualification tests conducted by the Contractor, will not be acceptable. The Contractor shall assume the costs for all tests.

B. Welding and fabrication shall be accomplished in accordance with ASME B31.3 latest edition. Before welding, the piping or other equipment shall be carefully lined up so that no part is offset; flanges and branches shall be set square and true. This alignment must be preserved during the welding operation. If tack welds are used, they must be of the same quality and made by the said procedure as the completed weld. Backing rings shall not be used. No weld metal shall project within the pipe so as to restrict its area or cause danger of its loosening and falling into the pipe. The piping shall not be split, bent, flattened or otherwise injured before, during or after installation. During erection, care shall be taken to remove all dirt, scale and other foreign matter from inside the piping before tying in sections, valves, equipment or fittings.



C. All welded joints shall be made as recommended by the standards of the American Welding Society and B31.3. The welding shall ensure complete penetration of the deposited metal with the base metal. The filler shall be suitable for use with the base metal. Mitered joints shall not be used except where specifically allowed in this specification or on the Drawings.

D. All manual welds shall be made using downhill welding procedure. Shop welds utilizing machine-welding procedures do not have to qualify to the downhill requirement. Machine-welding procedures must be qualified and submitted to the COTR.

E. Inspection and Repair:

1. All below ground welds (100%) shall be radiographed in accordance with these specifications. All socket welds and fillet welds shall be inspected with magnetic particle testing.

2. Any weld that is determined to be defective by the testing laboratory shall be repaired in accordance with ASME B31.3. The Contractor shall be responsible for all costs associated with the weld repair.

F. Qualifications and Approval:

1. Welding procedures that are intended to be used on the job shall be submitted for approval. The Contractor shall be responsible to assure that all welding procedures, welders, and welding operators have been qualified in accordance with applicable code requirements before work is started. Shop and field procedures shall be submitted to the COTR for approval. The procedure specifications shall be as follows:

a. Include copies of the qualification test records as evidence that the procedures have been qualified in accordance with the latest revisions of the following code:

1) ASME B31.3 - Chemical Plant and Petroleum Refinery Piping

b. Developed for the conditions of this Contract and be complete and specific, and if necessary, differentiate between shop and field welding.

c. Welder Performance Qualification Test Certificates:

1) Furnish welder performance qualification test certificates prior to starting work for position 6G for the pipe being installed as part of this project made in strict compliance with the above code.

2) Submit qualification test records for each welder on the project and keep record files.

2. Costs: Costs incident to procedure and welders qualification tests shall be the responsibility of the Contractor.

G. Each welder shall identify each of his welds with a specific code or identifier. The Contractor shall keep an as built fabrication drawing on the site that identifies the location of each weld made and also indicates the welder who made the weld. The weld shall be made with a “low stress” steel stamp or permanent ink marking.



H. The Authority reserves the right to place welding inspectors (at the Authority’s cost) in the shop where off site welding is taking place.

3.5 CONNECTION TO ACTIVE PIPING

A. Active piping shall not be cut, tapped or disturbed until the Contractor has obtained the necessary written approvals from the COTR and the Fuel System Operator.

B. Each active fuel line shall be substantially drained prior to cutting into the line. Fuel shall not remain in the piping as it is cut. The contractor shall exercise extreme caution during the cutting of existing piping and shall not use cutting torches and spark producing cutting tools and methods.

C. The Contractor shall have the necessary number of drip pans and vacuum trucks on site during cutting operations. Any and all fuel spilled during the cutting procedure shall be immediately cleaned up and removed from the site by the Contractor at no additional cost to the Contract.

D. The Contractor shall take adequate measures for fire protection during modifications to existing piping and equipment. Such measures shall include, as a minimum but not limited to, the following precautions:

1. Do not cut, bevel, weld, grind or otherwise generate sparks near open sources or spills of jet fuel.

2. Provide a fire extinguisher, 2.5 gallons Class AB Foam Type, at each welding operation.

3. Protect adjacent services from weld splatter and sparks by use of welding blankets.

4. Obtain necessary hot work permits from the Airport.

5. Notify the Airport Fire Department at least 48 hours in advance of the intended operation. In the event the Fire Department elects to have equipment present during the operation, the Contractor shall coordinate the construction area with the Fire Chief to allow proper positioning of equipment.

E. Welding to existing piping:

1. Flow nitrogen through piping and weld area to eliminate all measurable oxygen.

2. Weld piping in accordance with API, NFPA and 0SHA requirements.

3. Use Plidco fittings to eliminate welding directly within the vapor space of existing piping.

F. Plidco Fittings:

1. Plidco fittings (“weld + ends”) shall be employed at each saw cut into existing underground piping. Each fuel line shall be substantially drained prior to cutting into the line.

2. Follow the manufacturer’s printed installation procedure. Flow fuel prior to weld-out.



3. Installing Plidco “weld +ends”:

a. The existing piping shall be cleaned of all old coating in the area where the Plidco is to be installed. The pipe shall be cleaned of burrs and other surface irregularities that might damage the Plidco seals during operation.

b. Slide Plidco “weld + ends” completely over one end of pipe. Mark off one-half of Plidco “weld + ends” coupling length from middle of gap in pipe joints. Slide fitting back to mark to divide coupling equally over joint.

c. After coupling is positioned, torque clamping and thrust screws tight, following the manufacturers installation instructions for torque values and sequence.

d. Pipeline shall be put in operation. Thrust screws shall be burned off flush. Ends of coupling shall be fillet-welded around circumference, including seal welding of thrust screws. Clamping screws shall be cut or burned off and seal-welded also.

e. For critical, limited schedule, tie-in operations the Contractor shall have an extra pair of seals on hand for each size of Plidco coupling.

3.6 WELD INTEGRITY TESTING

A. All butt welds for field and shop fabricated piping for belowground installation (including those welds within a pit/vault) shall be 100 percent radiographed. All socket welds for field and shop fabricated piping for installation within a pit or vault, shall be 100 percent magnetic particle inspected. Ten percent of the aboveground piping shall be randomly selected for radiographic and/or magnetic particle inspection.

B. All fillet welds on hot tap weldolets and on Plidco couplings shall be magnetic particle tested.

C. Piping where factory welds have been performed, must also be radiographed or tested by an approved testing laboratory with results provided to the Contractor upon delivery and receipt of the piping. Forward results of the testing to the COTR.

D. All weld integrity-testing costs, including test reports and interpretation, are the responsibility of the Contractor. An independent testing laboratory employed by the Contractor, and subject to approval by the COTR, shall perform the weld integrity testing. All testing shall be performed in accordance with ASME B31.3.

E. One film negative of each radiograph shall be made. Each negative shall be identified as to location. Negatives shall be turned over to the Authority at the end of the project. An expert interpretation by a recognized testing laboratory shall be submitted in report form for every weld to the COTR throughout the progress of the work. The report shall show date of test, location, area, film number, weld number and other pertinent information.

F. Permanent radiographic identification stamps shall be located on the piping near the welds.

G. The Independent Laboratory making the tests shall interpret test results and any defects found shall be repaired by the Contractor and a new radiograph taken of the repair. The cost for inspection of defective welds shall be the responsibility of the Contractor at no cost to the Authority.



H. The Contractor shall coordinate the weld integrity testing with the testing lab, making certain that adequate notices are given that the welds are available for testing.

I. Backfilling of the piping shall not commence until tests have been approved by the COTR and pressure tests have been completed.

3.7 PNEUMATIC PRESSURE TESTING OF FUEL PIPING

A. General: The entire newly installed, fuel distribution piping shall be pneumatically pressure tested after all joints are completed, in accordance with ASME B31.3 and API RP 1110. Sections of the system may be tested and accepted in order to expedite the work or as required due to phasing requirements. These sections shall be tagged by the Contractor to indicate compliance with the tests.

B. Install temporary closures or other fittings, including plugs, weld caps, blind flanges, etc., as necessary to facilitate the testing process.

C. Test Procedure: Tests shall be made with clean dry-filtered and oil-free compressed air (-20oF pressure dew point) or compressed nitrogen gas and shall be made in accordance with all applicable codes particularly with regard to safety precautions and the following:

1. A preliminary check of the fuel distribution piping at 25 psig shall be made.

2. The pressure shall be increased gradually in steps, providing sufficient time to allow the piping to equalize strains during the test, and to be checked for leaks. Final test pressure shall be 100 psig for four hours.

D. The Contractor shall provide certified and calibrated temperature and pressure instruments and chart recorders and a deadweight tester to provide continuous calibration and direct readings of time, temperature, and pressure on the same scale and chart during the tests. Test Certifications and recorder charts shall be submitted to the COTR for approval prior to final acceptance of the piping. Calibrated thermocouples may be surface applied.

E. Repair any leaks detected. Retest at 4-hour pressure cycles, as described above after all leaks have been repaired. Repeat repair and testing cycles until the system is acceptable to COTR.

F. Equipment, which is not rated by the manufacturer for the test pressure, shall be removed or isolated prior to testing. Install temporary connections as necessary. All permanent butterfly and plug valves and equipment, which are rated at the test pressure or greater, shall be in place during the pneumatic tests.

G. The 4 hour recordings shall be made after temperature and pressure has stabilized and shall be conducted in accordance with NFPA Codes and API RP1110 and this specification.

H. The pneumatic test shall be finalized before paving is started.

I. Pneumatic testing shall be completed in segments as Phasing construction is completed.

3.8 HYDROSTATIC PRESSURE TESTING OF FUEL PIPING



A. After a successful pneumatic test has been completed, the Contractor shall begin preparation for hydrostatic testing.

B. The Contractor shall remove all control valves, meters, and other equipment, which are not rated by the manufacturer for the test pressure of 275 psig. Piping spools and blind flanges shall be provided and installed by the Contractor.

C. Prior to hydrostatic testing the Contractor shall carefully fill the fuel system piping with the proper grade of fuel. During the filling process care should be taken to properly vent all high points to disperse all air pockets.

D. The Fuel System Operator will provide the required amount of fuel for the initial line fill and hydrostatic testing. Contractor shall assist in confirming the line fill volume.

E. The hydrostatic testing shall be in accordance with ASME B31.3 and shall include a two step process. The initial step will be to gradually bring system pressure up to 100 psig and inspect all joints, components and connections. The second step will be to gradually bring system pressure up to 275 psig and recheck all joints, components, and connections.

F. The actual test shall be to hold pressure at 275 psig for eight hours.

G. During the testing period, if a leak develops, the Contractor shall abort the test, repair the defect and restart the test from the beginning.

H. The Contractor shall provide certified and calibrated temperature and pressure instruments and chart recorders and a deadweight tester to provide continuous calibration and direct readings of time, temperature, and pressure on the same scale and chart during the tests. Test Certifications and recorder charts shall be submitted to the COTR for approval prior to final acceptance of the piping. Calibrated thermocouples may be surface applied.

3.9 PIPE HANGERS AND SUPPORTS

A. Pipe hangers and supports shall meet the requirements of ASME B31.3 and shall be as detailed.

B. Where changes in direction occur, reduce the spacing allowed in ASME B31.3 by three-quarters.

C. Not all supports are shown. Furnish and install all rigid supports, whether or not they are shown and detailed, but are required to adequately support the piping systems. Include all necessary structural steel, brackets, concrete inserts, etc., which are required to properly support the piping systems.

D. Install piping and provide necessary support and anchors to prevent forces from being imposed on equipment that would exceed the limits specified by the equipment manufacturer.

E. Provide complete assemblies that are rated for a minimum of 200% of the applied load.

F. Provide galvanized concrete inserts and shop- or field- fabricated galvanized brackets or structural steel shapes where necessary to meet field conditions.



G. Observe the flushing system in operation and make adjustments as necessary to support the system under dynamic loads.

H. Expansion bolts shall be self-drilling anchors, or insert type. Powder driven fasteners shall not be used.

I. Fabricate anchors welded to the pressure barrier from the same materials as the pipe and fasten securely to structure at points of adequate structural strength.

J. Support locations configuration and orientation shall be identified and submitted to the COTR prior to beginning installation.

3.10 SAFETY PRECAUTIONS AND FUEL SYSTEM MODIFICATIONS

A. Safety procedures are the responsibility of the Contractor. All operations in the construction area that involve open flames or the possibility of arcing or sparking shall be conducted in a "Gas-Free" condition.

B. It shall be the responsibility of the Contractor to monitor the use and suitability of the equipment and procedures on the job and maintain a safe "Gas-free" condition when necessary during construction.

C. Prior to commencing any phase of the work requiring a gas-free condition, the Contractor shall make the following minimum provisions:

1. Empty pipes containing fuel and purge all vapors.

2. Isolate, blank off, and adequately ventilate open piping sections so that no part of the pipe containing fuel or vapors is exposed.

3. Inspect for, and confirm that there are no open pools of fuel, or soil contaminated to a combustible limit, in the area of the work.

4. Drain and ventilate storage tanks prior to working on the tanks or tank connections.

D. Utilize a combustible gas analyzer or similar device to make certain that concentrations of combustible gas do not exist in the construction area when performing these operations.

E. Perform all safety precautions as required to assure that the work is conducted in a safe manner and to conform to applicable codes.

PART 4 - FIELD QUALITY CONTROL 4.1 Conform to all applicable provisions of Division 01 Section “Quality Requirements", Section

335243.10 10 and the requirements of this Section. Be responsible for periodic inspections for conformance with the approved SPPP. The results of the periodic inspections shall be submitted to the COTR upon completion.




FUEL SYSTEM GENERAL VALVES 335243.15 10-1

SECTION 335243.15 10 - FUEL SYSTEM GENERAL VALVES

PART 1 - GENERAL

1.1 SUMMARY

A. This section of the specification includes general valves for use in isolating various segments of the jet fuel system including motor operators. General valves specified in this section include the following:

1. Ball Valves

2. Butterfly Valves

3. Wafer Check Valves

4. Flanged Insert Check Valves

5. Pressure Relief Valves

6. Fusible Link Emergency Valves

7. Double Block and Bleed Plug Valves


A. Section 335243.13 10 – Fuel System Pipe, Fittings and Installation

B. Section 335243.17 10 – Fuel System Service Pits

C. Section 335243.10 10 – Fuel System General Provisions

D. Section 335243.80 10 – Fuel System Coating

1.3 REFERENCES

A. American Petroleum Institute (API)

1. 6D – Specification for Pipeline Valves

2. 6FA – Specification for Fire Test for Valves

3. 607 – Fire Test for Soft-Seated Quarter-Turn Valves

4. 609 – Butterfly Valves: Double Flanged, Lug and Wafer-Type

B. American Society of Mechanical Engineers



1. 16.34 – Valves – Flanged, Threaded and Welding End

C. Underwriters Laboratory (UL)

D. Oil Companies Materials Association (OCMA)

E. American Society of Mechanical Engineers (ASME)

F. Factory Mutual (FM)

1.4 SUBMITTALS

A. Submit Compliance Submittals in accordance with Section 335243.00 and on all valves and accessories, indicating the make, model, type, material, size and pressure rating.


A. No foreign made equipment, fittings, bolts or any other accessory may be used in this work. All such items shall be American made, manufactured in the United States of America. If any foreign items are found within the work supplied under this contract, the Contractor shall remove and replace them with American made items at no additional charge to the Authority.

B. The valve and motor operator manufacturers shall have products in satisfactory use in similar applications for a minimum of five years.

PART 2 - MATERIALS

2.1 BALL VALVES (2-inch and smaller):

A. The valve shall be Apollo model 87A-24X-2729, Jamesbury model 29150-31-3636TTT2, or approved equal. The valve shall be of two-piece full port ball valve. The valve shall be capable of not less than 275 psi, and shall have a working temperature range of at least -20F to 300F.

B. Valves shall consist of stainless steel, two part assembly with replaceable body seal of SS316/Graphite. The ball and stem shall be 316 Stainless Steel. The replaceable ball seat shall be 15%RPTFE and stem packing shall be constructed of Graphite.

C. Valves shall have a “fire safe” rating per API 607.

D. Valves shall have a lever type handle with vinyl grip and a 90-degree stop on the extended stem. Handle shall be suitable for padlocking in both the open or closed position.

E. All valves shall have ANSI 150# raised face flanged connections.



2.2 BALL VALVES (2-1/2-inch and larger):

A. The valve shall be Flow-Tek Model RF15 or approved equal. The valve shall be of two-piece full port ball valve. The valve shall be capable of not less than 275 psi, and shall have a working temperature range of at least -20F to 300F.

B. Valves shall consist of carbon steel, two part assembly with replaceable body seal of SS316/Graphite. The ball and stem shall be 316 Stainless Steel. The replaceable ball seat shall be 15%RPTFE and stem packing shall be constructed of Graphite.

C. Valves shall have a “fire safe” rating per API 607.

D. Valves shall have a lever type handle with vinyl grip and a 90-degree stop on the extended stem. Handle shall be carbon steel suitable for padlocking in both the open or closed position.

E. Where indicated on the Drawings, valves shall be equipped with spring return devices in the actuator as part of the manufacturer’s complete assembly.

F. All valves shall have ANSI 150# raised face flanged connections.

2.3 BUTTERFLY VALVES

A. Butterfly valves shall be used for bi-direction bubble-tight shut-off of flow within the system. Valves shall be mounted between ANSI Class 150 flanges with rated working pressure of the valve to be not less than 275 psi.

B. The valves shall have a carbon steel ASTM, A216 full lug body, drilled and tapped lugs, 316 ASTM stainless steel disc, stainless steel stem, and 316 stainless steel seat with TFE insert material. The operator shall be a spring loaded 10-position manual operator with locking device for valves 4” or smaller and a self locking worm gear operator for valves 6” or larger with the exception of Valve V-3 which shall be provided with a 10 position manual operator. Valves shall have a “fire safe” rating per OCMA and/or API 607.

C. Valves shall be WKM “Dynacentric”, Posi-Seal “Phoenix III”, FlowSeal “Fire-Flow”, or approved equal.

2.4 DOUBLE BLOCK AND BLEED PLUG (ISOLATION) VALVES

A. Plug valves shall be used for tight shut-off of flow within the system where verification of no-flow is required. The valves shall have a cast carbon steel body and plug with Viton seals. Slip replacement shall be from the bottom of the valve. Valve shall be rated for 275 psi working pressure and suitable for installation between ANSI Class 150 raised face flanges.

B. Accessories include a thermal relief valve for the body cavity which discharges to upstream flow and a manual body bleed valve. Valves shall have weatherproof operators with mechanical position indicator flags of metal construction. All operators shall have a stainless steel indicator shaft.

C. Operators on valves sized 6-inch and larger shall include a right angle self-locking gear operated handwheel. Where indicated on drawings, provide a mechanical extension to extend



the operator up into the valve vault access cover. Ensure proper clearance of handwheel and gear operator with the vault access cover frame and lid.

D. Valves shall be Cameron General Valve Model C8811 or approved equal.

2.5 WAFER STYLE CHECK VALVES:

A. Wafer style check valves shall be used on all piping 1-1/2” and larger.

B. Check valves shall be used to limit flow to one direction in the system. Valves shall be bubble-tight spring-loaded, non-slamming, silent closing type rated for not less than 285 psi working pressure at 100F.

C. The valves shall be manufactured with renewable seat and disc. Disc shall be guided at both ends, body shall be carbon steel with stainless steel trim. Valves shall be suitable for installation between ANSI Class 150 raised face flanges.

D. Valves shall be Mueller Steam Specialty Co. 101M-DT or approved equal.

2.6 FLANGED INSERT CHECK VALVES

A. Flanged insert check valves shall be used on all small bore piping 1” and smaller.

B. Check valves shall be used to limit flow to one direction in the system. Valves shall be rated for not less than 285 psi working pressure at 100F.

C. The valve shall a stainless steel body, viton seat, and stainless steel spring with a 10 psi spring cracking pressure. Valves shall be suitable for installation between ANSI Class 150 raised face flanges. Provide a flag tag to indicate the check valve is present in the piping.

D. Valves shall be manufactured by Check-All Valve Mfg. Co. or approved equal.

2.7 PRESSURE/THERMAL RELIEF VALVES:

A. Pressure and temperature relief valves shall be used to relieve pressure increases within the piping system due to thermal changes in the piping system. The valves shall be designed, constructed, and shall be labeled in accordance with Section VIII or the ASME Boiler and Pressure Vessel Code. Valves shall relieve at pressure indicated on drawings. Operating pressure shall be adjustable by means of an enclosed adjusting screw. The valves shall have a minimum capacity of 20 gpm at 10 percent overpressure and shall operate at rated capacity with a back pressure not exceeding 50 psi.

B. The valve body shall be of stainless steel construction with a 1” flanged inlet and 1” flanged outlet. Extend discharge piping full size and as indicated on the drawings.

C. Valves shall be Taylor Series 8200 or approved equal.

2.8 FUSIBLE LINK EMERGENCY VALVE (FLANGED)



A. The fusible link emergency valve located at the bulk loading operation shall be provided with a ductile iron body with stainless steel lever arm. Provide UL listed 165 degrees F fusible link.

B. Valve shall have ANSI 150 # raised face flanged connections.

C. Valve shall be Morrison Brothers Fig. 346FDI or approved equal.

PART 3 - EXECUTION

3.1 METHOD OF INSTALLATION

A. Valves shall be of the same Manufacturer throughout, where possible. Manufacturer’s name and pressure rating shall be located on a permanent nameplate on outside of valve.

B. Valves shall be installed in accordance with manufacturer’s recommendations and as indicated on the plans.

C. Each valve shall be installed in an easily accessible location such that valve operator shall not have to interfere with adjacent equipment for operation and maintenance. Provide spool piping, whether indicated on the drawings or not, if required for proper movement of valve operator and disc.

D. A union connection shall be installed within two feet of any screw end valve. Valves and specialty items shall be rated for not less than the system pressure.

E. Replace any and all valves that prove defective during system testing.

F. Install all butterfly valves with valve shaft in the horizontal position






FUEL SYSTEM CONTROL VALVES 335243.16 10 - 1

SECTION 335243.16 10 - FUEL SYSTEM CONTROL VALVES

PART 1 - GENERAL

1.1 DESCRIPTION:

A. Control valves specified in this section include the following:

1. High Level Shut-off Valve

2. Loading Control Valve

3. Back Pressure Control Valve

B. All control valves and accessories shall be provided from the same manufacturer.

1.2 Related Sections:

A. Section 099713.10 10 - Fuel System Coatings.

B. Section 335243.18 10 - Fuel System Inspection, Testing and Flushing

C. Section 335243.13 10 - Fuel System Pipe, Fittings, and Installation

D. Section 260500.00 10 - Fuel System Electrical

E. Section 330950.00 10 - Fuel System Instrumentation

F. Section 330951.00 10 - Fuel System Controls

G. Section 330952.00 10 - Fuel System Description of Operation

1.3 REFERENCES:

A. American National Standard Institute - (ANSI)

B. National Electrical Manufactures Association - (NEMA)

1.4 SUBMITTALS:

A. Compliance Submittals shall indicate the make, model, location, type, material, size, pressure/flow rating, and code/standard conformance.




A. All valves shall be factory tested to verify flow, function and specified control features are satisfied. Provide certification as part of submittals.

PART 2 - MATERIALS

2.1 CONTROL VALVES:

A. Control valves include blocking flow valves, high-level shutoff valves, and flow control valves. The valves shall have ductile iron bodies suitable for 275 PSIG working pressure with ANSI 150 flat-face flanges, and stainless steel trim including seats, guides, control pilots, and tubing systems. Elastomers shall be Buna-N in main valve and Viton control pilots. All surfaces in main valve body which are in contact with fuel shall have a 3 mil minimum electroless nickel plating. All valves to have enclosed valve stem position indicators. Main valve parts including strainers, valve seat, stem bearings and control system shall be replaceable without removing the main valve from the line. All non-metallic parts shall be replaceable.

B. The main valve body shall be cast with the pressure class, size, material, foundry heat number and identification, manufacturer and flow pattern.

C. Brass name plates shall be fastened to the valve. Body name plates shall list the size, model number, stock number, manufacturer/supplier and manufacturer inspection stamp.

D. Valve size, function, and components shall be as indicated on the layout drawings, equipment details and control valve schematics.

E. Manufacturers shall be Cla-Val or approved equal.

2.2 TANK HIGH LEVEL SHUTOFF VALVE:

A. The valve shall be located in the fill piping and mounted at the tank fill connection and be designed to close by fluid pressure when the designated level in the tank reaches the “Hi-Hi” condition.

B. Provide the following trim/accessories:

1. Normally open, fuel level to close, non-throttling type

2. Integrated reverse flow-check valve feature

3. Opening and closing speed control

4. Junction box factory prewired for control from the Main Control Panel.

5. Single-pole double -throw limit switch for valve position indication mounted in NEMA 4, NEMA 7 enclosure. Entire limit switch assembly shall be mounted within a weatherproof enclosure.



6. Tank mounted remote float pilot/chamber assembly. Mount float pilot Model Cla-Val CFM2 internal to tank on the tank ladder. Control tubing shall pass through the full coupling on the manway neck.

C. Manufacturers shall be Cla-Val or approved equal.

2.3 ANTI-SIPHON SOLENOID VALVE

A. Provide immediately downstream of the vertical turbine pump to serve as an anti-siphon valve and shall close within 10 seconds, from a 100% open position, with no pressure differential. This valve shall also be provided with rate of flow control to limit the pump discharge to 1000 gpm. Valve shall be normally closed, flow to open.

B. Valve shall be energized open when pump is energized.

C. provide the following trim/accessories;

1. Opening and closing speed adjustment

2. Explosionproof, 120Vac control solenoid. Solenoid shall close valve upon deenergization.

3. Rate of flow pilot with orifice plate on downstream side of main valve and sensing lines completely piped and self-contained on valve. Orifice plate position per recommendation of manufacturer. Orifice plate holder shall be ductile iron or cast steel.

4. Single-pole double -throw limit switch for valve position indication mounted in NEMA 4, NEMA 7 enclosure. Entire limit switch assembly shall be mounted within a weatherproof enclosure.

D. Manufacturers shall be Cla-Val or approved equal.

2.4 BACK PRESSURE CONTROL VALVE BPCV-1

A. Control of upstream pressure when operating the Hydrant System Transfer Pump. The valve will maintain pressure, as sensed at the hydrant valve, at 120 psi.

B. Provide the following trim/accessories:

1. Opening and closing speed adjustment

2. Single-pole double -throw limit switch for valve position indication mounted in NEMA 4, NEMA 7 enclosure.

3. Explosionproof, 120Vac control solenoid. Solenoid shall close valve upon deenergization. Valve shall close when existing 6" motor operated double block and bleed plug valve from the existing hydrant system is in the open position.

4. Valve shall close within 5 seconds, from a 100% open position, with no pressure differential.



5. Pressure control pilot, field adjustable, to control upstream pressure to 125 psi. Sensing point for the control pilot will be remote to the valve.

C. Valve shall operate with a 125 psi pressure differential. The valve manufacturer shall provide an anti-cavitation device for the valve if required.

D. Manufacturers shall be Cla-Val or approved equal.

PART 3 - EXECUTION

3.1 MANUFACTURER’S SERVICE ENGINEER:

A. Furnish the services of an experienced service engineer for a minimum of two days on the jobsite to verify proper installation and assist in start-up, check-out and calibration. Allow for two separate trips to the jobsite if required by the construction schedule.





FUEL SYSTEM METERING EQUIPMENT 335243.17 10-1

SECTION 335243.17 10 - FUEL SYSTEM METERING EQUIPMENT

PART 1 - GENERAL

1.1 DESCRIPTION

A. Components specified in this section shall address the metering equipment to be used in the Jet-A Hydrant Cart Test Stand.



B. Section 260500.10 10 – Fuel System Electrical

1.3 REFERENCES

A. American Society for Testing and Materials (ASTM)


C. American Society of Mechanical Engineers (ASME)


A. Compliance submittals shall be in accordance with Section 335243.10 10 and shall be provided for all equipment specified in this Section.


A. The equipment shall be manufactured by a company regularly engaged in the manufacturer of the devices specified herein, and whose products have been in similar service for a minimum of 5 years.

PART 2 - MATERIALS

2.1 HYDRANT CART TEST STAND METER

A. All meters shall be FMC Measurement Solutions Smith Model G6-S3 or approved equal.

B. Meters shall be of the double-case, positive displacement, straight through design capable of metering jet fuel between 120 and 1,000 gpm with an accuracy of 1/4 of 1 percent.


FUEL SYSTEM METERING EQUIPMENT 335243.17 10-2

C. Construction shall be an outer housing and cover of cast steel, inner housing and rotor of cast iron, teflon packing gland with 6-inch 150-pound raised-faced flanged connections.

D. Accessories for jet fuel meter shall include a right angle drive for meter proving, and a mechanical flow rate indicator. Provide a resettable large numeral counter and a non resettable totalizer. Meter shall read in gross gallons.

PART 3 - EXECUTION

3.1 MANUFACTURER’S SERVICE ENGINEER

A. Furnish the services of an experienced service engineer for a minimum of two days on the jobsite to verify proper installation and assist in start-up, check-out and calibration. Allow for two separate trips to the jobsite if required by the construction schedule.

B. Provide third party meter proving agency to verify calibration of all meters at start-up.





FUEL SYSTEM SERVICE PITS AND VALVE VAULT ACCESS COVERS 335243.20 10-1

SECTION 335243.20 10 - FUEL SYSTEM SERVICE PITS AND VALVE VAULT ACCESS COVERS

PART 1 - GENERAL

1.1 SUMMARY

A. This section includes the prefabricated high point vent pits, low point drain pits, and valve vault covers.


A. Section 312323.13 10 – Fuel System Excavation, Bedding and Backfill

B. Section 335243.13 10 – Fuel System Pipe, Fitting and Installation

C. Section 335243.15 10 – Fuel System General Valves

D. Section 335280.10 10 – Fuel System Coatings

E. Section 335243.11 10 – Fuel System Piping Specialties

1.3 REFERENCES

A. American Petroleum Institute (API):

B. National Electric Manufacturer’s Association (NEMA):

1. 250-1997 - Enclosures for Electrical Equipment (1000 volts maximum)

C. U.S. Department of Transportation:

1. AC 150/5320-6C - Airport Pavement Design and Evaluation


A. Compliance submittals shall be processed in accordance with Section 335243.10 10 - Fuel System General Provisions.

B. Installation instructions shall be supplied by the manufacturer of all pits.

C. Product Information (pit contents):

1. Prefabricated low point drain pit



a. Pipe and fittings

b. Manual valves

c. Hose adaptors

d. Coatings

e. Steel casing insulator

f. Link seals

g. Pull-on and wraparound sleeves

2. Prefabricated high point vent pit

a. Pipe and fittings

b. Manual valves

c. Hose adaptors

d. Coatings

e. Steel casing insulator

f. Link seals

g. Pull-on and wraparound sleeves

3. Prefabricated valve vault access cover and ladder

1.5 DRAWINGS AND INSTALLATION INSTRUCTIONS

A. Drawings shall include complete assembly layouts of internal piping and components with all dimensional information included.

1. Prefabricated low point drain

2. Prefabricated high point vent

3. Prefabricated valve vault access covers and ladder

1.6 CERTIFICATION OF COMPLIANCE

A. Load test requirements

B. Water tightness tests

C. Welder qualifications (shop welder)



D. Radiographic Test Reports (shop welder)


A. All equipment shall be supplied from a company regularly engaged in the manufacture of the items specified herein and whose products have been in similar service at airports for a minimum of 5 years.

B. When two or more units of the same class of equipment are required they shall be the products of a single manufacturer.

C. All cover assemblies and pits as installed shall be capable of accommodating wheel loads of any aircraft in commercial service. Cover shall comply with D.O.T. AC 150/5320-6C, Appendix 3. Submit test reports from an independent test company stating and certifying that the pit or cover as manufactured, meets this requirement with a maximum 0.450-inch full load deflection at center and deflection “rebound” within 0.020-inch after load release

D. Weight bearing mating flange surfaces of the pits and corresponding covers shall be flat to within 0.050-inch total indicator reading.

E. Water resistant covers shall be provided. The manufacturer shall submit test reports from an independent test company certifying the following:

1. The totally submerged cover shall pass less than 100 ml of water per hour when cycled through hot (160o F) and cold (-40o F) conditions and also when subjected to seal contamination.

2. The cover and pit assembly shall pass the hose-down test of NEMA 250.

F. All service pits shall be prefabricated in the factory, including all internal piping and components. The pits shall be shipped to the site as a complete assembly with all internal piping in place and pipe sleeve seals installed. Valves may be shipped separately for installation in the field. At the option of the Contractor, the pits may be purchased empty and the Contractor shall purchase and field-install all internal piping and components. The quality of the finished product shall be comparable to that of the factory furnished assemblies, including internal/external coating of pipe and fittings, dimensional tolerances and satisfactory operation.

PART 2 - PRODUCTS

2.1 GENERAL

A. All pit covers shall be cast aluminum. Cover must be free of visual shrink porosity cavity areas, weldments, fillers and paint.

B. All pit covers shall have service lettering as specified, which is abrasion/corrosion/chemical-resistant and color-coded. Covers shall have high visibility orange panels on topside and underside for safety.



C. The pipe penetrations through the pit wall shall be sealed by means of an external heat shrink sleeve and an internal, Buna-N “S” type boot as detailed on the drawings. A casing insulator shall keep the carrier pipe centered in the steel piping sleeve and link seals shall be installed on each side of the insulator as detailed on the drawings.

D. Casing sleeves shall extend 8-inches into the interior of the pit and 16-inches outside of the pit side wall or floor. Carrier pipe shall extend a minimum of 22-inches outside of all pit side-walls and/or below the floors for field connection.

E. The pit cover seals shall automatically engage the sloped wall of the cover frame when cover is seated in the closed position without any secondary latching motions. Seal shall be affixed without mechanical fasteners, have a minimum field life of one year after installation acceptance and be ozone/UV resistant. Sealing surface shall be separate from load bearing surface.

F. Provide one (1) spare cover seal per pit.

G. The pit form shall be fabricated of fiberglass to the dimensions as indicated on the drawings.

2.2 LOW POINT DRAIN PIT

A. General:

1. Pit shall consist of a molded prefabricated fiberglass low point drain pit. Pit shall come complete with valves and piping accessories. Cover shall be of water resistant construction.

2. Service lettering shall read “Fuel Low Point Drain”.

3. Cover shall open with a maximum 19 lb. lift. Cover shall provide a minimum 18” diameter opening.

B. Pit cover – shall be primary metal cast aluminum, alloy No. A356.2, Fed. Spec. QQ-A-601F with T-6 heat treat per Mil-Spec. H-6088F.

1. Service lettering shall be abrasion/corrosion/chemical-resistant color-coded. Cover shall have high visibility orange panels on topside and underside for safety.

2. Cover shall have handhole with minimum 1.4” depth. Entire cover assembly shall be removable.

3. Cover shall open with a maximum 25 lb. lift. Hinge mechanism shall be a non-load bearing, internally mounted hinge. Cover shall provide a minimum 17” diameter opening.

4. Entire cover assembly and pit as installed shall be capable of accommodating wheel loads of any aircraft in commercial service. Submit test reports from an independent test company stating and certifying the prototype design meets this requirement with a maximum 0.15-inch full load deflection at center and deflection “rebound” within 0.250-inch after load release. Cover shall also comply with D.O.T. AC 150/5320-6C.



5. Cover must be free of visual shrink porosity cavity areas, weldments, fillers and paint.

6. Weight bearing mating flange surfaces of the pit and cover shall be flat to within 0.050-inch total indicator reading.

C. Pit Cover Seal

1. Sealing surface shall be separate from load bearing surface. Seal shall automatically engage cover frame sloped wall when cover is seated in the closed position without any secondary latching motions. Seal shall be affixed without mechanical fasteners, have a minimum field life of one year and be ozone/UV resistant.

D. Pit/Form

1. Pit/form shall be prefabricated per the drawing detail dimensions.

2. Pipe Seal: The pipe penetration through the pit floor shall be sealed by means of a steel casing, external heat shrink sleeve, an internal “S” type pull-on seal, a casing insulator and link seals. The sleeves shall be fastened with stainless steel bands.

3. Individual Pit Requirements: Pits shall be furnished complete with valves and equipment as described and indicated. All valves, equipment and piping furnished shall comply with the requirements specified herein. All valves of the same type shall be of the same manufacturer.

4. Fuel pipe shall extend a minimum of 22 inches below the floor for field connection.

E. Pit Manufacturer:

1. Provide Cavotec pits. No Substitutions.

2.3 HIGH POINT VENT PIT

A. General - One-piece molded prefabricated fiberglass high point vent pit assembly complete with valves and piping accessories. Cover shall be of water resistant construction.

B. Pit cover - shall be all primary metal cast aluminum, alloy No. A356.2, Fed. Spec. QQ-A-601F with T-6 heat treat per Mil-Spec. H-6088F.

1. Service lettering shall be abrasion/corrosion/chemical-resistant color-coded. Lettering shall read “Fuel - High Point Vent”. Cover shall have high visibility orange panels on topside and underside for safety.








C. Pit Cover Seal


D. Pit/Form


2. The pipe penetrations through the pit wall shall be sealed by means of link seals, shrink and pull-on sleeves, a casing sleeve and a pipe insulator as indicated. The sleeves shall be fastened with stainless steel bands.


4. Fuel pipe shall extend a minimum of 22 inches outside of pit wall for field connection.



2.4 DUAL VENT PIT

A. General - One-piece molded prefabricated fiberglass dual vent pit assembly complete with valves and piping accessories. Cover shall be of water resistant construction.

B. Pit cover - shall be all primary metal cast aluminum, alloy No. A356.2, Fed. Spec. QQ-A-601F with T-6 heat treat per Mil-Spec. H-6088F.

1. Service lettering shall be abrasion/corrosion/chemical-resistant color-coded. Lettering shall read “Fuel - Vent”. Cover shall have high visibility orange panels on topside and underside for safety.








C. Pit Cover Seal


D. Pit/Form


2. The pipe penetrations through the pit wall shall be sealed by means of link seals, shrink and pull-on sleeves, a casing sleeve and a pipe insulator as indicated. The sleeves shall be fastened with stainless steel bands.


4. Fuel pipe shall extend a minimum of 22 inches outside of pit wall for field connection.



2.5 VALVE VAULT ACCESS COVER & LADDER

A. Access Cover Door and Frame

1. Cover shall have integral, automatic latches with no above grade protrusions. Latches shall be interconnected so that operation of one latch will activate the other latch.

2. Cover shall be one piece with torsion spring assist such that it will open to 90 degrees with a maximum 35 lb. lift and close with a maximum 50 lb. push. The cover shall have a hold open bar that locks the cover in the open position.



3. Floor grating shall be cut to accommodate valves and handles. Cut locations are to be reinforced.

4. Cover and frame shall be all primary metal cast aluminum, alloy No. A356.2, per Fed. Spec. QQ-A-601F, with T-6 heat treat per Mil. Spec. H-6088F.

5. Service lettering shall be abrasion/corrosion/chemical-resistant color coded.

6. Cover shall have hand-holes with a minimum 1.4" depth and 14 cu. in. volume, and integral automatic latches.

7. Cover shall not pop open when a latch is released and shall be designed to fail-safe open once lifted beyond the 80-degree point in the opening arc.

8. Highest pit internal component shall be accessible from a maximum of 5.5" from pit top in non-arm/latch areas.

9. Cover shall have high visibility orange panels on both the topside and underside.

10. Prototype test report, for each cover style, shall be submitted and the test shall have been conducted by an independent testing company in the following manner: cover loading over each (or each of two spaced at a maximum of 36" on centers for pit with inside length greater than 60") 200 sq. in. footprint(s) shall withstand a minimum 1,000 PSI load with a maximum 0.150" full load deflection at center indicator(s) and deflection "rebound" within 0.025" after load release.

11. Cover shall also comply with D.O.T. AC 150/5320-6C.

12. Cover shall be free of visible porosity, fillers, weldments and paint to hide them.

13. Load-bearing flange surfaces of the pit and cover shall be flat to within 0.050" total indicator reading.

14. Cover shall be water resistant with a replaceable seal at the mating surface.

15. Door seal shall automatically engage a sloped wall when cover door is seated in the closed position without any secondary latching motions. Seal shall be affixed without mechanical fasteners or adhesives, have a minimum field life of 1 year and be ozone/UV-resistant.

16. Sealing surface shall be separate from load-bearing surface.

17. Prototype cover's environmental test report shall be submitted and the test shall have been conducted by an independent testing company in the following categories and standards:

a. Totally submerged cover shall pass less than 100 ml of water per hour following: a) hot (160° F) and cold (-40° F) cycling conforming to Mil Std 810, and b) seal contamination (cover seal & sealing flange coated with sand and soil mixture).

b. Cover shall pass corrosion and hose-down tests equal to NEMA 250 standards for Type 6 exterior enclosures except that cover shall be tested in 6" deep standing water.



c. Cover frame shall have its own seal.

B. Cover Manufacturer Model: Valve vault access covers shall be Cavotec Model DAB-741WP-VA and Cavotec Model DAB-38WP-VA as shown on the drawings. Covers shall be complete with a ladder assembly where indicated on the drawings. Each ladder assembly shall include an adjustable floor mount for a vault depth up to 12 feet. No Substitutions.

PART 3 - EXECUTION

3.1 INSTALLATION

A. The Contractor shall execute the installation of all service pits in accordance with the manufacturer recommendations. Contractor shall provide personnel during fuel system paving activities to assist in the proper installation of service pits and service pit covers.

B. Fuel System Service Pits – One piece molded fuel pits will require the paving contractor to pour panels containing fuel pits separately from continuous ramp paving activities. Contractor shall remain onsite during pavement placement to ensure proper completion of pits including installation of reinforcement and crowning of pavement surrounding pits.

C. Protect pit covers, vaults, vault covers and CP test points from paving activities by temporarily covering with plastic sheeting taped to the top surface. Remove immediately after concrete has been placed.

3.2 TESTING

A. All service pit and valve pit covers shall be tested for proper operation.

B. After the pits have been installed and backfilled, fill the pits with water and monitor the water level for 24 hours. The test will be considered acceptable if there is no reduction in the water level within the pit for a 24-hour period. This test shall be completed prior to paving activities. Remove water immediately after testing is completed.

C. Pressure test the link seals where installed in pipe penetrations at fiberglass pit and concrete vault walls. Using compressed Nitrogen or dry compressed air, fill the void between carrier pipe and casing pipe up to 5 PSIG and record the pressures for a one-hour period. Adjust the link seals until the pressure is maintained. The tests must be performed before back-fill operations. Seal the casing pipe test port with a NPT plug when testing is finalized.







FUEL SYSTEM PUMPS 335243.23 10-1

SECTION 335243.23 10 - FUEL SYSTEM PUMPS

PART 1 - GENERAL

1.1 SUMMARY

A. Components specified in this section shall be fuel system pumps to be used for the hydrant cart test stand and loading Jet-A aviation kerosene.


A. Section 335243.13 10 – Fuel System Pipe, Fittings, and Installation

B. Section 335280.10 10 – Fuel System Coatings

C. Section 330850.10 10 – Fuel System Inspection, Testing and Flushing

1.3 REFERENCES


1. D1655 – Standard Specification for Aviation Turbine Fuels

B. American Society of Mechanical Engineers (ASME)

C. American Petroleum Institute (API):

D. National Electrical Manufacturer’s Association (NEMA).

1.4 DEFINITIONS

A. Unless otherwise specified, the working pressure ratings as used in these specifications for valves, fittings, unions, and other piping specialties refer to pressure ratings in pounds per square inch above atmosphere (PSIG) in accordance with applicable ASME Standards.

1.5 SUBMITTALS

A. General: Compliance Submittals shall be in accordance with Division 1 and Section 335243.13 10.

B. Submit manufacturer’s certified pump test curves showing pump performance characteristics with pump and system operating point plotted.




A. The pumps shall be manufactured by a company regularly engaged in the manufacturer of the devices specified herein, and whose products have been in similar service for a minimum of 5 years.

B. The drawings and specifications shall be considered complementary, one to the other, so that materials and labor indicated, or called for, or implied by the one and not the other, shall be supplied and installed as though specifically called for by both.

C. All materials and equipment provided under these specifications shall be new, unused products of manufacturers regularly engaged in production of such equipment for a minimum of 5 years. All products shall conform to the applicable code or standard for its manufacturing, fabricating and installation.

PART 2 - MATERIALS

2.1 VERTICAL TURBINE PUMPS

A. General requirements

1. Pump(s) shall be a multistage, vertical, centrifugal design for outdoor installation on an underground storage tank with an integral floating suction arm, Type VS1. Assembly shall be complete with pump, motor, coupling, mounting flanges, accessories and all other parts and materials necessary for a complete installation. Pump shall be Goulds, Flowserve, Union, or equal.

2. Pump shall conform to the standards of API-610, tenth edition.

3. The bottom pump impeller bowl shall be modified to accommodate a flanged swivel joint and floating suction arm as detailed.

4. Base flange shall be machined to match a 16-inch diameter, 150-pound ANSI, tank flange.

B. Pump Characteristics

1. Pumps shall be suitable for the fluid temperature and suction head conditions listed at any flow between 50 to 120% of design flow.

2. Total dynamic head shall be a maximum at no flow and decrease continually from no flow to design flow.

3. Pump design working pressure shall not be less than the sum of the pump shutoff head and the maximum suction pressure listed.

4. All pumps and components shall be suitable for pumping Jet-A fuel.

5. Pump shafts shall be free from excessive vibration at all flow rates from 20 to 120% of design flow.



6. Pumps shall be free of flashing and cavitation at all flow rates from 20 to 120% of design flow at the section conditions listed.

7. Combined pump and motor efficiency shall be a minimum of 65%.

C. Tests

1. Shop tests shall be conducted on all pumps in the manufacturer’s shop in accordance with standards of the Hydraulic Institute.

2. Perform hydrostatic pressure tests of casings at 150% of maximum working pressure.

3. Perform dynamic and static balance tests of impellers.

4. Furnish performance curves of head, horsepower, and efficiency at all flow rates from shutoff to 120% of design flow for all pumps.

5. Furnish shop test reports and submit to the Engineer including performance curves specified in this section certified by the test engineer.

D. Construction

1. Pumps shall meet the requirements of API 610, tenth edition.

2. Pump speed shall not exceed 3,600 rpm.

3. The pump casings shall be fabricated of carbon steel with a 8-inch discharge flange, raise faced, and rated at 300 lb ANSI.

4. Casing shall have tapped openings with plugs for vent, gauge, and drain connections.

5. In general, the pump materials of construction shall adhere to S-4 specifications. The impeller will be constructed of carbon steel. The impeller wear ring and wear rings will be composed of cast iron. The pump shaft will be constructed of AISI 4140 material.

6. Provide mechanical seals, John Crane Type 48 Low Emission or equivalent.

7. Bearings shall be ball type, lubricated with constant level oiler. Bearings shall be designed for 100,000 hours minimum life under design conditions and shall limit impeller and shaft deflection to 0.002-inch maximum. Thrust and axial ball bearings shall be manufactured from carbon steel.

8. Provide API Plan 14 seal flush with 316 SS threaded pipe.

9. Couplings shall be Thomas DBZ-C, or approved equal, with sufficient spacer length to permit maintenance or removal of the mechanical seal and/or rotating element without removing the motor or disturbing the piping connections.

10. Baseplate shall be fabricated of structural steel shapes suitable for mounting and maintaining alignments of pump, coupling, coupling guard, and motor.



11. Exterior Primer Coat: Exterior surfaces of the pump assembly shall be primed by the manufacturer. Surface cleaning shall meet requirements of SSPC SP10. Metal primer shall be zinc rich paint conforming to specification MIL-P-24441 Type 1, Class 3. Dry film thickness shall be 2 to 4 mils.

12. Exterior Topcoat: Manufacturer’s Standard exterior topcoat shall be factory applied and shall be white.

13. Motors shall be as follows: Motors will be installed in a Class I, Division 1, Group D hazardous location. Sliding contacts, centrifugal or other type switching mechanisms (including motor over-current, overloading and over-temperature devices), or integral resistance devices which may be provided shall be approved for installation in a Class I, Division 1 location in accordance with the NEC. a. Shall have sufficient capacity to drive the pump through the entire operating range

of the pump performance, without exceeding nameplate data. b. Provide pump motor temperature limiting thermostats within motor frame, pre-

wired to motor terminal box. Maximum temperature rating of motor shall be T3-392° F as defined by NFPA 70. Thermostats shall automatically set.

c. Shall have performance characteristics which allow accelerating the WK² of the load from standstill to rated speed under conditions of six starts per our without damage of overheating the motor.

d. Shall be NEMA Design B squirrel-cage induction type suitable for use with reduced voltage starter.

e. Motor shall have nonhygroscopic NEMA Class F insulation, and shall operate below a Class F design temperature rise. Insulation system shall meet the requirements described in NEMA MG1-2003, part 31. Stator winding shall be epoxy impregnated by vacuum and pressure process.

f. Voltage rating shall be 460 V, 3 phase, 60 hertz. Motors shall be capable of delivering rated horsepower output successfully and continuously under conditions of voltage variations of 10% above and below rated voltage.

g. Motors shall be standard efficiency and have a service factor of 1.15. h. Enclosure shall be TEFC and suitable for outdoor installation in Class I, Division

2, Group D hazardous areas. Furnish with drain/breather assembly. Provide motor winding space heater suitable for 460V. Motor winding space heater shall be suitable for use in Class I, Division 2, Group D

i. Bearings shall be grease lubricated ball bearing with AFBMA L10 life of 100,000 hours when running at specified operating conditions. Bearing shall be re-greaseable. Provide insulated opposite drive end bearing.

j. Pump motors shall be furnished with lifting lugs on the motor casing. k. Motor shall have stainless steel nameplate indicating motor parameters including a

U.L. listing for the motor that states the motor is listed for use in Class I, Division 2, Group D hazardous locations.

l. Motor terminal box shall be suitably sized, tapped and threaded for the conduit size and quantities as indicated on the plans. Motor terminal box shall be pre-wired to accept power, ground, space heater, and thermal winding temperature sensor leads.

14. Floating Suction Assembly:



a. It shall be the responsibility of the manufacturer to design, fabricate and install the swing line pipe and float assembly to ensure satisfactory operation in Jet-A (specific gravity 0.79-0.82).

b. Provide swing line pipe fabricated of 10-gauge aluminum, stainless steel or carbon steel conforming to ASTM A283C. Provide dielectric connection (e.g., insulating flange) for connection of dissimilar metals.

c. Provide at swing pipe inlet a short-radius, seamless pipe suction elbow, light weight or Schedule 10, aluminum, stainless steel or carbon steel conforming to ASTM A234, with bell mouth and antivortex baffles or other turbulence-minimizing devices. Provide 1/8” vent hole on top of elbow for venting of air upon initial tank fill. Floats and vent hole location shall be designed so that the vent hole is always submerged during normal operation.

d. A support shall be provided and attached to the tank bottom to provide a stop/support for the floating suction assembly in the full down position. Height of the support shall be such that the bottom of the antivortex baffle will be 6 inches above the tank bottom.

e. Provide floats as necessary to ensure floatation of swing line in fuel product. Floats to be fabricated of 10-gauge aluminum, stainless steel or carbon steel conforming to ASTM A283C.

f. Pneumatically test floats for leaks.

g. Provide swing line pipe of suitable length to limit the floating suction arm assembly vertical travel to 60 degrees relative to a horizontal line extended from the centerline of the tank connection.

h. Floating Suction shall be manufactured by OPW, GNY, or approved equal.

E. Operating Conditions

1. Capacity: 1,000 gpm

2. Total discharge head: 425 feet

3. Fluid pumped: Jet Fuel (Jet-A)

4. NPSH available at suction nozzle: 37 feet

5. Minimum pump efficiency: 75%

6. Maximum pump speed: 1800 rpm

7. Minimum fluid temperature: 40°F

8. Maximum fluid temperature: 125°F



9. Motor Horsepower: 125 hp

10. Site elevation: 325 feet above sea level

11. Pump column overall length: 10 feet

2.2 HAND PUMP

A. General requirements

1. Pump(s) shall be hand operated piston style pumps. Shall be nominally 20 gallons per 100 strokes. Pump shall be used a water draw-off pump on horizontal aboveground storage tanks and to return fuel to tank from sump separator.

2. The pumps and components shall be suitable for pumping aviation Jet Fuel.

3. FM approved for handling Class I and Class II flammable and combustible liquids. Hand pump(s) shall be Fill-rite FR150 or equal.

B. Construction

1. Materials: Pump shall have an aluminum body with stainless steel liner. Suction pipe o-ring shall be Buna-N.

2. Hand pump shall be UL Listed piston hand pump with 1" NPT inlet and 3/4" NPT outlet or approved equal.

3. Exterior Topcoat: Manufacturer’s Standard exterior topcoat shall be factory applied and shall be red.

PART 3 - EXECUTION

3.1 DELIVERY, STORAGE AND HANDLING

A. Store pumps in a dry location.

B. Retain shipping flange protective covers and protective coatings during storage.

C. Protect bearing and couplings against damage from grit, sand, or other foreign matter.

D. Comply with pump manufacturer’s rigging instructions.

E. Connect and operate motor space heaters during storage as recommended by motor manufacturer.

3.2 INSTALLATION



A. Pumps shall be furnished and installed with adequate support so that transfer of strain vibration to connecting piping is eliminated. Provide pump complete with motor, coupling, coupling guard, and mounting base.

B. Pumps shall have statically and dynamically balanced rotating parts at the factory and after installation.

C. Replace any and all equipment items that prove defective during testing.

3.3 START-UP, MOTORS AND DRIVES

A. Check all motors and drives for proper rotation and alignment prior to placing in operation.

B. Disconnect and realign all coupling before placing into service or testing.

C. Install oil in all couplings, reducers, etc, prior to start up. Ensure all bearing are lubricated.

3.4 SETTING AND ALIGNMENT EQUIPMENT

A. Set and align all equipment supplied under this Section in accordance with manufacturer’s recommendations.

B. Level and true all equipment at the locations indicated. Demonstrate proper leveling of equipment.

C. Provide coupling alignment records indicating parallel and angular dial indicator readings as well as coupling manufacturer’s tolerances. Alignment for pumps, couplings, and drivers requiring “cold” and “hot” settings shall be checked in both conditions and so indicated on the alignment record.

D. Retighten all bolted connections after installation to the proper torque.

3.5 EQUIPMENT TEST AND CHECKOUT

A. All equipment shall be tested and demonstrated to be correctly connected and installed before Owner will accept.

B. All testing and checkout procedures of the manufacturer shall be carried out completely. Contractor shall initial each test of the installation manual and provide to Engineer.

C. Any equipment found to be defective shall be reported to the Owner immediately.

D. Any operating difficulty or defective item as a result of Contractor’s work shall be repaired or replaced and put into proper operation by the Contractor immediately.

3.6 MANUFACTURER’S SERVICE ENGINEER



A. Provide the services of manufacture’s representative (factory trained) for one (1) day on the site to certify proper installation (or assign repairs), assist in startup, and provide training of Owner’s operating personnel.





FUEL SYSTEM COATING 335280.10 10-1

SECTION 335280.10 10 - FUEL SYSTEM COATING

PART 1 - GENERAL

1.1 DESCRIPTION

A. The work to be performed in this specification includes the cleaning, preparation, painting, coating, and identification of fuel system piping materials, equipment and components.

B. The preparation and application for the system shall include both field and shop operations.

C. The applicable methods and system identification to be used shall be as follows. Reference the data sheets included in this section for individual systems:

Item Surface Application SystemAll Piping, Fittings and Equipment Interior Shop 1 Above Ground Piping, Fittings and Equipment Exterior Field 2 Below Ground Piping Exterior Shop 3 Below Ground Fittings and Coating Repair Exterior Field 4 Below Ground Pit Piping, Fittings & Valves Exterior Field 5

1.2 REFERENCES

A. American Petroleum Institute (API):

1. STD. 1542 - Airport Equipment Marking for Fuel Identification

B. American Society of Mechanical Engineers (ASME):

1. A13.1 – Scheme for the Identification of Piping System

2. Z53.1 - Safety Color Code for Marking Physical hazards

C. Military Specifications

1. MIL-C-4556 - Epoxy for Interior of Steel Fuel Tanks

D. National Fire Protection Association

1. NFPA 407 - Aircraft Fuel Servicing

2. NFPA 704 - Standard System for the Identification of the Fire Hazards of Materials for Emergency Response

E. Steel Structures Painting Council

1. SP-1 - Solvent Cleaning



2. SP-3 - Power Tool Cleaning

3. SP-5 - White Metal Blast Cleaning

4. SP-6 - Commercial Blast Cleaning

5. SP-10 - Near White Blast Cleaning

1.3 SUBMITTALS

A. Submit as specified in Section 335243.10 10 – Fuel System General Provisions. Submittals shall include, but not be limited to:

1. Surface preparation requirements

2. Product manufacturer, name of coating, and number designation of coating

3. Method of application and the minimum and maximum dry film thickness of coating (per coat) to be applied

4. Certification from the manufacturer that the unthinned maximum VOC content of the field applied coating products is below the maximum allowable for the project location

5. Color charts for selection of paint color by the Authority

6. Technical and material safety data sheets

7. Pipe/Equipment labels:

a. Submit a drawing that clearly indicates the proposed location of piping labels.

b. Catalog cuts and samples of the piping and equipment labels

8. Third party testing agency and their graphical report indicating test locations and results


A. The coating applicator for field operations or for shop operations shall have a minimum of 5 years of experience in the Systems specified. The coating applicator shall certify in writing that he has previous experience applying all of the coating systems in this specification for which he is responsible.

B. Compliance submittals and certification of experience shall be submitted to the COTR prior to starting the work.

C. The coating applicator shall provide a certificate of quality control procedures utilized during application of internal and external coatings. The certification shall include surface preparation, film thickness per coat, curing procedures and holiday testing.

D. The coating manufacturer shall certify that the internal pipe coating used in all fuel contact locations is compatible for submersible use in Jet-A fuel.



E. All coatings shall be applied in strict accordance with the manufacturer’s recommendations including environmental conditions, surface preparation, coating method and coverage, etc.

F. Piping and equipment labels shall comply with listed codes and standards for color coding, lettering size, and length of color field.

G. Contractor shall ensure that all newly painted surfaces remain clean and are not contaminated by subsequent blasting and painting operations. Contractor shall clean and/or recoat surfaces deemed not acceptable due to product contamination at no cost to the Authority.

H. Contractor shall employ the services of a third party testing agency to perform all dry film thickness testing on all field applied coatings. Contractor shall submit to the COTR the proposed testing agency for approval.

PART 2 - MATERIALS

2.1 SYSTEM TABLES

A. System tables for interior and exterior coatings are included within this specification to indicate the degree of preparation, methods of application, finish thickness, manufacturer names and product numbers. This specification addresses coatings for components and materials for the fuel systems.

2.2 IDENTIFICATION OF PIPING

A. The identification of fuel system piping shall be through a combination of pressure sensitive labels, bands and flow arrows.

B. The materials shall be as manufactured by W.H. Brady, Seton Corp. or approved equal and shall conform to ASME A.13.1.

C. Legend designations for all fuels shall be in accordance with API Std. 1542.

D. Direction of flow arrows shall be coordinated with pipe size and shall be of the same color code as stated in API 1542 for Jet A fuel.

2.3 IDENTIFICATION OF EQUIPMENT

A. Pressure sensitive labels or stenciling with paint shall be used for the identification of equipment. If paint is used, it shall conform to these specifications.

B. Equipment to be identified shall be as follows:

1. Horizontal fuel storage tanks – 4 inches high in four locations (one label per quadrant). Identification shall include the number that corresponds to the P&ID and the control system screens, product type and useable volume in gallons.

2. Pumps – 3 inches high in two locations. Identification shall include the number that corresponds to the P&ID and the control system screens.



C. Tanks shall have a decal stating “Tank Last Cleaned On” with a space for filling in dates.

D. Tanks shall have a 4” high black lettering decal stating” FLAMMABLE” AND “NO

SMOKING”

E. Tanks shall have a hazardous materials identification marker located on four sides in

accordance with NFPA 704. Lettering shall be 4” high.

F. Provide custom valve and equipment tags. Signs shall be made of two color laminated

fiberglass 1/8-inch thick with contrasting color for the engraved color. Signs shall be laminated sealed with a clear epoxy coating, which is scratch, chemical and ultraviolet resistant. Lettering shall have minimum height of ½-inch. Provide an aluminum bracket to securely hold sign. Bracket shall be mounted to valve or equipment on a bolt, flange, cap or other feature that will allow a secure attachment. Locate tag so it is easily visible. 1. Provide a graphic display (flow diagram) to depict the process and components of the

skid system. The process schematic shall utilize conventional symbols when possible. Symbols, valve numbers and flow lines shall be sized and spaced so as to provide a clear representation of the system process. Graphic shall be adhered to permanent aluminum substrate. All background colors, lettering and detail colors shall be laminated sealed with a clear epoxy coating, which is scratch, chemical and ultraviolet resistant. Lettering shall have minimum height of 3/16-inch. Submit schematic for approval. Mount display on skid in a convenient location.

2.4 IDENTIFICATION OF OPERATIONS

A. This section of the specification addresses the identification of operational areas and operational conditions within the facility.

B. Two color laminated fiberglass signs 1/4-inch thickness with contrasting color for the engraved color shall be used.

C. The signs shall come complete with self-tapping metal screws for attachment.

D. Lettering shall be 2-inch high Eurostile Bold Extended in white for U.S. Standard Red backgrounds.

E. Signage shall identify the following:

1. EMERGENCY FUEL SHUT-OFF

2. JET-A FUEL

3. NO SMOKING

PART 3 - EXECUTION



3.1 INTERNAL COATING of PIPING, FITTINGS AND EQUIPMENT

A. Reference System 1 of the attached tables.

B. This section shall apply to shop applied epoxy internal coatings for piping, fittings and any equipment where applicable.

C. All fuel contact surfaces shall receive the epoxy coating.

D. The surfaces to be painted shall be sandblasted or shot blasted immediately before applying the prime coat. Remove all surface irregularities such as burrs, weld splatter, etc., before proceeding with blasting. Blasting shall be in strict accordance with Steel Structures Painting Council Surface Preparation Specification. Care shall be taken to prevent grease, oil or other organic matter from contacting the blasted surface prior to application of the prime coat. Blasting shall be coordinated with primer application, which shall be applied as soon as possible after blasting. If the blasted surface remains uncoated overnight, it shall be reblasted.

E. Coatings shall be a two (2) coat system of epoxy paint qualified to meet government Specification MIL-C-4556-E and be applied in accordance with the manufacturer’s instruction and procedure and shall be approved by the manufacturer’s representative. Paint shall be applied to the full length of pipe and fittings. The total dry film thickness of the paint shall be within the range recommended by the manufacturer. The ends of the pipe and fittings shall have the paint wiped back 1-1/2” with cloth or other approved absorbent material. Masking the ends will not be acceptable.

F. Dry film thickness shall be spot checked at random, or as indicated by the COTR, on the coated surfaces after each coat has been applied and has cured. At a minimum, the thickness shall be checked every 20 linear feet of piping and at each fitting, flanges, etc. At a minimum every 100 square feet of tank shall be tested. If film thickness is not found to be uniform and to specification by the COTR, the Contractor shall be required to apply additional coats at no cost to the Authority until the specified film thickness has been obtained. If the dry film thickness exceeds the maximum allowable film thickness per the manufacturer, the Contractor shall remove and reapply the coating in those areas at no cost to the Authority. Dry film thickness is to be checked by the Contractor at his expense by a third party NACE certified testing agency.

G. After the paint has dried to its maximum hardness, the ends of all pipes are to be closed with plastic cap seals manufactured for this purpose.

H. If, in the opinion of the COTR the coatings show ridges, waves, runs, orange peeling or holidays indicating uneven coverage or improper application, the Contractor shall be required to remove and re-apply the coating at no cost to the Authority.

3.2 EXTERNAL COATING OF ABOVE GROUND PIPING, FITTINGS AND EQUIPMENT


B. All pipe, fittings and equipment which are installed above ground shall be given a protective covering applied with equipment especially designed for this purpose. Before the coating is applied, the surface of the pipe, fittings and equipment shall be thoroughly cleaned of all rust, scale, oil, grease and other matter that will interfere with the proper adhesion of the primer coat. Those pieces of equipment, valves, actuators, etc. that have been shop primed or delivered to



the site with a finish coat shall be properly prepared for application of the coating. Contractor shall coordinate with the equipment suppliers and the coating manufacturer on the proper preparation and application of the coating.

C. The surfaces to be painted shall be sandblasted or shot blasted immediately before applying the prime coat. Remove all surface irregularities such as burrs, weld splatter, etc., before proceeding with blasting. Blasting shall be in strict accordance with Steel Structures Painting Council Surface Preparation Specification. Care shall be taken to prevent grease, oil or other organic matter from contacting the blasted surface prior to application of the prime coat. Blasting shall be coordinated with primer application, which shall be applied as soon as possible after blasting. If the blasted surface remains uncoated overnight, it shall be reblasted.

D. All fieldwork shall be done in a manner and with materials that will produce a covering equal in effectiveness to that of the factory applied coating.

E. Prepare the surface as specified, defined and remove any loose rust, scale, dust or dirt. Oil and grease are to be removed with suitable solvent. All field-applied coatings shall conform to the contour of the pipe or fitting leaving no moisture traps between or under the coating.

F. External coating shall be applied with rollers and brushes. Spray application is not allowed.

G. ALL equipment labels, data plates, control tubing, pressure gauges, etc., shall be masked prior to painting adjacent piping. If these items are painted, the Contractor shall clean them to the satisfaction o of the Authority or replace them at no cost to the Authority at the direction of the COTR.

H. Coatings shall be a two (2) coat system with an epoxy first coat and a polyurethane top coat applied in accordance with the manufacturer’s instruction and procedure and shall be approved by the manufacturer’s representative. The total dry film thickness of the paint shall be within the range recommended by the manufacturer.

I. Dry film thickness shall be spot checked at random, or as indicated by the COTR, on the coated surfaces after each coat has been applied and has cured. At a minimum, the thickness shall be checked every 20 linear feet of piping and at each fitting, flange, etc. The tank exterior shall be tested once every 100 square feet. If film thickness is not found to be uniform and to specification by the COTR, the Contractor shall be required to apply additional coats at no cost to the Authority until the specified film thickness has been obtained. If the dry film thickness exceeds the maximum allowable film thickness per the manufacturer, the Contractor shall remove and reapply the coating in those areas at no cost to the Authority. Dry film thickness is to be checked by the Contractor at his expense by a third party NACE certified testing agency.

3.3 EXTERNAL COATING OF BELOW GROUND PIPING


B. External coating of below ground pipe shall be factory or mill applied in the pipe manufacturer’s shop or in the mill of the custom external coater.

C. The pipe coating shall be a Fusion Bonded Epoxy (FBE) coating.



D. Holiday test all coatings and repair. All holidays shall be patched prior to shipment of pipe to the jobsite.

E. Application, testing and inspection shall be in accordance with manufacturer’s recommendations.

F. Pipe Shall be protected for shipment.

3.4 EXTERNAL COATING OF BELOW GROUND PIPING JOINTS, REPAIRS AND FITTINGS


B. On field applications requiring open flames, the Airport Fire Department must be notified prior to their use.

C. Joint coatings for piping to be pressure tested shall be applied after testing and acceptance.

D. Prime surfaces to receive a shrink wrap coating, by brushing or spraying.

E. Application shall be in accordance with manufacturer’s published instructions.

F. Coating and wrapping of pipe to be buried shall include welded joint connections.

3.5 EXTERNAL COATING OF BELOW GROUND PIT/VAULT PIPING, FITTINGS AND VALVES


B. All pipe, fittings, pipe supports, base plates and equipment that are installed belowground in pits and vaults shall be given a protective coating, applied with equipment especially designed for this purpose.

C. Before the coating is applied, the surface to be coated shall be thoroughly cleaned of all rust, scale, oil, grease and other material that may interfere with the adhesion of the primer coat.

D. Valve coatings shall be applied in the factory when possible.

E. All fieldwork shall be done in a professional manner and with materials that will produce a coating equivalent to that of a factory applied coating.

F. All field-applied coatings shall conform to the contour of the pipe or fittings leaving no moisture traps between or under the coating.

3.6 PIPING AND EQUIPMENT IDENTIFICATION

A. Clean area of surface to receive label or other pressure-sensitive item free of oil, grease, dust, dirt, or other substances that would affect adhesion.



B. On painted surfaces, install label only after coating system is complete and dry film thickness testing completed and accepted.

C. Use proper label type suitable for interior or exterior location as applicable.

D. Locate labels on piping near connections to equipment, adjacent to valves or fittings, and at intervals not to exceed 25 feet. Final location shall be determined by COTR.

E. For piping with arrows to indicate direction of flow, place arrows adjacent to or below labels, depending upon visibility. For dual-flow piping, indicate both directions.

F. Locate legends and labels so as to be visible from normal line of vision above finished floor or grade level.

3.7 PROTECTION

A. Cover and protect all surfaces that are not to be painted which are in close proximity to the painting operation. Remove all protective materials when appropriate and before materials such as masking tape becomes difficult to remove.

B. Provide signs to indicate fresh paint areas.

C. Mask, remove, or otherwise protect finish hardware, control tubing, pressure gauges, control devices, and equipment nameplates as necessary. Provide cover to prevent paints from entering orifices in electrical or mechanical equipment.

D. Provide daily cleanup of both storage and working areas and removal of all paint refuse, trash, rags, thinners, etc. Dispose of leftover containers, thinners, rags, brushes, rollers, etc. in accordance with applicable regulations.

3.8 CLEANING

A. Touch up and restore damaged finishes to original condition as required. Remove all masking tape residue and glues that may be left on surfaces.

B. Remove spilled, dripped or splattered paint from all surfaces.

3.9 COATING REPAIRS

A. Repair all damages to pipe coating systems before the piping is holiday tested. This includes all cuts, breaks, voids, bruised or scarred spots, or other damage caused prior to delivery, or resulting from handling or installation of the pipe, or from any cause whatsoever.

B. Included also are damaged coatings where new connections are made to existing coated pipes or where existing coated pipes are uncovered or exposed for any reason.

C. Also repair the coating where welds are made and where damaged or broken by the installation of instrumentation or other accessories or appurtenances.



D. Repair all holidays detected during inspection of coatings. Use the same coatings for repair as was used for the base coating with the exception of belowground piping which shall use System 4.

3.10 INSPECTION

A. Use wet film gauges to check each application about every 15 minutes in order to correct low or heavy film build immediately.

B. Use dry film gauge to check each coat when dry, and the total system when completed.

C. Use holiday or pinhole detector to detect and correct voids when indicated on system sheet.

D. Provide daily reports of environmental conditions including ambient temperature, substrate temperature, relative humidity, wind speed and direction.





FUEL SYSTEM COATINGS SYSTEM - 1 SERVICE: All Piping, Fittings, Equipment - Interior

Surface Preparation: SSPC-SP 10 to a profile depth recommended by product manufacturer. First Coat: High solids amine epoxy with minimum of 71% solids by volume. Apply at a rate

to meet the manufacturer’s recommended dry film thickness. Do not exceed the maximum dry film thickness as published by the manufacturer. Wipe coating 1-1/2” from end of pipe.

Second Coat: Same as first coat except color shall be different than first coat to distinguish

between coats. Second coat shall be white, light gray, or beige for light reflectance and to facilitate inspection. Wipe coating 1-1/2” from end of pipe

Third Coat: Not required. System Total: System total shall meet the recommended dry film thickness. Volatile Organic Content: Maximum 2.3 lbs/gal

Manufacturer First Coat Touch Up Second Coat Third Coat Tnemec Tneme-liner 61 N/A Tneme-liner 61 Notes:

1. Upon completion, check for voids with a suitable electric holiday detection operating at the proper voltage as recommended by the manufacturer. Repair all holidays.



FUEL SYSTEM COATINGS SYSTEM - 2 SERVICE: Above Ground Piping, Fittings, Equipment - Exterior

Surface Preparation: SSPC-SP 6 to a profile depth recommended by product manufacturer.

First Coat: High build, high solids epoxy low sheen enamels with minimum 56% solids by volume. Apply at 5.0 mils dry film thickness.

Second Coat: High build, high solids polyurethane low sheen enamels with minimum 64% solids by volume. Apply at 5.0 mils dry film thickness.

Third Coat: Not required.

System Total: System total shall meet the recommended dry film thickness.

Volatile Organic Content: Maximum lbs/gal: 3.02 epoxy, 2.5 urethane.

Manufacturer First Coat Touch Up Second Coat Third Coat Tnemec

66-Hi Build Epoxoline (epoxy)

Same as first coat 1075 Endura-shield II (polyurethane)

Notes:

1. A low sheen material is required. Gloss or high gloss will not be acceptable.



FUEL SYSTEM COATINGS SYSTEM - 3 SERVICE: Below Ground Piping- Exterior

Surface Preparation: SSPC-SP 6 to a profile depth recommended by product manufacturer.

First Coat: Shop applied, fusion bonded epoxy powder. Apply at 14 mils minimum dry film thickness. Wipe back the coating 2” from the end of the piping.

Second Coat: Not required.


System Total: Minimum 14.0 mils dry film thickness.

Touch Up: Field applied, two component catalyzed epoxy as recommended by the manufacturer.

Manufacturer First Coat Touch Up Second Coat Third Coat 3M Lily Coatings

Skotch-Kote 6233 PipeClad 1500

Skotch-Kote 226P Hot Melt Patch Compound PipeClad Patch Compound

Notes:



FUEL SYSTEM COATINGS SYSTEM - 4 SERVICE: Below Ground Fittings and Coating Repair - Exterior

Surface Preparation: SSPC SP-1 and SP-3. Clean free of dirt, mill lacquer, oil, millscale and all other foreign material.

First Coat: Apply primer without runs, drips or sags.

Second Coat: Apply polyethylene tape of proper width for pipe diameter. Apply joint wrap in a spiral fashion with 50% overlap. Overlap end splices 6”.


System Total: N/A.

Inspection: Check for voids with an electronic holiday detector.

Manufacturer First Coat Touch Up Second Coat Third Coat Polyken (YG111 System)

Polyken 1027 Primer

Polyken 930

Notes:



FUEL SYSTEM COATINGS

SYSTEM - 5

SERVICE: Below Ground Vault/Pit Pipe, Fittings and Valves - Exterior

Surface Preparation: SSPC-SP-10

First Coat: Cycloaliphatic amine epoxy coating with a minimum of 82% solids content by volume. Apply at 4-6 dry mils per coat. Beige first coat color.

Second Coat: Same as first – gray color.


System Total: Minimum of 10 dry mils. (5 dry mils per coat)

Volatile Organic Content (Unthinned): Maximum of 2.5 lbs/gallon

Manufacturer First Coat Touch Up Second Coat Third Coat

Tnemec Series 61 Same Same

Notes: 1. Finish to be satin or semi-gloss.

2. Jet A and directional stenciling shall be provided in valve vaults.



FUEL SYSTEM CATHODIC PROTECTION SYSTEM 335343.91 10

SECTION 335343.91 10 – FUEL SYSTEM CATHODIC PROTECTION SYSTEM

PART 1 - GENERAL

1.1 DESCRIPTION:

A. This section specifies providing and connecting cathodic-protection equipment.

B. Installation of corrosion control components shall be in accordance with the following specification and accompanying design drawings. All installation practices and components shall be approved by COTR.

C. The corrosion control system shall include electrical continuity (joint bonding), insulated flanges, sacrificial anode (magnesium) ground beds, permanent reference cells and corrosion control test facilities.

D. Related Work Specified Elsewhere:

1. Corrosion control system testing: Section 335343.92 10, Fuel System Cathodic Protection System Testing.


A. Codes, Regulations, Reference Standards and Specifications:

1. Comply with codes and regulations of jurisdictional authorities.

2. NACE International SP0169-2007.

3. ASTM: B418, D256, D570, D638, D693, D1248, E11.

4. MS: MIL-A-18001.

1.3 SUBMITTALS:

A. Submit the following for approval in accordance with Section 335243.10 10 Fuel System General Provisions, the General Requirements and with the additional requirements as specified for each:

1. Product Data: Submit manufacturer catalog cuts or other descriptive information for the specific materials required on this project for approval.

a. Packaged Magnesium Anodes

b. Test Stations and Terminal Boards

c. Shunt



d. Wire and Cable

e. Thermite Welding Equipment

f. Coating for Thermite Welds

g. Insulating Flanges: High and Low Temperature

h. Insulated Flange External Coating

i. Test Station and Terminal Lugs

j. Electrical Tape

k. Rubber Splice Tape

l. Electrical Coating Compound

m. Field Test Equipment and Calibration Sheets

n. Warning Tape

o. Solder

p. Separator Mesh

q. Permanent CuCuSO4 Reference Cell

2. Quality Assurance: Submit in conjunction with product data:

a. Installation and Test Personnel Qualifications for Pipe Joint Bonding and Corrosion Control Hardware.

b. Qualifications of NACE International Certified Cathodic Protection Specialist

c. Proposed Test Data Forms

3. Close-Out: Submit no later than 10 working days before application for beneficial use:

a. Letter of Compliance

b. Record Drawings

c. Test Report.

4. Certification:

a. Certified test reports of field quality-control testing.

1.4 PRODUCT DELIVERY, STORAGE AND HANDLING:



A. Mark each item with manufacturer’s name, brand designation, referenced standard, type, class and rating, as applicable.

B. Ship each unit securely packaged and labeled for safe handling in shipment and to avoid damage or distortion.

C. Store equipment in secure and dry storage facility.


A. Qualifications: Installation, quality assurance, and testing personnel must have demonstrated experience with similar work.

1. Must be specifically named in qualification submittal and have completed at least three successful corrosion control systems within last three years for underground pipelines of similar type, similar size and equal complexity.

2. Must be full-time contractor or subcontractor employees. Part-time or contract personnel hired only for this work will not be permitted.

3. Only personnel approved by the COTR are permitted. Personnel changes during course of project must be minimized and submitted to the COTR at least two weeks prior to plan implementation.

B. Supervision: Employ a Cathodic Protection Specialist certified by NACE International to perform the following:

1. Oversee and certify installation and related testing. Including pipe joint bonding, magnesium anodes groundbeds, and corrosion control equipment. Individual must participate in field activities to extent required by work.

2. Issue letter of compliance indication all corrosion control measures are satisfactorily installed and comply with contract documents. The letter of compliance shall be signed by the NACE International Cathodic Protection Specialist.

1.6 RECORD DRAWINGS:

A. General: Document installed location and configuration of each test station and each insulating device as-built sketch plate, including:

1. Test station with corresponding station number.

2. Three-dimensional ties between test station and existing permanent datum.

3. Distance from test station to guard post, where installed.

4. Wire routing, size, insulation color and termination configuration on terminal board.

5. Anode locations, where installed, including pipeline station number, depth and distance from pipe.



PART 2 - PRODUCTS

2.1 PRODUCTS AND MATERIALS:

A. Magnesium Anodes: Packaged high potential type comprised of magnesium ingot, wire, and prepared backfill.

1. Chemical Composition for 20# high-potential D2 shaped type anodes:

ELEMENT PERCENT

Aluminum 0.010 maximum Manganese 0.050 - 1.30

Zinc 0.050 maximum Silicon 0.050 maximum Nickel 0.001 maximum

Iron 0.030 maximum Other metallic

elements 0.050 each or

0.300 maximum total Magnesium Remainder

2. Lead wire: Single-conductor insulated cable, 12AWG minimum, factory-connected to anode with connection sealed with cast epoxy-resin encapsulation.

3. Anode packaged in permeable cloth sack containing compacted backfill of mixture with the following requirements:

MATERIAL PERCENT

Gypsum 75 Bentonite 20

Sodium Sulphate 5

4. Open Circuit Potential: Minimum negative potential of 1.65 volts referenced to copper/copper sulfate.

B. Reference Electrode: Coupon Reference Electrode: Shall be a Zinc-Zinc Sulfate (Zn/ZnSO4) IR-Free probe manufactured with 1- 10cm2 coupon and Bullet Box interrupter providing ON & OFF potentials, 100 mV shift, and current readings for chloride free environments.

1. The Coupon Reference Electrode shall be constructed with a three conductor cable, AWG #16 for each conductor, RHH-RHW insulation, with two each attached to each coupon and one attached to the reference electrode element. The cable length shall be adequate to allow for a minimum of 1-foot of slack above the finished grade.

2. No splices shall be allowed in the coupon reference electrode cable. Approved Manufacturers/Suppliers:



. Borin Manufacturing, Inc., Culver City, CA. Borin Stelth 7 or approved equal

2.2 TEST BOXES:

A. Cathodic-protection test boxes: Plastic, each five inches inside diameter by 18 inches long, with cast-iron lid, collar and terminal board.

1. The lid shall be coated with two coats of shop applied OSHA safety yellow polyurethane or epoxy paint.

2. The terminal board shall be 4 inch by 6 inch by 0.25 inch thick polycarbonate board. 7 terminals, one 0.01 ohm (8 ampere) shunt, 2 copper shorting straps (0.50 inch wide by 0.03 inch thick by 1.5 inches long, with 2 holes predrilled for mounting) and 0.25 inch diameter nickel plated brass hardware. Bingham and Taylor or approved equal.

2.3 CURRENT MEASURING SHUNT:

A. Materials:

1. Test station shunts shall be constructed to fit the terminal posts for the specified test station. The resistance shall be 0.01 ohm with a current capacity of 8 amperes. Cott Manufacturing, Promark or approved equal.

2.4 WIRE AND CABLE:

A. Materials:

1. All wiring shall be stranded copper wire of the AWG wire size and color shown on the drawings.

2. Wire for bonded joints shall be single conductor, stranded copper with high molecular weight polyethylene (HMWPE) insulation (black). Wire size shall be AWG No. 6. Anode header shall be #8 HMWPE. Kalas Wire or approved equal

3. Wire for test stations shall be single conductor, stranded copper wire with 600-volt THWN or HMWPE insulation (colors, size and insulation as shown on details).

2.5 THERMITE WELDING EQUIPMENT:

A. Approved Manufacturers:

1. Erico Products, Inc., Cleveland, OH: Cadweld.

2. Continental Industries, Inc., Tulsa, OK: ThermOweld.



B. Materials: Mold, weld metal, other material and equipment per manufacturer’s recommendations for particular pipe/cable material and size. Only material and equipment from same manufacturer is allowed. Adapter sleeves shall be utilized for all thermite welds.

2.6 THERMITE WELD COATING MATERIALS:

A. Thermite weld coating material:

1. Thermite welds shall be coated with a prefabricated assembly specially designed for covering cathodic protection wire connections to piping and fittings. The prefabricated assembly shall consist of the following components: 1) top plastic sheet formed with an igloo shaped dome and entry tunnel for the lead wire; 2) a special elastomeric compound in the plastic dome firm enough to resist flow at normally encountered application and operating temperatures, but soft enough to mold itself around and completely cover the irregular welded profile; 3) a double row of parallel, flexible serrations on either side of the dome to assist with conforming around small diameter pipe; 4) a base of black un-backed elastomeric tape with exceptional adhesive properties for bonding firmly to a surface when used with the appropriate primer.

2.7 WIRE CONNECTORS & TERMINATIONS:

A. Terminal Lugs:

1. Materials: One-hole, compression terminal lugs for 0.25 inch bolt size.

B. Butt Splices:

1. Materials: Non-insulated type.

C. Crimp Connections:

1. Materials: C type crimp for specific wire sizes Burndy, Thomas and Betts or approved equal.

2. Make connections with ratchet type compression crimping tool specifically design for the approved crimps.

2.8 ELECTRICAL TAPE:

A. Vinyl Plastic:

1. Approved Manufacturers: 3M Company, St. Paul, MN: Scotch 88 or approved equal.

B. Rubber Splicing:

1. Approved Manufacturers: 3M Company, St. Paul, MN: Scotch 130C or approved equal.

2.9 ELECTRICAL COATING COMPOUND:



A. Approved Manufacturers: 3M Company, St. Paul, MN: Scotchkote or approved equal.

2.10 FIELD TEST EQUIPMENT:

A. As determined by Contractor to meet specific requirements. All electrical instruments must bear evidence of calibration within 1 year of testing.

B. See Spec Section 335343.92 10, Fuel System Cathodic Protection System Testing

2.11 TEST STATION CONCRETE:

A. Materials: Ready-mix concrete conforming to ASTM C94. Minimum allowable 28-day compressive field strength shall be 3,000 psi when cured and tested in conformance with ASTM C31 and ASTM C39. Portland cement shall be Type 1.

2.12 SOLDER:

A. Materials: 0.062 inch diameter 60/40 Solder with 3.5 percent type RMA rosin core.

2.13 SEPARATOR MESH:

A. Materials: Medium density flexible polyethylene webbing pad (mesh pattern), nominal thickness 0.156 inch.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Thermite Welding: Attach test wires and bond cables to the piping by thermite welding.

1. General: All thermite welds shall be made as shown on the Drawings and in accordance with the manufacturer’s recommendations using the proper combination of equipment for the pipe and wire size being welded. All welding materials and equipment shall be the product of a single manufacturer.

2. Area preparation: Assure that the area where the attachment is to be made is absolutely dry. Remove mill coating, dirt, grime and grease from the pipe or fitting surface at the weld location by wire brushing or by the use of suitable safety solvents. Clean an area (two inches square) of the pipe or fitting surface at the weld location to a bright shiny surface, free of all serious pits and flaws by use of a mechanical grinder.

3. Cable preparation: Prepare the wire for welding by assuring that the cable is absolutely dry. The cable shall be free of dirt, grease and other foreign products. Cut the cable in such a way as to avoid flattening or forcing out of round. To prevent deformation of the cable, cut the cable with cable cutters. Remove the insulation in a manner that will avoid damage to strands. Install adapter sleeves for all bonds and test wires in accordance



with the manufacturer’s recommendations prior to welding. Either prefabricated factory sleeve joint bonds or bond wire with formed sleeves made in the field is acceptable. Hold the cable at an approximate 30 degree angle to the pipe surface when welding.

4. Installation. Install thermite welds in accordance with the manufacturer’s written instructions. Deliver packaged weld charges to job site in new, unopened dry containers. Replace completed welds having burnt wire strands and wire strands not completely covered with weldment.

5. Testing: When the weld has cooled, remove the weld slag and test the weldment for strength by striking a sharp blow with a two pound hammer while pulling firmly on the wire in direction parallel to pipe. Replace unsound welds and retest weldments.

a. Documentation: Record adequacy of each bond cable and test wire weld based on the above procedure and visual inspection before and after coating welds area. Data recorded for each bond cable and test wire to include date of inspection, name of inspection personnel, pipeline station number, quantity and gauge of wire installed, and simple statement (e.g. “satisfactory”) regarding proper installation.

6. Cleaning and Replacing Molds: Thoroughly clean mold and mold covers after completion of each weld to assure that no slag will penetrate into the next weld. Replace molds periodically and where there is pitting or other wear conditions.

7. Coating Thermite Welds: After soundness of the weld has been verified, thoroughly clean with a stiff wire brush and coat with an elastomeric cap. The elastomeric cap shall extend on all four sides beyond the cleaned area onto the pipe surface. Apply primer over the entire weld area and over the entire area where the elastomeric cap will be placed. Allow primer to dry. Push the dome of the prefabricated cap containing elastomeric material firmly into weld area. Lift the wire away from the pipe and apply the elastomeric material completely around and underneath the wire. Push the wire back down on the pipe.

B. Bonded Joints: Install bond cables across each joint in accordance with corrosion schedule indicated in the Drawings using the thermite weld process.

1. All underground new mechanical pipeline joints, including those on pipe, fittings, valves and branch connections including hydrants. Do not bond across insulating devices.

C. Test Stations: Includes terminal box, concrete pad, guard post, survey marker, wire leads, PVC conduit, utility warning tape and monitoring equipment.

1. General: Type of test station; number, size and color of wires; and wire routing are shown on the Drawings. Unless otherwise noted or approved by the COTR, test stations for pipelines buried under pavement shall be located outside paving limits. Test stations shall be sufficiently set back from vehicle traffic lanes so that they can be accessed for maintenance without extensive traffic control or other special safety precautions.

2. Wire Routing: Install test and monitoring equipment wires in a wiring harness arrangement routed along the bottom of the pipe trench where practical. Form harness



by taping wires together at intervals of 10 feet. Install wires leaving the pipe trench in PVC conduit when terminal box is not installed over water main.

3. Utility Warning Tape: Install 1 foot above PVC conduit.

4. Concrete Pad:

a. Concrete Pad: Provide for each flush mount test station. Non reinforced concrete pad formed around test station shall be 24 inches by 24 inches by 8 inches sloped away from terminal box.

D. Magnesium Anode Lead Wire Splices, Wire Connectors and Terminations:

1. Magnesium Anode Lead to Header Cable Splices: Splice the AWG No. 12 solid copper wire supplied with the anode to an AWG No. 8 HMWPE stranded copper cable through the use of a compression connector as shown. Tape the splice with three layers of high voltage rubber splicing tape (50% overlap), followed by three layers of vinyl electrical tape (50% overlap). Coat entire splice with electrical coating compound. Terminate the ends of the AWG No. 8 anode header cable in the test stations as indicated.

2. Terminal Board Connectors: Crimp and solder each terminal box wire to one-hole terminal lug. Clean and dry wire and lug connector before soldering.

3. Wire Splicing: When wire splicing is required, use butt splice connector crimped, soldered, and insulated. Insulate splices by spirally wrapping (minimum 50% overlap) with three layers of rubber splicing electrical tape and three layers of vinyl plastic electrical tape. Coat taped splice with electrical coating compound.

4. General: No splices allowed in individual anode wires, joint bonds and pipe wires.

E. Magnesium Anodes:

1. Positioning: Horizontally or vertically to suit field conditions, with closest part of anode a minimum of 2 feet from main at or below elevation shown on Drawings. Spacing between anodes installed in a group is 10 feet unless noted otherwise.

2. Installation in Rock Areas: If solid rock is encountered at a depth which will not accommodate normal installation, investigate immediate proximity to determine if anode can be installed at specified depth at another location in the immediate area.

3. Backfill: Use soil free from rocks and organic material. Do not use sand or clay. After anode is covered with 1 foot of soil, pour 10 gallons of water over covered portion of anode.

4. Wiring: Unless noted otherwise, connect grouped anodes though a AWG No. 8 stranded copper header cable. Terminate each end of anode cable in designated test stations with only splicing of cable at anode wire attachments. Anode header cables shall be buried a minimum of 2 feet below grade. Handle wire with care.

5. Documentation: Include location and orientation of each anode on record drawings.



F. Insulated Flanges: Unless noted otherwise, install with a test station and two test wires attached to pipe on each side of flange.

1. Preparation: Clean must, dirt, grease, oil and other contaminants from flange surfaces. Check flange face and bolt hole tolerances and verify clearances prior to installing insulating materials.

2. Installation: Install insulated flange gasket, sleeves and washers under clean and dry conditions in accordance with manufacturer’s written instructions. Two insulating washers required for each bolt (one for each side of flange). Properly torque bolts per insulating material manufacturer’s instructions to avoid damage to insulating components and otherwise ensure electrical separation between flange faces and between each bolt and each flange. Do not use conductive grease or other material to facilitate flange assembly which could compromise electrical integrity of insulating materials.

3. Initial Testing: After assembly, test with radio frequency insulation tester

4. Gas Electronic Model 601 or approved equal. Directly measure electrical resistance between each bolt and one flange using an ohm meter or other approved low voltage resistance meter. Resistances less than 10 megohm are not acceptable and require insulator replacement, cleaning and drying of insulator surfaces, and/or other corrective action. If any bolt fails the 10 megohm minimum resistance requirements, all bolts must be retested after corrections are made. Tests shall also be performed across the insulating flange to assure that the central gasket is providing effective insulation between the flanged faces prior to coating. See Section 13115.

G. Clearance of Piping to Other Structures:

1. 12 inches of natural clearance shall be maintained between the piping and other structures, where possible. When 12 inches of clearance cannot be maintained, install a medium density flexible polyethylene mesh pattern webbing pad, nominal thickness 0.156 inch, around piping and secure with non-metallic tape.

2. Thoroughly mix the mastic coating and apply a coat of approximately 12 mils if coating to the piping surface. Allow the coating to dry to touch (approximately 20 minutes) and apply a second coat of mastic of approximately 12 mils in thickness. Allow to dry before placing the concrete.





FUEL SYSTEM CATHODIC PROTECTION SYSTEM TESTING 335343.92 10-1

SECTION 335343.92 10 - FUEL SYSTEM CATHODIC PROTECTION SYSTEM TESTING

PART 1 - GENERAL

1.1 DESCRIPTION:

A. This section specifies test procedures for corrosion-control systems.

B. All testing shall be in accordance with NACE SP0169-2007, State of Virginia and Federal Regulations for underground metallic fuel piping

C. Related Work Specified Elsewhere:

1. Section. 335343.91 10 – Fuel System Cathodic Protection System


A. Codes, Regulations, Reference Standards and Specifications:

1. Comply with codes and regulations of jurisdictional authorities.

B. Instrument Calibration:

1. Calibrate test instruments within twelve months prior to use on this project.

C. Qualifications:

1. The Contractor shall employ an independent corrosion control firm to perform all post installation testing.

2. The corrosion control firm shall perform post installation testing of all corrosion control components. The corrosion control firm must have at least five years’ experience of testing similar types of cathodic protection systems on pipelines. The testing shall be performed under the direct supervision of a NACE Cathodic Protection Specialist. The minimum requirement for the tester (if someone other than the CP Specialist) shall be NACE CP Level 2. The testing shall be performed in accordance with the following NACE Recommended Practices:

3. SP-0169-2007: Control of External Corrosion on Underground or Submerged Metallic Piping Systems.

4. The repair or replacement of any defective or improperly installed systems shall be the sole responsibility of the Contractor. All repairs or replacement of defective or improperly installed cathodic protection systems shall be performed by the Contractor at no additional cost to the Authority.

1.3 SUBMITTALS:



A. Submit the following for approval in accordance with Section 335243.10 10 Fuel System General Provisions, the General Requirements and with the additional requirements as specified for each:

1. Work Drawings:

a. Layout of system being tested, showing location of system components, including test stations.

b. Instrument hook-up for each test.

c. Sample test forms

2. Certification:

a. Certified test report for each test conducted including the following:

1) Types, models, serial numbers and dates of calibration of all instruments.

2) Data resulting from specified test procedures, in approved format.

b. Certificates of calibration.

3. Qualifications of personnel:

a. Submit the testing firm’s qualifications along with job experience with the scope and contact information for previously performed projects.

b. Cathodic Protection Specialist’s qualification along with the field tester (if a different person).

PART 2 - PRODUCTS

2.1 MATERIALS

A. Wire and Cable: All cable shall be stranded. Factory installed solid type TW is acceptable for the anode leads.

B. #10 THHN wire for all test wires, color as shown

C. High Molecular Weight Polyethylene (HMWPE) header cable and bond wires

D. See Spec Section 335343.91 10, Fuel System Cathodic Protection System.

PART 3 - EXECUTION

3.1 TEST EQUIPMENT



A. Provide all required test equipment to include, but not limited to the following:

1. DC Voltmeter: Multi-scale, center zero, minimum sensitivity 50,000 ohm/volt, accurate to within one percent of full scale, covering the following full-scale ranges: 0-10 and 0-100 millivolts; 0-1, 0-10, 0-100 volts.

2. DC Ammeter: Multi-scale, maximum shunt drop of 20-mV sensitivity, ormillivolt meter and shunts, accurate to within one percent of full scale, covering the following full-scale ranges: 0-1, 0-10, 0-100 amperes.

3. Radio frequency insulating flange tester.

4. Reference Half-Cell: 7/8-inch diameter by eight inches long, saturated copper-copper sulfate. Cell must be calibrated.

5. Test Cable: Single-conductor cable, stranded copper, assorted sizes and lengths to suit test conditions.

6. High Voltage Spark Holiday Tester Tinker and Rasor Model AP/W or approved equal.

3.2 TESTS

A. General: The COTR will witness test to ensure proper operation and compliance of test stations installation in accordance with contract requirements and plan details of the Cathodic Protection system. The Contractor shall coordinate with the COTR. to schedule field test with the COTR, at least two weeks in advance. Note: In the event field tests indicate deficiencies in the system, the Contractor will be responsible for all costs associated with correcting deficiencies, retesting the Cathodic Protection system, including payment for additional site visits by the Engineer’s representative, at no additional cost to the Authority.

1. Test Data Forms: Record test data in a uniform format pre-approved by the COTR. Include test data, personnel, and instrumentation used on each sheet.

2. Testing Summary:

a. Pre - Backfill Tests:

1) Coating Holiday Test

2) Test Wire Continuity

3) Pipe-to-soil DC potential measurements

4) Anode potential measurements

5) Insulated joint effectiveness

b. Post - Backfill Tests:

1) Test Wire Continuity



2) Pipe-to-soil DC potential measurements

3) Interference Testing

4) Anode potential and current measurements

5) Insulated joint effectiveness

c. Improper materials or installation determined by Contractor performed tests, and/or tests performed by the COTR, shall be corrected by the Contractor.

3. Schedule:

a. Post-Backfill Tests: Start no sooner than 30 days before scheduled application for Beneficial Use.

b. Test Report: Letter of Compliance; Record Drawings: Submit no later than 10 working days before application for Beneficial Use.

4. Test Report:

a. Field test data for all pre-backfill and post-backfill tests.

b. Test set-ups and schematics.

c. Summary tabulations and theoretical calculations.

d. Letter of Compliance.

e. Record Drawings.

B. Test Procedures:

1. Insulated joint effectiveness tests:

a. Test electrical effectiveness of each buried dielectric insulating joint after installation into pipe system and no sooner than two days before backfilling.

b. Perform initial resistance tests between each bolt and flange in accordance with installation section of this Specification.

c. Perform tests for complete insulators by a) use of high-frequency isolation tester manufactured specifically for this purpose, and by b) measuring electrical potential between mating flanges before, during and immediately after application of a direct test current to the pipe on one side of the flange of no less than 1 ampere. Documented data for test b) shall include all potentials and applied test current.

d. Acceptance Criteria:

1) High frequency isolation tester: “Acceptable”, “Satisfactory” or other similar direct meter reading, and



2) Electrical potential/applied current: Apply test current to one side of the flange insulator; a positive potential shift on the side of the flange where current is applied, and a negative potential shift on the side of the flange opposite of where current is applied indicates that the insulator is effective.

2. Pipe-to-Soil Potential Measurements:

a. Record at all test stations and at a maximum spacing of 200’where soil access is available.

b. Collect using a temporary copper/copper sulfate reference electrode placed on grade within one foot of test station and using buried reference electrode where installed.

c. Collect at all locations prior to connecting anodes at test stations and then after anodes have been connected at all test stations for a minimum of 2 hours.

d. Utilize the coupon reference electrode to obtain the permanent polarization of the coupon. Follow NACE International procedures to perform the test. A minimum of 100 millivolts of permanent polarization is required.

3. Anode Potential and Current Measurements:

a. Measure and record open-circuit potential between each anode cable at each test station and a temporary copper/copper sulfate reference electrode placed on grade within one foot of test station. Collect open circuit potential data with no other influencing anodes connected to main.

b. Measure and record anode current at each test station using permanently installed current measuring shunt. Document shunt voltage drop, shunt resistance, and calculated current.

c. Acceptance Criteria:

1) Open-Circuit Potential: Magnitude 1.6 volts or greater.

2) Anode Current: Minimum 0.015 ampere per anode, adjusted to account for number of anodes included in circuit at any given location (e.g. 10 anodes - minimum 0.15 ampere).

4. Insulated Joint Effectiveness Tests: Test each joint. Procedures and acceptance criteria in accordance with pre-backfill insulated joint effectiveness tests.

5. The NACE Cathodic Protection Specialist responsible for over-seeing the project shall sign all of the test reports. The reports shall be submitted to the COTR for approval


4.1 Conform to all applicable provisions of Division 01 Section “Quality Requirements", Section 335243.10 10 and the requirements of this Section. Be responsible for periodic inspections for



conformance with the approved SPPP. The results of the periodic inspections shall be submitted to the COTR upon completion.



FUEL SYSTEM ABOVEGROUND HORIZONTAL TANKS 33 56 43.14 10 - 1

SECTION 335643.13 10 – FUEL SYSTEM ABOVEGROUND HORIZONTAL TANKS

PART 1 - GENERAL

1.1 SUMMARY:

A. This section includes the fabrication, and delivery of (1) 18,600-gallon aboveground horizontal double wall (containment style) cylindrical fuel tank for Jet-A service. Tank shall be constructed in accordance with UL-2085 and so labeled.

B. The tank and components shall be suitable for use with the product stored in them.

C. Tank shall be equipped with specified appurtenances and all specified equipment. The arrangement of nozzles and appurtenances is shown on the drawings.

D. The Manufacturer shall not supply, furnish, or install any pipe flanges, fittings, bolts or nuts of foreign manufacture. All pipe flanges, fittings, bolts and nuts shall be manufactured in the United States of America, and the Manufacturer warrants the U.S.A. origin of all such items. The Manufacturer shall provide written certification from the manufacturer as to the origin of all flanges, fittings, bolts, and nuts installed on the project.


A. Section 099713.10 10 - Fuel System Coatings

B. Section 335243.10 10 - Fuel System General Provisions

C. Section 260500.00 10 - Fuel System Electrical

D. Section 330951.00 10 - Fuel System Controls

E. Section 335243.23 10 - Fuel System Pumps

1.3 REFERENCES

A. Applicable Standards:

1. Recognized Aboveground Storage Tank System Codes Including:

a. American National Standards Institute (ANSI):

1) B1.20.1 - General Purpose Pipe Threads

b. National Electrical Manufacturers Association (NEMA)

c. Military Specifications:

1) MIL-C-4556 - Coating Kit, Epoxy, for Interior of Steel Fuel Tanks.



d. Underwriters’ Laboratories (UL):

1) 142 – Steel Aboveground Tanks for Flammable and Combustible Liquids

2) 2085 - Protected Aboveground Tanks for Flammable and Combustible Liquids

e. American Society of Mechanical Engineers

1) International Boiler and Pressure Vessel Code

f. National Fire Protection Association (NFPA)

1) NFPA 30, Flammable and Combustible Liquids Code

g. International Fire Code

h. OSHA 29CRF1910 – Occupational Safety and Health Standards

i. API 2000 – Venting Atmospheric and Low-Pressure Storage Tanks

j. Joint Industry Group (JIG)

1) Bulletin 35 - Soak Testing

1.4 SUBMITTALS

A. Submit compliance submittals in accordance with Section 335243.10 10 and include the following:

1. Complete tank layout drawing including material thickness

2. Drawing showing proposed labeling.

3. Tank specifications

4. Complete details of tank, saddle supports, and piping, including critical dimensions and locations of all fittings, equipment, man-ways, ladders, platforms, accessories, and tank anchor locations.

5. Tank strapping chart based on tank slope and installed appurtenances

6. Coatings with documented quality control criteria and procedures

7. Bill of materials

8. Product data on all equipment

9. Manufacturer shall submit certification that equipment will comply with performance requirements as specified



10. Manufacturer shall submit certification that the tank has successfully completed all required shop leakage hydrostatic strength tests and per UL-142 and other applicable codes.

11. Mill certifications on all steel, pipe and fittings used

12. Welding procedures and welding qualifications

13. Signage and nameplate data

14. Warranty information


A. Manufacturer’s Qualifications: All equipment and material shall be the latest design, new, and the highest quality standard product of manufacturers regularly engaged in the production of such equipment and material for a minimum of 5 years. The manufacturer shall have assemblies that have been in satisfactory use in similar service for not less than 5 years.

B. Qualify welding processes and welding operators in accordance with ASME Boiler and Pressure Vessel Code, Section IX. Submit qualification reports in the format as suggested in Appendix B of Section IX.

C. When two or more units of the same class of equipment are required, they shall be the products of a single manufacturer.

D. Coating applicator shall have a minimum of 5 years of experience in the application of the type of coating system used.

E. Performance Characteristics: Tank shall be built in strict accordance with NFPA 30, UL 142, UL-2085 and shall be inspected and labeled by Underwriters Laboratories, Inc.

F. All steel shall be new and shall not have been used previously for any other purpose and shall be of U.S. origin.

1.6 DELIVERY, STORAGE AND HANDLING

A. Provide and pay all freight, express, trucking, transportation, cartage and handling for equipment and materials. Pay for extra handling and shipping expenses incurred in expediting material, etc., to prevent interruption of the overall job progress.

B. Protect internal and external parts against rust and corrosion.

C. Pack items with factory applied covers, caps or blinds on all flanges and connections.

D. Protect internal components against damage from rattling, shifting and moving.

E. Spot paint all equipment where the shop paint has been damaged or flaked off in accordance with the coating manufacturer's recommendations.



F. Pay all demurrage charges resulting from the unloading operation.

1.7 WARRANTY

A. The manufacturer’s 20-year warranty of the storage tank shall be submitted before delivery.

B. All equipment shall be new and have a one-year warranty by the tank manufacturer or the supplier after system installation and factory training has taken place. If defects arise, the manufacturer shall replace or repair the equipment at the Owner’s discretion at no cost to the Owner.

PART 2 - MATERIALS

2.1 DOUBLE WALL HORIZONTAL CYLINDRICAL TANK

A. Tank shall be as manufactured by a facility licensed by the Steel Tank Institute and be experienced in the construction of UL 2085 horizontal steel tanks.

B. The tank shall be horizontal, cylindrical, and shall be of a double wall steel construction conforming to UL2085 and so labeled. The secondary tank shall be a complete 360 degree wrap. The primary tank shall have a nominal capacity of 18,600 U.S. gallons and the overall tank shall be nominally 10’-7” dia. X 32’-3-1/2” in length.

C. The tank shall be supported by two saddles on each tank. Saddles shall be designed to UL 142 requirements and shall be welded to the tank. Saddles shall provide 4-inch clearance between bottom of tank and bottom of saddle. Saddles shall be designed to meet the Uniform Building Code.

D. The tank shall be internally coated and externally painted in accordance with Section 335243 80.10 10. All internal tank surfaces in contact with fuel including piping, ladders, etc., shall be coated.

E. The tank shall have a tank-strapping table developed by an independent contractor after the tank is fabricated. Strapping chart shall take the 2.5% slope into account as the tank will set when installed and shall be based on readings at the nozzle connection for the manual stick gauge.

F. Shell and head joints shall be butt joints with full penetration welds. Welds located on the interior of the tank shall be ground smooth removing all weld splatter to accommodate the internal coating of the tank. The interior welds along the bottom 6-inches of the tank shall be ground flush prior to coating to allow any water in the fuel tank to migrate to the sump location to allow for removal. Joint details shall be shown on the manufacturer drawings.

G. All piping shall include pipe, fittings, valves, supports, and shall be of carbon steel construction and in conformance with the materials specified in this specification.

H. The tank shall be installed off level as shown on the design drawings. This will provide a 2.5% slope of the tank draining to the low end with the water draw off connection. The tank saddles shall be designed to accommodate this slope.



2.2 APPURTENANCES

A. All appurtenances shall be at the locations indicated on the drawings. The following table provides a schedule of the tank appurtenances.

Appurtenance 18,600 Gallon – Jet-A Tank 2” MNPT Interstitial Monitor

6” FNPT Normal Vent

8” MNPT Secondary Emergency Vent

8” MNPT Primary Emergency Vent

4” MNPT Level Transmitter with stilling well

30” Manway Manway – provide one with ladder and 1/2" full coupling in manway neck for high level float pilot

control tubing

3” MNPT Manual Gauge

8” ANSI 150 R.F. FLANGE

Tank fill with drop tube and 90 elbow diffuser

16” ANSI 150 R.F. FLANGE Vertical Turbine Pump

2” FNPT Floating Suction Position Indicator

2”ANSI 150 R.F. FLANGE

Water Drawoff Connection

2” FNPT Direct Reading Level Gauge

1” FNPT Fuel Return

B. Tank fill drop tubes to extend to the tank bottom and be provided with a diffuser as indicated on the drawings.

C. One 30-inch manway with bolted cover shall be provided at the top of the tank for internal access. An internal ladder shall extend from top of the manway to tank floor as indicated. Provide strike plate under manway/ladder. The manway shall be equipped with a 3” NPT manual gauging hatch as indicated. The manway neck shall be provided with a 1/2" full coupling for installation of the control tubing from the high level control valve to the high level float pilot installed in the tank and mounted to the internal ladder.

D. One 16" ANSI 150 raised face flange shall be provided for connection of the vertical turbine pump. Tank nozzle shall be designed to support the weight of the supplied pump.



E. Water draw-off connection shall be located on the top of the tank as indicated on the drawings.

2.3 LADDERS AND PLATFORMS

A. A platform shall be factory fabricated to provide access to the manway and tank nozzles. One set of stairs shall be provided as indicated. The access stairs and platform shall be OSHA approved with required toe plate and railings. The grating shall be galvanized steel with additional supports provided where grating is cut to fit around manways and nozzles. Platform and stairs shall be bolted to the tanks once they are set in their final location. Any platform/stair attachment hardware which requires welding to the tank shall be installed prior to coating the tank.

1. Exterior ladders shall comply with the construction requirements in accordance with the current edition of Occupational Safety and Health Standards, Title 29 of the Code of Federal Regulations, Part 1910, Subpart D, Section 1910.27 - Fixed Ladders.

2. Interior ladders shall comply with the exterior ladder requirements except that the climbing surface must be vertical and directly in line with the edge of the tank manhole.

3. Guardrails shall comply with Sub-paragraph 1910-23(d)(1) of the current edition of Occupational Safety and Health Standards, Title 29 of the Code of Federal Regulations.

4. Runways (catwalks) shall comply with the construction requirements in accordance with the current edition of Occupational Safety and Health Standards, Title 29 of the Code of Federal Regulations, Part 1910, Subpart D, Section 1910.23 - Guarding Floor and Wall Openings and Holes, sub-paragraph (c) – Protection of open-sided floors, platforms, and runways.

2.4 EQUIPMENT

A. All equipment shall be provided with the tanks and shall be new and have a one year warranty by the tank manufacturer or the supplier. If defects arise, the manufacturer shall replace or repair the equipment at the Owner’s discretion at no cost to the Owner

B. Normal Vent (Jet-A Tank)

1. Normal vent cap shall mate to 6” ANSI 125 flat face flange connection. Nozzle on tank shall be a 6" NPT connection for field installation of a vent riser to extend vent to 12-'0" minimum above grade. Materials of construction shall be stainless with a stainless screen and stainless steel hood.. Vent shall be sized for a minimum 8,450 SCFH inbreathing and 8,841 SCFH outbreathing with a maximum fill rate of 1000 gpm and a maximum withdrawal rate of 1000 gpm. Vent shall be Shand & Jurs Model 94241 or approved equal.

C. Emergency Vent (Jet-A Primary and Secondary Tanks)

1. Emergency vent shall be an automatically resetting 8” NPT connection, cast iron painted cover, viton o-ring seat, iron body, with 16 oz. pressure setting or approved equal. Vent shall be sized for a minimum 495,000 SCFH.



D. Manual Gauge Hatch

1. The stick gauging hatch shall be a cam and groove side seal adapter with locking cap.

E. Manual Stick Gauge

1. Provide a wooden stick gauges 16’ in length with units of measure in inches and minimum resolution of 1/8” for the tanks. Provide a 1 ½” dia. PVC pipe, 16’ in length mounted to the platform railing at the tank to house the gauge stick.

F. Suction Connection for Vertical Turbine Pump:

1. Suction nozzle connection shall be a 16" ASNI 150 Raised Face Flange connection located as indicated.

2. See Section 335243.23 10 for vertical turbine pump requirements.

G. Tank Gauging and High Level Alarm

1. Provide a manual direct reading tank level gauge. Gauge shall read in gallons and shall have an external high level alarm. Alarm console shall be intrinsically safe and shall be battery operated. Gauge face plate shall be selected based upon the tank dimensions. Provide Morrison Brothers. Fig. 918C-0100AG. Gauge shall mount in a 2" FNPT tank connection.

H. Tank Interstitial Monitor

1. The interstitial space of the double wall tank shall be a float type manual sensor. The presence of liquid in the interstitial space shall cause the float to rise and provide a visual indication on top of the tank. The gauge shall mount in a 2” FNPT tank connection. Shall be Krueger Sentry Type K Interstitial Leak Gauge or approved equal.

I. Floating Suction Position Indicator:

1. The internal floating suction assembly shall have a clock gauge to provide a means to display movement of the floating suction arm as the liquid level rises. The clock gauge shall be mounted in a 2" FNPT fitting located above the floating suction assembly. This will allow the operator to visually inspect the floating suction movement. Clock gauge assembly shall be Morrison Brothers Fig. 818I or approved equal.

2.5 FINISHES

A. Coatings and finishes shall be per Specification Section 335280.10 10 – Fuel System Coatings.

2.6 NAMEPLATE

A. Certification Label: Each tank shall bear a permanently affixed certification label. Nameplate shall be stainless steel stamped with the following:

1. Underwriters Laboratory label



2. Name of manufacturer

3. A unique identification number

4. Dimensions, design and working capacity and model number of the tank

5. Year of manufacture

6. Tank supplier shall not provide additional labeling of the tank advertising the manufacturer, steel construction, and the UL 142 (UL2085) rating. The dataplate shall suffice for identification of the tank fabrication. Only the items required by code and that are required in these specifications shall be included. Provide drawings depicting the proposed labeling.

PART 3 - EXECUTION

3.1 REGISTRATION

A. Contractor shall prepare all required tank registration paperwork for submittal by the Authority.

3.2 FABRICATION FACILITY INSPECTIONS

A. Manufacturer shall establish an inspection visit schedule with dates at key points in the fabrication of the tank systems. Provide schedule of dates to the Owner and Engineer four weeks prior to first inspections.

3.3 TESTING

A. Perform all shop performance tests required by UL 142, including, but not limited to, tank leakage and hydrostatic strength tests. Test both the primary and secondary containment tanks. Provide all test results.

B. Double wall tank shall be shipped with the interstitial space under pneumatic test. Provide pressure gauge assembly to allow the receiving agent/Engineer to verify the interstitial space is holding pressure after delivery.

C. Perform all coating inspections as specified in Section 335280.10 10.

D. Following commissioning and fuel delivery, complete a soak test of the tank per JIG Bulletin 35. Soak test shall be a minimum of 7 days. A retention sample shall be collected at the beginning of the test. Fuel shall be circulated daily for a minimum of 5 minutes. Following the test period, a fuel sample shall be taken and sent to an approved laboratory and the following tests performed:

Test Method Jet Fuels Avgas ASTM IP Appearance ● ● D4176 Gum ● ● D381 540



Water Reaction ● D1094 289 MSEP ● D3948 Conductivity ● D2624 274 Saybolt Colour ● D156 Thermal Stability (JFTOT)

● D3241 323

Distillation ● ● D86 123 Flash Point ● D56 170

3.4 DELIVERY

A. The delivery of the tank(s) shall be coordinated with the Contractor to ensure the site is ready for delivery.

B. The tank(s) shall be clean and wiped down prior to shipment. All nozzles shall either have the specified equipment installed or temporary covers to prevent contamination during storage and delivery.

3.5 INSTALLATION:

A. The tank manufacturer shall provide the tank vents and floating suction as specified and shall install all equipment either at the factory or on site at the time of delivery.

B. The tanks are designed to rest at a slope as shown on the drawings.

C. It shall be the Contractor’s responsibility or his designee to offload and set the tanks and install the platforms. Provide any manufacturer instructions required to perform proper installation.

D. The Contractor shall field repair any damage to coatings as a result of delivery and installation. Coating system shall be identical to the system used by the tank manufacturer.






FUEL SYSTEM LEAK DETECTION SYSTEM 335800.10 10-1

SECTION 335800.10 10 - FUEL SYSTEM LEAK DETECTION SYSTEM

PART 1 - GENERAL

1.1 DESCRIPTION

A. Below ground fuel piping at Washington Dulles International Airport is monitored by an intricate leak detection system manufactured by Hansa Consult of North America. To comply with Virginia Department of Environmental Quality (VDEQ) requirements, the piping system has been sectionalized to provide lower detectable leak rates. Testing occurs on a nightly basis and is monitored from the remote Fuel Storage Facility.

B. Various aspects of the Hydrant Fuel Line Improvements project will either add to or eliminate piping from the various segments of the system that is monitored by the leak detection system. The Contractor shall make appropriate programming changes to the leak detection system to accommodate for the piping modifications.




A. Compliance submittals shall be in accordance with Section 335243.10 10 and shall be provided for all equipment changes specified in this Section.

B. Commissioning Plan

C. Commissioning and test certification

D. Screen Shots from the Revised Hansa Control Screen


Provide the services of competent and effective manufacturer’s representative to reprogram and commission the system after each stage of construction.

PART 2 - MATERIALS

2.1 Not Applicable.

PART 3 - EXECUTION


FUEL SYSTEM LEAK DETECTION SYSTEM 335800.10 10-2

3.1 START UP SERVICES

A. Contractor shall retain the original leak detection equipment manufacturer to reprogram the monitoring software, revise the control panel screens, and recertify piping systems as new piping is brought into service or existing segments of piping are decommissioned or abandoned.

B. Specific work areas that will require reprogramming and commissioning include: 1. Area A – Remove Lines at Concourses C and D 2. Area B – Remove/Install Lines to Signature Flight 3. Area C – Preserve Existing Line from C1IVV to RMIDIVV.





FUEL SYSTEM DESCRIPTION OF OPERATION 335809.93 10-1

SECTION 335809.93 10 - FUEL SYSTEM DESCRIPTION OF OPERATION

PART 1 - GENERAL

1.1 SUMMARY

A. This section describes the operation of the fuel system control logic to include alarms, interlocks, and operation of the hydrant cart test stand facility.


A. Section 260500.10 10 - Fuel System Electrical

B. Section 260900.10 10 – Fuel System Instrumentation

1.3 SUBMITTALS

A. The control system integrator shall submit the description of operation if any clarifications or changes are made to the following text. The control system integrator shall submit the description of operation prior to beginning any programming. Submit proposed graphics screens at the same time. The integrator shall meet with the Operator and the Engineer to discuss and reach consensus before beginning programming.

B. The existing Tank Farm HMI shall be modified to include an overall screen of the hydrant cart test stand, with annunciation as described below. The existing Tank Farm HMI screen which shows the fuel storage tanks shall be modified to include the new hydrant cart test stand horizontal fuel storage tank showing level, temperature, interstitial monitor and pump run signal.

PART 2 - PRODUCTS (NOT USED)

PART 3 - EXECUTION

3.1 FUEL STORAGE TANK OPERATION

A. The tank will be an 18,600 gallon horizontal tank of carbon steel construction. The purpose of the tank is to provide storage in support of the hydrant cart testing operations. Fuel will be pumped from this tank to the hydrant valve, through the hydrant cart being tested, and back into this same storage tank.

B. All new valves associated with this tank are manually operated.

C. The tank shall be depicted on the Tank Farm HMI screen which currently shows the Tank Farm storage tanks, showing liquid level and fuel temperature and interstitial monitor.



D. The tank shall be equipped with a magnetostrictive level sensor with an integrated single point temperature RTD. The fuel temperature sensing point is 12 inches above bottom of tank. Tank level will be continuously updated on each HMI screen. Fuel temperature level will also be indicated on the HMI screen.

1. High level (set at 80%) will alarm the local horn at the hydrant cart test stand and also annunciate the condition on the Tank Farm HMI screen.

2. Redundant High Level integral to the direct reading level dial gauge mounted on top of the tank (set at 80%) will alarm at the hydrant cart test stand.

3. High-high level (set at 90%), will again alarm the local horn at the hydrant cart test stand and also annunciate the condition at the Tank Farm HMI screen. It shall also close the existing 6" motor operated double block and bleed valve on the supply line from the hydrant system.

4. Redundant high-high level (set at 95%) is a float operated diaphragm valve. This hydraulically operated valve shall close independently of the aforementioned to provide a mechanical means of high level shutoff.

5. Low level (set 1’-3” above bottom of tank) will alarm as described above but will also stop the hydrant cart test pump TP-1 mounted in the tank.

6. High temperature is set at 1000 F and is measured at 1’-0” from the tank bottom as part of the liquid level device. During extended hydrant cart test operations, as the fuel is continuously recirculated through TP-1, the fuel will pick up heat from the pump. Should the fuel reach a temperature of 1000 F, it will alarm as described above stop the hydrant cart test pump TP-1. The pump will be allowed to restart once fuel cools to 900 F or if placed in hand operation to allow the warm fuel to be removed from the tank by loading onto a refueler and replaced with fuel from the hydrant system. The high temperature shall be indicated on the Test Stand Control Panel (TSCP).

3.2 Hydrant Cart Test Stand

A. The hydrant cart test stand system will be capable of testing hydrant carts with flow rates from 200 gpm up to 1000 gpm while maintaining 120 psi at the bottom of the hydrant valve. The test stand will also be capable of testing refueler vehicles by creating a closed loop system and circulating fuel via the onboard fuel transfer pump through the test stand and back onto the refueler vehicle.

B. The pump serving the hydrant cart test stand operation is pump TP-1.

C. Valve alignment will be such that there is a flow path from the tank through the pump and to the existing hydrant pit. Pump TP-1 shall be protected by a timer and position switch on the anti-siphon valve (ASCV) in the event that a flow path does not exist. When the operator presses the start button, a 20 minute timer and a 30 second timer shall begin. When the 30 second timer expires, if the ASCV is not open, the pumps shall shut down. Otherwise, the pump is allowed to run until the 20 minute timer expires, at which point it will be automatically shut down.



D. After the hydrant cart is grounded, coupled to the hydrant valve and connected to either the low or high aircraft adapters, pump TP-1 is started by manually pressing the start button mounted adjacent to the pump following authorization through the Fuelmaster. Pump run status will be annunciated on the Tank Farm HMI screen. The operator will squeeze the deadman to open the hydrant valve and allow flow to start through the hydrant cart. At the completion of the test, the operator will depress the stop button.

E. Just downstream of pump TP-1 is a back pressure control valve, BPCV-1. The purpose of this valve is to maintain a relatively constant pressure at the bottom of the hydrant valve. The centrifugal pump will by nature vary pressure as flow rates vary. The hydrant cart test stand will see flow rates between 200 gpm and 1000 gpm which would result in different pressures at the hydrant pit valve. In order to be consistent in the setup of all hydrant carts, regardless of flow rate, the back pressure control valve will bleed off pressures in excess of 120 psi (field adjustable). This is accomplished by routing a portion of the flow back to the storage tank. The sensing point for pressure control will be near the bottom of the hydrant valve and the hydraulic signal tubed back to the control valve.

F. There is a butterfly valve, with 10 position throttling operator, located just downstream of the aircraft adapters. This will allow the operator to introduce backpressure and test the primary and secondary controls of the hydrant cart. There is a 0 to 160 psi pressure gauge immediately upstream of this valve to record the backpressure on the system.

G. Fuel will be returned to the horizontal tank through the HCTS meter. The meter will be equipped with a mechanical flow rate indicator and a large numeral counter. The meter will be set up for gross meter reading only. Just downstream of the test meter is a meter proving station to allow periodic calibration of the test meter by certified third parties.

3.3 HYDRANT CART TEST STAND TANK FILL

A. In order to fill the hydrant cart test stand tank from the hydrant system, the Operator shall open MOV-1, V-1, V-2, and V7. The tank will then be filled via the hydrant system. The tank levels can be monitored via the direct reading level dial gauge mounted on top of the tank and through existing Veeder Root ATG display panel mounted in the existing electrical enclosure nearby. The Operator shall monitor the tank levels and shall close MOV-1 when the tank reaches a high level indicated by the high level alarm annunciation at 80%. MOV-1 shall close automatically when then tank level reaches 90%. At the completion of the tank fill operation, Valve V-1 shall be manually closed by the Operator.

B. The tank may also be filled via a refueler vehicle. For this operation, a refueler vehicle is positioned in the test stand and fuel is pumped off the refueler vehicle via the onboard pump through the test stand and into the tank. The high level alarms shall annunciate as indicated and the mechanical high level control valve shall close when the tank reaches a 95% level.

3.4 HYDRANT CART TEST STAND TANK DRAIN

A. In order to drain the tank and replenish the fuel, the operator must complete a refueler truck loading operation from the test stand tank as described herein.



3.5 REFUELER TRUCK LOADING OPERATION

A. The existing refueler loading position at the hydrant cart test stand shall remain fully functional. Refuelers may be loaded either via the existing hydrant system or via the hydrant cart test stand tank and pump TP-1.

B. Loading via the hydrant system requires MOV-1 to be in the open position and V-2 in the closed position. The Operator is required to gain access via the existing FuelMaster. The FuelMaster shall be reprogrammed to allow for different keys to access either the Refueler Truck Loading Operation Mode or Hydrant Cart Test Stand Mode. When Refueler Truck Loading Operation Mode is selected, MOV-1 shall be commanded open if not already to allow fueling operations. All other controls from the Fuelmaster shall remain to include control of the low flow and high flow solenoids on the existing loading control valve. When MOV-1 is not reported to be in the fully closed position, the solenoid on BPCV-1 shall be energized and BPCV-1 shall be closed. No other modifications to the controls are required for loading via the hydrant system.

C. Loading refueler vehicles via the hydrant cart test stand requires MOV-1 to be in a closed position. The Operator is required to gain access via the existing FuelMaster. The FuelMaster shall be reprogrammed to allow for different keys to access either the Refueler Truck Loading Operation Mode or Hydrant Cart Test Stand Mode. When Hydrant Cart Test Stand Mode is selected, MOV-1 shall be commanded closed if not already to allow fueling operations. Pump TP-1 shall not operate unless MOV-1 is in a closed position. The existing FuelMaster shall be modified to add the HCTS mode. When HCTS mode is selected, MOV-1 shall be commanded to close if not already closed and BPCV-1 solenoid shall be deenergized to allow it to open. When MOV-1 is reported closed, pump TP-1 shall start operation when the HOA switch is in Automatic mode. When the HOA switch is set to local mode, the pump may be started with the START pushbutton located adjacent to the FuelMaster. When the pump starts, a 20 minute timer and a 30 second timer begin. When the 30-second timer expires, if the anti-siphon valve (ASCV) is not open, the pump shall be shutdown. Otherwise, the pump is allowed to run until the STOP button is pressed or the 20 minute timer expires.

3.6 EMERGENCY FUEL SHUTOFF (EFSO)

A. Load Rack/HCTS EFSO

1. Actuation of Load Rack/HCTS EFSO system shall:

a. Drive shut the motor operated plug valves on the three Jet-A load positions.

b. EFSO activation shall also shutdown the pump TP-1 operation.

3.7 TANK OVERFILL PROTECTION AND REFUELER TESTING

A. To prevent an overfill of the tank during a refueler test, a high level control valve (HLCV-1) shall hydraulically close in the cart re-circulation line to segregate the refueler fuel from ST-1 should the internal float indicate a high-high level condition. The float shall be set one inch above the automatic internal level gauge ‘High-High Level”.



B. Actuation of the HLCV-1 level control valve shall be annunciated to the local control panel and the Operations Office control PC. The operator must silence the alarm from either the local or the office control panel. The test shall be invalidated if ST-1 is filled to this point by the refueler.

3.8 PUMP OPERATION

A. Pumps shall shut off when any fuel facility EFSO button is activated.

B. Pump shall not operate unless MOV-1 is in the closed position.

C. Pump shall not operate if motor winding temperature switch is activated. This shall be alarmed on Panel TSCP with a red indicating light.

D. Pumps shall not shut off when the cart dead-man is released or the hydrant pit valve servo is closed by release of the deadman or the cart’s EFSO switch is activated.

E. For any cart test, the User/Tester shall initiate the start of the pump through the Fuelmaster. The FuelMaster shall be programmed such that certain keys activate only the HCTS or Loading functions. For any refueler test, the pump shall not run.

F. The pump shall not start until the cart test is ready to begin and the cart hoses have been connected. Prior to pump start, the system shall prompt the User/Tester to verify that the cart is chalked, and hoses connected.

G. Software shall not allow pump to be restarted within 30 seconds after stopping any pump (adjustable).

H. Software shall track the operation of the pump as on or off.

I. Pump shall stop when the position switch on the Anti-siphon/Rate of Flow control valve located immediately downstream of the pump does not indicate and open signal via the valve position limit switch within 30 seconds of the pump command to start or if at any time the valve appears closed after receiving an open signal, the pump shall shutoff.

3.9 TEST OPTIONS

A. The User/Tester may complete any number of tests as required by ATA 103 and the airline auditors. Tests may include the following and the sequence of each test is described in the following paragraphs.

1. Full-flow tests

2. Surge tests

3. Pressure control tests based on varying back pressure

4. Meter Calibration and proving

5. A meter calibration test.



3.10 FULL FLOW TEST PROCEDURE AND SEQUENCE

A. The operator prior to pump start must validate satisfaction of the refueler/cart grounding connection via the Fuelmaster. All record keeping for the tests will be manually collected by the Operator/User/Tester.

B. Full-flow tests: The Operator shall manually set the backpressure on the system by adjusting the position of the 6" butterfly valve (V-3). When the valve is full open, this provides the lowest backpressure and the maximum flow rate through the equipment being tested. (Recognizing that the maximum flowrate through the cart is limited in fact by its on-board flow control valve.) The Operator shall manually record the maximum flowrate via the rate of flow dial indicator on the HCTS meter.

C. Full-flow test sequence and procedure.

1. The User/Tester shall depress the equipment deadman allowing flow through the cart/refueler being tested.

2. The User/Tester shall read and record the differential pressure across the equipment’s filter separator while holding the cart/refueler deadman closed.

3. The User/Tester shall perform a millipore test. The User/Tester shall save and label the millipore sample.

4. Overshoot testing for PRIMARY controls:

a. The User/Tester shall confirm that the cart/Refueler is operating on the primary cart/refueler controls.

b. Overshoot testing is to be completed for the cart/refueler deadman and each Emergency Shut Down device on the cart/refueler. The User/Tester equipment log shall include the location and number of ESD’s on the cart/refueler.

c. Deadman test.

1) Overshoot shall manually be recorded as the User/Tester. The User/Tester shall release the deadman on the cart when the HCTS meter is on an even number, i.e. 500 gallons.

2) An overshoot test is passing if the total flow (gallons) is less than or equal to 10% of the maximum flow rate value (GPM) achieved through the rate of flow indicator on the HCTS meter prior to the test.

3) An overshoot test fails if the amount of fuel exceeds the 10% rule by more than 1% of the maximum flow rate in gallons.

4) The User/Tester shall record, the overshoot in gallons and the flow rate in gallons per minute manually.

d. Emergency Shut Down (ESD) test.



1) Overshoot shall manually be recorded as the User/Tester. The User/Tester shall activate the ESD device on the cart when the HCTS meter is on an even number, i.e. 500 gallons.




5) Repeat test for each ESD device.

5. Overshoot testing for SECONDARY controls:

a. The User/Tester shall confirm to the screen that the cart/refueler is operating on the secondary cart/refueler controls.

b. Overshoot testing is to be completed for the cart/refueler deadman and each Emergency Shut Down device on the cart/refueler. The User/Tester equipment log shall include the location and number of ESD’s on the cart/refueler.

c. Deadman Test.

1) Overshoot shall manually be recorded as the User/Tester. The User/Tester shall release the deadman on the cart when the HCTS meter is on an even number, i.e. 500 gallons.




d. Emergency Shut Down (ESD) test.

1) Overshoot shall manually be recorded as the User/Tester. The User/Tester shall activate the ESD device on the cart when the HCTS meter is on an even number, i.e. 500 gallons.






5) Repeat test for each ESD device.

3.11 SURGE TEST

A. Surge tests: The User/Tester shall position valve V-3 in the full open position to provide the lowest backpressure setting to allow the maximum flow rate through the equipment being tested. (Recognizing that the maximum flowrate through the cart is limited in fact by its on-board flow control valve.) The User/Tester shall verify the maximum flow rate is reached using data from the rate of flow indicator on the HCTS meter and comparing this information manually to the information in the equipment log for the equipment being tested. If flowrate is not reached within 10%, then User/Tester shall terminate the surge test and investigate as to why the maximum flow rate was not achieved.

B. Surge test sequence and procedure.

1. The User/Tester shall depress the equipment deadman allowing flow through the cart/refueler being tested. Flowrate shall then be verified by User/Tester within 20 seconds and after the User/Tester has confirmed that the cart/refueler is operating on its PRIMARY controls.

a. The surge test is initiated by manually closing valve V-3. The User/Tester shall manually close valve in a linear function and shall close valve fully in two second.

b. The User/Tester shall manually record the peak pressure indicated on the pressure gauge assembly immediately upstream of valve V-3.

c. Once the test is completed and the data recorded, then valve V-3 shall be manually opened and the peak hold pressure cleared.

2. The User/Tester shall depress the equipment deadman allowing flow through the cart/refueler being tested. Flowrate shall then be verified by User/Tester within 20 seconds and after the User/Tester has confirmed that the cart/refueler is operating on its SECONDARY controls.

a. The surge test is initiated by manually closing valve V-3. The User/Tester shall manually close valve in a linear function and shall close valve fully in two second.

b. The User/Tester shall manually record the peak pressure indicated on the pressure gauge assembly immediately upstream of valve V-3.

c. Once the test is completed and the data recorded, then valve V-3 shall be manually opened and the peak hold pressure cleared.

3.12 PRESSURE CONTROL TEST BASED ON VARYING BACK PRESSURE



A. When a pressure control test based on varying backpressure is completed by the User/Tester, the valve V-3 shall be manually adjusted and the upstream pressure recorded.

B. Pressure control tests: The User/Tester shall select the position for V-3 to the lowest backpressure setting. The lowest setting on the V-3 is intended to allow the maximum flow rate through the equipment being tested. (Recognizing that the maximum flowrate through the cart is limited in fact by its on-board flow control valve.) The User/Tester shall verify the maximum flow rate is reached using data from the rate of flow indicator on the HCTS meter and comparing this information to the equipment log for the equipment being tested.

C. The User/Tester shall verify that the cart is using PRIMARY controls. The User/Tester shall then depress the deadman.

1. The User/Tester shall manually adjust valve V-3 by closing the valve to the next set point to increase the backpressure. The second lowest backpressure setting is intended to reduce the flow rate through the equipment being tested. (Recognizing that the maximum flowrate through the cart is limited in fact by its on-board flow control valve.) Once a steady flow rate is achieved via the rate of flow indicator, the User/Tester shall record the backpressure and flow rate.

a. The User/Tester shall then compare the reading of pressure to the primary control set point target and determine if it is equal to or less than the target within 10%. If not, then the User/Tester shall indicate that the test failed. Otherwise the test shall proceed to the next primary backpressure set point.

2. The User/Tester shall continue to repeat the test for each of the 10 locking positions on the manual operator of the butterfly valve until the backpressure created by the valve is greater than the set point on the cart and the flow rate goes to zero. The User/Tester will now move on to the SECONDARY evaluation and log all primary data.

D. The User/Tester shall verify that the cart is using SECONDARY controls. The User/Tester shall then depress the deadman.

1. The User/Tester shall manually adjust valve V-3 by closing the valve to the next set point to increase the backpressure. The second lowest backpressure setting is intended to reduce the flow rate through the equipment being tested. (Recognizing that the maximum flowrate through the cart is limited in fact by its on-board flow control valve.) Once a steady flow rate is achieved via the rate of flow indicator, the User/Tester shall record the backpressure and flow rate.

a. The User/Tester shall then compare the reading of pressure to the primary control set point target and determine if it is equal to or less than the target within 10%. If not, then the User/Tester shall indicate that the test failed. Otherwise the test shall proceed to the next primary backpressure set point.

2. The User/Tester shall continue to repeat the test for each of the 10 locking positions on the manual operator of the butterfly valve until the backpressure created by the valve is greater than the set point on the cart and the flow rate goes to zero.

3.13 METER CALIBRATION AND REPORTING



A. The User/Tester shall fully open V-3 to the lowest backpressure setting to allow the maximum flow rate through the equipment being tested. (Recognizing that the maximum flowrate through the cart is limited in fact by its on-board flow control valve.) The User/Tester shall verify the maximum flow rate is reached using data from the rate of flow indicator on the HCTS meter and comparing this information to the equipment log for the equipment being tested.

B. The User/Tester shall verify that the cart is using PRIMARY controls. The User/Tester shall then depress the deadman.

C. The User/Tester shall pass one thousand gallons through the HCTS meter and then the User/Tester shall release the deadman. The User/Tester shall then record the reading on the cart/refueler meter and the HCTS meter. The User/Tester shall compare the HCTS meter to the cart/refueler input. If the comparison is higher or lower by more that 0.5% of the total volume read by the HCTS meter, the User/Tester shall record that the meter is out of calibration and the data logged.


