DESIGN CERTIFICATION - Tracy · 2018. 10. 24. · DESIGN CERTIFICATION The Plans and Technical...

DESIGN CERTIFICATION The Plans and Technical Specifications contained herein have been prepared by, or under the responsible charge of, the following registered person(s): CH2M HILL 2485 Natomas Park Drive, Suite 600 Sacramento, CA 95833

Vijay C. Kumar

License # C59044 Exp. Date: 06/30/2019

CITY OF TRACY WASTEWATER TREATMENT PLANT EFFLUENT OUTFALL PIPELINE IMPROVEMENTS

PW/WBG/179201 RESPONSIBLE AUTHORS OCTOBER 2018 FOR SPECIFICATIONS ©COPYRIGHT 2018 CH2M HILL 00 01 06 - 1

INITIALS NAME

AJF Andrew J. Finney

BW Benjamin Wright

BMI Brett M. Isbell

CRB Chad R. Burke

DNA Dhumal N. Aturaliye

LAA Lisa A. Alliger

MRR Michael R. Riess

TJP Thomas J. Price

TJH Travis J. Howard

VCK Vijay C. Kumar

WKV William K. Vollmers Note: Initials shown in parenthesis after the title of each Specification Section indicate the responsible author for that section.


PW/WBG/179201 SEALS PAGE OCTOBER 2018 00 01 07 - 1 ©COPYRIGHT 2018 CH2M HILL

08/xx/16

10/20/17

9/26/18 9/26/18 9/26/18

9/26/18 9/26/18 9/26/18 9/26/18

9/26/18 9/26/18 9/26/18

6/30/2019


PW/WBG/179201 TABLE OF CONTENTS OCTOBER 2018 00 01 10 - iii ©COPYRIGHT 2018 CH2M HILL

TABLE OF CONTENTS

Pages

VOLUME 1 — BIDDING AND CONTRACT REQUIREMENTS, TECHNICAL PROVISIONS

INTRODUCTORY PAGES

Cover page (VCK) ................................................................................................. 1- 1 Design Certification (VCK) ................................................................................... 1- 1 Responsible Authors for Specifications (VCK) ..................................................... 1- 1 Seals Page (VCK) .................................................................................................. 1- 1 Location Map (VCK) ............................................................................................. 1- 1 Invitation for Bids (VCK) ...................................................................................... 1- 1 Notice to Bidders (VCK) ...................................................................................... 1- 3 Schedule of Required Bid Documents and Agreement Forms (VCK) .................. 1- 1

BID PROPOSAL

Bid Proposal (VCK) ............................................................................................... P- 1 Bidding Requirements (VCK) ............................................................................... P- 2 Bid Schedule (VCK) .............................................................................................. P- 4 Designation of Subcontractors (VCK) ................................................................... P- 7 City Business License Requirement (VCK) .......................................................... P- 8 Non-Collusion Affidavit (VCK) ............................................................................ P- 9 Bidder’s Qualifications (VCK) .............................................................................. P- 10 Bidder’s References (VCK) ................................................................................... P- 11 Signature of Bidder (VCK) .................................................................................... P- 12 Bidder’s Bond (VCK) ............................................................................................ P- 14

AGREEMENT AND AGREEMENT FORMS

Agreement for Public Improvements (VCK) ........................................................ A- 1 Agreement Forms Faithful Performance Bond (VCK) ........................................................... A- 8 Labor and Material Bond (VCK) .............................................................. A- 9 Warranty Bond (VCK) .............................................................................. A- 10 General Liability Endorsement (VCK) ..................................................... A- 11 Automobile Liability Endorsement (VCK) .............................................. A- 13 Worker’s Compensation / Employers Liability Endorsement (VCK) ...... A- 15 Workers’ Compensation Certification (VCK) .......................................... A- 17

CITY OF TRACY WASTEWATER TREATMENT PLANT EFFLUENT OUTFALL PIPELINE IMPROVEMENTS Pages

TABLE OF CONTENTS PW/WBG/179201 00 01 10 - iv OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

Certification of Safety Requirements for Contractors and Vendors (VCK) ............................................................................... A- 18

Escrow Agreement for Security Deposits in Lieu of Retention (Optional) (VCK) ................................................................................... A- 19

Guarantee (VCK) ...................................................................................... A- 21

GENERAL PROVISIONS

Terms and Definitions......................................................................................... GP- 1 Proposal Requirements and Conditions .............................................................. GP- 5 Award and Execution of Contract ...................................................................... GP- 9 Scope and Control of the Work .......................................................................... GP- 14 Changes in the Work ......................................................................................... GP- 18 Control of Materials ......................................................................................... GP- 23 Utilities ............................................................................................................... GP- 26 Prosecution, Progress and Acceptance of Work ................................................. GP- 29 Responsibilities of the Contractor ....................................................................... GP- 39 Measurement and Payment ................................................................................. GP- 53 Guarantee ............................................................................................................ GP- 58 SPECIAL PROVISIONS

Underground Utilities & Services ........................................................................ SP- 1 Hazardous Environmental Conditions ................................................................. SP- 2 Disposal of Water Due to Trenches Dewatering and Other Construction Activities ..................................................................................... SP- 2 Permits ................................................................................................................. SP- 3 Staging and Storing Area ..................................................................................... SP- 3 Construction Management and Resident Engineering ......................................... SP- 3

TECHNICAL PROVISIONS

DIVISION 01—GENERAL REQUIREMENTS

01 11 00 Summary of Work (VCK)........................................................ 1- 1 01 26 00 Contract Modification Procedures (VCK) ............................... 1- 6 01 29 00 Payment Procedures (VCK) ..................................................... 1- 12 01 30 00 Environmental Mitigation and Compliance (VCK) ................. 1- 13 01 31 13 Project Coordination (VCK) .................................................... 1- 6 01 31 19 Project Meetings (VCK) .......................................................... 1- 3 01 32 00 Construction Progress Documentation (VCK) ........................ 1- 8


PW/WBG/179201 TABLE OF CONTENTS OCTOBER 2018 00 01 10 - v ©COPYRIGHT 2018 CH2M HILL

01 33 00 Submittal Procedures (VCK) ................................................... 1- 9 Supplement: Transmittal of Contractor's Submittal ...................................... 1- 1 01 42 13 Abbreviations and Acronyms (VCK) ...................................... 1- 5 01 43 33 Manufacturers’ Field Services (VCK) ..................................... 1- 4 Supplements: Manufacturer’s Certificate of Compliance .............................. 1- 1 Manufacturer’s Certificate of Proper Installation .................... 1- 1 01 45 00 Permits (VCK) ......................................................................... 1- 6 Supplements: Section 404 Permit ................................................................... 1- 48 Section 401 Permit ................................................................... 1- 15 Section 1602 Permit ................................................................. 1- 52 Encroachment Permit – San Joaquin County (to be

included as an addendum during the Bid period) Encroachment Permit – Reclamation District 2058 ................ 1- 7 Encroachment Permit – CVFPB .............................................. 1- 8 01 45 16.13 Contractor Quality Control (VCK) .......................................... 1- 9 01 50 00 Temporary Facilities and Controls (VCK) .............................. 1- 16 01 57 13 Temporary Erosion and Sediment Control (VCK) .................. 1- 8 01 61 00 Common Product Requirements (CRB) .................................. 1- 8 01 77 00 Closeout Procedures (VCK) .................................................... 1- 4 01 78 23 Operation and Maintenance Data (VCK) ................................ 1- 6 Supplement: Maintenance Summary Form ................................................... 1- 2 01 88 15 Seismic Anchorage and Bracing (CRB) .................................. 1- 5 01 91 14 Equipment Testing and Facility Startup (VCK) ...................... 1- 6 Supplements: Unit Process Startup Form ....................................................... 1- 1 Facility Performance Demonstration/Certification Form ........ 1- 1

DIVISION 02—EXISTING CONDITIONS

02 40 00 Crossings (AJF) ....................................................................... 1- 4 02 41 00 Demolition (BW) ..................................................................... 1- 6 DIVISION 03—CONCRETE

03 10 00 Concrete Forming and Accessories (CRB) .............................. 1- 4 03 15 00 Concrete Joints and Accessories (CRB) .................................. 1- 7 03 21 00 Reinforcing Steel (CRB) .......................................................... 1- 3


TABLE OF CONTENTS PW/WBG/179201 00 01 10 - vi OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

03 30 00 Cast-In-Place Concrete (CRB) ................................................. 1- 23 Supplements: Concrete Mix Design, Class 4500F2S1P1C1 .......................... 1- 2 Concrete Mix Design, Class 4500F1S1P0C1 .......................... 1- 2 Concrete Mix Design, Class 4000F0S1P0C0 .......................... 1- 1 Concrete Mix Design, Class TC00F0S1P1C1 ......................... 1- 2 03 39 00 Concrete Curing (CRB) ........................................................... 1- 3 03 40 00 Precast Concrete (CRB) ........................................................... 1- 5 03 62 00 Nonshrink Grouting (CRB) ..................................................... 1- 6 Supplement: 24-hour Evaluation of Nonshrink Grout Test Form and Grout

Testing Procedures ................................................................ 1- 3

DIVISION 04—MASONRY (NOT USED)

DIVISION 05—METALS

05 50 00 Metal Fabrications (CRB) ........................................................ 1- 17 05 53 00 Metal Gratings (CRB) .............................................................. 1- 5 DIVISIONS 06—08 (NOT USED)

DIVISION 09—FINISHES

09 90 00 Painting and Coating (TPJ) ...................................................... 1- 16 Supplements: Paint System Data Sheet (PSDS) ............................................. 1- 1 Product Data Sheet (PDS) ........................................................ 1- 1 09 90 05 Polyurethane Coating (TPJ) ..................................................... 1- 11

DIVISION 10—SPECIALTIES 10 14 00 Signage (VCK)......................................................................... 1- 4 Supplement: Sign Schedule .......................................................................... 1- 1

DIVISIONS 11—22 (NOT USED)

DIVISION 23—HEATING, VENTILATING, AND AIR-CONDITIONING (HVAC)

23 34 00 Exhaust Fans (MRR) ............................................................... 1- 9 23 34 00.01 Fans Schedule Supplement (MRR) .......................................... 1- 1


PW/WBG/179201 TABLE OF CONTENTS OCTOBER 2018 00 01 10 - vii ©COPYRIGHT 2018 CH2M HILL


DIVISION 26—ELECTRICAL

26 05 02 Basic Electrical Requirements (WKV) .................................... 1- 5 26 05 04 Basic Electrical Materials and Methods (WKV) ..................... 1- 9 26 05 05 Conductors (WKV) .................................................................. 1- 11 26 05 26 Grounding and Bonding for Electrical Systems (WKV) ......... 1- 6 26 05 33 Raceway and Boxes (WKV) .................................................... 1- 25 26 08 00 Commissioning of Electrical Systems (WKV) ........................ 1- 10 26 20 00 Low-Voltage AC Induction Motors (WKV)............................ 1- 9 26 22 00 Low-Voltage Transformers (WKV) ........................................ 1- 2 26 27 26 Wiring Devices (WKV) ........................................................... 1- 7 26 29 23 Low-Voltage Adjustable Frequency Drive System (WKV) .... 1- 11 26 42 01 Pipe Bonding and Test Stations (TJP) ..................................... 1- 12 Supplement: Joint Bond Continuity Test Schematic .................................... 1- 1 26 42 02 Galvanic Anode Cathodic Protection System (TJP) ................ 1- 6 26 50 00 Lighting (WKV) ....................................................................... 1- 3 DIVISIONS 27—30 (NOT USED)

VOLUME 2 — TECHNICAL PROVISIONS

DIVISION 31—EARTHWORK

31 10 00 Site Clearing (BW) .................................................................. 1- 4 31 22 21 Agricultural Land Grading (BW) ............................................ 1- 2 31 23 13 Subgrade Preparation (BW) ..................................................... 1- 2 31 23 16 Excavation (BW) ..................................................................... 1- 4 31 23 19.01 Dewatering (BW) ..................................................................... 1- 5 31 23 23 Fill and Backfill (BW) ............................................................. 1- 9 31 23 23.15 Trench Backfill (BW) .............................................................. 1- 12 31 32 19.16 Geotextile (AJF) ...................................................................... 1- 8 31 32 50 Ground Improvement (AJF) .................................................... 1- 12 31 37 00 Riprap (TJH) ............................................................................ 1- 3 31 41 00 Shoring (AJF) .......................................................................... 1- 6 31 60 00 Installation of Carrier Pipe in Steel Casing (AJF) ................... 1- 5 31 74 28 Backfill Grouting (AJF) ........................................................... 1- 10 31 79 13 Microtunneling (AJF) .............................................................. 1- 20 Supplement: Underground Classification ..................................................... 1- 1 31 80 00 Geotechnical Instrumentation (AJF) ........................................ 1- 5


TABLE OF CONTENTS PW/WBG/179201 00 01 10 - viii OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

DIVISION 32—EXTERIOR IMPROVEMENTS

32 11 23 Aggregate Base Courses and Gravel Surfacing (BW) ............. 1- 5 32 12 16 Asphalt Paving (BW) ............................................................... 1- 9 32 16 00 Curbs and Gutters (VCK) ........................................................ 1- 3 32 17 23 Pavement Markings (VCK) ..................................................... 1- 4 32 31 13 Chain Link Fences and Gates (BW) ........................................ 1- 11 32 91 13 Soil Preparation (BMI) ............................................................ 1- 4 32 92 00 Hydroseeding (VCK) ............................................................... 1- 5 32 93 00 Plants (BMI) ............................................................................ 1- 8 Supplement: Plant Listing ............................................................................. 1- 1

DIVISION 33—UTILITIES

33 05 01 Conveyance Piping—General (BW)........................................ 1- 10 33 05 01.01 Welded Steel Pipe and Fittings (BW) ...................................... 1- 21 33 05 01.02 Ductile Iron Pipe and Fittings (BW) ........................................ 1- 9 33 05 01.04 Bar-Wrapped Concrete Cylinder Pipe and Fittings (BW) ....... 1- 15 33 05 01.10 High-Density Polyethylene (HDPE) Pressure Pipe

and Fittings (BW) .................................................................... 1- 9 33 12 16.29 Air and Vacuum Release Valve Assemblies (BW) ................. 1- 4 33 41 01 Storm Drain Sanitary Sewer and Drainage Piping (BW) ........ 1- 2 Supplements: Data Sheets 33 41 01.01 Corrugated Metal Data Sheet (BW) ......................................... 1- 1 33 41 01.03 Polyvinyl Chloride (PVC) Data Sheet (BW) ........................... 1- 1 33 41 01.04 Nonreinforced Concrete Data Sheet (BW) .............................. 1- 2 33 41 01.05 Reinforced Concrete Data Sheet (BW) .................................... 1- 2 33 41 01.07 Polyethylene (PE) Profile Wall Data Sheet (BW) ................... 1- 1 33 41 01.08 Corrugated Polyethylene (CPE) Data Sheet (BW) .................. 1- 1 DIVISION 34—TRANSPORTATION (NOT USED)

DIVISION 35—WATERWAY AND MARINE CONSTRUCTION

35 01 01 Marine Construction (BW) ...................................................... 1- 8 35 20 16.25 Fabricated Stainless Steel Slide Gate (MRR) .......................... 1- 9 DIVISIONS 36—39 (NOT USED)


PW/WBG/179201 TABLE OF CONTENTS OCTOBER 2018 00 01 10 - ix ©COPYRIGHT 2018 CH2M HILL

DIVISION 40—PROCESS INTEGRATION

40 05 15 Piping Support Systems (MRR) .............................................. 1- 6 40 27 00 Process Piping—General (MRR) ............................................. 1- 13 Supplements: Data Sheets 40 27 00.01 Cement-Lined Ductile Iron Pipe and Fittings

Data Sheet (MRR) ................................................................ 1- 3 40 27 00.07 Galvanized Steel Pipe and Malleable

Iron Fittings Data Sheet (MRR) ............................................ 1- 2 40 27 00.10 Polyvinyl Chloride (PVC) Pipe and Fittings

Data Sheet (MRR) ................................................................ 1- 2 40 27 00.27 Steel Casing Pipe (AJF) ........................................................... 1- 4 40 27 01 Process Piping Specialties (MRR) ........................................... 1- 8 40 27 02 Process Valves and Operators (MRR) ..................................... 1- 14 Supplement: Electric Motor Actuator Schedule ........................................... 1- 1 40 90 01 Instrumentation and Control for Process Systems (DNA) ....... 1- 27 Supplements: Component Specifications ....................................................... 1- 9 Field Instrument List, Control Panel Schedule and Major

Network Component ............................................................. 1- 2 Loop Specifications ................................................................. 1- 4 PLC Input and Output Summary Lists ..................................... 1- 3 Instrument Calibration Sheet ................................................... 1- 2 I&C Valve Adjustment Sheet .................................................. 1- 2 Performance Acceptance Test Sheet ........................................ 1- 2


DIVISION 44—POLLUTION CONTROL EQUIPMENT

44 42 56.03 Vertical Turbine Pumps (MRR) .............................................. 1- 7 Supplement: Pump and Motor Data Sheet .................................................... 1- 3 44 42 56.04 Submersible Non-Clog Pumps (MRR) .................................... 1- 6 44 42 56.18 Submersible Sump Pump (MRR) ............................................ 1- 3



TABLE OF CONTENTS PW/WBG/179201 00 01 10 - x OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

VOLUME 3 — STANDARD DETAILS (BOUND SEPARATELY)

VOLUME 4 — DRAWINGS (BOUND SEPARATELY)

VOLUME 5 — GEOTECHNICAL REPORTS (BOUND SEPARATELY)

Geotechnical Baseline Report, City of Tracy WWTP Outfall Pipeline, August 2012

Geotechnical Data Report, City of Tracy WWTP Preliminary Design of Effluent Outfall Pipeline and Diffuser Improvements, August 2012

Supplemental Geotechnical Data Report – Old River Boring, October 12, 2012

END OF SECTION

VOLUME 2

TECHNICAL PROVISIONS


PW/WBG/179201 SITE CLEARING OCTOBER 2018 31 10 00 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 31 10 00 SITE CLEARING

PART 1 GENERAL

1.01 DEFINITIONS

A. Interfering or Objectionable Material: Trash, rubbish, and junk; vegetation and other organic matter, whether alive, dead, or decaying; topsoil.

B. Clearing: Removal of interfering or objectionable material lying on or protruding above ground surface.

C. Grubbing: Removal of vegetation and other organic matter including stumps, buried logs, and roots greater than 2-inch caliper to a depth of 6 inches below subgrade.

D. Scalping: Removal of sod without removing more than upper 3 inches of topsoil.

E. Stripping: Removal of topsoil remaining after applicable scalping is completed.

F. Project Limits: Areas, as shown or specified, within which Work is to be performed.

1.02 SUBMITTALS

A. Action Submittals: Drawings clearly showing clearing, grubbing, and stripping limits.

1.03 SCHEDULING AND SEQUENCING

A. Prepare Site only after adequate erosion and sediment controls are in place. Limit areas exposed uncontrolled to erosion during installation of temporary erosion and sediment controls to maximum of 10 acres.

PART 2 PRODUCTS (NOT USED)

PART 3 EXECUTION

3.01 GENERAL

A. Clear, grub, and strip areas actually needed for waste disposal, borrow, or Site improvements within limits shown or specified.


SITE CLEARING PW/WBG/179201 31 10 00 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

B. Do not injure or deface vegetation that is not designated for removal.

3.02 LIMITS

A. As follows, but not to extend beyond Project limits.

1. Excavation: 5 feet beyond top of cut slopes. 2. Fill:

a. Clearing and Grubbing: 5 feet beyond toe of permanent fill. b. Stripping and Scalping: 2 feet beyond toe of permanent fill.

3. Waste Disposal: a. Clearing: 5 feet beyond perimeter. b. Scalping and Stripping: Not required. c. Grubbing: Around perimeter as necessary for neat finished

appearance. 4. Structures: 15 feet outside of new structures. 5. Roadways: Clearing, grubbing, scalping, and stripping 5 feet from

roadway shoulders. 6. Overhead Utilities:

a. Clearing and Grubbing: Entire width of easements and rights-of-way.

b. Scalping and Stripping: Wherever grading is required. 7. Other Areas: As shown.

B. Remove rubbish, trash, and junk from entire area within Project limits.

3.03 TEMPORARY REMOVAL OF INTERFERING PLANTINGS

A. Remove and store shrubs and trees that are not designated for removal but do interfere with construction or could be damaged by construction activities.

B. Photograph and document location, orientation, and condition of each plant prior to its removal. Record sufficient information to uniquely identify each plant removed and to assure accurate replacement.

3.04 CLEARING

A. Clear areas within limits shown or specified.

B. Fell trees so that they fall away from facilities and vegetation not designated for removal.

C. Cut stumps not designated for grubbing flush with ground surface.

D. Cut off shrubs, brush, weeds, and grasses to within 2 inches of ground surface.


PW/WBG/179201 SITE CLEARING OCTOBER 2018 31 10 00 - 3 ©COPYRIGHT 2018 CH2M HILL

3.05 GRUBBING

A. Grub areas within limits shown or specified.

3.06 SCALPING

A. Do not remove sod until after clearing and grubbing is completed and resulting debris is removed.

B. Scalp areas within limits shown or specified.

3.07 STRIPPING

A. Do not remove topsoil until after scalping is completed.

B. Strip areas within limits to minimum depths shown or specified. Do not remove subsoil with topsoil.

C. Stockpile strippings, meeting requirements of Section 32 91 13, Soil Preparation, for topsoil, separately from other excavated material.

3.08 TREE REMOVAL OUTSIDE CLEARING LIMITS

A. Remove Within Project Limits (After Obtaining Engineer’s Approval):

1. Dead, dying, leaning, or otherwise unsound trees that may strike and damage Project facilities in falling.

2. Trees designated for removal as shown on the Project Drawings.

B. Cut stumps off flush with ground, remove debris, and if disturbed, restore surrounding area to its original condition.

3.09 DISPOSAL

A. Clearing and Grubbing Debris:

1. Dispose of debris offsite. 2. Burning of debris onsite will not be allowed. 3. Woody debris may be chipped. Chips may be sold to Contractor’s

benefit. Dispose of chips that are unsaleable with unchipped debris. 4. Limit offsite disposal of clearing and grubbing debris to locations that

are approved by federal, state, and local authorities, and that will not be visible from Project.

B. Scalpings: As specified for clearing and grubbing debris.


SITE CLEARING PW/WBG/179201 31 10 00 - 4 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

C. Strippings:

1. Dispose of strippings that are unsuitable for topsoil or that exceed quantity required for topsoil offsite.

2. Stockpile topsoil in sufficient quantity to meet Project needs. Protect stockpiles of topsoil from wind, water and weed growth with protective coating. Dispose of excess strippings as specified for clearing and grubbing.

END OF SECTION


PW/WBG/179201 AGRICULTURAL LAND GRADING OCTOBER 2018 31 22 21 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 31 22 21 AGRICULTURAL LAND GRADING

PART 1 GENERAL

1.01 DEFINITIONS

A. Field Capacity: Moisture content of soil following irrigation or rainfall after sufficient time has elapsed for water to fully drain by gravity.

B. Requirements specified herein shall apply to areas with native earth backfill, except with areas with improved surfacing, unless otherwise shown or specified.

1.02 SUBMITTALS

A. Action Submittals:

1. Base map of each field showing field boundaries and existing ground surface elevations.

2. Base map of each field showing, at each staked location, estimated final grade elevation, and areas of topsoil removal and replacement.

3. Shrinkage factors used for estimating final grades. 4. Adjusted shrinkage factors used for adjusting final grades.

B. Informational Submittals: Documentation of previous land grading experience.

1.03 QUALITY ASSURANCE

A. Demonstrate at least 5 years’ prior experience in land grading of agricultural fields.

1.04 WEATHER AND SOIL MOISTURE RESTRICTIONS

A. Do not operate equipment on fields during wet weather and whenever soil moisture content exceeds field capacity.


A. Complete clearing and grubbing, as specified in Section 31 10 00, Site Clearing, before staking fields.

B. Do not begin land grading until all vegetation has been cleared or incorporated into soil to a minimum depth of 6 inches.


AGRICULTURAL LAND GRADING PW/WBG/179201 31 22 21 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL


PART 3 EXECUTION

3.01 FIELD STAKING

A. Stake each field on 100-foot grid and determine elevation of each grid corner. Stake intersections of grid lines and field boundaries. Stake intermediate points where irregular topography necessitates doing so. Promptly replace or restore stakes that are lost or disturbed to their original location.

B. Promptly remove stakes after they are no longer needed.

3.02 BASE MAP PREPARATION

A. Prepare base map of each field, using scale of 1 inch equals 100 feet, showing field boundaries and existing ground surface elevations determined at each staked location.

3.03 GRADING

A. Laser plane shall be used for to control land grading.

B. Grade each field to original grade prior to construction. Final ground surface shall not deviate more than 0.1 foot above or below the original grade.

C. Remove topsoil to 12-inch depth from areas of agricultural land within the limits of the entire construction work area and staging area. Stockpile topsoil until replaced in manner that topsoil cannot become mixed with subsoil. Deep rip soil to depth of 3 feet below original grade after completion of construction. Replace topsoil in agricultural land areas and specific properties from where it was removed back to original grade once work in that area has been completed.

D. See Section 31 23 23, Fill and Backfill, for backfill requirements.

END OF SECTION


PW/WBG/179201 SUBGRADE PREPARATION OCTOBER 2018 31 23 13 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 31 23 13 SUBGRADE PREPARATION

PART 1 GENERAL

1.01 DEFINITIONS

A. Optimum Moisture Content: As defined in Section 31 23 23, Fill and Backfill.

B. Prepared Ground Surface: Ground surface after completion of clearing and grubbing, scalping of sod, stripping of topsoil, excavation to grade, and scarification and compaction of subgrade.

C. Relative Compaction: As defined in Section 31 23 23, Fill and Backfill.

D. Relative Density: As defined in Section 31 23 23, Fill and Backfill.

E. Subgrade: Layer of existing soil after completion of clearing, grubbing, scalping of topsoil prior to placement of fill, roadway structure or base for floor slab.

1.02 SEQUENCING AND SCHEDULING

A. Complete applicable Work specified in Sections 02 41 00, Demolition; 31 10 00, Site Clearing; and 31 23 16, Excavation, prior to subgrade preparation.


A. Notify Engineer when subgrade is ready for compaction or whenever compaction is resumed after a period of extended inactivity.


PART 3 EXECUTION

3.01 GENERAL

A. Keep subgrade free of water, debris, and foreign matter during compaction.

B. Bring subgrade to proper grade and cross-section and uniformly compact surface.

C. Do not use sections of prepared ground surface as haul roads. Protect prepared subgrade from traffic.


SUBGRADE PREPARATION PW/WBG/179201 31 23 13 - 2 OCTOBER 2018 COPYRIGHT 2018 CH2M HILL

D. Maintain prepared ground surface in finished condition until next course is placed.

3.02 COMPACTION

A. Under Earthfill: Compact upper 6 inches to minimum of 90 percent relative compaction as determined in accordance with ASTM D1557.

B. Under Pavement Structure, Floor Slabs On Grade, or Granular Fill Under Structures: Compact the upper 6 inches to minimum of 95 percent relative compaction as determined in accordance with ASTM D1557.

3.03 MOISTURE CONDITIONING

A. Dry Subgrade: Add water, then mix to make moisture content uniform throughout.

B. Wet Subgrade: Aerate material by blading, discing, harrowing, or other methods, to hasten drying process.

3.04 CORRECTION

A. Soft or Loose Subgrade:

1. Adjust moisture content and recompact, or 2. Overexcavate as specified in Section 31 23 16, Excavation, and replace

with suitable material from the excavation, as specified in Section 31 23 23, Fill and Backfill.

B. Unsuitable Material: Overexcavate as specified in Section 31 23 16, Excavation, and replace with suitable material from the excavation, as specified in Section 31 23 23, Fill and Backfill.

END OF SECTION


PW/WBG/179201 EXCAVATION OCTOBER 2018 31 23 16 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 31 23 16 EXCAVATION

PART 1 GENERAL

1.01 SUBMITTALS

A. Informational Submittals:

1. Excavation Plan, Detailing: a. Methods and sequencing of excavation. b. Proposed locations of stockpiled excavated material. c. Proposed onsite and offsite spoil disposal sites. d. Numbers, types, and sizes of equipment proposed to perform

excavations. e. Anticipated difficulties and proposed resolutions. f. Reclamation of onsite spoil disposal areas.


A. Provide adequate survey control to avoid unauthorized overexcavation.

1.03 WEATHER LIMITATIONS

A. Material excavated when frozen or when air temperature is less than 32 degrees F shall not be used as fill or backfill until material completely thaws.

B. Material excavated during inclement weather shall not be used as fill or backfill until after material drains and dries sufficiently for proper compaction.


A. Demolition: Complete applicable Work specified in Section 02 41 00, Demolition, prior to excavating.

B. Clearing, Grubbing, and Stripping: Complete applicable Work specified in Section 31 10 00, Site Clearing, prior to excavating.

C. Dewatering: Conform to applicable requirements of Section 31 23 19.01, Dewatering, prior to initiating excavation.


EXCAVATION PW/WBG/179201 31 23 16 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

D. Excavation Support: Install and maintain, as specified in Section 31 41 00, Shoring, as necessary to support sides of excavations and prevent detrimental settlement and lateral movement of existing facilities, adjacent property, and completed Work.


PART 3 EXECUTION

3.01 GENERAL

A. Excavate to lines, grades, and dimensions shown and as necessary to accomplish Work. Excavate to within tolerance of plus or minus 0.1 foot, except where dimensions or grades are shown or specified as maximum or minimum. Allow for forms, working space, granular base, topsoil, and similar items, wherever applicable. Trim to neat lines where concrete is to be deposited against earth.

B. Do not overexcavate without written authorization of Engineer.

C. Remove or protect obstructions as shown and as specified in Section 01 50 00, Temporary Facilities and Controls, Article Protection of Work and Property.

3.02 UNCLASSIFIED EXCAVATION

A. Excavation is unclassified. Complete all excavation regardless of the type, nature, or condition of the materials encountered.

3.03 TRENCH WIDTH

A. Minimum Width of Trenches:

1. Construct trenches of sufficient width to meet trench backfill requirements shown in Standard Detail 3123-110 in the Project Drawings.

2. Increase trench widths by thicknesses of sheeting.

B. Maximum Trench Width: Unlimited, unless otherwise shown or specified, or unless excess width will cause damage to existing facilities, adjacent property, or completed Work. Pipe of greater strength or superior pipe bedding, when approved in writing by Engineer, may be used in lieu of maintaining the pipe widths shown or specified.


PW/WBG/179201 EXCAVATION OCTOBER 2018 31 23 16 - 3 ©COPYRIGHT 2018 CH2M HILL

3.04 EMBANKMENT AND CUT SLOPES

A. Shape, trim, and finish cut slopes to conform with lines, grades, and cross-sections shown, with proper allowance for topsoil or slope protection, where shown.

B. Remove stones and rock that exceed 3-inch diameter and that are loose and may roll down slope. Remove exposed roots from cut slopes.

C. Round tops of cut slopes in soil to not less than a 6-foot radius, provided such rounding does not extend offsite or outside easements and rights-of-way, or adversely impacts existing facilities, adjacent property, or completed Work.

3.05 STOCKPILING EXCAVATED MATERIAL

A. Stockpile excavated material that is suitable for use as fill or backfill until material is needed.

B. Post signs indicating proposed use of material stockpiled. Post signs that are readable from all directions of approach to each stockpile. Signs should be clearly worded and readable by equipment operators from their normal seated position.

C. Confine stockpiles to within easements, rights-of-way, and approved work areas. Do not obstruct roads or streets.

D. Do not stockpile excavated material adjacent to trenches and other excavations, unless excavation side slopes and excavation support systems are designed, constructed, and maintained for stockpile loads.

E. Do not stockpile excavated materials near or over existing facilities, adjacent property, or completed Work, if weight of stockpiled material could induce excessive settlement.

3.06 DISPOSAL OF SPOIL

A. Dispose of excavated materials, which are unsuitable or exceed quantity needed for fill or backfill offsite within 28 days of excavation.

B. Dispose of debris resulting from removal of underground facilities as specified in Section 02 41 00, Demolition, for demolition debris. Disposal shall be within 28 days of removal.


EXCAVATION PW/WBG/179201 31 23 16 - 4 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

C. Dispose of debris resulting from removal of organic matter, trash, refuse, and junk as specified in Section 31 10 00, Site Clearing, for clearing and grubbing debris. Disposal shall be within 28 days of removal.

END OF SECTION


PW/WBG/179201 DEWATERING OCTOBER 2018 31 23 19.01 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 31 23 19.01 DEWATERING

PART 1 GENERAL

1.01 DISCLOSURE

A. Based on the geotechnical investigation for the Project, there is significant potential for shallow groundwater to be encountered during construction.

B. Groundwater information collected for design of the Effluent Outfall Pipeline is presented in the Project Geotechnical Data Report (GDR), prepared by CH2M HILL and dated August 2012. Groundwater conditions reported in the GDR reflect conditions only at the specific locations and times observed and explored. Local groundwater levels are likely to be affected by seasonal variations in temperature and precipitation, surface runoff, subsurface drainage, irrigation, water levels in nearby rivers, streams, ponds and/or drainage channels, soil conditions and the presence of buried utilities. Groundwater conditions encountered during construction could vary significantly from conditions encountered during the investigation.

C. The Contractor is solely responsible for the interpretation and use of groundwater data contained in the GDR. Groundwater information presented in the GDR is subject to limitations as described in the report. Additional groundwater data may be necessary to evaluate the potential for groundwater to be encountered in Project excavations and develop appropriate groundwater control measures. It is the responsibility of the Contractor to identify the need for additional groundwater information and collect such information as necessary for Project construction.

1.02 SUBMITTALS


1. Water Control Plan submitted to Engineer at least 30 days prior to start of dewatering system installation.

2. Well permits. 3. Discharge permits. 4. Water Level Elevations Observed in Observation Wells: Submit same

day measured. 5. Settlement Benchmark Elevations: Submit weekly record. 6. Inflow Measurements: Submit weekly record.


DEWATERING PW/WBG/179201 31 23 19.01 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

1.03 WATER CONTROL PLAN

A. Water Control Plan shall be prepared and sealed by a licensed Civil Engineer or Hydrogeologist registered in the state of California.

B. As a minimum, include:

1. Descriptions of proposed groundwater and surface water control facilities including, but not limited to, equipment; methods; standby equipment and power supply, means of measuring inflow to excavations, pollution control facilities, discharge locations to be utilized, and provisions for immediate temporary water supply as required by this section.

2. Drawings showing locations, dimensions, and relationships of elements of each system.

3. Schedule for dewatering specific areas or structures and anticipated duration.

4. Design calculations prepared by hydrogeologist demonstrating adequacy of proposed dewatering systems and components.

C. If system is modified during installation or operation, Contractor and independent hydrogeologist shall revise or amend and resubmit Water Control Plan.

PART 2 PRODUCTS

2.01 SEALING MATERIAL

A. Sealing material shall consist of neat-cement, sand-cement grout, bentonite or concrete as specified in the Department of Water Resources (DWR) Bulletin No. 74-81, Bulletin No. 74-90, and San Joaquin County, CA County Ordinance Code Section 9-1115.6 Well Standards.

PART 3 EXECUTION

3.01 GENERAL

A. Continuously control water during course of construction until all Project facilities are installed and backfilled to the extent that water will not affect their condition, including weekends and holidays and during periods of work stoppages, and provide adequate backup systems to maintain control of water.



3.02 SURFACE WATER CONTROL

A. See Section 01 50 00, Temporary Facilities and Controls, Article Temporary Controls.

B. Remove surface runoff controls when no longer needed.

3.03 DEWATERING SYSTEMS

A. Provide, operate, and maintain dewatering systems of sufficient size and capacity to permit excavation and subsequent construction in dry conditions and to lower and maintain groundwater level a minimum of 2 feet below the lowest point of excavation. Continuously maintain excavations free of water, regardless of source, and until backfilled to final grade.

B. Dewatering systems shall include wells or well points, and other equipment and appurtenances installed outside limits of excavations and sufficiently below lowest point of excavation, or to maintain specified groundwater elevation.

C. Provide all piping, valving and other appurtenances necessary to convey flows to designated discharge locations.

D. Design and Operate Dewatering Systems:

1. To prevent loss of ground as water is removed. 2. To avoid inducing settlement or damage to existing facilities, completed

Work, or adjacent property. 3. To relieve artesian pressures and resultant uplift of excavation bottom. 4. To prevent collapse and widening of trenching.

E. Provide sufficient redundancy in each system to keep excavation free of water in event of component failure.

F. Provide 100 percent emergency power backup with automatic startup and switchover in event of electrical power failure.

3.04 WELLS

A. Obtain all necessary permits for well construction, operation, and destruction.

B. Construct, monitor, and operate wells and well points in accordance with permit requirements and all applicable laws and regulations.


DEWATERING PW/WBG/179201 31 23 19.01 - 4 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

C. Pumping Wells: Install pumping wells, well points, and associated equipment and appurtenances outside excavation limits and sufficiently deep to maintain specified groundwater elevations.

D. Observation Wells: Install observation wells as necessary to evaluate groundwater levels for design, construction, operation, and monitoring of dewatering systems.

E. See GDR for locations of existing monitoring wells installed during geotechnical investigation. Existing monitoring wells may be used by the Contractor for monitoring groundwater levels during construction.

3.05 MONITORING FLOWS

A. Monitor volume of water pumped per calendar day from excavations, as Work progresses. Also monitor volume of water introduced each day into excavations for performance of Work. Monitor flows using measuring devices acceptable to Engineer.

3.06 DISPOSAL OF WATER

A. Dispose of water at locations as shown on the Drawings.

B. Obtain discharge permit for water disposal from authorities having jurisdiction.

C. Treat water collected by dewatering operations, as required by regulatory agencies, prior to discharge.

D. Discharge water as required by discharge permit and in manner that will not cause erosion or flooding, or otherwise damage existing facilities, completed Work, or adjacent property.

E. Remove solids from treatment facilities and perform other maintenance of treatment facilities as necessary to maintain their efficiency.

3.07 PROTECTION OF PROPERTY

A. Make assessment of potential for dewatering induced settlement. Provide and operate devices or systems, including but not limited to reinjection wells, infiltration trenches and cutoff walls, necessary to prevent damage to existing facilities, completed Work, and adjacent property.



B. Securely support existing facilities, completed Work, and adjacent property vulnerable to settlement due to dewatering operations. Support shall include, but not be limited to, bracing, underpinning, or compaction grouting.

3.08 REMOVAL AND ABANDONMENT OF MONITORING AND DEWATERING WELLS

A. Remove all dewatering wells and abandon all monitoring wells when they are no longer needed to support the Work.

B. Contractor shall obtain, comply with, and bear all associated costs for any and all permits required for the abandonment of monitoring wells.

C. Wells installed by Contractor for dewatering shall be abandoned as follows:

1. All codes, rules, and regulations of the State and County pertaining to abandonment or destruction of wells.

2. Pull all well casing and remove any surface completion elements. 3. Remove all filter material and annular seal material using a vacuum

truck or auger. 4. Overbore the original borehole by at least 2 inches. 5. Place Sealing Material conforming.

D. Monitoring wells installed during the design phase, as shown on the Drawings and defined in Table 1, and those installed by the Contractor shall be abandoned according to County of San Joaquin and State of California requirements and in accordance with San Joaquin County Standards.

E. Permits obtained by the City for the monitoring wells are listed in Table 1.

Table 1 Existing Monitoring Wells to be Abandoned

Well County Permit Number

B-2 0058739

B-4 0058739

END OF SECTION


PW/WBG/179201 FILL AND BACKFILL OCTOBER 2018 31 23 23 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 31 23 23 FILL AND BACKFILL

PART 1 GENERAL

1.01 DEFINITIONS

A. Relative Compaction:

1. Ratio, in percent, of as-compacted field dry density to laboratory maximum dry density as determined in accordance with ASTM D1557.

2. Apply corrections for oversize material to either as-compacted field dry density or maximum dry density, as determined by Engineer.

B. Optimum Moisture Content:

1. Determined in accordance with ASTM Standard specified to determine maximum dry density for relative compaction.

2. Determine field moisture content on basis of fraction passing 3/4-inch sieve.

C. Relative Density: Calculated in accordance with ASTM D4254 based on maximum index density determined in accordance with ASTM D4253 and minimum index density determined in accordance with ASTM D4254.

D. Prepared Ground Surface: Ground surface after completion of required demolition, clearing and grubbing, scalping of sod, stripping of topsoil, excavation to grade, and subgrade preparation.

E. Completed Course: A course or layer that is ready for next layer or next phase of Work.

F. Lift: Loose (uncompacted) layer of material.

G. Geosynthetics: Geotextiles, geogrids, or geomembranes.

H. Well-Graded:

1. A mixture of particle sizes with no specific concentration or lack thereof of one or more sizes.

2. Does not define numerical value that must be placed on coefficient of uniformity, coefficient of curvature, or other specific grain size distribution parameters.

3. Used to define material type that, when compacted, produces a strong and relatively incompressible soil mass free from detrimental voids.


FILL AND BACKFILL PW/WBG/179201 31 23 23 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

I. Influence Area: Area within planes sloped downward and outward at 60-degree angle from horizontal measured from:

1. 1 foot outside outermost edge at base of foundations or slabs. 2. 1 foot outside outermost edge at surface of roadways or shoulder. 3. 0.5 foot outside exterior at spring line of pipes or culverts.

J. Borrow Material: Material from required excavations or from designated borrow areas on or near Site.

K. Selected Backfill Material: Materials available onsite that Engineer determines to be suitable for specific use.

L. Imported Material: Materials obtained from sources offsite, suitable for specified use.

M. Structural Fill: Fill materials as required under structures, pavements, and other facilities.

N. Embankment Material: Fill materials required to raise existing grade in areas other than under structures.

1.02 SUBMITTALS


1. Certification, test results and source for all imported material to be used on the Project. Submit not less than 30 days prior to delivery.

2. Samples: Imported material taken at source. 3. Documentation that imported materials are free of hazardous and

deleterious substances.

B. Informational Submittals:

1. Statement of Qualifications for soils testing laboratory and field testing service.

2. Manufacturer’s data sheets for compaction equipment. 3. Certified test results from independent testing agency.

a. Laboratory test results for physical and engineering properties of soil mechanics, including gradation and compaction characteristics.

b. Field moisture and density testing results.




A. Notify Engineer when:

1. Structure is ready for backfilling, and whenever backfilling operations are resumed after a period of inactivity.

2. Soft or loose subgrade materials are encountered wherever embankment or site fill is to be placed.

3. Fill material appears to be deviating from Specifications. 4. Quality Control test results indicate noncompliance with required

Specifications.


A. Complete applicable Work specified in Section 02 41 00, Demolition, Section 31 10 00, Site Clearing, Section 31 23 16, Excavation, and Section 31 23 13, Subgrade Preparation, prior to placing fill or backfill.

B. Backfill against concrete structures only after concrete has attained compressive strength, specified in Section 03 30 00, Cast-in-Place Concrete. Obtain Engineer’s acceptance of concrete work and attained strength prior to placing backfill.

C. Backfill around water-holding structures only after completion of satisfactory leakage tests as specified in Section 03 30 00, Cast-in-Place Concrete.

D. Do not place granular base, subbase, or surfacing until after subgrade has been prepared as specified in Section 31 23 13, Subgrade Preparation.

PART 2 PRODUCTS

2.01 SOURCE QUALITY CONTROL

A. Gradation Tests:

1. Perform gradation analysis in accordance with ASTM C136 and C117 for: a. Granular fill. b. Sand. c. Base course rock. d. Foundation stabilization rock.

2. Test as necessary to locate acceptable sources of imported material. 3. During production of imported material, test at the start of production.



B. Samples:

1. Samples of proposed import materials shall include approximately 10 pounds of material collected in accordance with ASTM D75. Samples shall be representative of material schedule for delivery to the Project Site.

2. During production of imported material, provide Samples as follows: a. Granular Fill: One sample per proposed offsite source. b. Sand: One sample per proposed offsite source. c. Base Course Rock: One sample per proposed offsite source. d. Foundation Stabilization Rock: One sample per proposed offsite

source. 3. Clearly mark Samples to show source of material and intended use.

C. Material Tests: As necessary to document that imported materials are free of hazardous and deleterious substances.

2.02 EARTHFILL

A. Excavated material from required excavations free from rocks larger than 3 inches, from roots and other organic matter, ashes, cinders, trash, debris, and other deleterious materials.

B. Material containing more than 10 percent gravel, stones, or shale particles is unacceptable.

C. Provide imported material of equivalent quality, if required to accomplish Work.

2.03 GRANULAR FILL

A. 1 inch minus crushed gravel or crushed rock.

B. Free from dirt, clay balls, and organic material.

C. Well-graded from coarse to fine and containing sufficient fines to bind material when compacted, but with maximum 8 percent by weight passing No. 200 sieve.

D. With a minimum Durability Index of 35, as determined in accordance with Caltrans Test Method 229.

2.04 SAND

A. Free from clay, organic matter, or other deleterious material.



B. Gradation as determined in accordance with ASTM C117 and ASTM C136:

Sieve Size Percent Passing by Weight

1/4-inch 100

No. 4 95 - 100

No. 200 0 - 8

C. With a minimum Durability Index of 35, as determined in accordance with Caltrans Test Method 229.

2.05 GRANULAR DRAIN MATERIAL

A. As specified in Section 31 23 23.15, Trench Backfill.

2.06 WATER FOR MOISTURE CONDITIONING

A. Free of hazardous or toxic contaminates, or contaminants deleterious to proper compaction.

2.07 BASE COURSE ROCK

A. As specified in Section 32 11 23, Aggregate Base Courses and Gravel Surfacing.

2.08 FOUNDATION STABILIZATION ROCK

A. Crushed rock or pit run rock.

B. Uniformly graded from coarse to fine.

C. Free from excessive dirt and other organic material.

D. Maximum 2-1/2-inch particle size.

E. With a minimum Durability Index of 35, as determined in accordance with Caltrans Test Method 229.

2.09 SOIL COVER OVER GEOTEXTILES

A. Free of sharp angular pieces that may damage geotextile.

2.10 TOPSOIL

A. As specified in Section 32 91 13, Soil Preparation.



PART 3 EXECUTION

3.01 GENERAL

A. Keep placement surfaces free of water, debris, and foreign material during placement and compaction of fill and backfill materials.

B. Place and spread fill and backfill materials in horizontal lifts of uniform thickness, in a manner that avoids segregation, and compact each lift to specified densities prior to placing succeeding lifts. Slope lifts only where necessary to conform to final grades or as necessary to keep placement surfaces drained of water.

C. During filling and backfilling, keep level of fill and backfill around each structure even.

D. Do not place fill or backfill, if fill or backfill material is frozen, or if surface upon which fill or backfill is to be placed is frozen.

E. Tolerances:

1. Final Lines and Grades: Within a tolerance of 0.1 foot unless dimensions or grades are shown or specified otherwise.

2. Grade to establish and maintain slopes and drainage as shown. Reverse slopes are not permitted.

F. Settlement: Correct and repair any subsequent damage to structures, pavements, curbs, slabs, piping, and other facilities, caused by settlement of fill or backfill material.

3.02 BACKFILL UNDER AND AROUND STRUCTURES

A. Under Facilities: Within influence area beneath structures, slabs, pavements, curbs, piping, conduits, duct banks, and other facilities, backfill with granular fill, unless otherwise shown. Place granular fill in lifts of 6-inch maximum thickness and compact each lift to minimum of 95 percent relative compaction as determined in accordance with ASTM D1557.

B. Around Buried Walls, Vaults, and Other Structures: Backfill with granular fill unless otherwise shown. Place granular fill in lifts of 6-inch maximum thickness and compact each lift to a minimum of 95 percent relative compaction as determined in accordance with ASTM D1557. Bring backfill up uniformly on all sides of the structure or facility. Compaction equipment or methods that may cause displacement of or damage to structures shall not be used.



C. Subsurface Drainage: Backfill with granular drain material, where shown. Place granular drain material in lifts of 6-inch maximum thickness and compact each lift to minimum of 90 percent relative density.

D. Other Areas: Backfill with earthfill to lines and grades shown, with proper allowance for topsoil thickness where shown. Place in lifts of 8-inch maximum thickness and compact each lift to minimum 90 percent relative compaction as determined in accordance with ASTM D1557.

3.03 FILL

A. Outside Influence Areas beneath Structures, Tanks, Pavements, Curbs, Slabs, Piping, and Other Facilities: Unless otherwise shown, place earthfill as follows:

1. Allow for topsoil where required. 2. Maximum 8-inch thick lifts. 3. Place and compact fill across full width of embankment. 4. Compact to minimum 90 percent relative compaction as determined in

accordance with ASTM D1557. 5. Dress completed embankment with allowance for topsoil, crest

surfacing, and slope protection, where applicable.

3.04 SITE TESTING

A. Gradation:

1. One sample from each 1,500 tons of finished product or more often as determined by Engineer, if variation in gradation is occurring, or if material appears to depart from Specifications.

2. If test results indicate material does not meet Specification requirements, terminate material placement until corrective measures are taken.

3. Remove material placed in Work that does not meet Specification requirements.

B. In-Place Density Tests: In accordance with ASTM D1556. During placement of materials, test as follows:

1. Granular Fill: At least one moisture density test for each lift or 50 cubic yards of material placed. Minimum of one test per location where granular fill is placed.

2. Sand: Minimum of one test per location where material is placed. 3. Base Course Rock: Minimum of one test per location where material is

placed.



4. Foundation Stabilization Rock: Minimum of one test per location where material is placed.

5. Soil Cover Over Geotextiles: Minimum of one test per location where material is placed.

3.05 GRANULAR BASE, SUBBASE, AND SURFACING

A. Place and compact as specified in Section 32 11 23, Aggregate Base Courses and Gravel Surfacing.

3.06 REPLACING OVEREXCAVATED MATERIAL

A. Replace excavation carried below grade lines shown or established by Engineer as follows:

1. Beneath Footings: Granular fill. 2. Beneath Fill or Backfill: Same material as specified for overlying fill or

backfill. 3. Beneath Slabs-On-Grade: Granular fill. 4. Permanent Cut Slopes (Where Overlying Area is Not to Receive Fill or

Backfill): a. Flat to Moderate Steep Slopes (3:1, Horizontal Run: Vertical Rise

or Flatter): Earthfill. b. Steep Slopes (Steeper than 3:1):

1) Correct overexcavation by transitioning between overcut areas and designed slope adjoining areas, provided such cutting does not extend offsite or outside easements and right-of-ways, or adversely impacts existing facilities, adjacent property, or completed Work.

2) Backfilling overexcavated areas is prohibited, unless in Engineer’s opinion, backfill will remain stable, and overexcavated material is replaced as compacted earthfill.

3.07 PLACING FILL OVER GEOSYNTHETICS

A. General:

1. Place fill over geosynthetics with sufficient care so as not to damage them.

2. Place fill only by back dumping and spreading only. 3. Dump fill only on previously placed fill. 4. While operating equipment, avoid sharp turns, sudden starts or stops

that could damage geosynthetics.

B. Hauling: Operate hauling equipment on minimum of 3 feet of covering.



C. Spreading:

1. Spreading equipment shall be track-mounted, low ground pressure, D-6 or lighter.

2. Operate spreading equipment on minimum of 12 inches of fill over geosynthetics.

3. Spread fill in same direction as unseamed overlaps to avoid separation of seams and joints.

4. Never push fill downslope. Spread fill over sideslopes by pushing up from slope bottom. If access to bottom of slope is unavailable, progressively place fill, beginning at toe of slope and working upslope, with backhoe or dragline operated from top of slope. Limit distance material falls onto the geosynthetics to maximum of 2 feet.

5. Correct wrinkles in geotextiles as specified in Section 31 32 19.16, Geotextile.

6. Maintain proper overlap of unseamed geosynthetics. 7. Avoid overstressing geosynthetics and seams.

D. Compaction: Compact fill only after uniformly spread to full thickness shown.

E. Geosynthetic Damage:

1. Mark punctures, tears, or other damage to geosynthetics, so repairs may be made.

2. Clear overlying fill as necessary to repair damage. 3. Repairs to geosynthetics shall be made by respective installers as

specified in respective specification section for each geosynthetic.

3.08 ACCESS ROAD SURFACING

A. Place and compact as specified in Section 32 11 23, Aggregate Base Courses and Gravel Surfacing.

END OF SECTION


PW/WBG/179201 TRENCH BACKFILL OCTOBER 2018 31 23 23.15 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 31 23 23.15 TRENCH BACKFILL

PART 1 GENERAL

1.01 DEFINITIONS

A. Base Rock: Granular material upon which manhole bases and other structures are placed.

B. Bedding Material: Granular material upon which pipes, conduits, cables, or duct banks are placed.

C. Imported Material: Material obtained by Contractor from source(s) offsite.

D. Lift: Loose (uncompacted) layer of material.

E. Pipe Zone: Backfill zone that includes full trench width and extends from prepared trench bottom to an upper limit above top outside surface of pipe, conduit, cable or duct bank.

F. Prepared Trench Bottom: Graded trench bottom after excavation and installation of stabilization material, if required, but before installation of bedding material.

G. Relative Compaction: The ratio, in percent, of the as-compacted field dry density to the laboratory maximum dry density as determined by ASTM D1557. Corrections for oversize material may be applied to either as-compacted field dry density or maximum dry density, as determined by Engineer.

H. Relative Density: As defined by ASTM D4253 and ASTM D4254.

I. Selected Backfill Material: Material available onsite that Engineer determines to be suitable for a specific use.

J. Controlled Low Strength Material (CLSM): A mixture of portland cement fly ash, aggregates or native material approved by Engineer, water, and admixtures proportioned to provide a nonsegregating, self-consolidating, free-flowing, and excavatable material that will result in a hardened, dense, nonsettling fill.

K. Well-Graded: A mixture of particle sizes that has no specific concentration or lack thereof of one or more sizes producing a material type that, when compacted, produces a strong and relatively incompressible soil mass free


TRENCH BACKFILL PW/WBG/179201 31 23 23.15 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

from detrimental voids. Satisfying both of the following requirements, as defined in ASTM D2487:

1. Coefficient of Curvature: Greater than or equal to 1 and less than or equal to 3.

2. Coefficient of Uniformity: Greater than or equal to 4 for materials classified as gravel, and greater than or equal to 6 for materials classified as sand.

1.02 SUBMITTALS


1. Certification, test results, and source for all imported materials to be used on the Project. Submit not less than 30 days prior to delivery.

2. Shop Drawings: Manufacturer’s descriptive literature for marking tapes. 3. Samples:

a. Trench stabilization material. b. Bedding and pipe zone material. c. Granular drain. d. Granular backfill. e. Earth backfill. f. Sand(s).

4. Documentation that imported materials are free of hazardous and deleterious substances.


1. Statement of Qualifications for soils testing laboratory and field testing service.

2. Catalog and manufacturer’s data sheets for compaction equipment. 3. Certified Gradation Analysis: Submit not less than 30 days prior to

delivery for imported materials or anticipated use for excavated materials, except for trench stabilization material that will be submitted prior to material delivery to Site.

4. Controlled Low Strength Material: Certified mix design and test results. Include material types and weight per cubic yard for each component of mix. Provide test results indicating compliance of each CLSM component with specified material properties.

5. Certified test results and reports from independent testing agency (Quality Control). a. Laboratory test results for physical and engineering properties of

soil materials.



b. Laboratory test results for compressive strength of CLSM Samples.

c. Field moisture and density testing results. d. Field ball-drop test results.

PART 2 PRODUCTS

2.01 GEOTEXTILE

A. As specified in Section 31 32 19.16, Geotextile.

2.02 MARKING TAPE

A. Nondetectable:

1. Inert polyethylene, impervious to known alkalis, acids, chemical reagents, and solvents likely to be encountered in soil.

2. Thickness: Minimum 5 mils. 3. Width: 12 inches. 4. Identifying Lettering: Minimum 1-inch high, permanent black lettering

imprinted continuously over entire length. 5. Manufacturers and Products:

a. Reef Industries; Terra Tape. b. Mutual Industries; Non-detectable Tape. c. Presco; Non-detectable Tape.

B. Detectable:

1. Solid aluminum foil, visible on unprinted side, encased in protective high visibility, inert polyethylene plastic jacket.

2. Foil Thickness: Minimum 0.35 mils. 3. Laminate Thickness: Minimum 5 mils. 4. Width: 12 inches. 5. Identifying Lettering: Minimum 1-inch high, permanent black lettering

imprinted continuously over entire length. 6. Joining Clips: Tin or nickel-coated furnished by tape manufacturer. 7. Manufacturers and Products:

a. Reef Industries; Terra Tape, Sentry Line Detectable. b. Mutual Industries; Detectable Tape. c. Presco; Detectable Tape.



C. Color: In accordance with APWA Uniform Color Code.

Color* Facility

Red Electric power lines, cables, conduit, and lightning cables

Orange Communicating alarm or signal lines, cables, or conduit

Yellow Gas, oil, steam, petroleum, or gaseous materials

Green Sewers and drain lines

Blue Potable water

Purple Reclaimed water, irrigation, and slurry lines

*As specified in NEMA Z535.1, Safety Color Code.

2.03 TRENCH STABILIZATION MATERIAL

A. Base Rock:

1. Clean, hard, durable 3-inch minus crushed rock or gravel, or pit run, free from clay balls, other organic materials, or debris.

2. Uniformly graded from coarse to fine, less than 8 percent by weight passing the 1/4-inch sieve.

3. With a minimum Durability Index of 35, as determined in accordance with Caltrans Test Method 229.

2.04 BEDDING MATERIAL AND PIPE ZONE MATERIAL

A. Unfrozen, friable, and no clay balls, roots, or other organic material.

B. With a minimum Durability Index of 35, as determined in accordance with Caltrans Test Method 229.

C. Clean or gravelly sand with less than 5 percent passing No. 200 sieve, as determined in accordance with ASTM D1140, or gravel or crushed rock within maximum particle size and other requirements as follows unless otherwise specified.

1. Duct Banks: 3/4-inch maximum particle size. 2. PVC Irrigation System Piping and Ductile Iron Pipe with Polyethylene

Wrap: 3/8-inch maximum particle size. 3. Pipe Under 18-Inch Diameter: 3/4-inch maximum particle size, except

1/4 inch for stainless steel pipe, copper pipe, tubing, and plastic pipe under 3-inch diameter.



4. Pipe 18-Inch Diameter and Greater: 1-1/2-inch maximum particle size for ductile iron pipe, concrete pipe, welded steel pipe, and pretensioned or prestressed concrete cylinder pipe.

5. Perforated Pipe: Granular drain material. 6. Conduit and Direct-Buried Cable:

a. Sand, clean or clean to silty, less than 12 percent passing No. 200 sieve.

b. Individual Particles: Free of sharp edges. c. Maximum Size Particle: Pass a No. 4 sieve. d. If more than 5 percent passes No. 200 sieve, the fraction that

passes No. 40 sieve shall be nonplastic as determined in accordance with ASTM D4318.

2.05 GRANULAR DRAIN MATERIAL

A. Crushed rock, gravel, or pit run rock, free from clay balls, organic matter, and other deleterious materials.

B. Gradation: ASTM C117 and ASTM C136.

Sieve Size Percent Passing By Weight

3 inches 100

1-1/2 inches 75 - 100

3/4 inch 45 - 100

3/8 inch 5 - 70

No. 4 0 - 50

No. 16 0 - 30

No. 50 0 - 5

No. 200 0 - 5

C. With a minimum Durability Index of 35, as determined in accordance with Caltrans Test Method 229.

2.06 EARTH BACKFILL

A. Soil, loam, or other excavated material suitable for use as backfill.

B. Free from roots or organic matter, refuse, boulders and material larger than 1/2 cubic foot, or other deleterious materials.



2.07 PROCESSED EARTH BACKFILL

A. Class A Backfill: Earth backfill, meeting the following additional requirement.

1. Free of boulders and cobbles that would be retained on a 6-inch screen.

2.08 CONTROLLED LOW STRENGTH MATERIAL (CLSM)

A. Select and proportion ingredients to obtain compressive strength between 50 psi and 150 psi at 28 days in accordance with ASTM D4832.

B. Materials:

1. Cement: ASTM C150/C150M, Type I or Type II. 2. Aggregate: ASTM C33/C33M, Size 7. 3. Fly Ash (Pozzolan): Class C fly ash in accordance with ASTM C618,

except as modified herein: a. ASTM C618, Table 1, Loss on Ignition: Unless permitted

otherwise, maximum 3 percent. 4. Water: Clean, potable, containing less than 500 ppm of chlorides.

2.09 CONCRETE BACKFILL

A. Provide as specified in Section 03 30 00, Cast-in-Place Concrete.

2.10 GRAVEL SURFACING ROCK

A. As specified in Section 32 11 23, Aggregate Base Courses and Gravel Surfacing.

2.11 RIVER BACKFILL ROCK

A. Imported, washed, and well-graded.

B. 1/2-inch by 3-inch angular material.

C. Free of deleterious materials

D. Maximum passing the No. 200 sieve shall be 0.5 percent.

2.12 TOPSOIL

A. As specified in Section 32 91 13, Soil Preparation.




A. Perform gradation analysis in accordance with ASTM C136 for:

1. Earth backfill, including specified class. 2. Trench stabilization material. 3. River backfill material. 4. Bedding and pipe zone material.

B. Certify Laboratory Performance of Mix Designs:

1. Controlled low strength material. 2. Concrete backfill.

PART 3 EXECUTION

3.01 TRENCH PREPARATION

A. Water Control:

1. As specified in Section 31 23 19.01, Dewatering. 2. Remove water in a manner that minimizes soil erosion from trench sides

and bottom. 3. Provide continuous water control until trench backfill is complete.

B. Remove foreign material and backfill contaminated with foreign material that falls into trench.

3.02 TRENCH BOTTOM

A. Protect trench bottom from loosening or softening that might result in loss of support for backfill materials or detrimental pipe settlement, particularly during wet periods.

B. Firm Subgrade: Grade with hand tools, remove loose and disturbed material, and trim off high areas and ridges left by excavating bucket teeth. Allow space for bedding material if shown or specified.

C. Soft Subgrade: If subgrade is encountered that may require removal to prevent pipe settlement, notify Engineer. Engineer will determine depth of overexcavation, if any required.

3.03 GEOTEXTILE INSTALLATION

A. Where shown and as specified in Section 31 32 19.16, Geotextile.



3.04 TRENCH STABILIZATION MATERIAL INSTALLATION

A. Rebuild trench bottom with trench stabilization material.

B. Place material over full width of trench in 6-inch lifts to required grade, providing allowance for bedding thickness.

C. Compact each lift so as to provide a firm, unyielding support for the bedding material prior to placing succeeding lifts.

D. Fully encapsulate trench stabilization material with geotextile as specified in Section 31 32 19.16, Geotextile.

3.05 BEDDING

A. Furnish imported bedding material where, in the opinion of Engineer, excavated material is unsuitable for bedding or insufficient in quantity.

B. Place over full width of prepared trench bottom in two equal lifts when required depth exceeds 8 inches.

C. Hand grade and compact each lift to provide a firm, unyielding surface.

D. Minimum Thickness: As shown in Standard Detail 3123-110 in Project Drawings.

E. Check grade and correct irregularities in bedding material. Loosen top 1 inch to 2 inches of compacted bedding material with a rake or by other means to provide a cushion before laying each section of pipe, conduit, direct-buried cable, or duct bank.

F. Install to form continuous and uniform support except at bell holes, if applicable, or minor disturbances resulting from removal of lifting tackle.

G. Bell or Coupling Holes: Excavate in bedding at each joint to permit proper assembly and inspection of joint and to provide uniform bearing along barrel of pipe or conduit.

H. Unless otherwise shown or specified, compact pipe zone material to at least 90 percent relative compaction and within 2 percent of the optimum moisture content.



3.06 BACKFILL PIPE ZONE

A. Upper limit of pipe zone shall not be less than following:

1. Pipe: 12 inches, unless shown otherwise. 2. Conduit: 3 inches, unless shown otherwise. 3. Direct-Buried Cable: 3 inches, unless shown otherwise. 4. Duct Bank: 3 inches, unless shown otherwise.

B. Restrain pipe, conduit, cables, and duct banks as necessary to prevent their movement during backfill operations.

C. Place material simultaneously in lifts on both sides of pipe and, if applicable, between pipes, conduit, cables, and duct banks installed in same trench.

1. Pipe 10-Inch and Smaller Diameter: First lift less than or equal to 1/2 pipe diameter.

2. Pipe Over 10-Inch Diameter: Maximum 6-inch lifts.

D. Thoroughly tamp each lift, including area under haunches, with handheld tamping bars supplemented by “walking in” and slicing material under haunches with a shovel to ensure voids are completely filled before placing each succeeding lift.

E. Unless otherwise shown or specified, compact pipe zone material to at least 90 percent relative compaction and within 2 percent of the optimum moisture content.

F. No flooding or jetting is allowed.

G. Do not dump or pour pipe zone backfill material directly on top of pipe. Use caution during placement and compaction of pipe zone material to avoid damage to pipe and/or coatings.

H. Do not use power-driven impact compactors to compact pipe zone material. After full depth of pipe zone material has been placed as specified, compact material by a minimum of three passes with a vibratory plate compactor only over area between sides of pipe and trench walls.

I. CLSM:

1. Place in lifts, as necessary, to prevent uplift (flotation) of new and existing facilities.

2. Use sufficient shores or other supports to prevent soil from caving onto pipe. Remove soil fallen into trench before placing CLSM.



3. Pour CLSM in horizontal lifts. 4. Where installing CLSM backfill on slopes, construct bulkheads within

the trench to prevent CLSM from flowing more than 50 feet laterally from the point at which it is discharged into the trench. Within the pipe zone, construct maximum 3-foot wide bulkheads using sandbags. Above the pipe zone, construct bulkheads using sandbags or earth backfill material in accordance with requirements for trench backfill presented in this section.

5. Allow CLSM to set before placing backfill. Prior to placing backfill over CLSM, CLSM shall achieve an indentation diameter less than or equal to 75 mm (3 inches) as determined in accordance with ASTM D6024.

6. Prevent CLSM from entering bell holes before joint welding, coating, and testing are complete.

7. Place protective blankets over joints to keep CLSM spatter off of joint prior to coating of joints.

3.07 MARKING TAPE INSTALLATION

A. Continuously install marking tape along centerline of buried piping, on top of last lift of pipe zone material. Coordinate with piping installation drawings.

1. Detectable Marking Tape: Install with nonmetallic piping and waterlines.

2. Nondetectable Marking Tape: Install with metallic piping.

3.08 BACKFILL ABOVE PIPE ZONE

A. General:

1. Process excavated material to meet specified gradation requirements. 2. Adjust moisture content as necessary to obtain specified compaction. 3. Do not allow backfill to free fall into trench or allow heavy, sharp

pieces of material to be placed as backfill until after at least 2 feet of backfill has been provided over top of pipe.

4. Do not use power driven impact type compactors for compaction until at least 4 feet of backfill is placed over top of pipe.

5. Backfill to grade with proper allowances for topsoil, crushed rock surfacing, and pavement thicknesses, wherever applicable.

6. Backfill around structures with same class backfill as specified for adjacent trench, unless otherwise shown or specified.

7. Backfill around vertical risers and appurtenances with pipe zone material unless otherwise shown or specified.



B. Class A Backfill:

1. Place in lifts not exceeding thickness of 9 inches. 2. Mechanically compact each lift to a minimum of 95 percent relative

compaction prior to placing succeeding lifts.

C. Concrete Backfill:

1. Place above bedding. 2. Minimum Concrete Thickness: 12 inches on top and sides of pipe. 3. Do not allow dirt or foreign material to become mixed with concrete

during placement. 4. Allow sufficient time for concrete to reach initial set before additional

backfill material is placed in trench. 5. Prevent flotation of pipe. 6. Do not encase pipe joints.

D. Controlled Low Strength Material:

1. Place in lifts as necessary to prevent uplift (flotation) of new and existing facilities.

2. Remove soil fallen into trench before placing CLSM. 3. Allow CLSM to set before placing backfill. Prior to placing backfill

over CLSM, CLSM shall have an indentation diameter less than or equal to 75 mm (3 inches) as determined in accordance with ASTM D6024.

4. Blade finish surface true to grade and crown before proceeding with surfacing.

E. Earth Backfill: Compact to a level suitable to prevent trench settlement.

3.09 REPLACEMENT OF TOPSOIL

A. Replace topsoil in top 12 inches of backfilled trench.

B. Maintain finished grade of topsoil even with adjacent area and grade as necessary to restore drainage.

3.10 MAINTENANCE OF TRENCH BACKFILL

A. After each section of trench is backfilled, maintain surface of backfilled trench even with adjacent ground surface until final surface restoration is completed.



B. Gravel Surfacing Rock: Add gravel surfacing rock where applicable and as necessary to keep surface of backfilled trench even with adjacent ground surface, and grade and compact as necessary to keep surface of backfilled trenches smooth, free from ruts and potholes, and suitable for normal traffic flow.

C. Topsoil: Add topsoil where applicable and as necessary to maintain surface of backfilled trench level with adjacent ground surface.

D. Concrete Pavement: Replace settled slabs as specified in Section 32 12 16, Asphalt Paving.

E. Asphaltic Pavement: Replace settled areas or fill with asphalt as specified in Section 32 12 16, Asphalt Paving.

F. Other Areas: Add excavated material where applicable and keep surface of backfilled trench level with adjacent ground surface.

3.11 SETTLEMENT OF BACKFILL

A. Settlement of trench backfill, or of fill, or facilities constructed over trench backfill will be considered a result of defective compaction of trench backfill, and shall be remediated at no additional cost.

END OF SECTION


PW/WBG/179201 GEOTEXTILE OCTOBER 2018 31 32 19.16 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 31 32 19.16 GEOTEXTILE

PART 1 GENERAL

1.01 DEFINITIONS

A. Fabric: Geotextile, a permeable geosynthetic comprised solely of textiles.

B. Maximum Average Roll Value (Max ARV): Maximum of series of average roll values representative of geotextile furnished.

C. Minimum Average Roll Value (Min ARV): Minimum of series of average roll values representative of geotextile furnished.

D. Nondestructive Sample: Sample representative of finished Work, prepared for testing without destruction of Work.

E. Overlap: Distance measured perpendicular from overlapping edge of one sheet to underlying edge of adjacent sheet.

1.02 SUBMITTALS


1. Shop Drawings: a. Manufacturer material specifications and product literature. b. Installation drawings showing geotextile sheet layout, location of

seams, direction of overlap, and sewn seams (if applicable). c. Description of proposed method of geotextile deployment, sewing

equipment, sewing methods, and provisions for holding geotextile temporarily in place until permanently secured.

2. Samples: a. Geotextile: One-piece, minimum 18 inches long, taken across full

width of roll of each type and weight of geotextile furnished for Project. Label each with brand name and furnish documentation of lot and roll number from which each Sample was obtained.

b. Securing Pin and Washer: One each.

B. Informational Submittals: Certifications from each geotextile manufacturer that furnished products have specified property values. Certified property values shall be either minimum or maximum average roll values, as appropriate, for geotextiles furnished.


GEOTEXTILE PW/WBG/179201 31 32 19.16 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

1.03 DELIVERY, STORAGE, AND HANDLING

A. Deliver each roll with sufficient information attached to identify it for inventory and quality control.

B. Handle products in manner that maintains undamaged condition.

C. Do not store products directly on ground. Ship and store geotextile with suitable wrapping for protection against moisture and ultraviolet exposure. Store geotextile in way that protects it from elements. If stored outdoors, elevate and protect geotextile with waterproof cover.


A. Where geotextile is to be laid directly upon ground surface, prepare subgrade as specified in Section 31 23 13, Subgrade Preparation, first.

B. Notify Engineer whenever geotextiles are to be placed. Do not place geotextile without Engineer’s approval of underlying materials.

PART 2 PRODUCTS

2.01 WOVEN GEOTEXTILE

A. Composed of polymeric yarn interlaced to form planar structure with uniform weave pattern.

B. Calendared or finished so yarns will retain their relative position with respect to each other.

C. Polymeric Yarn: Long-chain synthetic polymers (polyester or polypropylene) with stabilizers or inhibitors added to make filaments resistant to deterioration due to heat and ultraviolet light exposure.

D. Sheet Edges: Selvaged or finished to prevent outer material from separating from sheet.

E. Unseamed Sheet Width: Minimum 6 feet.



Physical Properties: Conform to requirements in Tables 1 and 2 as manufactured by TC Mirafi or equivalent.

Table No. 1 Physical Property Requirements for Type I Woven Geotextile

Property Requirement Test Method

Apparent Opening Size (AOS)

#50 - #70 U.S. Standard Sieve Size

ASTM D4751

Grab Tensile Strength 160 lb, Min ARV ASTM D4632

Grab Elongation 25 percent, Max ARV ASTM D4632

Ultraviolet Radiation Resistance

70 percent strength retention, Min ARV after 500 hours

ASTM D4355

Weight per Square Yard 4 oz/yd2 Min ARV ASTM D5261

Table No. 2 Physical Property Requirements for Type II Woven Geotextile



#70 U.S. Standard Sieve Size

ASTM D4751





ASTM D4355


2.02 NONWOVEN GEOTEXTILE

A. Pervious sheet of polyester, polypropylene, or polyethylene fabricated into stable network of fibers that retain their relative position with respect to each other. Nonwoven geotextile shall be composed of continuous or discontinuous (staple) fibers held together through needle-punching, spun-bonding, thermal-bonding, or resin-bonding.



B. Geotextile Edges: Selvaged or otherwise finished to prevent outer material from pulling away from geotextile.

C. Unseamed Sheet Width: Contractor shall provide sufficient geotextile material width to fully wrap the required area as indicated in the Plans with only one overlap located as close to the top center of the wrapped area as practical. If trench width is too great to allow the longitudinal placement of the geotextile, the geotextile shall be placed transversely with only one longitudinal overlap located at the top center of the section. Use the maximum available roll width to minimize transverse seams.

Physical Properties: Conform to requirements in Table 3 as manufactured by TC Mirafi or equivalent.

Table No. 3 Physical Property Requirements for Type I Nonwoven Geotextile



#100 U.S. Standard Sieve Size

ASTM D4751





ASTM D4355

Puncture Strength 175 lb, Min ARV ASTM D4833


2.03 SEWING THREAD

A. Polypropylene, polyester, or Kevlar thread.

B. Durability: Equal to or greater than durability of geotextile sewn.

2.04 SECURING PINS

A. Steel Rods or Bars:

1. 3/16-inch diameter. 2. Pointed at one end. 3. With head on other end sufficiently large to retain washer. 4. Minimum Length: 12 inches.



B. Steel Washers for Securing Pins:

1. Outside Diameter: Not less than 1.5 inches. 2. Inside Diameter: 1/4 inch. 3. Thickness: 1/8 inch.

C. Steel Wire Staples:

1. U-shaped. 2. 10 gauge. 3. Minimum Length: 6 inches.

PART 3 EXECUTION

3.01 LAYING GEOTEXTILE

A. Lay and maintain geotextile smooth and free of tension, folds, wrinkles, or creases.

3.02 JOINTS

A. Unseamed Joints:

1. Overlapped. 2. Overlap, unless otherwise shown:

a. Foundation/Subgrade Stabilization: Minimum 18 inches. b. Riprap: Minimum 18 inches. c. Drain Trenches: Minimum 18 inches, except overlap shall equal

trench width if trench width is less than 18 inches. d. Other Applications: Minimum 12 inches.

B. Seamed Joints: In accordance with the manufacturer’s recommendations for the intended application.

3.03 INSTALLING GEOTEXTILE ON SLOPES BENEATH RIPRAP

A. Use Type II woven geotextile.

B. Orient geotextile with long dimension of each sheet parallel to direction of slope.

C. Provide key trenches, as required, as per manufacturer’s requirements.

D. Overlap geotextile at each joint with upstream sheet of geotextile overlapping downstream sheet.



E. Limit height of riprap fall onto geotextile to 6 inches to prevent damage.

3.04 INSTALLING GEOTEXTILE IN TRENCHES AND EXCAVATIONS

A. Use Type I nonwoven geotextile.

B. Place nonwoven geotextile in a way that will completely envelope granular drain material to be placed in trench and with specified overlap at joints. Overlap nonwoven geotextile in direction of flow. Place nonwoven geotextile in a way and with sufficient slack for geotextile to contact trench bottom and sides fully when trench is backfilled.

C. After granular drain material is placed to required grade, as directed by Engineer, fold nonwoven geotextile over top of granular drain material, unless otherwise shown. Maintain overlap until overlying fill or backfill is placed.

3.05 SOIL EROSION STABILIZATION APPLICATIONS

A. Utilize Type I woven geotextile.

B. Install geotextile in one piece, or continuously sewn to make one piece, for full length and height of fence, including portion of geotextile buried in toe trench.

C. Install bottom edge of sheet in toe trench and backfill in a way that securely anchors geotextile in trench.

D. Securely fasten geotextile to wire mesh backing and each support post in a way that will not result in tearing of geotextile when fence is subjected to service loads.

E. Promptly repair or replace silt fence that becomes damaged.

3.06 SECURING GEOTEXTILE

A. Secure geotextile during installation as necessary with sandbags or other means approved by Engineer.

B. Secure Geotextile with Securing Pins or Staples:

1. Insert securing pins with washers through geotextile. 2. Securing Pin Alignment:

a. Midway between edges of overlaps. b. 6 inches from free edges.



3. Spacing of Securing Pins:

Slope Maximum Pin Spacing

Steeper than 3:1 2 feet

3:1 to 4:1 3 feet

Flatter than 4:1 5 feet

4. Install additional pins across each geotextile sheet as necessary to prevent slippage of geotextile or to prevent wind from blowing geotextile out of position.

5. Push each securing pin through geotextile until washer bears against geotextile and secures it firmly to subgrade.

6. Where staples are used instead of securing pins, install in accordance with alignment and spacing above. Push in to secure geotextile firmly to subgrade.

3.07 PLACING PRODUCTS OVER GEOTEXTILE

A. Before placing material over geotextile, notify Engineer. Do not cover installed geotextile until after Engineer provides authorization to proceed.

B. If tears, punctures, or other geotextile damage occurs during placement of overlying products, remove overlying products as necessary to expose damaged geotextile. Repair damage as specified in Article Repairing Geotextile.

3.08 REPAIRING GEOTEXTILE

A. Repair or replace torn, punctured, flawed, deteriorated, or otherwise damaged geotextile.

B. Repair Procedure:

1. Place patch of undamaged geotextile over damaged area and at least 18 inches in all directions beyond damaged area.

2. Remove interfering material as necessary to expose damaged geotextile for repair.

3. Sew patches or secure them with heat fusion tacking or with pins and washers, as specified above in Article Securing Geotextile, or by other means approved by Engineer.



3.09 REPLACING CONTAMINATED GEOTEXTILE

A. Protect geotextile from contamination that would interfere, in Engineer’s opinion, with its intended function. Remove and replace contaminated geotextile with clean geotextile.

END OF SECTION


PW/WBG/179201 GROUND IMPROVEMENT OCTOBER 2018 31 32 50 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 31 32 50 GROUND IMPROVEMENT

PART 1 GENERAL

1.01 SUMMARY

A. This section includes requirements for ground improvement to stabilize soils and groundwater at shaft locations to facilitate launching and retrieving the microtunnel boring machine (MTBM). Ground improvement shall consist of jet grouting or other methods suitable to stabilize the ground, subject to the Engineer’s written approval.

B. The Contractor shall design, construct, and test stabilized soil-cement columns by the jet grouting method for:

1. Stability of ground and groundwater during exit of Microtunnel Boring Machine (MTBM) from jacking shaft and entry of MTBM into reception shaft where necessary, or where shown on the Plans.

2. Stability of shaft excavations including walls and bases at the Contractor’s option.

C. The Work includes mobilizing equipment for jet grouting, determining suitable grouting procedures and grout mixes, installing test and production jet grout columns, and control, containment, cleanup, and disposal of waste materials resulting from jet grouting.

D. The Contractor may propose other soil improvement procedures satisfying the performance requirements of this specification, subject to Engineer’s written approval.

E. Loading caused by the ground improvement on the Contractor-designed excavation shoring shall be assessed by the Contractor.


GROUND IMPROVEMENT PW/WBG/179201 31 32 50 – 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

1.02 SUBMITTALS


1. Quality Control: a. Qualifications: The Contractor shall submit evidence for approval

that the Contractor or Subcontractor is experienced in jet grouting in a variety of subsurface conditions and in conditions similar to those specific to this Project. As described in Article Definitions, Paragraph A. below, qualifications shall be submitted for: 1) Grouting Subcontractor. 2) Designer of jet grouting program. 3) Grouting manager.

b. Certifications and Permits: 1) Certificates of compliance for materials specified in Part 2,

Products, herein. 2) Required permits for disposing of waste materials.

c. Quality Control Plans: 1) Sampling and testing methods, where not otherwise

specified, for determining compliance with design criteria. 2) Methods for controlling and verifying the vertical limits of

the jet grouting operation and the amount of grout column overlap.

3) Criteria, equipment, and procedures for abandoning or remedying grout columns occasioned by equipment failure, inadequacy of grout mix or delivery systems, or other cause.

d. Coring: 1) Sampling and testing procedures. 2) Core log. 3) Results of laboratory strength testing.

2. Daily Records shall be submitted by noon of the day following the shift to which the daily records pertain, and shall include: a. Grout hole geometry comprising location, design column

diameter, spacing, depth and casing details. b. Grout column information comprising start and finish times, upper

and lower elevation limits, grout mix data, grout take, rates of rotation and withdrawal of monitor, jet pressures, and other observations, such as grout leakage and ground heave.

c. Quality control sampling, measurements, and results. d. Nature, causes, duration, and impacts of interruptions and delays

to the jet grouting operation. 3. Notifications:

a. At least one week in advance of performing jet grouting at test section, provide location of jet grouting test section to Engineer.



b. Notify Engineer at least three days in advance of performing jet grouting at all other work areas.

4. As-built drawings indicating the locations of jet grout columns.

B. Action Submittals:

1. Shop Drawings, Methods Statements, Calculations, and Information: a. List and description of locations, including test section, where jet

grouting is to be performed, with description of the size of the grouted zone and column layout (Length, width, depth, referenced to stations and elevations).

b. Design calculations with clearly identified design parameters and assumptions for the jet grouted soil-cement columns based on anticipated subsurface conditions indicating the arrangement, spacing, and diameter of boreholes relative to the grout mix used, diameter of grout column, and depth of the grouted mass.

c. Equipment and methods for drilling and casing boreholes. Equipment, methods, and details of jet grouting operation sequence and details of grout column placement, and minimum set time and strength before jet grouting adjacent columns.

d. Sketch of Work staging area layout and access plans for areas to be treated.

e. Means and methods for handling, containing, treating, and disposing of excess or spilled materials generated during the jet grouting operation.

f. Preconstruction photographs, videotape, and survey, documenting conditions in areas to be treated before construction. Two copies of photographs, videotapes, and survey shall be submitted to Engineer at least one week before grouting begins.

2. Materials: a. The Contractor shall submit the source of all materials to be used in

the jet grout mix along with laboratory test results for each material, including soil to be stabilized, water, cement, bentonite and admixtures.

b. Mix Design: The Contractor shall submit the proposed proportions for soil-cement mixture along with results of laboratory testing of trial mixtures using the proposed material components.

1.03 QUALITY CONTROL

A. Qualifications:

1. Jet grouting Subcontractor shall have not less than five projects completed within the last 10 years comprising the planning and



execution of a jet grouting program of the scope and type required for this Project.

2. The design of the jet grouting program shall be performed or supervised by a registered Professional Engineer in the United States who has experience in the design of such jet grouting programs. The calculations and Plans shall be sealed and signed by the registered professional Engineer.

3. Jet grouting manager shall be a full-time, onsite individual with responsibility for all jet grouting operations, and shall have at least 10 years of experience in the design and field application of jet grouting technology similar to that required for this Project.

B. The Contractor shall be responsible for all quality control testing of jet grouted columns. All test results shall be submitted to Engineer.

C. Grout Mix: Grout mix uniformity shall be verified by unit weight (density) measurements of the mixed grout by mud balance, Marsh funnel viscosity, and bleed from Samples taken from the grout return line. Testing shall be performed in accordance with API Standard 13B test method. Testing frequency shall be as specified in Article Quality Control, Paragraph D below. Complete and accurate records shall be submitted to the Engineer to verify that grout mix is as approved.

D. Grout Mix and Soil-Cement Samples:

1. During execution of the production columns, the following shall be measured on liquid Samples of grout: a. Unit Weight or Specific Gravity (daily). b. Marsh Funnel Viscosity (daily). c. Bleeding at 1 and 2 hours (daily).

2. A minimum of every 150 cubic yards of treated volume or twice per treated zone, the following Samples shall be taken: a. One set of four Samples of the cement grout used for the

construction of one of the columns shall be prepared in accordance with ASTM C109.

b. One set of four Samples of wet soil-cement from construction of one of the columns shall be prepared in accordance with ASTM C109. 1) Each of these Samples shall be stored in a damp

environment at constant temperature in accordance with applicable ASTM procedures.

2) After the Samples have cured sufficiently, they shall be tested by a qualified laboratory that has been approved by the Engineer.



3) Two grout Samples and two soil-cement Samples shall be tested for compressive strength at 24 hours and at 7 days in accordance with ASTM C39 or C109 and ASTM C1633, respectively.

E. Core Samples:

1. When ground improvement is complete at any excavation and has reached sufficient strength, vertical core samples shall be taken of the entire treated zone, outside of the tunnel envelope, at locations selected by the Contractor and approved by the Engineer. Core Samples shall be taken a minimum of every 150 cubic yards of treated volume or twice per treated zone, whichever is greater.

2. The coring or sampling operations shall be scheduled according to the jet grouting and construction activities schedule and performed with suitable equipment and a qualified driller.

3. Triple tube core barrels with thin walls shall be employed to obtain a continuous core sample of the jet grout columns. The size of the core barrel shall be NX or greater. Drilling shall be performed using rotary wash or air rotary methods by an experienced driller familiar with the double tube coring process, and coring and sampling of jet grouted columns.

4. All cores and Samples shall be taken to an independent laboratory, approved by the Engineer, where they shall be stored in a moist environment at constant temperature. Extreme care shall be exercised in handling the cores at the Site, in transport, and at the laboratory such that the cores do not become disturbed or otherwise damaged prior to testing.

5. The cores of jet-grouted soil shall be examined for continuity of the treatment and subjected to unconfined compressive strength tests at ages corresponding to design assumptions. All testing results shall be recorded on a quality control sheet.

6. If the cores display zones of untreated soil or the Samples tested do not meet specified strength requirements then additional replacement jet grout columns shall be installed by the Contractor, or other provisions shall be implemented, as approved by Engineer, and at no additional cost to the Owner, to compensate for the lower strength columns.

7. All cores or sampling holes shall be backfilled with cement grout at the completion of coring or sampling. The compressive strength of the backfill material shall not be greater than that of the soil-cement columns.



F. Acceptance Criteria:

1. The continuity and average strength of the soil-cement column mass shall be determined by sampling the production jet grouting, as specified in this section under Quality Control.

2. Production Jet Grouting: Results shall be considered acceptable when: a. All tested specimens of jet grouted soil-cement meet minimum

and maximum design strengths. b. Core lengths containing jet grouted soil-cement mixture comprise

at least 90 percent of the core runs. 3. Ultimate acceptance shall be subject to successful completion of the

probing, as defined in Section 31 41 00, Shoring.

1.04 DEFINITIONS

A. Ground Improvement: A process of binding, strengthening, and stabilizing native soils to prevent movement of soil and water into the jacking and receiving shafts during launch and recovery of the MTBM. Ground improvement shall consist of jet grouting as specified herein, or other suitable methods, subject to the Engineer’s written approval.

B. Jet Grouting: A soil stabilization process accomplished by the in-situ mixing of soils using a high pressure stabilizing fluid. The stabilization fluid (usually a cement grout slurry) is injected using a one, two, or three fluid jet grouting system. A borehole is drilled to the depth to be treated. The fluids are injected into the soil at high pressure through horizontal nozzles in a monitor drill pipe. The monitor is rotated and lifted at a controlled rate allowing the fluid to mix with the soil creating soil-cement columns.

C. Monitor: A single, double, or triple fluid drill pipe designed to deliver one to three elements of grout, air, and water. The monitor has one or more injection ports. The nozzle(s) inject fluid into the soil at high velocity to erode and mix the soil and grout.

D. Single Fluid System: The single fluid system involves the injection of grout at high pressure causing it to mix with the in-situ soil.

E. Double Fluid System: Grout and air are injected into the soil from concentric nozzles. The grout is injected at a lower pressure and is shrouded by a high pressure air. The air allows the grout to be injected and mixed further into the ground, producing larger diameter soil columns compared to the single fluid method.

F. Triple Fluid System: This system uses high pressure air and water to erode the soil, while grout is injected at lower pressure through nozzles located below



the air and water nozzles. The air and water is injected similar to the method used for grout in the double fluid system, to produce columns or treated zones that are larger than can be produced with the single or double fluid systems.

G. Soil-Cement: The mixture created by mixing in-situ soils with a stabilizing cement grout mix.

H. Primary Columns: Jet grout columns constructed into soils to provide stability for shaft, cofferdam, and tunnel excavations.

I. Secondary Columns: Jet grout columns constructed between and overlapping with the primary columns to tie into the adjacent primary columns providing continuous stability for shaft, cofferdam, or shaft and tunnel excavations.

1.05 DESIGN CRITERIA

A. Soil-Cement Columns:

1. The Contractor shall treat 100 percent of the soil within the limits indicated on the Drawings. Ground improvement shall consist of overlapping continuous jet grouted columns or other ground improvement methods, subject to Engineer’s written approval. Where treated zones are adjacent to jacking shafts or cofferdam walls, soil treatment shall extend to, and be in complete contact with, the completed walls. Jet grouting at shaft locations shall be performed in a manner that prevents loss of soil or groundwater into shafts during the launch or retrieval of the MTBM through the shaft wall and seals.

2. For the entry and exit seals at the shafts, the maximum 28-day compressive strength of the grout shall be of a strength that can be efficiently excavated by the MTBM. The jet grouting Subcontractor shall coordinate with the microtunneling Subcontractor to ensure that cured soil-cement is excavatable.

3. Column Overlap: Column overlap shall be the larger of 1/8 of the column diameter or 9 inches.

4. For grout used at shaft exit and entry locations, Contractor shall confirm the adequacy of the design criteria as related to the behavior of anticipated soils and groundwater conditions and as integrated with the Contractor’s means and methods for performing the work. Contractor may propose deviations, subject to Engineer’s written approval.



B. Heave and Settlement Tolerances:

1. Contractor shall control settlement and heave to prevent damage to surface features and utilities.

2. Maximum allowable heave or settlement shall conform to Section 31 80 00, Geotechnical Instrumentation.

3. Contractor shall repair any damage to utilities or surface facilities at no cost to the Owner.

C. Perform jet grouting so that the stabilized soil-cement grout columns produced meet the following requirements:

1. The columns shall consist of soil mixed with cement grout, by the jet grouting method using a single, double, or triple fluid system, as described in approved Submittals.

2. Jet grout injection, rotation, and extraction rates shall be sufficient to produce soil-cement columns meeting the diameter, depth, overlap, continuity, and material property requirements shown on the Plans and specified herein.

3. The completed columns shall be a homogeneous mixture of grout and in situ soils. Mixing is to be controlled by shaft rotational speed, drilling speed, and grout injection rate.

4. Consideration shall be given to deflections of shoring elements during excavation and unwatering of the shafts when planning continuous ground improvement.

5. If the performance requirements for the jet grout columns specified herein are not achieved, additional jet grout columns shall be installed, as directed by the Engineer, at no additional cost to the Owner.

D. Drill rig, tooling, and bits shall be capable of advancing through soil conditions described in the Geotechnical Baseline Report.

E. The jet grouting work shall be scheduled and performed so that columns have achieved adequate strength to support the ground outside shafts at entry/exit locations and prevent inflows of soil or groundwater prior to excavation.

PART 2 PRODUCTS

2.01 MATERIALS

A. Grout: Grout to be used in jet grouting shall be a mixture of portland cement, water, and bentonite or other nontoxic, biodegradable admixtures as needed. The grout shall be mixed in a grout plant that combines dry cement and water in predetermined proportions. Grout mixes shall have a consistency that is fluid



and pumpable. Grout mixes shall be proportioned to provide the required strength and mixing consistency.

B. Cement: Portland cement, ASTM C150, Type I or II.

C. Bentonite: Premium grade Wyoming Sodium Montmorillonite, manufactured in accordance with API Standard 13A.

D. Water: Only fresh and potable water shall be used for mixing grout.

E. Admixtures: Admixtures may be used as necessary to improve pumpability, to control set time, and to prevent segregation and bleeding. Admixtures shall be non-toxic and biodegradable and conform to ASTM C494.

2.02 EQUIPMENT

A. Drilling Equipment: All jet grouting equipment used for drilling boreholes; lowering, raising and rotating grout tubes; mixing grout; and injecting grout shall have proven performance for use in performing jet grouting work.

B. Mixers: Grout mixers, holding tanks, and associated equipment shall be of a type and capacity for producing uniform grout mixtures at all times, and in the quantities required for the timely execution of the work.

C. Jet Pumps: Pumps shall be high-pressure pumps capable of delivering the grout at the flow rates and pressures required.

D. Recording Equipment: Provide automatic recording equipment with a meter to determine the volume of grout injected. The meter shall be calibrated in gallons to the nearest quarter-gallon (1/4 gallon).

E. Spare parts and/or equipment shall be available on site to maintain the jet grouting equipment in satisfactory operating condition at all times during execution of the grouting work.

PART 3 EXECUTION

3.01 GENERAL

A. All ground improvement work shall be performed in accordance with all local, state, and federal safety regulations and permits required for the Project.



B. The general procedure for constructing each individual jet grouted column shall be as follows:

1. The jet grout column shall be constructed into soils as shown on the approved Shop Drawings.

2. The grout shall be pumped through the nozzles. The rods shall be rotated and withdrawn in prescribed increments creating the jet-grouted column.

3. Excess grout and soil from jet grouting operations shall be contained in mud tanks or by other approved methods to facilitate rapid cleanup at the end of each shift.

4. Equipment for mixing, holding, and pumping grout shall be in a secure location and shall be operated to prevent spillage of material. No water, waste, grout, or soil shall be allowed to discharge into any body of water, sewer, or storm drain.

5. At the completion of daily jet grouting operations, thoroughly clean site and dispose of all debris, water, waste grout, and spilled material.

3.02 COLUMN LOCATIONS

A. The jet-grouted column locations shall be surveyed and checked by the Contractor before commencement of drilling. Column layout shall be based on the minimum column diameter and column overlap shown on the approved submittal including provisions for a minimum overlap of the larger of 1/8 the column diameter or 9 inches in all directions and control of ground water inflow. Provide additional overlap if required for adequate support of shaft and trench excavations. The location of each column shall be noted and recorded on the daily shift report.

3.03 COLUMN INCLINATIONS

A. The drilling/grouting rods shall be of sufficient stiffness to ensure that the deviation of jet-grouted columns from the theoretical axis is maintained at 1:100 (horizontal to vertical) or better.

B. Vertical columns shall be installed unless utilities or other obstructions require the columns to be inclined to avoid conflicts. The inclination of each column shall be noted and recorded on the daily shift report.

3.04 COLUMN DEPTH AND HEIGHT

A. Column depth shall be measured with respect to ground surface by observing the length of the rods inserted. Markings shall be located on the drill mast in 1 foot increments to assist the drill operator in determining depth.



B. Column length shall also be measured by observing the length of the rods withdrawn while grouting.

C. The depth to the bottom and length of each column shall be noted and recorded on the daily shift report.

3.05 GROUT MIXING

A. A mixing plant shall be used for the preparation of the grout. The mixing plant shall consist of a high-speed grout mixer, grout agitator, grout pumps and control unit, as required. The plant shall be capable of supplying a uniform grout mixture in the quantities required for timely execution of the work.

B. Mix cement, water, and any admixtures in the proportions indicated in the approved submittals. If bentonite is used, add bentonite to water and mix thoroughly to fully hydrate prior to adding cement. Time of mixing shall be as required to fully hydrate the bentonite but not less than 5 minutes. Any grout not injected within 90 minutes shall be wasted.

3.06 GROUT INJECTION RATE AND PRESSURE

A. The appropriate grout injection rate and pressure shall be determined during the test program and this injection rate and pressure shall be maintained during construction of the production columns.

B. The grout injection rate shall be monitored by counting the strokes of the piston pump in a fixed period of time if piston displacement calibration is available or by using a flowmeter.

C. The grout injection pressure shall be monitored with calibrated pressure gauges mounted on the injection lines. Prior to the start of each column, the pressure shall be checked to verify that there is no blockage in the jet grout rods.

D. The grout injection rate, volumes injected, and injection pressure for each column shall be noted and recorded on the daily shift reports.

3.07 AIR/WATER PRESSURE

A. The necessary air and/or water pressure shall be determined during the test program and maintained during construction of the production columns. The air pressure shall be checked on the pressure gauges mounted on the compressor and drill rig.

B. The air pressure shall be noted and recorded for each column on the daily shift reports.



3.08 ROTATION AND WITHDRAWAL RATE

A. The appropriate rate of rotation and withdrawal of the jet grout monitor shall be determined during the test program and maintained during construction of the production columns.

B. The rate of rotation shall be controlled by adjusting the rotary head speed. The rate shall be checked by counting the number of rotations of the drilling/grouting rods in a fixed period of time.

C. The rate of withdrawal shall be controlled by an electronic sensor mounted to the mast.

D. The rate of rotation and withdrawal of the jet rods shall be noted and recorded for each column on the daily shift reports.

3.09 PREVENTION OF GROUND HEAVE

A. In order to prevent ground heave and the potential for discharging grout into water ways during jet grouting, the drilling shall be carried out with an oversize drill bit with respect to the drilling/grouting rods. Appropriate drilling procedures shall be determined during the test program and utilized during construction of the production columns.

B. The annulus between the rods and the borehole shall be kept clear at all times during grouting.

C. Monitoring points to be installed according to Section 31 80 00, Geotechnical Instrumentation.

3.10 CONTAINMENT OF GROUT DISCHARGE

A. All grout, water, and other drilling/grouting waste material shall be contained within the work areas with berms, hay bales, silt fences, or other measures to prevent discharge of grout into the storm drains, sewers, drainage channels, or waterways.

3.11 CLEANUP

A. The Contractor shall complete cleanup of the work area after jet grouting operations as soon as possible, and remove all grout spillage and residue from the work area prior to shaft excavation.

END OF SECTION


PW/WBG/179201 RIPRAP OCTOBER 2018 31 37 00 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 31 37 00 RIPRAP

PART 1 GENERAL

1.01 DEFINITIONS

A. Refer to applicable definitions in Section 31 23 23, Fill and Backfill.

B. Standard Specifications, as used in this section, refer to the California Department of Transportation (Caltrans) Standard Specifications, 2010.

1.02 SUBMITTALS


1. Shop Drawings: Description and location of proposed sources of riprap bedding and riprap.


1. Quarry Certificate of Conformance and supporting documentation showing proposed riprap bedding or riprap meet Standard Specification gradation and materials requirements for the Class or Type specified.

2. Certified Test Results: a. Riprap:

1) Gradation. 2) Abrasion resistance. 3) Bulk density.

3. Trip tickets showing source, type, and weight of each load of material delivered to Site.


A. Riprap Source: Quarry that has produced riprap and has performed satisfactorily on other projects for at least 5 years.

B. Site Visit: Make arrangements for Engineer to visit quarry site to observe materials proposed for riprap and riprap bedding.


A. Complete subgrade preparation as specified in Section 31 23 13, Subgrade Preparation, and geotextile installation as specified in Section 31 32 19.16, Geotextile, prior to placing riprap bedding or riprap.


RIPRAP PW/WBG/179201 31 37 00 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

PART 2 PRODUCTS

2.01 GEOTEXTILE RIPRAP BEDDING

A. Bedding geotextile as specified in Section 31 32 19.16, Geotextile.

2.02 RIPRAP

A. Riprap shall be 1/4 ton as specified in Section 72-2.02A of the Standard Specifications.

B. Riprap shall be graded for Method A Placement as specified in Section 72-2.02A of the Standard Specifications.

C. Hard and durable quarry stone free from fractures, bedding planes, pronounced weathering, and earth or other adherent coatings.

D. Minimum Dimension of Individual Pieces: Not less than 1/3 maximum dimension.

E. Abrasion Resistance: Maximum 35 percent wear as determined in accordance with ASTM C535.

F. Bulk Density: Minimum 160 pounds per dry cubic foot.

2.03 CONCRETE GROUT

A. Portland cement concrete as specified in Section 03 30 00, Cast-in-Place Concrete, having a 28-day compressive strength of 3,000 psi.

PART 3 EXECUTION

3.01 PLACING RIPRAP

A. Place riprap using Placement Method A as specified in Section 72-2.03B of the Standard Specifications.

B. Place riprap over geotextile to uniform thickness shown.

C. No mechanical compaction of riprap is required; however, work riprap as necessary to distribute it and to eliminate detrimental voids. Avoid overworking or long pushes that result in segregation of particle sizes.


PW/WBG/179201 RIPRAP OCTOBER 2018 31 37 00 - 3 ©COPYRIGHT 2018 CH2M HILL

D. Place and grade riprap in a manner that avoids subgrade disturbance and displacement or damage to geotextile. Do not push riprap down slope. If wrinkles form in geotextile as riprap is placed, correct them as specified in Section 31 32 19.16, Geotextile.

E. Place riprap on geotextile without puncturing or damaging geotextile. If accidentally damaged, repair geotextile prior to proceeding.

3.02 GROUTING RIPRAP

A. Remove dirt and foreign substances from surfaces of riprap and then moisten.

B. Deposit grout by means of chutes, tubes, or buckets, or place by means of pneumatic equipment or other mechanical methods. Place grout in a continuous operation for any day’s run at any one location.

C. Limit flow distance of grout along slope to less than 10 feet.

D. Spade and rod grout into place with suitable spades, trowels, or other approved means immediately after depositing grout. Depths of grout shall be approximately 6 to 12 inches.

E. Following placement of grout, thoroughly brush rocks so top surfaces are exposed. Outer rocks shall project 1/3 to 1/4 their diameter above grout surface. Brushing shall follow closely behind rodding such that grout shall not be in place more than 1 hour before brushing.

F. Once brushing of area is complete, no worker or load will be permitted on surface for period of at least 24 hours, or longer if so required by Engineer.

G. Cure grout as provided in Section 03 30 00, Cast-in-Place Concrete.

END OF SECTION


PW/WBG/179201 SHORING OCTOBER 2018 31 41 00 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 31 41 00 SHORING

PART 1 GENERAL

1.01 SUBMITTALS


1. Name and qualifications of the Professional Engineer(s) registered in the State of California responsible for shaft excavation support system and trench excavation support design.

2. Shaft excavation support plan (for trenchless crossings): a. Scaled drawings (plan and section views with dimensions and

sizes) showing the proposed shaft elements, including the concrete working slab; adjacent and nearby existing structures and utilities; details of tunneled pipe penetrations; details of pipe penetrations for connection to open cut sections of the pipeline; staging areas for all shaft construction operations such as storage, polymer tanks, and/or caisson form storage; and minimum setbacks from the excavation.

b. Details of procedures for preloading bracing members, if applicable.

c. Details for locating and protecting existing utilities and structures. d. Methods and sequencing of excavation and installation of staged

excavation support including a schedule with major milestones such as pouring and excavation of sunken caisson lifts, drilling and backfilling secant piles, pouring of concrete working slab, grouting, etc.

e. Methods and details of containment, hauling, and disposal of the excavated materials, all spoils and other materials used in shaft construction. Written documentation signed by the disposal site owner or manager indicating that the Site will accept the muck and that the Site is in compliance with all applicable local, state, and federal regulations. If a grading permit is required, submit a copy of the approved permit. Submit muck transport plans including route to be used and measures to avoid spillage onsite or onto streets and highways. Submit proposed locations of stockpiled excavated material.

f. Procedures for dewatering the interior of the shaft and disposal of the water.

g. Procedures for checking and maintaining plumbness of the shaft and ensuring proper elevation is reached.


SHORING PW/WBG/179201 31 41 00 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

h. Concrete mix information and placement procedures for the required working slab.

i. Procedures for backfilling of voids as required to minimize ground movement and protect adjacent property.

j. Procedures for tunnel portal probing and remedial ground improvement.

k. Anticipated difficulties and proposed resolutions, including excessive movement of shaft elements, excavation difficulty bottom heave, excessive groundwater inflows, soil and water inflow at the tunnel portals, and inability to install the shaft to the required depth.

3. Trench excavation plan addressing the following topics: a. Details of shoring, bracing, sloping, or other provisions for worker

protection from hazards of caving ground. b. Design assumptions and calculations. c. Methods and sequencing of installing excavation support. d. Procedures for dewatering the trench and disposal of the water. e. Proposed locations of stockpiled excavated material. f. Minimum lateral distance from the crest of slopes for vehicles and

stockpiled excavated materials. g. Anticipated difficulties and proposed resolutions.

4. Movement measurement and data and reduced results indicating movement trends.

5. Calculations a. The excavation support plan and the trench excavation plan shall

be sealed by a professional engineer licensed in the State of California.

b. Calculations for the shaft support elements and any bracing, indicating it can withstand all earth and groundwater pressures, equipment, applicable traffic, and construction loads and other surcharges in accordance with the soil conditions presented in Section 02 40 00, Crossings, and any other requirements described in the Drawings and Specifications.

B. Action Submittals: Not Used.


A. Provide surveys to monitor movements of critical facilities.

B. Shaft and trench excavation support systems shall be designed by a professional engineer registered in the State of California who has a minimum of 5 years of experience in the design of retaining structures.




A. The type and design of shoring and protection methods that meet the specification requirements herein are the Contractor’s responsibility and will be of a size large enough to facilitate all the necessary groundwater control, construction operations, pipeline equipment and operations, backfill, tunneling operations, and to accommodate indicated connections.

B. Design excavation support systems for all areas to support earth pressure, unrelieved hydrostatic pressures, bottom heave, utility loads, equipment, jacking loads, applicable traffic and rail loads, and other surcharge loads in such manner as will allow safe construction and will prevent damage to adjacent structures (including existing pipelines and utilities) and injury to workers and the public. In addition, the installation of excavation support systems will not cause a disruption to public convenience or access.

C. Design shaft excavation support systems to be compatible with the geologic conditions presented in Section 02 40 00, Crossings.

D. Design the excavation support systems to protect adjacent utilities from damage and to minimize horizontal and vertical movements to the maximum allowable values for deformation which are specified in Section 31 80 00, Geotechnical Instrumentation.

E. Install a reinforced concrete invert slab at each tunnel shaft excavation designed to protect the excavation invert and capable of supporting such combined dead and live loads as are required by the Contractor’s means and methods and resisting uplift pressures.

F. Do not discharge water pumped from within the shaft into storm sewers, sanitary sewers, water bodies, ditches, or streets without an approved discharge permit. Discharge must comply with all applicable permit requirements. Water contaminated in any way by polymer or other additives or water that does not the requirements must be transported offsite to an acceptable disposal location.

G. Design shaft excavation support for removal of all of the upper 5 feet to accommodate future construction and to permit installation of the open cut portion of the pipeline.

H. Cover shafts not in active use for a period of 12 hours or longer with traffic plates or a lockable safety net to prevent unauthorized entry or access.



PART 2 PRODUCTS

2.01 GENERAL

A. Structural Steel: ASTM A36 or better, unless otherwise approved.

B. Concrete: In accordance with Section 03 30 00, Cast-in-Place Concrete.

PART 3 EXECUTION

3.01 GENERAL

A. Design, provide, and maintain shoring, sheeting, and bracing as necessary to support the sides of excavations and to prevent detrimental settlement and lateral movement of existing facilities, adjacent property, and completed the Work. Excavation support systems for the shafts associated with the trenchless crossings will be designed to be compatible with the geologic conditions defined in Section 02 40 00, Crossings. Caissons and secant pile shafts, if utilized, shall include soft eyes.

B. Before beginning construction, install, and survey monitoring points as per Section 31 80 00, Geotechnical Instrumentation, adequately protect existing structures, utilities, trees, shrubs, and other existing facilities. The repair of or compensation for damage to existing facilities will be at no additional cost to the Owner.

C. All welding will conform to the applicable provisions of ANSI/AWS D1.1.

3.02 SHAFT WALL PENETRATION

A. Demonstrate the stability of the soils at the entry and exit seals prior to initiating penetration through a shaft wall for trenchless crossings as follows:

1. Cut a 2-inch diameter hole in the shoring wall near the center of the bore. Progress to the next demonstration step if no movement of soil or water inflows over 0.5 gpm into the shaft occurs. Seal the demonstration hole and conduct additional ground improvement at no additional cost to the Owner if soil or excess water movement into the shaft occurs in accordance with the methods outlined in the Contractor’s submittals. Repeat the first demonstration step.

2. Demonstrate the suitability of the ground improvements after successful completion of the first demonstration step by cutting a 12-inch diameter hole in the shoring wall at the location of previous demonstration hole. Progress to the next demonstration step if no movement of soil or excess water is visible. Seal the demonstration hole if soil or excess water



movement is visible and further improve the ground until they wish to repeat the demonstration step.

B. Proceed with remainder of the shaft wall penetration procedures, after successful completion of the first two demonstration steps, and if the ground improvements are sufficient to prevent loss of ground during launch or recovery of the tunnel boring machine.

C. Successful completion of shaft wall penetrations and related activities necessary to demonstrate such will be at the Contractor’s sole expense. Performance of the shaft wall penetrations does not relieve the Contractor of the responsibility to prevent loss of ground and settlement.

3.03 TRENCHES

A. For trench excavation exceeding 5 feet in depth, provide adequate safety system meeting requirements of California Labor Code Section 6707, applicable local construction safety orders, and federal requirements.

B. At any time, Contractor’s personnel are not present with the immediate vicinity of the Work. Open excavations will be plated, barricaded, or fenced as necessary to protect the public and worker safety.

3.04 REMOVAL OF SUPPORT SYSTEM

A. Excavation support will not be removed until support can be removed without damage to existing facilities, completed Work, or adjacent property.

B. As a minimum, excavation support will be removed between the existing adjacent surface grade and 5 feet below the adjacent surface grade. As-built Drawings will be prepared showing location of temporary shoring and bracing that remains in place.

C. Excavation support will be removed in a manner that will maintain support as excavation is backfilled and will not leave voids in backfill. Removal of the support system will be performed in a manner that will not disturb the pipeline, the compacted backfill, or adjacent construction or facilities.

D. Any void left by shoring system or voids created by the removal of the shoring system will be filled with controlled low strength material (CLSM), lean concrete, or cement grout, as approved by the Engineer to provide soil support between backfill zone and the native soil.



E. Sheet piling removal will be performed in a manner that will not result in “vibro-consolidation” of sandy or granular material below the excavation that could lead to settlement of the pipeline or other works of construction.

F. The support system removed from the excavation will remain the property of the Contractor and will be removed from the Site.

END OF SECTION


PW/WBG/179201 INSTALLATION OF CARRIER OCTOBER 2018 PIPE IN STEEL CASING ©COPYRIGHT 2018 CH2M HILL 31 60 00 - 1

SECTION 31 60 00 INSTALLATION OF CARRIER PIPE IN STEEL CASING

PART 1 GENERAL

1.01 SUMMARY

A. This section includes requirements for installation of carrier pipe into jacked steel casings at locations shown on the Drawings. For requirements regarding the steel casings, see Section 40 27 00.27, Steel Casing Pipe. For requirements regarding the installation of tunneled crossings, see Section 02 40 00, Crossings.

1.02 SUBMITTALS


1. Submit the following describing the carrier pipe installation equipment, materials, and construction methods to be employed. a. A safety plan for the carrier pipe installation operations including

air monitoring equipment and procedures and provisions for lighting, ventilation, and electrical system safeguards. Provide name of Site Safety Representative responsible for implementing safety program. Notify Engineer if safety plan is the same as for tunneling operations.

b. Emergency Response Plan for rescuing personnel trapped in a shaft, pipe, or tunnel.

2. Describe methods, procedures, and equipment for installing carrier pipe inside the casing, and methods for backfilling the annular space between the carrier pipe and the casing. Include methods for checking backfill progress.

B. Action Submittals: Shop Drawings of carrier pipe supports, casing end seals, bulkheads, grout pipes, vent pipes, and drain lines.


A. Carrier Pipe Installation Experience: Similar to Section 31 79 13, Microtunneling.

B. The surveyor responsible for carrier pipe line-and-grade control shall be a Licensed Surveyor registered in the State of California who has prior experience in similar projects.


INSTALLATION OF CARRIER PW/WBG/179201 PIPE IN STEEL CASING OCTOBER 2018 31 60 00 – 2 ©COPYRIGHT 2012 CH2M HILL

C. Tolerances: The carrier pipe shall be installed in accordance with the following tolerances:

1. Variations from Design Line: As specified in Section 33 05 01.01, Welded Steel Pipe and Fittings.

2. Variations from Design Grade: As specified in Section 33 05 01.01, Welded Steel Pipe and Fittings.

1.04 DEFINITIONS

A. Carrier Pipe: As specified in Section 31 79 13, Microtunneling.

B. Casing: As specified in Section 31 79 13, Microtunneling.

1.05 BASIS OF DESIGN

A. Carrier pipe shall be installed within the horizontal and vertical tolerances as indicated in the Contract Documents incorporating all support/insulator dimensions required.

B. Fill all voids between the carrier pipe and the casing with backfill grout as indicated. All exterior carrier pipe surfaces and all interior casing surfaces shall be in contact with the pressurized backfill grout as specified.

PART 2 PRODUCTS

2.01 MATERIALS

A. Spacers for Single Carrier Casings:

1. 12-inch wide, steel band with steel risers and 2-inch nonconductive wide glass reinforced polyester runners.

2. Suitable for supporting weight of carrier pipe. 3. Runner lubrication shall be environmentally safe and within

manufacturer’s recommendations. 4. Steel band to have nonconductive polyvinyl chloride inner liner. 5. Steel riser height with attached runner to be sufficient to provide a

minimum clearance of 1 inch and a maximum of 2 inches between the outside of carrier pipe bells or couplings and the inside of the casing.

6. Studs, nuts, and washers shall be cadmium plated. 7. Manufacturers:

a. PSI Products, Inc. b. Cascade Waterworks Manufacturing Co.



B. Backfill grout shall be Low Density Cellular Concrete as specified in Section 31 74 28, Backfill Grouting.

PART 3 EXECUTION

3.01 GENERAL

A. Do not begin carrier pipe installation until the following is completed:

1. Casing joints and grout ports are watertight. 2. No water enters casing from any sources. 3. Contact grouting of the casing is complete in accordance with

Section 31 79 13, Microtunneling. 4. Casing has been cleaned of tunneled materials and debris. 5. Rough welds at casing joints have been ground smooth.

B. The carrier pipe shall be installed within the casing to the line and grade indicated on the Drawings, and utilizing methods which include due regard for safety of workers, adjacent structures and improvements, utilities, and the public.

C. Furnish all necessary equipment, power, water, and utilities for carrier pipe installation, insulator runner lubricant, grouting, and other associated Work required for the Contractor's methods of construction.

D. Conduct all operations such that trucks and other vehicles do not interfere with traffic or create a dust or noise nuisance in the streets and to adjacent properties. Promptly clean up, remove, and dispose of spoils and slurry spillage and any slurry discharges.

E. All work shall be done so as not to disturb roadways, adjacent structures, landscaped areas, or existing utilities. Any damage shall be immediately repaired to original or better condition and to the satisfaction of the Engineer and facility/utility owner.

3.02 CONTROL OF LINE AND GRADE

A. Allow Engineer to check line and grade of casing pipe set up prior to beginning carrier pipe installation. Provide access for Engineer to perform survey checks of line-and-grade of carrier pipe on a daily basis during installation operations. The Contractor is fully responsible for the accuracy of the Work and the correction of it, as required.


INSTALLATION OF CARRIER PW/WBG/179201 PIPE IN STEEL CASING OCTOBER 2018 31 60 00 – 4 ©COPYRIGHT 2012 CH2M HILL

B. Where the carrier pipe installation exceeds the tolerances specified in Section 33 05 01.01, Welded Steel Pipe and Fittings, correct the installation, including, if necessary, redesign of the pipe, supports, or structures. All corrective Work shall be performed as approved by Engineer at no additional cost to Owner.

3.03 INSTALLATION OF CARRIER PIPE

A. Pipe Installation: Install carrier pipe as shown on the Drawings in accordance with specified tolerances and approved submittals. Remove all loose soil from casing. Grind smooth all rough welds at casing joints. Provide casing spacers, or insulators, or other approved devices, as required, to prevent flotation, movement, or damage to the pipe during installation and grout backfill placement. Every individual pipe section should be supported by at least two spacers. Carrier pipe shall be installed without sliding or dragging it on the ground or in the casing in a manner that could damage the coatings on the pipe. Coat the casing spacer runners with a noncorrosive/environmentally safe lubricant to minimize friction when installing the carrier pipe.

B. Welding: Weld carrier pipe sections together and test welds in accordance with the requirements of Section 33 05 01.01, Welded Steel Pipe and Fittings. Repair protective coatings at pipe joints as specified.

C. Testing of Carrier Pipe: Hydrostatic testing of the carrier pipe shall be completed prior to the backfilling of the annular space between the casing and carrier pipe with grout. Pressure testing shall be performed in accordance with Section 33 05 01.01, Welded Steel Pipe and Fittings. Any leakage found during this inspection shall be corrected.

D. Electrical Isolation: Verify that the casing and carrier pipe are electrically isolated prior to backfilling and again after backfilling is complete. If electrical isolation is not achieved, perform the necessary work, including, but not limited to, removing and replacing the carrier pipe within the casing until isolation is achieved.

E. Backfill annular space between casing and carrier with Low Density Cellular Concrete (LDCC) in accordance with Section 31 74 28, Backfill Grouting.

3.04 SAFETY

A. The Contractor is responsible for safety on the Job Site. Perform all Work in accordance with the current applicable regulations of the federal, state, and local agencies. In the event of conflict, comply with the more restrictive applicable requirement.



B. No gasoline powered equipment shall be permitted in jacking shafts and receiving shafts/pits. Diesel, electrical, hydraulic, and air powered equipment is acceptable, subject to applicable local, state, and federal regulations.

C. Methods of construction shall be such as to ensure the safety of the Work, Contractor's and other employees on Site, and the public.

D. Furnish and operate a temporary ventilation system in accordance with applicable safety requirements when personnel are underground. Perform all required air and gas monitoring. Ventilation system shall provide a sufficient supply of fresh air and maintain an atmosphere free of toxic or flammable gasses in all underground Work areas.

E. Perform all Work in accordance with all current applicable regulations and safety requirements of the federal, state, and local agencies. Comply with all applicable provisions of Tunnel Safety Orders of the State of California and 29 CFR Part 1926, Subpart S, Underground Construction and Subpart P, Excavations, by OSHA. In the event of conflict, comply with the more stringent requirements.

F. If personnel will enter the pipe during construction, the Contractor shall develop an emergency response plan for rescuing personnel trapped underground in a shaft excavation or pipe. Keep onsite all equipment required for emergency response in accordance with the agency having jurisdiction.

END OF SECTION


PW/WBG/179201 BACKFILL GROUTING OCTOBER 2018 31 74 28 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 31 74 28 BACKFILL GROUTING

PART 1 GENERAL

1.01 SUMMARY

A. The Work specified in this section includes requirements for filling the annular space and any voids between the outside of carrier pipe installed in tunnel and the inside of the tunneled casing with Low-Density Cellular Concrete (LDCC).

1.02 SUBMITTALS

A. Informational:

1. Qualifications: Qualifications of contractor or subcontractor personnel (superintendent and foreman) and manufacturer supplying and placing the LDCC.

2. Daily reports and records of backfill grout placement, including but not limited to: a. A delivery ticket with the information stated in Section 16 of

ASTM C94; except actual scale weights of materials shall be furnished to the Engineer with each batch of concrete before unloading at the site.

b. A printout of the actual scale weights for all loads batched shall be submitted to the Engineer at the end of each working day.

c. Volumes placed and lift (stage) heights achieved. d. Stationing of LDCC placement. e. Injection locations and pressures. f. Unit weight and air content testing results. g. Time of placement. h. Designation of cylinder samples prepared that day. i. Compressive strength tests reports from a certified testing

laboratory.

B. Action:

1. Shop Drawings: Casing bulkheads, grout pipes, vent pipes, and drain lines.


BACKFILL GROUTING PW/WBG/179201 31 74 28 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

2. Product Data: a. Submit mix designs for each LDCC mix proposed for use. Each

mix design shall show the ingredients of the mix and shall include: 1) Type, brand, source, and amounts of cement, pozzolans,

admixtures, and other additives. 2) Source and amount of water. 3) Combined grading of each mix design. 4) Specific gravity of all materials. 5) Results of air content, unit weight, and 28-day compressive

strength tests. 3. Submit a certificate of compliance signed by the supplier identifying the

type of fly ash (if used) and stating that the fly ash is in accordance with ASTM C618 and these specifications. Supporting test data shall be furnished when requested by the Engineer. All testing and sampling procedures shall be in accordance with ASTM C311.

4. Submit material specifications and instructions for use of any proposed concrete admixtures, including evidence from foam manufacturer that proposed admixtures are compatible with the foaming agent.

5. Equipment: submit the following for each type of LDCC proposed: a. Manufacturer's specifications and operation instructions for

conveyance equipment. 1) Pump specifications. 2) Grout hose, valve and port sizes and specifications. 3) Foam generators and ancillary equipment.

6. Submit a work plan for placing LDCC including: a. Sequence of work including sequence of placement and staging of

backfill lifts and pumping. b. Type(s) and locations of equipment. c. Placing procedures, (i.e., batching, mixing, and pumping location

and procedures). d. Pump line arrangement. e. Maximum pipe length to be backfilled. f. Maximum LDCC age before set initiation. g. Method of determining LDCC levels placed or completion of void

filling. h. Communications provisions. i. Pumping pressures, rates, and volumes to be placed per day. j. Maximum injection pressures injection locations. k. Methods for monitoring mix. l. Method of surveying or monitoring carrier pipe for movement

during LDCC placement. m. Methods and approaches to prevent deformation of carrier pipe

during LDCC placement.



n. Testing procedures. o. Cleanup procedures.

7. Preplacement Test Reports and Certifications: a. Mill test reports for Portland cement. b. Certificates of compliance for each load of Portland cement and

fly ash (if used). c. Certificates of compliance for foaming agent and all admixtures.

1.03 DEFINITIONS

A. Low-Density Cellular Concrete (Foam Grout): A lightweight cementitious material that contains stable air or gas cells uniformly distributed throughout the mixture and with a minimum air percentage of 20 percent.

PART 2 PRODUCTS

2.01 MATERIALS

A. Cement: Portland Cement, ASTM C150, Type I or II.

B. Flyash: Type F, ASTM C618.

C. Water: Use potable water free from deleterious amounts of alkali, acid, and organic materials which would adversely affect the setting time or strength of the backfill grout.

D. Admixtures: Admixtures may only be used when specifically approved by foaming agent supplier in writing.

E. Foaming Agent:

1. Foaming agent shall comply with ASTM C869 when tested in accordance with ASTM C796.

2. Type and Manufacturer: a. Mearl Geofoam Liquid Concentrate manufactured by Cellular

Concrete Solutions. b. Foam Liquid Concentrate manufactured by Concrete

Technologies, LLC c. Or equal.

2.02 MIX DESIGN

A. General: LDCC mix shall be designed in accordance with the requirements of Section 03 30 00, Cast-in-Place Concrete, ACI 523.IR, ACI 523.3R, and the additional requirements herein. Mixes shall be adjusted in the field as



necessary to meet the requirements of these specifications. The foaming agent material manufacturer's field services representative shall approve all changes to the mix designs.

B. Minimum 28-day compressive strength in accordance with ASTM C495: 200 psi.

C. Limiting Requirements: Unless otherwise specified, each LDCC mix shall be designed and controlled within the following limits:

1. Wet Density: Wet density (unit weight) of the foam grout shall be not less than 50 pcf, at the point of placement.

2. Preformed Foam: Preformed foam shall be generated by combining controlled quantities of air, water, and foaming agent under pressure. Foam shall retain its stability until the cement sets to form a self-supporting matrix. The resulting LDCC shall have closed cell and low water absorptive characteristics. The concentration of foam agent shall be in accordance with the foaming agent material manufacturer's recommendations.

3. Admixtures: The admixture content, batching method, and time of introduction to the mix shall be in accordance with the manufacturer's recommendations for minimum shrinkage and for compliance with these specifications. Admixtures may be used when specifically approved by foaming agent material manufacturer and shall be in accordance with their recommendations. No calcium chloride or admixture containing chloride from other than impurities from admixture ingredients will be acceptable.

4. A tentative mix shall be designed and tested in accordance with ASTM C796 for each consistency intended for use. These results will be compared with field test results to confirm consistent properties are obtained in the field. Testing for each mix shall be as follows: a. Two sets of compression test cylinders (3 inches by 6 inches),

three cylinders per set, shall be made from each proposed backfill grout mix. One set of three cylinders shall be tested at an age of 7 days and the other set shall be tested at an age of 28 days. Foam grout specimens shall be made, cured, stored, and tested in conformity with ASTM C 495.

b. Determine total air content of each proposed foam grout mix in accordance with ASTM C796.

c. Determine unit weight of each proposed foam grout mix in accordance with ASTM C567.



2.03 EQUIPMENT

A. General:

1. Use equipment for mixing and injecting foam grout, which is designed for underground backfill grouting service. Maintain equipment in good operating condition, capable of satisfactorily mixing, agitating, and forcing LDCC into injection ports at a uniform flow rate under the required constant pressure.

2. Backfill grouting equipment shall be configured so flushing can be accomplished with grout intake valves closed, with water supply valve open, and with grout pump running at full speed.

3. An adequate inventory of spare parts or backup equipment shall be provided to ensure that operable backfill grouting equipment is available at all times during the work. Maintain sufficient quantities of spare pressure gauges, stop valves, and other wear parts on site.

B. A foam generator shall be used to produce a predetermined quantity of preformed foam, which shall be injected into the mixer and blended with the cement slurry. A foam generator shall be used to produce a predetermined quantity of foam, which shall be injected into the mixer and blended with the cement slurry. The foam generator shall be timer-controlled to repetitively discharge a preselected quantity or to discharge continuously at a fixed rate. Foam generating equipment shall be tested and calibrated for dilution percentage, density, and volume output. Two types of foam generating systems, batch and continuous generating, are acceptable.

1. The batch system shall consist of a tank in which the foam liquid concentrate and water are first premixed. This dilute solution is then discharged from either a pressurized tank or by means of a mechanical pump through a foam-making nozzle in which this solution is blended with compressed air in fixed proportions.

2. A continuous generating system container, which continuously draws the concentrate directly from its shipping container, automatically blends it with water and compressed air in fixed proportions, and forms the stable micro-bubbled foam.

3. Both types utilize foam refining columns or nozzles calibrated for foam quality and discharge rate. The foam nozzles may be timer-controlled to repetitively discharge any preselected quantities or to discharge continuously at a fixed rate.

4. Batching, mixing and pumping equipment shall be compatible and of sufficient size and capacity to place LDCC to distances and volumes proposed by the Contractor.



5. Provide graphical or digital printout records of batch scale readings, accurate to one (1) pound, of the dry mix ingredients before delivery to mixer.

C. Specially designed batch mixers may also be used in conjunction with surge hopper equipped pumps. The rates of mixing and pumping shall be properly adjusted and a continuous flow of foam grout shall be obtained at the point of placement.

D. Injection Hoses and Connections:

1. Use hose of proper type and diameter to withstand maximum injection pressures used.

2. At the point of injection, suitable valves and calibrated pressure gauges shall be provided so that the pressure and grout flow at the grout hole may be regulated and monitored. A meter shall be provided to measure the total volume of LDCC pumped into each port. Provide at or very near the point of injection, a system of valves in the line transporting the grout that will allow easy access for collection of test specimens. Provide an automatic bypass valve set to the maximum pressure specified.

3. Injecting connections shall be a minimum of 1.5 and a maximum of 2.5 inches in diameter.

4. Provide suitable stop valves at collar of hole for use in maintaining pressure, as required, until LDCC has set.


A. Qualifications:

1. The Contractor or Subcontractor supplying and placing LDCC shall be capable of developing a mix design, and batching, mixing, handling and placing LDCC under tunnel conditions; shall have furnished and placed LDCC on at least three tunnels of the general type and the size specified herein which have been in successful operation; and shall have a record of experience and quality of work using foam grout that is satisfactory to the Engineer.

2. As an alternative, the Contractor may employ a manufacturer's representative to supervise supplying and placing of LDCC. The manufacturer's representative shall be capable of complying with the qualifications specified for the Contractor and shall be acceptable to the Engineer. The manufacturer's representative shall supervise all LDCC operations including training the Contractor's personnel, mixing designs, and placement of LDCC in the tunnel.



3. Personnel Qualifications: Workers, including the LDCC contractor's superintendent and foreman, shall be fully qualified to perform the work. The LDCC contractor's superintendent shall have had previous experience under similar ground and tunnel conditions, or the foam grout supplying and placing shall be under the supervision of the foaming agent supplier's representative.

4. Field Services: The foaming agent material manufacturer shall provide engineering field services to review the project and the material application prior to any preparation; to approve the applicator, the material used, the equipment, and the procedure to be used; to approve setup before production of LDCC; and to observe during initial application. The field representative of the material manufacturer shall submit, in writing, approvals of proposed material, equipment, application procedures, applicator, and setup before production.

PART 3 EXECUTION

3.01 GENERAL

A. LDCC shall be properly placed as specified herein. LDCC shall be made using preformed foam process equipment approved by the foaming agent material manufacturer.

B. Methods for completely filling the annular space between carrier pipe and the casing shall be utilized in accordance with submittals that are reviewed and approved by the Engineer. No standing water shall be allowed where LDCC is to be placed.

C. Construct bulkheads at the end of each reach of pipe to be backfilled.

1. Bulkheads shall be constructed so the annular space will be completely backfilled.

2. Bulkheads shall incorporate a minimum l-inch diameter drainpipe in the invert of the tunnel to facilitate drainage of water during LDCC backfilling. This pipe shall be securely capped and plugged once LDCC begins to flow from the drain line.

3. An opening shall be provided in the tunnel crown to allow entrapped air to escape. Vent outlets shall be provided as required.

D. Inform the Engineer at least 24 hours in advance of the times and place where placement of LDCC is anticipated.



3.02 BATCHING AND MIXING

A. General: Conform to the requirements of accepted submittals and the foaming agent manufacturer's recommendations.

B. Mixing:

1. All LDCC shall be mechanically mixed to produce a uniform distribution of the materials with a suitable consistency and the specified limiting requirements. Excessive mixing shall be avoided in order to reduce the possibility of changes in unit weight and consistency.

2. In batch mixing operations, follow the manufacturer's recommendations concerning the order of charging the mixer with the various ingredients. The as-cast unit weight shall be monitored at the point of placement. Allowance should be made for any additional mixing that may result from the method of placement, such as mechanical or pneumatic pumping, and for any unit weight changes that may result from these methods.

3. For continuous mixing operations, provision shall be made for reasonably uniform and continuous rate of addition of all mix components at appropriate positions in the mixing machine, and in the correct ratio, to assure uniformity and the specified limiting requirements at the point of placement.

4. Alternative methods for batching and mixing LDCC will be considered by and must be acceptable to the Engineer.

3.03 PLACING LOW-DENSITY CELLULAR CONCRETE

A. General Requirements: All void space outside of the carrier pipe shall be completely filled with LDCC. Provide air release piping in the crown of the tunnel to allow displaced air and air lost from LDCC to escape and be replaced with LDCC. Place LDCC in accordance with approved submittals.

B. Backfilling of the annular space between the pipe and the casing shall be accomplished by placing LDCC in one or more stages (lifts). Monolithic placements (one stage) may be acceptable, provided the Contractor can demonstrate that his placement techniques will not induce movement of the pipe, pipe overstressing, or excessive deformation. The LDCC shall be placed through grout pipes installed within the annular space between the carrier pipe and casing. Multiple grout pipes should be installed to provide redundancy.

C. Pressure gauges of appropriate range for monitoring the backfill grout injection pressures shall be located in the line transporting the LDCC at the point of injection. Injection pressure shall be low enough to prevent pipe



movement and shall not exceed 15 psi at the point of injection for stages below the crown of the pipe. Injection pressure shall not exceed 60 psi or a lower limit as submitted and approved by the Engineer at the point of injection for stages above the crown of the pipe.

D. Volume of LDCC injected shall be measured, recorded and compared with the anticipated volume per foot of pipe backfilled.

E. Provide a means of direct communication between the injection point and the pump operator.

3.04 FIELD QUALITY CONTROL

A. General: Field control tests, including unit weight (wet density), air content test, and compression tests shall be performed by the Contractor and the results submitted to the Engineer.

1. The frequency specified herein for each field control test is approximate. A greater or lesser number of tests may be made, as required by the Engineer.

2. Test specimens shall be collected within the shaft at or near the connection where the LDCC is being injected.

3. The Contractor shall assist the Engineer in obtaining additional test cylinders. Supply all materials necessary for fabricating the test cylinders.

4. Provide at or very near the point of injection, a system of valves in the line transporting the LDCC, which will allow easy access for collection of test specimens without disconnecting the line from the outlet. Submit the valve arrangement to the Engineer for review at least 15 days prior to commencing LDCC backfilling operations.

B. Unit Weight: Unit weight (wet density) tests shall be made from the first batch mixed each day, after a change in mix design, every 30 minutes during pumping, and from each batch of LDCC from which compression test cylinders are made. Unit weight shall be determined in accordance with ASTM C567. Unit weight at the point of placement shall be within plus or minus 5 percent of the unit weight established for the mix design being placed. Adjust mix as required to obtain the specified wet density.

C. Air Content: An air content test shall be made from the first batch mixed each day, and from each batch of LDCC from which concrete compression test cylinders are made. Air content at the point of placement will be the difference between the wet density at the point of placement less the wet density at the point immediately before the addition of preformed foam. Air



content shall be determined in accordance with ASTM C138 except there shall be no vibration or rodding of the sample.

D. Compression Tests: One set of four (4) test cylinders (3 inches by 6 inches) shall be made for each shift when LDCC is placed. One additional set shall be made from each additional 200 cubic yards, or major fraction thereof, placed in any one shift. Two cylinders from each set will be tested at an age of 28 days.

1. Compressive strength of LDCC shall be considered satisfactory if both of the following requirements are met: a. Average of three consecutive compressive strength tests equal or

exceed the specified unconfined compressive strength. b. No individual compressive strength test (average of two cylinders)

is below the specified unconfined compressive strength by more than 20 percent.

2. A strength test shall be the average of two compressive strengths of two cylinders made from the same concrete sample and tested at 28 days.

3. Test cylinders shall be made in the field, cured and stored in the laboratory, and tested in accordance with ASTM C495.

4. Each set of compression test cylinders shall be marked or tagged with the date and time of day the cylinders were made, the location in the work where the LDCC represented by the cylinder was placed, batch number, unit weight (wet density), and the air content.

3.05 PROTECTION AND CLEAN UP

A. Take all necessary precautions to protect and preserve the carrier pipe from damage.

B. Spills shall be minimized and shall be cleaned up immediately. Any damage to the pipe caused by or occurring during the backfilling operations shall be repaired by a method approved by the Engineer, at no additional cost to the Owner.

END OF SECTION


PW/WBG/179201 MICROTUNNELING OCTOBER 2018 31 79 13 -1 ©COPYRIGHT 2018 CH2M HILL

SECTION 31 79 13 MICROTUNNELING

PART 1 GENERAL

1.01 WORK INCLUDED

A. The Contractor shall furnish all labor, equipment, and materials necessary for microtunneling pipe installation, and other associated Work.

1.02 SUBMITTALS


1. Qualifications: Submit the name of the Contractor that will perform the microtunneling Work and submit qualifications for the Contractor, Contractor’s superintendent, and Contractor’s MTBM operator(s) that meet the requirements of Article Quality Assurance. In addition, submit names and training/qualifications of personnel that will perform air quality monitoring, the Site Safety Representative, and the professional Land Surveyor.

2. Quality Control Methods: Submit a description of the quality control methods proposed for microtunneling at least 30 days prior to the start of tunneling. Include the following: a. Supervision. Supervisory control to ensure that Work is performed

in accordance with the Drawings and Specifications, and Tunneling Work Plan and Drawings.

b. Line and grade. Procedures for surveying, controlling and checking line and grade, including proposed field forms.

c. Tunneling Observation and Monitoring. Procedures for preparing and submitting daily logs of tunneling operations, including proposed field log forms.

d. Products and Materials. A plan for testing and submittal of test results to demonstrate compliance with the Specifications and Contractor’s criteria for permanent products, materials, and installations. Identify applicable standards and procedures for testing and acceptance.

3. Microtunneling Equipment: Submit the following describing the microtunneling equipment and construction methods to be employed: a. A detailed description of the methods and equipment to be used in

completing each microtunnel drive. b. Manufacturer's literature describing the microtunneling system

including the machine and all ancillary equipment. Provide descriptions of at least two projects on which this system has been


MICROTUNNELING PW/WBG/179201 31 79 13 – 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

successfully used including names, addresses, and telephone numbers of owner’s representatives for these projects as well as lengths, diameters, and pipe materials used. If a used or refurbished MTBM is proposed, list previous usage, modifications made and dates of modifications, and detailed description of the extent and dates of refurbishment. Include the following information concerning the MTBM: 1) Dimensions. 2) Torque, rotation speed range. 3) Cutter types, configuration, and gauge cutter setting for

overcut. 4) Articulation and steering capability. 5) Rock size and compressive strength ranges for rock crusher. 6) Cutterhead jets/ports. 7) Tail seal. 8) Face/excavation chamber pressure gauge locations and

types. c. A description of the alignment control systems including

manufacturer’s literature and drawings showing setup, support provisions, and other details for the laser or theodolite system. Submit a description of surveying methods to set guidance system positions and a description of procedures to check and reset or realign guidance system during construction. Submit a description of methods to ensure that thrust block, entry seal, and jacking frame are installed on proper line and grade. Confirm that these systems can achieve the required pipeline line and grade within the specified tolerances.

d. Capacity, number, and arrangement of main jacks including details of the thrust ring, thrust block, jacking frame, jacking controls, pressure gages, and jack calibration data (pressure vs. force relationship for each stage of the jacks).

e. Details of pipe lubrication injection system and pipe lubricants to be used during microtunneling, including manufacturer’s literature and MSDS sheets. Include a description of proposed lubrication procedures during jacking, including estimated volumes of lubricant that will be pumped. Confirm that sufficient volume of lubricant will be pumped at all times to completely fill the annular space outside the jacking pipe.

f. Details of spoil and slurry handling, separation, transport, and disposal equipment and procedures including details of slurry additives, slurry separation plant, and the location of slurry and spoil disposal sites. Provide manufacturers description for slurry additives and Material Safety Data Sheets (MSDSs). Provide written documentation from the disposal site(s) indicating that



they will accept the spoil or slurry and are in compliance with applicable regulations.

4. Intermediate Jacking Stations: Drawings and design details for intermediate jacking stations if proposed by the Contractor including shell materials, measures for corrosion protection, proposed spacing, criteria for installing, method of operation, and number of stations and method of jack removal and casing closure.

5. Pre- and Post-Construction Surveys: Submit pre- and post-construction surveys including photographs, videotapes, field notes, and sketches of levee, at a minimum, and other structures, as required by the Contractor.

6. Results of line and grade survey to ensure that the thrust block, jacking frame, guide rails, entry seal, and exit seals are installed properly prior to launch of each drive.

7. Safety Plan: A Safety Plan for the microtunneling operations including air monitoring equipment and procedures, and provisions for lighting, ventilation, and electrical system safeguards.

8. Schedule: Provide a schedule for all microtunneling Work, identifying all major construction activities as independent items. The schedule shall include, as a minimum, the following activities: mobilization, groundwater control at jacking and receiving shafts, shaft excavation and support, concrete working slab construction, thrust wall construction, jacking equipment setup, entry ring installation for launch of machine, ground improvement and proof probing, microtunneling, retrieval of the MTBM, contact grouting, installation of the carrier pipe inside jacked casing, annular space backfill grouting, cleaning of jacking pipe, shaft backfill, site restoration, cleanup, and demobilization. The schedule shall also include the Work hours and workdays for each activity, and a written description of the construction activities. The schedule will be reviewed by the Engineer and shall be updated and resubmitted by the Contractor every 2 weeks or more frequently if requested by the Engineer.

9. Daily Records: The following daily records shall be submitted to the onsite Engineer by noon on the day following the shift for which the data or records were taken. a. Jacking Records: The Contractor shall provide complete

electronic jacking records to the Engineer. These records shall include, at a minimum: date, time, name of operator, tunnel drive identification, installed pipe number and corresponding tunnel length, rate of advance, face/excavation chamber pressures, jacking forces, cutterhead speed and torque, slurry flow rates and pressures, bypass valve position, use of any cutting or high-pressure nozzles, face pressure, steering jack positions, line and grade offsets, any movement of the guidance system, machine inclination and roll, intermediate jacking station use and jacking



forces, pressure, volume, and location of any lubricant pumped, problems encountered with the tunneling machine or other components or equipment, and durations and reasons for delays. The computer-recorded data shall be referenced to time and distance and shall be recorded at time intervals of one minute or less. In addition, manually recorded observations of the same parameters shall also be made at intervals of not less than 5 feet of advance, as conditions change, and as directed by the Engineer. If electronic data cannot be read by MS Excel or MS Word, furnish copy of software capable of reading the electronic data. At least 7 days prior to the launch of the machine, the Contractor shall submit samples of the automated and manual jacking records. Samples shall include electronic data and any necessary programs to interpret data, and the manual logs or records to be used.

b. Lubrication Records: The Contractor shall provide lubrication records to the Engineer. These records shall include the injection locations along the pipe string and amount, in gallons, of lubricant pumped throughout a drive and injection pressure. The record will also include the type of additive used and date, time, and drive distance when used.

c. Slurry Additives: The Contractor shall provide records of all slurry additives including any bentonite and polymers. The time and volume, or weight, of the additive shall be noted. Measurements of mud weights, specific gravity and viscosity will be made at the beginning, middle, and end of each shift, and submitted with the daily logs. Measurements will be made on slurry samples taken from the slurry tanks and noted accordingly.

d. Survey Measurements: Survey measurements of pipe alignment and all settlement monitoring points.

e. Contact Grout Reports and Records: Maintain and submit daily logs of grouting operations, including grouting locations, pressures, volumes, and grout mix pumped, and time of pumping. Note any problems or unusual observations on logs.

B. Action Submittals:

1. Calculations: Calculations shall be submitted in a neat, legible format. Assumptions used in calculations shall be consistent with information provided in Section 02 40 00, Crossings. All calculations shall be prepared by a Professional Engineer licensed in the United States, who shall stamp and sign calculations. a. Estimate the maximum jacking force expected to complete each

drive, accounting for both face pressures and frictional resistance



along the pipe string. Also estimate possible maximum forces after delays (set-up) and highest value of side friction.

b. Calculations demonstrating that the soils behind the thrust block can transfer the maximum planned jacking forces exerted by the main jacks to the ground during pipe installation with the specified factors of safety and without excessive deflection or displacement.

2. Contact Grout Work Plan and Methods: a. Submit Work plan, for each type of contact grouting required,

including contact grouting methods and details of equipment, grouting procedures and sequences, injection pressures, monitoring and recording equipment, pressure gauge calibration data, methods of controlling grout pressure, method of transporting grouting equipment and materials within the pipe, and provisions to protect interior of pipe and shaft supports.

b. Submit details of grout mix proportions, admixtures, including manufacturers’ literature, and laboratory test data verifying the strength of the proposed grout mix.

3. Contingency Plans: The following list includes problem scenarios that may be encountered during the microtunneling operations. The Contractor shall submit contingency plans for dealing with each problem scenario while satisfying the specifications. These plans shall include the observations and measurements required to clearly identify the cause of the problems. a. Machine Unable to Advance:

1) Possible obstructions (including boulders, old foundations, metallic debris, or reinforced concrete).

2) Insufficient jacking capacity. 3) Machine malfunction. 4) Clay clogging of intake ports.

b. Slurry Separation Problems: 1) Cuttings are not separated using the slurry separation plant. 2) Cuttings settle out in the slurry lines before reaching the

separation plant. c. Strong hydrocarbon smell is detected in the slurry returns, the

muck, or in the shaft. d. Laser distorted by heat, humidity, or physical disturbance. e. Jacking Forces:

1) Jacking forces increase dramatically or suddenly. 2) Jacking forces reach design capacity of pipe, jacking frame,

or thrust wall (treat these scenarios as separate incidents). f. Settlement and Subsidence:

1) Survey measurements indicate deformations exceed allowable limits.



2) Excavated volumes significantly exceed pipe volume installed.

3) Slurry face pressures and/or torque on head decrease suddenly and significantly.

g. Steering difficulties result in line and grade tolerances being exceeded.

h. Pipe has been damaged or has been found to be out of compliance with specifications during or after installation.

i. Thrust block deforms excessively under jacking loads, or provides insufficient capacity to advance pipe.

j. Control signal is lost. Cannot monitor position, torque, thrust, steering jack position, or other performance parameters

1.03 DEFINITIONS

A. Microtunneling: A remotely controlled, guided, pipe jacking process that provides continuous support to the excavation face and uses a pressurized bentonite slurry spoil removal system. The microtunneling process does not require routine personnel entry into the tunnel. A key element of microtunneling is the ability to control the stability of the face by applying fluid and mechanical pressure to balance the earth and groundwater pressures.

B. Microtunnel Boring Machine (MTBM): Remote-controlled, guided slurry shield that provides continuous support to the excavation face. The MTBM is operated from a control container located on the ground surface. Soil excavation is achieved by a rotating cutter-wheel. Excavated soil enters a slurry chamber where it is mixed with clean slurry to form a slurry with cuttings. Pumps cycle the slurry to the surface where a separation plant removes the solids from the slurry. The recycled slurry is then returned to the face in a closed-system of pumps and hoses. Because of the remote-control operation and the closed spoil-removal system, routine personnel entry into the MTBM is not required. Slurry used to convey spoil contains additives such as bentonite that thicken the slurry, allowing it to carry more solids and providing gel strength to prevent the slurry from permeating the soils at the heading. The guidance system consists of a laser or theodolite and EDM device mounted in the jacking shaft communicating a reference line to a target mounted in the MTBM’s articulated steering head. The target in an MTBM provides the operator with information about machine attitude and pitch, and provides accurate steering control.

C. Jacking Pipe: Pipe jacked behind the microtunneling machine. The jacking pipe shall be the carrier pipe or casing pipe as shown on the plans, specifically designed to be installed by pipe jacking using microtunneling equipment.



D. Carrier Pipe: Permanent pipe for operational use that is used to convey flows.

E. Casing: A pipe installed by microtunneling that supports the ground and provides a stable underground excavation for the installation of a carrier pipe.

F. Intermediate Jacking Station (IJS): A fabricated steel cylinder fitted with hydraulic jacks spaced around the circumference which is incorporated into the jacking pipe between two specially fabricated pipe sections. The function of an intermediate jacking station is to distribute the jacking load along the jacking pipe string during pipe installation. The hydraulic jacks are removed at the completion of a drive and the gap between adjacent jacking pipe sections is fully closed by pushing the pipes together with the main shaft jacks or another IJS. The steel cylinder remains as an extended sleeve or coupling. The steel cylinder shall be protected from corrosion, consistent with corrosion protection used for the jacking pipe and joints.

G. Launch/Retrieval Seal or Entry/Exit Seal: A mechanical seal comprised of one or more rubber flanges attached to a steel housing that is mounted to the wall of the jacking/receiving shaft. The microtunneling machine distends the flange seal as it passes through, creating a seal to reduce water, slurry, or lubrication inflows into the shaft during microtunneling operations.

H. Lubrication/Grout Port: A port located within the MTBM or in the jacking pipe fitted with a one-way valve for injection of lubrication material or grout into the annular space between the pipe and the ground.

I. Jacking Record: A computer-generated (electronic jacking record) or manually recorded report that contains information on microtunneling operations and may include at a minimum: date, time, name of operator, tunnel drive identification, installed tunnel length, rate of advance, jacking forces, cutterhead speed and torque, slurry inflow and outflow rates and pressures, bypass valve position, use of any cutting or high-pressure nozzles, face pressure, steering jack positions, line and grade offsets, any movement of the guidance system, machine inclination and roll, intermediate jacking station use and jacking forces, pressure, volume, and location of any lubricant pumped, problems encountered with the tunneling machine or other components or equipment, and durations and reasons for delays.

J. Electronic Jacking Record: Electronic data in native format, such as ASCII, TXT or HTML, or as imported into Excel, and as recorded by the data logger of the microtunneling control system. In no case shall the term “electronic jacking record” be construed to mean a scan or printout of machine operating parameters submitted in portable document format (PDF).



K. Settlement Monitoring Point: Surface, subsurface, or utility monitoring points, as defined in Section 31 80 00, Geotechnical Instrumentation. The point is resurveyed periodically to monitor ground movements.


A. Microtunneling Equipment:

1. Only pressurized, closed-face, remotely operated microtunneling equipment using bentonite slurry spoil removal, shall be used for all microtunneling work required for this Project as defined in Article Design Criteria, Paragraph B. The microtunneling machine shall be manufactured by Akkerman, Herrenknecht, Iseki, Lovat, Soltau, Caterpillar, Rasa, or approved alternate company that specializes in the design and fabrication of this type of equipment. The machine shall be capable of fully supporting the face during both excavation and shutdown periods, and shall have the capability of exerting a continuous, measurable, controllable stabilizing pressure at the face as required to prevent loss of ground and groundwater inflows. The system shall be capable of adjustment required to counterbalance the groundwater and soil pressures at the tunnel face to an accuracy of plus or minus 0.1 bar. A pressure gauge shall be provided so the operator can monitor the pressure exerted at the heading.

2. Microtunneling equipment selected for the Project shall be suitable for and capable of efficiently advancing through the geologic conditions defined in Section 02 40 00, Crossings, and the geologic conditions anticipated by the Contractor. The microtunneling machine shall be capable of crushing or excavating boulders or other objects up to 33 percent of the outside diameter of the MTBM and up to an unconfined compressive strength of 30,000 psi.

3. The machine shall have a watertight articulation joint between two segments of the shield. The shield shall be steerable in both the vertical and horizontal directions to allow the operator to maintain line and grade within the specified tolerances. The guidance system shall be designed to function at the maximum required drive length without loss of accuracy or reliability of function. A display showing the position of the machine in relation to design line-and-grade shall be provided at the control panel to allow the operator to continuously monitor line and grade deviations.

4. The cutterhead shall have a reversible drive system so that it can rotate in either direction or other suitable provisions to minimize rotation or roll of the machine or pipe during installation.

5. The maximum radial overcut for each crossing is presented in Section 02 40 00, Crossings.



6. A lubrication injection system shall be provided to inject pipe lubricant around the MTBM and jacking pipe to decrease frictional resistance. Lubrication materials may include a mixture of bentonite and/or polymers and water. Lubrication ports shall be provided in the MTBM and jacking pipe to allow for lubrication along the pipe string at intervals of not more than 10 feet. The lubrication ports shall be used for annular space grouting.

7. The machine shall be equipped with a computerized data acquisition system for collecting information for the electronic jacking record. An onsite printer and disk drive will also be required for production of a printed daily jacking record and an electronic copy of the data. As a supplement to the computerized data acquisition system, the Contractor shall use manual data acquisition for collecting information for the jacking record. The Engineer and/or Owner’s representative shall have access to all areas of the Work, including the operations control container, the slurry separation plant, and shafts, for inspection and collection of data, measurements, and observations at all times, without restriction.

8. The machine shall have an automatic shutoff switch and provisions for continuous gas monitoring.

9. The MTBM shall bear the name of the Project, Owner, Contractor, Engineer, and other participating agencies. Lettering shall be black or dark blue applied on the side of the MTBM by an experienced sign painter. Paint shall be exterior type enamel. Information and logos to be included will be provided by the Engineer.

B. Methods and equipment shall control surface settlement and heave above the pipeline to prevent damage to existing utilities, facilities, and improvements. Any ground movements (settlement/heave) shall be limited to values that do not cause damage or distress to surface features, utilities, or improvements. In no case shall settlements exceed the applicable values listed in Section 02 40 00, Crossings. In addition, the Contractor shall comply with the requirements of Section 31 80 00, Geotechnical Instrumentation.

C. The slurry separation plant shall be designed to achieve the rates of spoil separation and slurry cleaning required for planned production rates. The separation plant must fit within the allowable easements shown on the Drawings. Excavated slurry pits or ponds will not be allowed. Onsite disposal shall not be permitted.

D. If required, intermediate jacking stations for steel casing shall be fabricated of the same materials as the casing.



E. Jacking pipe design for jacking loads and acceptable fabrication tolerances is the responsibility of the Contractor. Maximum jacking loads applied to the jacking pipe shall not exceed 50 percent of the ultimate compressive strength of the pipe material or the maximum allowable strength of the pipe as established by the manufacturer, whichever is lower. Each jacking pipe shall contain lubrication/grout ports in accordance with Section 40 27 00.27, Steel Casing Pipe, at a spacing not to exceed 10 feet along the pipe string.

F. A thrust block shall be used to transfer jacking loads to the soil behind the jacking shaft. The thrust block face shall be constructed perpendicular to the proposed pipe alignment. The thrust block shall be designed to withstand the maximum jacking forces developed by the main jacks, without excessive deflection or displacement. Forces applied to the soil shall not exceed the allowable passive earth pressure, with a minimum factor of safety of 2.0 for the regular condition and a minimum factor of safety of 1.5 for the maximum possible forces after delays (set-up), as estimated previously. The Contractor shall structurally connect shaft support components to achieve required thrust reaction capacity, and/or shall use grouting behind shaft walls to achieve sufficient thrust reaction capacity as necessary.

G. Provide launch and retrieval seals at all shaft exit and entry locations. Provide ground improvement to prevent loss of ground and uncontrolled inflows at entry and exit seal locations in accordance with Section 31 32 50, Ground Improvement.


A. Contact Grout Strength Tests: Prepare samples for 24-hour and 28-day compressive strength tests according to ASTM C31 for cylinders or ASTM C109 for cubes. Prepare cylinder molds at least 2 inches in diameter and 4 inches long. Prepare grout cubes either 2 inches or 50 millimeters square. Test samples according to ASTM C39 or C109 as applicable. Take grout for the cylinders or cubes from the nozzle of the contact grout injection line. Provide at least one set of four samples for each 100 cubic feet of grout injected but not less than one set for each grouting shift, unless directed otherwise by the Engineer.


A. All microtunneling Work shall be performed by an experienced Contractor who has at least 5 years of experience in performing microtunneling Work and has completed at least three similar projects involving at least 750 feet of microtunneling on each project. At least one of the projects shall have an individual drive equal to or greater in length than the longest drive on this



Project. The Project superintendent shall have at least 5 years of experience supervising microtunneling construction. The microtunneling machine operator(s) shall have technical training in the operation of the proposed microtunneling equipment and shall have completed, as a primary operator, at least three similar microtunneling projects involving at least 500 feet of microtunneling on each project. At least one of the projects shall have an individual drive equal to or greater in length than the longest drive on this Project. The Site Safety Representative and personnel responsible for air quality monitoring shall be experienced in tunnel construction. Welders for casing and carrier pipe welding shall meet the qualifications requirements in Section 33 05 01.01, Welded Steel Pipe and Fittings.

B. The Contractor’s surveyor responsible for line-and-grade control shall be a professional Land Surveyor licensed in the State of California who has prior experience in similar projects.

C. The Contractor shall provide at least 72 hours advance written notice to Engineer of the planned launch of the MTBM. The Contractor shall immediately notify the Engineer, in writing, when any problems are encountered with equipment or materials, or if the Contractor believes the conditions encountered are materially and significantly different than those represented within the Contract Documents. All Work by the Contractor shall be done in the presence of the Engineer, unless the Engineer grants prior written approval to perform such Work in Engineer’s absence.

D. The Contractor shall allow access to the Engineer and shall furnish necessary assistance and cooperation to aid the Engineer in observations, measurements, data, and sample collection, including, but not limited to the following:

1. The Owner and/or Engineer shall have full access to the operator control container prior to, during, and following all microtunneling operations. This shall include, but not be limited to, providing visual access to real-time operator control screens, gauges, and indicators.

2. The Owner and/or Engineer shall have full access to the jacking and reception shafts prior to, during, and following all jacking operations. This shall include, but not be limited to, visual inspection of installed pipes, launch and retrieval seals, and verification of line and grade. The Contractor shall provide safe access in accordance with all safety regulations.

3. The Owner and/or Engineer shall have full access to the slurry separation plant prior to, during, and following all microtunneling operations. This shall include, but not be limited to, full access to shaker screens, hydrocyclones, conveyor belts, centrifuge equipment, and slurry and spoil holding tanks. The Engineer shall be allowed to collect



soil samples from the shaker screens and/or spoil holding tanks on the slurry separation plant a minimum of once per installed pipe section, or every 10 feet, whichever is more often, and at any time when changes in soil conditions or obstructions are apparent or suspected.

4. The Owner and/or Engineer shall have full access to the bentonite lubrication plant prior to, during, and following all jacking operations. This shall include, but not be limited to, full access to visually inspect storage and mixing tanks, lubricant pressures and pumping rates, and amount and type of lubricants onsite.

1.07 SAFETY

A. The Contractor is responsible for safety on the job site. Methods of construction shall be such as to ensure the safety of the Work, Contractor's and other employees onsite, and the public. Perform all Work in accordance with all current applicable regulations and safety requirements of the federal, state, and local agencies. Comply with all applicable provisions of Cal/OSHA Title 8, Chapter 4, Subchapter 20 and OSHA 29 CFR Part 1926, Subpart S, Underground Construction and Subpart P, Excavations. In the event of conflict, comply with the more stringent requirements.

B. No gasoline powered equipment shall be permitted in jacking and receiving shafts. Diesel, electrical, hydraulic, and air powered equipment is acceptable, subject to applicable local, state, and federal regulations.

C. Furnish and operate a temporary ventilation system in accordance with applicable safety requirements when personnel are in the shaft or in the pipe. Perform all required air and gas monitoring. Ventilation system shall provide a sufficient supply of fresh air and maintain an atmosphere free of toxic or flammable gasses in all underground Work areas.

D. Owner has obtained from the State of California, Industrial Relations Department, Division of Occupational Safety and Health Administration, an Underground Classification for each tunnel. A copy of the classification is included at the end of this section.

PART 2 PRODUCTS

2.01 MATERIALS

A. Carrier Pipe: Welded steel pipe used as a carrier pipe, to be installed inside a jacked steel casing, shall conform to Section 33 05 01.01, Welded Steel Pipe and Fittings.



B. Steel Casing Pipe: Steel pipe to be installed by microtunneling to serve as continuous casing for carrier pipe shall conform to Section 40 27 00.27, Steel Casing Pipe.

C. Contact Grout:

1. Cement: Cement shall be Type II or Type V portland cement conforming to ASTM C150. Type II cement shall meet Table 4 false set requirements of ASTM C150.

2. Bentonite: Bentonite shall be a commercially processed powdered bentonite, Wyoming type, such as Baroid, Imacco-gel, and Black Hills.

3. Sand: Conform to ASTM C144 except where modified in the following subparagraphs. a. Fineness modulus: Between 1.50 and 2.00. b. Grading Requirements:

Sieve Sizes Percentage Passing by Weight

No. 8 100

No. 16 95 - 100

No. 30 60 - 85

No. 50 20 - 50

No. 10 10 - 30

No. 200 0 - 5

4. Fluidifier: Fluidifiers shall hold the solid constituents of the grout in colloidal suspension, be compatible with the cement and water used in the grouting work, and comply with the requirements of ASTM C937.

5. Admixtures: Other admixtures may be used subject to the written approval of the Engineer to improve the pumpability, to control set time, to hold sand in suspension, and to prevent segregation and bleeding.

PART 3 EXECUTION

3.01 GENERAL REQUIREMENTS

A. Microtunneling shall not begin until the following tasks have been completed:

1. All required submittals have been provided, reviewed, and approved. 2. Jacking shaft and receiving shaft excavations and support systems have

been completed in accordance with approved submittals. Locations and elevations of shafts shall have been surveyed to confirm that Work can



be completed in accordance with alignment and grade shown on Drawings.

3. All settlement monitoring points have been installed and baseline measurements established.

4. The Contractor has completed ground improvement behind the entry and exist seals in accordance with Section 31 32 50, Ground Improvement, to stabilize running or flowing soils.

5. The Contractor has demonstrated the water tightness and stability of the soils at the entry and exit seals in accordance with Section 31 41 00, Shoring.

6. The location, orientation and grade of the jacking frame or guide rails and entry/exit seals have been surveyed to ensure they are on the proper line and grade and to verify that they are properly supported. Special care shall be taken when setting the guide rails or jacking frame in the jacking shaft to ensure stability and accuracy of the alignment and grade. Guide rails or jacking frame shall be securely attached to the concrete working slab, with supplementary concrete or grout if necessary, to prevent movement or shifting during the Work.

7. A startup inspection of all mechanical and hydraulic systems associated with the microtunneling operations has been completed. The system shall be tested on the surface to ensure that the microtunneling machine and supporting equipment is functioning properly. The Engineer will be notified at least 72 hours prior to the startup inspection and a site inspector representing the Owner will be present during the startup inspection. Key machine performance data will be measured and recorded by the Contractor during this inspection, including cutterhead rotational torque, functionality of main and steering jacks, laser and target, and other components. The records of the startup inspection will be submitted to the Engineer within 24 hours of the completed inspection.

8. Site Safety Representative has conducted a safety meeting and provided safety instruction for new employees as required by OSHA. Arrange this meeting and inform the Engineer of the time and place of the meeting at least 7 days in advance.

B. The Contractor shall properly manage, treat, and dispose of groundwater inflows to the shafts. The Contractor shall not discharge groundwater inflows into storm sewers, sanitary sewers, drainage ditches, water bodies, or streets without an approved discharge permit. The Contractor may use settling tanks consistent with permit requirements.

C. Conduct all operations such that trucks and other vehicles do not interfere with traffic or create a mud, dust, or noise nuisance in the streets and to



adjacent properties. Promptly clean up, remove, and dispose of mud, spoils and slurry spillage, and any slurry discharges.

D. All Work shall be done so as not to disturb roadways, railroads, canal channels, adjacent structures, landscaped areas, or existing utilities. Any damage shall be immediately repaired to original or better condition and to the satisfaction of Engineer at no additional cost to the Owner.

E. Once tunneling commences, the Contractor shall operate with a full crew 24 hours a day, including weekends and holidays, without interruption, until the casing installation and contact grouting is complete.

3.02 JACKING OPERATIONS

A. Provide a suitable jacking frame and thrust block to carry out the Work. Provide intermediate jacking stations, if required, to complete the microtunneling drives indicated on the Drawings. If the Contractor elects to utilize IJSs, they shall be installed and operated in accordance with approved Submittals.

B. Transport the jacking pipe from storage to the jacking shaft without damage. Transport methods shall be acceptable to pipe manufacturer. Damaged jacking pipe shall not be used in the Work, unless permitted in writing by the Engineer. Set the pipe to be jacked on properly braced and supported guide rails or jacking frame.

C. Jacking pipe sections shall be jacked into position following the design line and grade without damaging the pipe. In the event a section of pipe is damaged during the jacking operation, the Contractor, with written approval from the Engineer, shall make temporary repairs to the pipe and shall jack the pipe through to the next shaft for removal. Other methods of repairing the damaged pipe may be used if approved in writing by the Engineer.

3.03 MICROTUNNELING

A. Microtunneling shall be completed in accordance with approved Submittals, and all applicable permit conditions.

B. Microtunneling operations shall control surface settlement and heave above the pipeline to prevent damage to existing utilities, facilities, and improvements. The Contractor shall repair any damage resulting from construction activities, at no additional cost to Owner and without extension of schedule for completion. The Contractor shall pressure grout any voids caused by or encountered during the shaft construction or microtunneling. The



Contractor shall modify equipment and procedures as required to avoid recurrence of excessive settlements or damage.

C. Provide a lubrication system, and inject pipe lubricants through injection ports at the rear of the microtunneling machine and ports in the jacking pipe as necessary, to minimize pipe friction. Pipe lubricants shall be injected continuously as the pipe is advanced.

D. Continuous pressure shall be applied at the tunnel face to maintain face stability and shall be monitored continuously.

E. The microtunneling machine shall be operated to restrict the excavation of the materials to a volume equal to the MTBM and pipe jacked, to prevent loss of ground and settlement or possible damage to overlying structures. Control the advance rate and monitor the volume of material excavated and adjust advance rate, as required, to avoid loss of ground, overexcavation, or surface heave.

F. Control slurry pressure and avoid excessive pumping pressures to prevent the discharge of slurry at the ground surface or into any water body. Contain and clean up any slurry discharges immediately. Wash any paved areas with water to avoid the tracking of slurry away from the discharge area.

G. Completely contain, transport, and dispose of all excavated materials, waste slurry, and drilling fluids away from the construction site. All spoils and slurry must be contained in trucks, tanks, or other containers at all times. Dumping of spoil or slurry on the ground, discharge into sewers or ditches, or discharge into the shafts is not permitted. Slurry shall be pumped into tanker trucks and disposed of at acceptable facilities in accordance with current State regulations for disposal of these materials. Only use the disposal sites identified in approved submittals for muck and slurry disposal.

H. Annular Space Grouting: After jacking pipe installation is complete, displace lubrication slurry and fill the annular space created by the overcut of the machine with contact grout.

3.04 CONTROL OF LINE AND GRADE

A. Contractor will establish and protect benchmarks as necessary prior to the start of construction.

B. After establishing all required benchmarks, use these benchmarks to furnish and maintain all reference lines and grades for microtunneling. The Contractor shall use these lines and grades to establish the exact location of the jacking pipe using a laser or theodolite guidance system. Submit to Engineer copies of



field notes used to establish all lines and grades and allow Engineer to check guidance system setup prior to beginning each microtunneling drive. Provide access for Engineer to perform survey checks of guidance system and line-and-grade of jacking pipe as necessary. The Contractor is fully responsible for the accuracy of the Work and the correction of it, as required.

C. The jacking pipe shall be installed in accordance with the following tolerances:

1. Variations from Design Line: 2 inches maximum. 2. Variations from Design Grade: 1 inch maximum.

D. The machine shall be steered to maintain line and grade within the tolerances specified. This shall be achieved by continuously monitoring and adjusting line, grade, machine inclination, roll, and steering attitude during the operation. If the installation is off line or grade, make the necessary corrections, and return to the design alignment and grade at a rate of not more than 1 inch per 25 feet.

E. The guidance system shall be mounted independently from the thrust block and jacking frame to maintain alignment if there is movement of equipment during jacking. Stop microtunneling operations and reset guidance system if its alignment shifts or is moved off design alignment and grade for any reason. Check guidance system setup at least once per shift. Guidance system shall only be reset by experienced, competent surveying personnel in accordance with approved procedures outlined in the Submittals.

F. Monitor line and grade continuously during microtunneling operations. Record deviation with respect to design line and grade at least once per foot and submit records to Engineer as requested. Control line and grade of the jacking pipe to within the specified tolerances.

G. If the pipe installation does not meet the specified tolerance, the Contractor shall correct the installation including any necessary redesign of the pipeline or structures and acquisition of necessary easements. All corrective Work shall be performed by the Contractor at no additional cost to the Owner and without schedule extension, and is subject to the written approval of the Engineer.

3.05 OBSTRUCTIONS

A. In accordance with Section 02 40 00, Crossings.



3.06 CONTACT GROUTING EQUIPMENT

A. Provide equipment for mixing and injecting grout to satisfactorily mix and agitate the grout and force it into the grout holes, in a continuous flow at the desired pressure. Provide pumps capable of continuously developing a sustained pressure of 50 pounds per square inch at the grout hole connections.

B. Provide two pressure gauges, one at the grout pump and one at the collar of each hole being grouted. Check the accuracy of the gauges periodically with an accurately calibrated pressure gauge. Make available a minimum of two spare pressure gauges onsite.

C. Provide the grouting equipment with a meter to determine the volume of grout injected. Calibrate the meter in cubic feet to the nearest one-tenth of a cubic foot.

D. Maintain the grouting equipment in satisfactory operating condition throughout the course of the Work to ensure continuous and efficient performance during grouting operations.

E. Provide suitable stop valves at the collar of each hole for use in maintaining pressure as required until the grout has set.

F. Provide grout hoses with an inside diameter not less than 1-1/4 inches nor greater than 2 inches and capable of withstanding the maximum water and grout pressures to be used.

3.07 MIXING AND INJECTION OF CONTACT GROUT

A. Provide materials free of lumps when put into the mixer. Constantly agitate the grout mix. Install grout that flows unimpeded and completely fill voids. Waste grout not injected after 90 minutes of mixing.

B. Operate and control the grouting process so that the grout will be delivered uniformly and steadily. The locations of contact grout holes in the pipe are shown on the Drawings. Drilling grout holes through pipe will not be permitted.

C. Recirculate grout mixes when any new mix is batched or after adding water, fluidifier, or sand to mix. Recirculate mix for at least 2 minutes prior to pumping grout into grout hole.

D. Grouting will be considered completed when less than one cubic foot of grout of the accepted mix and consistency can be pumped in 5 minutes under the



specified maximum pressure. After the grouting is finished, close the valve before the grout header is removed and leave closed until grout has set.

E. The maximum sustained grouting pressure shall be 30 pounds per square inch (psi) or 1/2 psi per foot of earth cover, whichever is less, at the grout hole collar connection unless otherwise approved in writing by the Engineer.

3.08 CONTACT GROUTING OF TUNNELED CASING

A. Commence contact grouting outside of the casing pipe within 24 hours following the completion of each tunneled drive of 30 inches or greater in diameter. Conduct grouting operations continuously until completed.

B. Install contact grout ports in the casing in accordance with Section 40 27 00.27, Steel Casing Pipe. Drilling grout holes through installed casing pipe will not be permitted. Provide grout ports threaded to accept valve fittings and plugs.

C. Attempt to hook up and pump grout at every tunneled pipe grout port or coupling unless approval is granted by the Engineer in writing to omit grouting of selected ports.

D. Inject grout through the tunneled pipe grout connections in such a manner as to completely fill voids outside the pipe resulting from, or encountered during, tunneling operations. Control grout pressure so as to avoid damaging the pipe, and to avoid movement of the surrounding ground or improvements.

E. Grout to generally progress sequentially in a constant upgradient direction from one grout port to the next grout port in the sequence indicated in the approved submittals.

F. During the grouting operations, clean and make ready for grouting the sufficient contact grout ports ahead of the port to be grouted. Attach valves or other suitable devices and place in the fully open position on ungrouted ports within the maximum grout communication distance.

G. For any hole ahead of the grouting operation, with a valve attached, and the valve in the open position, such hole shall be considered grouted if grout issues forth of the same consistency and color, and at the same rate as that being pumped. Replace grout plugs in pipe at the completion of grouting.

H. Seal pipe grout fittings with screw type plugs upon completion of grouting. Use dry pack mortar to fill any recesses, and to provide a smooth surface.



3.09 INSTALLATION OF CARRIER PIPE

A. Installation of carrier pipe in the microtunneled casing shall be in accordance with Section 31 60 00, Installation of Carrier Pipe in Steel Casing.

3.10 CLEANUP

A. After completion of microtunneling and prior to carrier installation, remove all construction debris, slurry, oil, grease, and other materials from the microtunneled pipe, jacking and receiving shafts, and all Contractor Work areas. Cleaning shall be incidental to the construction. No separate payment shall be made for cleanup.

3.11 SUPPLEMENT

A. The supplement listed below, following “End of Section”, is part of this Specification.

1. Attachment: Underground Classification.

END OF SECTION


PW/WBG/179201 GEOTECHNICAL INSTRUMENTATION OCTOBER 2018 31 80 00 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 31 80 00 GEOTECHNICAL INSTRUMENTATION

PART 1 GENERAL

1.01 WORK INCLUDED

A. The Work specified in this section includes furnishing and installing settlement instrumentation to monitor ground movements around and above tunneled crossings. The Work includes, but is not limited to, installing surface settlement instrumentation and recording observations and measurements from the monitoring points on a periodic basis before, during, and after tunneling.

1.02 SUBMITTALS


1. Qualifications: Submit surveying personnel qualifications in accordance with the requirements herein.

2. Submit the following, at least 1 month before scheduled installation of monitoring points: a. Instrumentation Schedule: Submit the proposed schedule for

installing the monitoring points. b. Drawings with locations of proposed monitoring points shown in

plan and profile where point locations differ from those shown in the Drawings.

c. Monitoring Plan: Submit the monitoring plan for each crossing separately. The plan should identify the procedures and frequency of measurements, the procedure by which the information tabulated graphically for each point and submitted electronically in Microsoft Excel format to the Engineer, and the procedures to be used to identify and communicate values that have exceeded the threshold values defined in this section.

3. Reports and Records: a. Within 72 hours following installation of the monitoring points,

submit drawings to the Engineer showing the actual as-built installed location, the identification number, the type, the installation date and time, the coordinates of the point (x, y, z), and the tip elevation and instrument length. Include details of installed instruments, accessories and protective measures including all dimensions and materials used.

b. At least 72 hours prior to commencement of any adjacent construction activities, including dewatering, submit to the


GEOTECHNICAL INSTRUMENTATION PW/WBG/179201 31 80 00 – 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

Engineer preconstruction survey of existing conditions, documenting any existing damage, distress, settlement, cracking, etc., of streets, roadways, sidewalks, curbs, gutter, utilities, buildings, and foundations. Include photographs, video, and written notes for each item or instance of damage or distress existing before construction.

1.03 DEFINITIONS

A. Monitoring point: Surface or subsurface monitoring points, as defined herein.

B. Surface Monitoring Point: Settlement monitoring point established as a reference for measuring elevation of the ground surface or structural element using optical survey methods.

C. Subsurface Monitoring Point: A cased borehole settlement monitoring point located above the tunnel crown used for detecting settlement between the location of the settlement point and the tunnel bore.


A. Surveyor Qualifications: Perform surveying for establishing surface monitoring points by a professional Land Surveyor licensed in the State of California with previous experience surveying for the detection of structural or surface deformations.

B. Install monitoring points within 0.5 foot of the horizontal and vertical locations described herein, shown on the Drawings, or as directed by the Engineer. Install additional monitoring points if directed by the Engineer.

C. Should actual field conditions prevent installation of instruments at the locations shown on the Drawings, or specified herein, obtain written acceptance from the Engineer for new instrument locations and elevations.

PART 2 PRODUCTS

2.01 MATERIALS

A. Surface Monitoring Point: Establish surface monitoring points by an inscribed marking or approved surveyor’s nail driven flush with the surface in asphalt or concrete paved areas. In unimproved areas, establish surface monitoring points by driving a 5/8-inch diameter by 30-inch long reinforcing bar flush with the ground. Provide each monitoring point with a tag or marking indicating the station and offset from centerline. Assign each point a unique



identification number and protect from damage or burial. Flag each point so as to remain visible.

A. Subsurface Monitoring Points: Subsurface monitoring points shall be established and installed as shown in the Drawings. Each point shall consist of a No. 6 rebar settlement rod installed within and isolated from a PVC cased borehole. Each point shall be assigned a unique identification number. The settlement rod shall be driven 6 to 12 inches past the bottom of the borehole casing and the tips shall be located 5 feet above the tunneled pipe crown centerline, as noted on the Drawings, or as directed by the Engineer. The settlement rod shall be secured to the PVC casing with a 12-inch length of loose cable or chain to prevent the rod from falling more than approximately 12 inches. The casing shall stick up between 30 and 40 inches from the ground surface and shall be protected from damage. If installed within traffic lanes, shoulders, parking lots, or bike lanes the casing shall be flush with pavement or recessed, and capped and protected with a road box in accordance with CalTrans and other applicable permit agencies.

PART 3 EXECUTION

3.01 GENERAL

A. Install instrumentation at the locations shown on the Drawings, as described in these Specifications, and as approved by the Engineer. Install instruments in accordance with the approved installation schedule.

B. Install instruments and perform a baseline survey of surface monitoring points at least 7 days prior to the commencement of any construction activities within 100 feet of the monitoring point, including the start of any dewatering.

C. Once tunneling commences, survey monitoring points located within 50 feet of the excavation face at least once per day and remaining settlement monitoring points at least every other day while shafts are open. Once tunneling operations are complete and the shafts backfilled, survey settlement monitoring points once every other day for a period of 1 week, and once again at 14 days after tunneling and shaft backfill is completed.

D. Provide access and assistance to the Engineer for obtaining additional monitoring data, as discussed herein and as requested by Engineer.


GEOTECHNICAL INSTRUMENTATION PW/WBG/179201 31 80 00 – 4 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

3.02 MONITORING POINT LOCATIONS

A. Establish an array of monitoring points in accordance with the Drawings.

B. Install the monitoring points as close as practicable to the locations shown on the Drawings or as defined in these specifications.

C. Locate and visually confirm utilities within 10 feet laterally of monitoring point locations, and protect utilities or relocate monitoring points as necessary to protect utilities. Follow accepted industry procedures for one-call notification (Underground Service Alert) and visual confirmation of locations of adjacent utilities.

3.03 INSTRUMENT PROTECTION, MAINTENANCE, AND REPAIR

A. Protect the monitoring points from damage. Replace or repair damaged installations within 24 hours prior to continuing dewatering, excavation, or tunneling, unless permitted otherwise in writing by the Engineer.

3.04 RESPONSE VALUES

A. Response Values:

Site Feature

Threshold Value (Action

Required)

Response

Value

Shutdown

Value

Surface Monitoring Points

0.50 inch V 0.90 inch V 1.00 inch V

Subsurface Monitoring Points

0.75 inch V 1.34 inch V 1.50 inch V

B. When the instruments indicate movement equal to 50 percent of the shutdown value has occurred, the Threshold Value is said to have been reached. Meet with the Engineer to discuss construction means and methods to determine what changes, if any, will be made to better control ground movement. Instrument readings will be taken by the Engineer on a daily basis until five consecutive working days of stabilized readings are observed, or more often as specified elsewhere in this section.

C. When the instruments indicate movement equal to 90 percent of the shutdown value has occurred, the Response Value is said to have been reached. Actively control ground movement in accordance with the approved plan to prevent reaching the Shutdown Value. Instrument readings will be taken by the



Engineer on a daily basis until 5 consecutive working days of stabilized readings are observed, or more often as specified elsewhere in this section.

D. When the verified instrument readings indicate movement equal to the Shutdown Value, Stop excavation Work immediately at the Engineer’s direction and at the expense of the Contractor. Meet with the Engineer to develop a plan of action before excavation Work can be resumed. No standby time will be paid if excavation Work is shut down because the Shutdown Value is reached.

3.05 ABANDONMENT OF INSTRUMENTS

A. Surface Monitoring Points: Keep in place the surface monitoring points on public property at the completion of the Work. Remove surface monitoring points on private property during the cleanup and restoration work, or as directed by the Engineer.

B. Subsurface Monitoring Points: Properly abandon all subsurface monitoring point boreholes, by overdrilling to remove PVC casing and grouting drilled holes with grout conforming to the requirements of Section 31 79 13, Microtunneling.

END OF SECTION


PW/WBG/179201 AGGREGATE BASE COURSES OCTOBER 2018 AND GRAVEL SURFACING ©COPYRIGHT 2018 CH2M HILL 32 11 23 - 1

SECTION 32 11 23 AGGREGATE BASE COURSES AND GRAVEL SURFACING

PART 1 GENERAL

1.01 DEFINITIONS

A. Completed Course: Compacted, unyielding, free from irregularities, with smooth, tight, even surface, true to grade, line, and cross-section.

B. Completed Lift: Compacted with uniform cross-section thickness.

C. Standard Specifications: When referenced in this section, shall mean 2010 California Department of Transportation Standard Specifications.

1.02 SUBMITTALS


1. Certified Test Results on Source Materials: Submit copies from commercial testing laboratory 20 days prior to delivery of materials to Project showing materials meeting the physical qualities specified.

2. Certified results of in-place density tests from independent testing agency.

PART 2 PRODUCTS

2.01 BASE COURSE

A. As specified for Class 2 Aggregate Base in Section 26-1.02B of the Standard Specifications.

B. Aggregate must be clean and consist of any combination of the following:

1. Broken stone. 2. Crushed gravel. 3. Natural rough surfaced gravel. 4. Sand.

C. Maximum Size: 3/4 inch.

D. Clean, hard durable, pit run gravel or crushed stone graded from coarse to fine containing enough fines to bind material when compacted.

E. Processed reclaimed asphalt concrete, PCC, LCB, or CTB is not permitted.


AGGREGATE BASE COURSES PW/WBG/179201 AND GRAVEL SURFACING SEPTEMBER 2018 32 11 23 - 2 ©COPYRIGHT 2018 CH2M HILL

2.02 LEVELING COURSE AND GRAVEL SURFACING

A. As specified for base course rock.

B. Physical Qualities: Same as for base course.


A. Perform tests necessary to locate acceptable source of materials meeting specified requirements.

B. Final approval of aggregate material will be based on test results of installed materials.

C. Should separation of coarse from fine materials occur during processing or stockpiling, immediately change methods of handling materials to correct uniformity in grading.

PART 3 EXECUTION

3.01 SUBGRADE PREPARATION

A. As specified in Section 31 23 13, Subgrade Preparation.

B. Obtain Engineer’s acceptance of subgrade before placing base course or surfacing material.

C. Do not place base course or surfacing materials in snow or on soft, muddy, or frozen subgrade.

3.02 EQUIPMENT

A. Compaction Equipment: Adequate in design and number to provide compaction and to obtain specified density for each layer.

3.03 HAULING AND SPREADING

A. Hauling Materials:

1. Do not haul over surfacing in process of construction. 2. Loads: Of uniform capacity. 3. Maintain consistent gradation of material delivered; loads of widely

varying gradations will be cause for rejection.



B. Spreading Materials:

1. Distribute material to provide required density, depth, grade, and dimensions with allowance for subsequent lifts.

2. Produce even distribution of material upon roadway or prepared surface without segregation.

3. Should segregation of coarse from fine materials occur during placing, immediately change methods of handling materials to correct uniformity in grading.

3.04 CONSTRUCTION OF COURSES

A. General: Complete each lift in advance of laying succeeding lift to provide required results and adequate inspection.

B. Base Course:

1. Maximum Completed Lift Thickness: 6 inches. 2. Completed Course Total Thickness: As shown. 3. Spread lift on preceding course to required cross-section. 4. Lightly blade and roll surface until thoroughly compacted. 5. Add keystone to achieve compaction and as required when aggregate

does not compact readily due to lack of fines or natural cementing properties, as follows: a. Use leveling course or surfacing material as keystone. b. Spread evenly on top of base course, using spreader boxes or chip

spreaders. c. Roll surface until keystone is worked into interstices of base

course without excessive displacement. d. Continue operation until course has become thoroughly keyed,

compacted, and will not creep or move under roller. 6. Blade or broom surface to maintain true line, grade, and cross-section.

C. Leveling Course:

1. Maximum Completed Lift Thickness: 4 inches. 2. Completed Course Total Thickness: As shown. 3. Spread on roadway or preceding course to depth, grade, and

cross-section shown. 4. Lightly blade surface and roll until thoroughly compacted to line and

grade shown. 5. Maintain moisture levels to prevent loss of fines during processing.


AGGREGATE BASE COURSES PW/WBG/179201 AND GRAVEL SURFACING SEPTEMBER 2018 32 11 23 - 4 ©COPYRIGHT 2018 CH2M HILL

D. Gravel Surfacing:

1. Maximum Completed Lift Thickness: 6 inches. 2. Completed Course Total Thickness: As shown. 3. Spread on preceding course in accordance with cross-section shown. 4. Blade lightly and roll surface until material is thoroughly compacted.

3.05 ROLLING AND COMPACTION

A. Commence compaction of each layer of base after spreading operations and continue to achieve a density of 95 percent relative compaction under California Test 231.

B. Commence rolling at outer edges and continue toward center; do not roll center of road first.

C. Apply water as needed to obtain specified densities.

D. Place and compact each lift to required density before succeeding lift is placed.

E. Remove floating or loose stone from surface of preceding course before placing leveling course.

F. Surface Defects: Remedy by loosening and rerolling. Reroll entire area, including surrounding surface, until thoroughly compacted.

G. Finished surface shall be true to grade and crown before proceeding with surfacing.

3.06 SURFACE TOLERANCES

A. Blade or otherwise work surfacing as necessary to maintain grade and cross-section at all times, and to keep surface smooth and thoroughly compacted.

B. Finished Surface of Untreated Aggregate Base and Leveling Course: Within plus or minus 0.04 foot of grade shown at any individual point.

C. Gravel Surfacing: Within 0.04 foot from lower edge of 10-foot straightedge placed on finished surface, parallel to centerline.

D. Overall Average: Within plus or minus 0.01 foot from crown and grade specified.



3.07 DRIVEWAY RESURFACING

A. Replace gravel surfacing on driveways that were gravel surfaced prior to construction.

B. Provide compacted gravel surfacing to depth equal to original, but not less than 4 inches.

C. Leave each driveway in as good or better condition as it was before start of construction.


A. In-Place Density Tests:

1. Provide testing laboratory at least 2 hours advance notification prior to testing.

2. Show proof that areas meet specified requirements before requesting that Engineer identify density test locations.

3. Refer to Table 2 for minimum sampling and testing requirements for aggregate base course and surfacing.

Table 2 Minimum Sampling and Testing Requirements

Property Test Method Frequency Sampling

Point

Gradation AASHTO T11 and AASHTO T27

One sample every 500 tons but at least every 4 hours of production

Roadbed after processing

Moisture Density (Maximum Density)

AASHTO T180, Method D

One test for every aggregate grading produced

Production output or stockpile

In-Place Density and Moisture Content

AASHTO T310, and AASHTO T265 for moisture content

One for each 500 ton but at least every 10,000 sq ft of area

In-place completed, compacted area

3.09 CLEANING

A. Remove excess material from the Work area. Clean stockpile and staging areas of all excess aggregate.

END OF SECTION


PW/WBG/179201 ASPHALT PAVING OCTOBER 2018 32 12 16 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 32 12 16 ASPHALT PAVING

PART 1 GENERAL

1.01 DEFINITIONS

A. Combined Aggregate: All mineral constituents of asphalt concrete mix, including mineral filler and separately sized aggregates.

B. RAP: Reclaimed asphalt pavement.

C. Standard Specifications: 2015 California Department of Transportation Standard Specifications.

1.02 SUBMITTALS


1. Asphalt Concrete Mix Formula: a. Submit minimum of 15 days prior to start of production. b. Submittal to include the following information:

1) Gradation and portion for each aggregate constituent used in mixture to produce a single gradation of aggregate within specified limits.

2) Bulk specific gravity for each aggregate constituent. 3) Measured maximum specific gravity of mix at optimum

asphalt content determined in accordance with ASTM D2041.

4) Properties as stated in Section 39 of the Standard Specifications, this section for at least four different asphalt contents other than optimum, two below optimum, and two above optimum.

5) Percent of asphalt lost due to absorption by aggregate. 6) Index of Retained Strength (TSR) at optimum asphalt

content as determined by AASHTO T283. 7) Percentage of asphalt cement, to nearest 0.1 percent, to be

added to mixture. 8) Optimum mixing temperature. 9) Optimum compaction temperature. 10) Temperature-viscosity curve of asphalt cement to be used. 11) Brand name of any additive to be used and percentage

added to mixture.


ASPHALT PAVING PW/WBG/179201 32 12 16 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

2. Test Report for Asphalt Cement: a. Submit minimum 10 days prior to start of production. b. Show appropriate test method(s) for each material and the test

results. 3. Manufacturer’s Certificate of Compliance, in accordance with

Section 01 43 33, Manufacturers’ Field Services, for the following materials: a. Aggregate: Gradation, source test results as defined in Section 39

of the Standard Specifications b. Asphalt for Binder: Type, grade, and viscosity-temperature curve. c. Prime Coat: Type and grade of asphalt. d. Tack Coat: Type and grade of asphalt. e. Additives. f. Mix: Conforms to job-mix formula.

4. Statement of qualification for independent testing laboratory. 5. Test Results:

a. Mix design. b. Asphalt concrete core. c. Gradation and asphalt content of uncompacted mix. d. Field density. e. Quality control.


A. Qualifications:

1. Independent Testing Laboratory: In accordance with ASTM E329. 2. Asphalt concrete mix formula shall be prepared by approved certified

independent laboratory under the supervision of a certified asphalt technician.

B. Compaction Control Strip:

1. General: a. Construct to approximately 400 square meters in area and at

location that will become a portion of completed paved area. b. Thickness: Typical of thickness to be paved on Project.

2. Rollers Used for Compaction: a. Steel Wheel Rollers: Minimum static weight 9 mg (10 tons). b. Pneumatic Rollers: Capable of exerting pressure of 550 kPa

(80 psi) on bituminous surface.



c. Vibratory Rollers: Static weight minimum 5.5 mg (6 tons), capable of applying a 9 mg (10-ton) impact force equipped with amplitude and frequency control specifically designed for compaction of bituminous mixtures.

3. Compaction: a. Compact bituminous mat, using a standard rolling pattern that

covers entire control strip. Request that Engineer performs final density test.

b. Continue rolling until no further compaction can be obtained as determined by field density testing.

c. Temperature and condition of bituminous mat shall be considered workable when further compaction can no longer be obtained.

4. Target Density Determination: a. Select test point near center of normal roller pass, but no closer

than 600 millimeters (2 feet) from edge of mat and 15 meters (50 feet) from either end of control strip. Mat thickness at this point shall be at least depth of finished pavement.

b. Point at which no further densification can be obtained. 5. Establish new target density if change is made in mix design, nominal

depth of mat being placed, aggregate source, or material properties.

1.04 ENVIRONMENTAL REQUIREMENTS

A. Temperature: Do not apply asphalt materials or place asphalt mixes when ground temperature is lower than 10 degrees C (50 degrees F) or air temperature is lower than 4 degrees C (40 degrees F). Measure ground and air temperature in shaded areas away from heat sources or wet surfaces.

B. Moisture: Do not apply asphalt materials or place asphalt mixes when application surface is wet.

PART 2 PRODUCTS

2.01 MATERIALS

A. Tack Coat: Emulsified asphalt, Grade SS-1h conforming to Section 94 of the Standard Specifications.

2.02 ASPHALT CONCRETE MIX

A. General:

1. Mix formula shall not be modified except with written approval of Engineer.



2. Source Changes: a. Should material source(s) change, establish new asphalt concrete

mix formula before new material(s) is used. b. Perform check tests of properties of plant-mix bituminous

materials on first day of production and as requested by Engineer to confirm that properties are in compliance with design criteria.

c. Make adjustments in gradation or asphalt content as necessary to meet design criteria.

B. Asphalt Concrete: Type A, 1/2-inch maximum coarse for top 2-inch lift and 3/4-inch maximum coarse for bottom 2-inch lift. AC shall be as specified in Section 39 of the Standard Specifications.

C. Composition: Hot-plant mix of aggregate, mineral filler if required, and paving grade asphalt cement. The several aggregate fractions shall be sized, uniformly graded, and combined in such proportions that resulting mixture meets grading requirements of mix formula.

D. Aggregate:

1. General: As specified in Section 39 of the Standard Specifications

E. Mineral Filler: In accordance with AASHTO M17.

F. Asphalt Cement: Paving Grade 64-10 as specified in Section 92 of the Standard Specifications.

PART 3 EXECUTION

3.01 GENERAL

A. Traffic Control:

1. In accordance with Section 01 50 00, Temporary Facilities and Controls.

2. Minimize inconvenience to traffic, but keep vehicles off freshly treated or paved surfaces to avoid pickup and tracking of asphalt.

B. Driveways: Repave driveways from which pavement was removed. Leave driveways in as good or better condition than before start of construction.

3.02 LINE AND GRADE

A. Provide and maintain intermediate control of line and grade, independent of underlying base, to meet finish surface grades and minimum thickness.



B. Shoulders: Construct to line, grade, and cross-section shown.

3.03 APPLICATION EQUIPMENT

A. In accordance with Section 39-3.03 of the Standard Specifications.

3.04 PREPARATION

A. Prepare subgrade as specified in Section 31 23 13, Subgrade Preparation.

B. Existing Roadway:

1. Modify profile by grinding, milling, or overlay methods as approved, to provide meet lines and surfaces and to produce smooth riding connection to existing facility.

2. Remove existing material to a minimum depth of 25 millimeters (1 inch).

3. Paint edges of meet line with tack coat prior to placing new pavement.

C. Thoroughly coat edges of contact surfaces (curbs, manhole frames) with emulsified asphalt or asphalt cement prior to laying new pavement. Prevent staining of adjacent surfaces.

3.05 PAVEMENT APPLICATION

A. General: Place asphalt concrete mixture on approved, prepared base in conformance with Section 32 11 23, Aggregate Base Courses and Gravel Surfacing.

B. Tack Coat:

1. Prepare material, as specified in Section 94 of the Standard Specifications, prior to application.

2. Apply uniformly to clean, dry surfaces avoiding overlapping of applications.

3. Do not apply more tack coat than necessary for the day’s paving operation.

4. Touch up missed or lightly coated surfaces and remove excess material. 5. Application Rate:

a. Minimum 0.25 liter to maximum 0.70 liter of asphalt (residual if diluted emulsified asphalt) per square meter (0.05 to 0.15 gallon per square yard) of surface area.



C. Pavement Mix:

1. Prior to Paving: a. Sweep primed surface free of dirt, dust, or other foreign matter. b. Patch holes in primed surface with asphalt concrete pavement

mix. c. Blot excess prime material with sand.

2. Place asphalt concrete pavement mix in two lifts. 3. Compacted Lift Thickness:

a. Minimum: Twice maximum aggregate size, but in no case less than 25 millimeters (1 inch).

b. Maximum: 100 millimeters (4 inches). 4. Total Compacted Thickness: As shown. 5. Apply such that meet lines are straight and edges are vertical. 6. Collect and dispose of segregated aggregate from raking process. Do not

scatter material over finished surface. 7. Joints:

a. Offset edge of each layer a minimum of 150 millimeters (6 inches) so joints are not directly over those in underlying layer.

b. Offset longitudinal joints in roadway pavements so longitudinal joints in wearing layer coincide with pavement centerlines and lane divider lines.

c. Form transverse joints by cutting back on previous day’s run to expose full vertical depth of layer.

8. Succeeding Lifts: Apply tack coat to pavement surface between each lift.

9. After placement of pavement, seal meet line by painting a minimum of 150 millimeters (6 inches) on each side of joint with cut-back or emulsified asphalt. Cover immediately with sand.

D. Compaction:

1. Roll until roller marks are eliminated and minimum density of 95 percent of mix design unit weight at optimum asphalt content is obtained.

2. Joint Compaction: a. Cut back previously compacted mixture when Work is resumed to

produce slightly beveled edge for full thickness of layer. b. Cut away waste material and lay new mix against fresh cut.



E. Tolerances:

1. General: Conduct measurements for conformity with crown and grade immediately after initial compression. Correct variations immediately by removal or addition of materials and by continuous rolling.

2. Completed Surface or Wearing Layer Smoothness: a. Uniform texture, smooth, and uniform to crown and grade. b. Maximum Deviation: 1/8 inch from lower edge of a 12-foot

straightedge, measured continuously parallel and at right angle to centerline.

c. If surface of completed pavement deviates by more than twice specified tolerances, remove and replace wearing surface.

3. Transverse Slope Maximum Deviation: 1/4 inch in 12 feet from rate of slope shown.

4. Finished Grade: a. Perform field differential level survey on maximum 50-foot grid

and along grade breaks. b. Maximum Deviation: 0.02 foot from grade shown.

F. Seal Coat:

1. General: Apply seal coat of paving grade or emulsified asphalt to finished surface at longitudinal and transverse joints, joints at abutting pavements, areas where asphalt concrete was placed by hand, patched surfaces, and other areas as directed by Engineer.

2. Preparation: a. Surfaces that are to be sealed shall be maintained free of holes,

dry, and clean of dust and loose material. b. Seal in dry weather and when temperature is above 2 degrees C

(35 degrees F). 3. Application:

a. Fill cracks over 1.5 millimeters (1/16 inch) in width with asphalt-sand slurry or approved crack sealer prior to sealing.

b. When sealing patched surfaces and joints with existing pavements, extend minimum 150 millimeters (6 inches) beyond edges of patches.

3.06 PAVEMENT OVERLAY

A. Preparation:

1. Remove fatty asphalt, grease drippings, dust, and other deleterious matter.



2. Surface Depressions: Fill with asphalt concrete mix, and thoroughly compact.

3. Damaged Areas: Remove broken or deteriorated asphalt concrete and patch as specified in Article Patching.

4. Portland Cement Concrete Joints: Remove joint filler to minimum 12 millimeters (1/2 inch) below surface.

B. Application:

1. Tack Coat: As specified in this section. 2. Place and compact asphalt concrete as specified in Article Pavement

Application. 3. Place first layer to include widening of pavement and leveling of

irregularities in surface of existing pavement. 4. When leveling irregular surfaces and raising low areas, the actual

compacted thickness of any one lift shall not exceed 50 millimeters (2 inches).

5. Actual compacted thickness of intermittent areas of 100 square meters (120 square yards) or less may exceed 50 millimeters (2 inches), but not 100 millimeters (4 inches).

6. Final wearing layer shall be of uniform thickness, and meet grade and cross-section as shown.

3.07 PATCHING

A. Preparation:

1. Remove damaged, broken, or unsound asphalt concrete adjacent to patches. Trim to straight lines exposing smooth, sound, vertical edges.

2. Prepare patch subgrade as specified in Section 31 23 13, Subgrade Preparation.

B. Application:

1. Patch Thickness: 75 millimeters (3 inches) or thickness of adjacent asphalt concrete, whichever is greater.

2. Place asphalt concrete mix across full width of patch in layers of equal thickness.

3. Spread and grade asphalt concrete with hand tools or mechanical spreader, depending on size of area to be patched.



C. Compaction:

1. Roll patches with power rollers capable of providing compression of 350 to 525 Newtons per linear centimeter (200 to 300 pounds per linear inch). Use hand tampers where rolling is impractical.

2. Begin rolling top course at edges of patches, lapping adjacent asphalt surface at least 1/2 the roller width. Progress toward center of patch overlapping each preceding track by at least 1/2 width of roller.

3. Make sufficient passes over entire area to remove roller marks and to produce desired finished surface.

D. Tolerances:

1. Finished surface shall be flush with and match grade, slope, and crown of adjacent surface.

2. Tolerance: Surface smoothness shall not deviate more than plus 6 millimeters (1/4 inch) or minus 0 millimeter when straightedge is laid across patched area between edges of new pavement and surface of old surfacing.


A. General: Provide services of approved certified independent testing laboratory to conduct tests.

B. Field Density Tests: Cores or cut Samples shall be tested to determine bulk specific gravity in accordance with California Test 308, Method A. Asphalt concrete pavement will be accepted for compaction when the in-place density is greater than or equal to 95 percent of the LTMD.

C. Testing Frequency:

1. Quality Control Tests: a. Asphalt Content, Aggregate Gradation: Once per every 400 mg

(500 tons) of mix or once every 4 hours, whichever is greater. b. Mix Design Properties, Measured Maximum (Rice’s) Specific

Gravity: Once every 900 mg (1,000 tons) or once every 8 hours, whichever is greater.

2. Density Tests: Once every 450 mg (500 tons) of mix or once every 4 hours, whichever is greater.

END OF SECTION


PW/WBG/179201 CURBS AND GUTTERS OCTOBER 2018 32 16 00 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 32 16 00 CURBS AND GUTTERS

PART 1 GENERAL

1.01 SUBMITTALS


1. Form Material: Information on metal forms, if used, including type, condition, surface finish, and intended function.

2. Complete data on concrete mix, including aggregate gradations and admixtures in accordance with requirements of ASTM C94.


1. Curing Compound: Manufacturer’s Certificate of Compliance and application instructions.

2. Ready-mix delivery ticket for each truck in accordance with ASTM C94.

PART 2 PRODUCTS

2.01 EXPANSION JOINT FILLER

A. Preformed asphalt-impregnated, expansion joint material meeting ASTM D994, 1/4-inch thick.

2.02 CONCRETE

A. As specified in Section 03 30 00, Cast-in-Place Concrete.

B. Maximum Aggregate Size: 3/4 inch.

C. Slump: 2 inches to 4 inches.

2.03 CURING COMPOUND

A. Liquid membrane forming, clear or translucent, suitable for spray application and meeting ASTM C309, Type 1.


CURBS AND GUTTERS PW/WBG/179201 32 16 00 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

PART 3 EXECUTION

3.01 FORMWORK

A. Lumber Materials:

1. 2-inch dressed dimension lumber, or metal of equal strength, straight, free from defects that would impair appearance or structural quality of completed curb and gutter.

2. 1-inch dressed lumber or plywood may be used where short-radius forms are required.

B. Metals: Steel in new undamaged condition.

C. Setting Forms:

1. Construct forms to shape, lines, grades, and dimensions. 2. Stake securely in place.

D. Bracing:

1. Brace forms to prevent change of shape or movement resulting from placement.

2. Construct short-radius curved forms to exact radius.

E. Tolerances:

1. Do not vary tops of forms from gradeline more than 1/8 inch when checked with 10-foot straightedge.

2. Do not vary alignment of straight sections more than 1/8 inch in 10 feet.

3.02 PLACING CONCRETE

A. Prior to placing concrete, remove water from excavation and debris and foreign material from forms.

B. Place concrete as soon as possible, and within 1-1/2 hours after adding cement to mix without segregation or loss of ingredients, and without splashing.

C. Place, process, finish, and cure concrete in accordance with applicable requirements of ACI 304, and this section. Wherever requirements differ, the more stringent shall govern.

D. To compact, vibrate until concrete becomes uniformly plastic.


PW/WBG/179201 CURBS AND GUTTERS OCTOBER 2018 32 16 00 - 3 ©COPYRIGHT 2018 CH2M HILL

3.03 CURB CONSTRUCTION

A. Construct ramps at pedestrian crossings.

B. Expansion Joints: Place at maximum 200-foot intervals, at the beginning and end of curved portions of curb, each side of structures, and at connections to existing curbs. Install expansion joint filler at each joint.

C. Curb Facing: Do not allow horizontal joints within 7 inches from top of curb.

D. Contraction Joints:

1. Maximum 15-foot intervals in curb. 2. Provide open joint type by inserting thin, oiled steel sheet vertically in

fresh concrete to force coarse aggregate away from joint. 3. Insert steel sheet to full depth of curb. 4. Remove steel sheet with sawing motion after initial set has occurred in

concrete and prior to removing front curb form. 5. Finish top of curb with steel trowel and finish edges with steel edging

tool.

E. Front Face:

1. Remove front form and finish exposed surfaces when concrete has set sufficiently to support its own weight.

2. Finish formed face by rubbing with burlap sack or similar device to produce uniformly textured surface, free of form marks, honeycomb, and other defects.

3. Remove and replace defective concrete. 4. Apply curing compound to exposed surfaces of curb upon completion of

finishing. 5. Continue curing for minimum of 5 days.

F. Backfill curb with earth upon completion of curing period, but not before 7 days has elapsed since placing concrete.

1. Backfill shall be free from rocks 2 inches and larger and other foreign material.

2. Compact backfill firmly.

END OF SECTION


PW/WBG/179201 PAVEMENT MARKINGS OCTOBER 2018 32 17 23 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 32 17 23 PAVEMENT MARKINGS

PART 1 GENERAL

1.01 DEFINITIONS

A. Standard Specifications: 2015 California Department of Transportation Standard Specifications.

1.02 SUBMITTALS


1. Shop Drawings: a. Product Data:

1) Paint. 2) Thermoplastic material. 3) Reflective markers. 4) Epoxies, resins, and primers to be used.

b. Glass Beads: Proposed gradation.


1. Description of proposed methods for removal of drips, overspray, improper markings, paint and thermoplastic material tracked by traffic, and existing markings.

2. Manufacturer’s Certificate of Compliance for products specified in this section.

3. Equipment List: Proposed equipment to be used, including descriptive data.

4. Manufacturer’s Instructions: a. Application of preformed tape. b. Application of portland cement concrete primer. c. Application of glass beads. d. Application of epoxy resin. e. Installation of reflective markers.


PAVEMENT MARKINGS PW/WBG/179201 32 17 23 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

PART 2 PRODUCTS

2.01 GENERAL

A. All products shall be in accordance with Section 84 of the Standard Specifications.

2.02 PAINT

A. Color: As shown on Drawings.

B. Traffic paint in accordance with Section 84-2.03C(3) of the Standard Specifications.

C. Homogeneous, easily stirred to smooth consistency, with no hard settlement or other objectionable characteristics during storage period of 6 months.

2.03 THERMOPLASTIC MARKING

A. Color: As shown on Drawings.

B. Thermoplastic markings in accordance with Section 84-2.03C(2) of the Standard Specifications.

2.04 GLASS BEADS

A. In accordance with Section 84-2.02D of the Standard Specifications.

PART 3 EXECUTION

3.01 GENERAL

A. Surface Preparation, Application, and Protection: In accordance with Section 84-2.03 of the Standard Specifications.

3.02 SURFACE PREPARATION

A. Cleaning:

1. Thoroughly clean surfaces to be marked before application of pavement marking material.

2. Remove dust, dirt, and other granular surface deposits by sweeping, blowing with compressed air, rinsing with water or a combination of these methods.


PW/WBG/179201 PAVEMENT MARKINGS OCTOBER 2018 32 17 23 - 3 ©COPYRIGHT 2018 CH2M HILL

3. Completely remove rubber deposits, surface laitance, existing paint markings, and other coatings adhering to pavement with scrapers, wire brushes, sandblasting, approved chemicals, or mechanical abrasion.

4. Scrub areas of old pavement affected with oil or grease with several applications of trisodium phosphate solution or other approved detergent or degreaser, and rinse thoroughly after each application.

5. Surfaces shall be completely free of dirt and ice, and dry of water at the time of application of materials specified herein.

6. Oil-Soaked Areas: After cleaning, seal with cut shellac to prevent bleeding through the new paint.

7. Reclean surfaces when the Work has been stopped due to rain. 8. Existing Pavement Markings:

a. Remove existing pavement markings that may interfere or conflict with newly applied marking patterns, or that may result in a misleading or confusing traffic pattern.

b. Do not apply thermoplastic markings over existing preformed or thermoplastic markings.

c. Perform grinding, scraping, sandblasting or other operations so finished pavement surface is not damaged.

B. Pretreatment for Early Painting: Where painting is required prior to 30 days after paving rigid pavements, pretreat with an aqueous solution containing 3 percent phosphoric acid and 2 percent zinc chloride.

3.03 PAINT APPLICATION

A. General: Mix and apply paint as specified in Section 84-2.03C of the Standard Specifications.

B. Drying:

1. Provide maximum drying time to prevent undue softening of bitumen and pickup, displacement, or discoloration by traffic.

2. If drying is abnormally slow, discontinue painting operations until cause is determined and corrected.

C. Protection:

1. Protect markings from traffic until paint is thoroughly dry. 2. Protect surfaces from disfiguration by paint spatters, splashes, spills, or

drips.


PAVEMENT MARKINGS PW/WBG/179201 32 17 23 - 4 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

D. Cleanup: Remove paint spatters, splashes, spills, or drips from the Work and staging areas including areas outside the immediate Work area where spills occur.

3.04 THERMOPLASTIC MARKING APPLICATION

A. Apply thermoplastic markings as specified in Section 84-2.03C of the Standard Specifications.

B. Cool completed marking to ambient temperature prior to allowing vehicular traffic.

END OF SECTION


PW/WBG/179201 CHAIN LINK FENCES AND GATES OCTOBER 2018 32 31 13 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 32 31 13 CHAIN LINK FENCES AND GATES

PART 1 GENERAL

1.01 DEFINITIONS

A. Terms as defined in ASTM F552.

1.02 SUBMITTALS


1. Shop Drawings: a. Product Data: Include construction details, material descriptions,

dimensions of individual components, and finishes for chain link fences and gates. 1) Fence, gate posts, rails, and fittings. 2) Chain link fabric. 3) Gates and hardware. 4) Accessories: Barbed wire, privacy slats.

2. Samples: a. Privacy Slats Including Manufacturer’s Color Selections:

Approximately 6 inches long.


1. Manufacturer’s recommended installation instructions. 2. Evidence of Supplier and installer qualifications.


A. Design, supply of equipment and components, installation, and on-call service shall be product of individual company with record of installations meeting requirements specified.


A. Deliver materials to Site in undamaged condition. Store materials off the ground to provide protection against oxidation caused by ground contact.


CHAIN LINK FENCES AND GATES PW/WBG/179201 32 31 13 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL


A. Complete necessary Site preparation and grading before installing chain link fence and gates.

PART 2 PRODUCTS

2.01 GENERAL

A. Match style, finish, and color of each fence component with that of other fence components.

2.02 CHAIN LINK FENCE FABRIC

A. Galvanized fabric conforming to ASTM A392, Class 1, galvanized after weaving.

B. Height: 72 inches, unless otherwise shown.

C. Core Wire Gauge: No. 9.

D. Pattern: 2-inch diamond-mesh.

E. Diamond Count: Manufacturer’s standard and consistent for fabric furnished of same height.

F. Loops of Knuckled Selvages: Closed or nearly closed with space not exceeding diameter of wire.

G. Wires of Twisted Selvages:

1. Twisted in a closed helix three full turns. 2. Cut at an angle to provide sharp barbs that extend minimum 1/4 inch

beyond twist.

2.03 POSTS

A. General:

1. Strength and Stiffness Requirements: ASTM F1043, heavy industrial fence except as modified in this section.

2. Round Steel Pipe, Schedule 40: ASTM F1083. 3. Roll-Formed Steel Shapes: Roll-formed from ASTM A1011/A1011M,

Grade 45, High-Strength Low-Alloy steel.



4. Lengths: Manufacturer’s standard with allowance for minimum embedment below finished grade of 34 inches.

5. Protective Coatings: a. Zinc Coating: ASTM F1043, Type A external and internal

coating.

B. Line Posts:

1. Round Steel Pipe: a. Outside Diameter: 2.375 inches. b. Weight: 3.65 pounds per foot.

C. End, Corner, Angle, and Pull Posts:

1. Round Steel Pipe: a. Outside Diameter: 2.875 inches. b. Weight: 5.79.

D. Posts for Swing Gates:

1. ASTM F900. 2. Round Steel Pipe:

a. For Gate Leaf Width of 4 to 10 Feet: 1) Outside Diameter: 2.875 inches. 2) Weight: 4.64 pounds per foot.

b. For Gate Leaf Width of 12 to 18 Feet: 1) Outside Diameter: 4.00 inches. 2) Weight: 6.56 pounds per foot.

2.04 TOP AND BRACE RAILS

A. Galvanized Round Steel Pipe:

1. ASTM F1083. 2. Outside Diameter: 1.66 inches. 3. Weight: 2.27 pounds per foot.

B. Protective Coatings: As specified for posts.

C. Strength and Stiffness Requirements: ASTM F1043, top rail, heavy industrial fence.



2.05 FENCE FITTINGS

A. General: In conformance with ASTM F626, except as modified by this Article.

B. Post and Line Caps: Designed to accommodate passage of top rail through cap, where top rail required.

C. Tension and Brace Bands: No exceptions to ASTM F626.

D. Tension Bars:

1. One-piece. 2. Length not less than 2 inches shorter than full height of chain link

fabric. 3. Provide one bar for each gate and end post, and two for each corner and

pull post.

E. Truss Rod Assembly: 3/8-inch diameter, steel, hot-dip galvanized after threading rod and turnbuckle or other means of adjustment.

F. Tie Wires, Clips, and Fasteners: According to ASTM F626.

G. Barbed Wire Supporting Arms: Pressed steel or cast iron with clips, slots, or other means for attaching strands of barbed wire integral with post cap for each post, with single 45-degree arms for supporting three strands of barbed wire. Arms shall withstand 250 pounds of downward pull at outermost ends of the arms without failure.

2.06 TENSION WIRE

A. Zinc-coated steel marcelled tension wire conforming to ASTM A824 Type II, Class 2.

2.07 BARBED WIRE

A. Zinc-Coated Barbed Wire: ASTM A121, Chain Link Fence Grade:

1. Line Wire: Two strands of No. 12-1/2 gauge. 2. Barbs:

a. Number of Points: Four. b. Length: 3/8 inch minimum. c. Shape: Round.



d. Diameter: No. 14 gauge. e. Spacing: 5 inches.

2.08 GATES

A. General:

1. Gate Operation: Opened and closed easily by one person. 2. Metal Pipe and Tubing: Galvanized steel. Comply with ASTM F1043

and ASTM F1083 for materials and protective coatings. 3. Frames and Bracing: Fabricate members from round galvanized steel

tubing with outside dimension and weight according to ASTM F900. 4. Gate leaves more than 8-feet wide shall have intermediate tubular

members and diagonal truss rods to provide rigid construction, free from sag or twist.

5. Gate Fabric Height: Same as for adjacent fence height. 6. Welded Steel Joints: Paint with zinc-based paint. 7. Chain Link Fabric: Attached securely to gate frame at intervals not

exceeding 15 inches. 8. Gate Posts and Frame Members: Extend gateposts and frame end

members above top of chain-link fabric at both ends of gate frame to attach barbed wire assemblies.

9. Latches: Arranged for padlocking so padlock will be accessible from both sides of gate.

B. Swing Gates: Comply with ASTM F900 for single and double swing gate types.

1. Leaf Width: As shown. 2. Hinges: Offset type, malleable iron.

a. Furnished with large bearing surfaces for clamping in position. b. Designed to swing either 180 degrees outward, 180 degrees

inward, or 90 degrees in or out, as shown, and not twist or turn under action of gate.

3. Latches: Plunger bar arranged to engage stop, except single gates of openings less than 10 feet wide may each have forked latch.

4. Gate Stops: Mushroom type or flush plate with anchors, suitable for setting in concrete.

5. Locking Device and Padlock Eyes: Integral part of latch, requiring one padlock for locking both leaves of double gate.

6. Hold-Open Keepers: Designed to automatically engage gate leaf and hold it in open position until manually released.



2.09 PRIVACY SLATS

A. Material: PVC, UV-light stabilized, flame resistant, 4 ply, not less than 0.006-inch thick attached to not less than 0.0475-inch diameter, twisted galvanized wire; hedge-type lattice; sized to fit mesh specified for direction indicated.

B. Color: Dark green.

C. Fabric Selvage: Knuckled.

D. Furnish continuous galvanized top rail, manufacturer’s standard heavyweight galvanized line, corner, gate, and end posts, and accessories and fasteners.

E. Gates: Manufacturer’s standard for use with chain link, wood slat fence. Furnish galvanized hardware for complete gate installation.

F. Hardware: Galvanized.

2.10 CONCRETE

A. Provide as specified in Section 03 30 00, Cast-in-Place Concrete.

2.11 FENCE GROUNDING

A. Conductors: Bare, solid wire for No. 6 AWG and smaller; stranded wire for No. 4 AWG and larger.

1. Material above Finished Grade: Copper. 2. Material on or below Finished Grade: Copper. 3. Bonding Jumpers: Braided copper tape, 1-inch wide, woven of No. 30

AWG bare copper wire, terminated with copper ferrules.

B. Connectors and Grounding Rods: Comply with UL 467.

1. Connectors for Below-Grade Use: Exothermic welded type. 2. Grounding Rods: Copper-clad steel.

PART 3 EXECUTION

3.01 GENERAL

A. Install chain link fences and gates in accordance with ASTM F567, except as modified in this section, and in accordance with fence manufacturer’s



recommendations, as approved by Engineer. Erect fencing in straight lines between angle points.

B. Provide necessary hardware for a complete fence and gate installation.

C. Any damage to galvanized surfaces, including welding, shall be repaired with paint containing zinc dust in accordance with ASTM A780.

D. Drainage Crossings: Where the chain-link fence must cross drainage ditches or swales, the main fence shall be carried across a ditch or swale with additional fence added below.

1. Frames and Bracing: The fence added below shall be fabricated with galvanized round steel pipe conforming to the requirements for top and brace rails.

2. The construction of the frame shall be welded or assembled with corner fittings. The frame shall be rigid and to the extent necessary to maintain a 2-inch clearance between bottom of the frame and finish grade. If necessary to maintain rigidity, attach to the frame a series of 3/8-inch diameter galvanized steel pipe stakes that are embedded a minimum of 2 feet to the sides and bottom of the ditch.

3. Attach chain link fabric securely to frame at intervals not exceeding 12 inches.

3.02 PREPARATION

A. Clear area on either side of fence to the extent specified in Section 31 10 00, Site Clearing. Eliminate ground surface irregularities along fence line to the extent necessary to maintain a 2-inch clearance between bottom of fabric and finish grade.

B. Stake locations of fence lines, gates, and terminal posts. Do not exceed intervals of 500 feet or line of sight between stakes. Indicate locations of utilities, lawn sprinkler system, underground structures, benchmarks, and property monuments.

C. Embedment Coating: Coat portion of galvanized or aluminum-coated steel posts that will be embedded in concrete as specified in Section 09 90 00, Painting and Coating. Extend coating 1 inch above top of concrete.

3.03 POST SETTING

A. Drill or hand-excavate holes for posts to diameters and spacing indicated, in firm, undisturbed soil. Driven posts are not acceptable. Postholes shall be



clear of loose materials. Waste materials from postholes shall be removed from Site or regraded into slopes on Site.

B. Posthole Depth:

1. Minimum 3 feet below finished grade. 2. 2 inches deeper than post embedment depth below finish grade.

C. Set posts with minimum embedment below finished grade of 34 inches and with top rail at proper height above finished grade. Verify posts are set plumb, aligned, and at correct height and spacing. Brace posts, as necessary, to maintain correct position and plumbness until concrete sets.

D. Backfill postholes with concrete to 2 inches above finished grade. Vibrate or tamp concrete for consolidation. Protect above ground portion of posts from concrete splatter.

E. Before concrete sets, crown and finish top of concrete to readily shed water.

F. Terminal Posts: Locate terminal end, corner, and gate posts in accordance with ASTM F567 and terminal pull posts at changes in horizontal or vertical alignment of 15 degrees or more.

G. Line Posts: Space line posts uniformly at 10 feet on centers between terminal end, corner, and gate posts.

3.04 POST BRACING

A. Install according to ASTM F567, maintaining plumb position, and alignment of fencing. Install braces at gate, end, pull, and corner posts diagonally to adjacent line posts to ensure stability. Install braces on both sides of corner and pull posts.

1. Locate horizontal braces at mid-height of fabric or higher, on fences with top rail, and 2/3-fabric height on fences without top rail. Install so posts are plumb when diagonal truss rod assembly is under proper tension.

3.05 TOP RAILS

A. Install according to ASTM F567, maintaining plumb position and alignment of fencing. Run rail continuously through line post caps and terminating into rail end attached to posts or posts caps fabricated to receive rail at terminal posts. Install top rail sleeves with springs at 105 feet maximum spacing to permit expansion in rail.



3.06 BARBED WIRE SUPPORTING ARMS

A. Barbed wire supporting arms shall be installed as indicated and as recommended by manufacturer. Bolt or rivet supporting arm to top of post in a manner to prevent easy removal with hand tools. Angle single arms to outside of fence.

3.07 TENSION WIRE

A. Install according to ASTM F567 and ASTM F1916, maintaining plumb position and alignment of fencing. Pull wire taut, without sags. Fasten fabric to tension wire with tie wires at a maximum spacing of 24 inches on center.

B. Install tension wire within 6 inches of bottom of fabric and tie to each post with not less than same diameter and type of wire.

3.08 CHAIN LINK FABRIC

A. Do not install fabric until concrete has cured minimum 7 days.

B. Install fabric with twisted and barbed selvage at top.

C. Apply fabric to outside of enclosing framework. Pull fabric taut to provide a smooth and uniform appearance free from sag, without permanently distorting fabric diamond or reducing fabric height. Tie fabric to posts, rails, and tension wires. Anchor to framework so fabric remains under tension after pulling force is released.

D. Splicing shall be accomplished according to ASTM F1916 by weaving a single picket into the ends of the rolls to be joined.

E. Leave 2 inches between finish grade or surface and bottom selvage, unless otherwise indicated.

F. Tension or Stretcher Bars: Thread through fabric and secure to end, corner, pull, and gate posts with tension bands spaced not more than 15 inches on center.

G. Tie Wires: Fasten ties to wrap a full 360 degrees around rail or post and a minimum of one complete diamond of fabric. Twist ends of tie wire three full twists, and cut off protruding ends to preclude untwisting by hand.

1. Maximum Spacing: Tie fabric to line posts at 12 inches on center and to brace and top rails at 24 inches on center.



3.09 PRIVACY SLATS

A. Install slats in chain link fabric to limits shown on Drawings.

B. Slats shall be installed vertically into locking channel at bottom of chain link fabric as recommended by manufacturer.

3.10 BARBED WIRE

A. Install barbed wire uniformly in configurations of three strands of barbed wire on supporting arms. Pull wire taut and install securely to supporting arms and secure to end terminal post or terminal arms.

3.11 GATES

A. Install gates according to manufacturer’s written instructions, level, plumb and secure for full opening without interference. Attach fabric and hardware to gate using tamper-resistant or concealed means. Adjust hardware for smooth operation and lubricate where necessary so gates operate satisfactorily from open or closed position.

B. Set gate stops in concrete to engage center drop rod or plunger bar.

3.12 ELECTRICAL GROUNDING

A. Ground fences at a maximum interval of 1,000 feet in accordance with applicable requirements of IEEE C2, National Electrical Safety Code.

B. Protection at Crossings of Overhead Electrical Power Lines: Ground fence at location of crossing and at a maximum distance of 150 feet on each side of crossing.

C. Grounding Method: At each grounding location, drive a grounding rod vertically until top is 6 inches below finished grade. Connect rod to fence with No. 6 AWG conductor. Connect conductor to each fence component at grounding location.


A. Post and Fabric Testing: Test fabric tension and line post rigidity according to ASTM F1916.



B. Gate Tests:

1. Prior to acceptance of installed gates, demonstrate proper operation of gates under each possible open and close condition specified.

2. Adjust gate to operate smoothly, easily, and quietly, free of binding, warp, excessive deflection, distortion, nonalignment, misplacement, disruption, or malfunction, throughout entire operational range.

3. Confirm that latches and locks engage accurately and securely without forcing and binding.

3.14 CLEANUP

A. Remove excess fencing materials and other debris from Site.

END OF SECTION


PW/WBG/179201 SOIL PREPARATION OCTOBER 2018 32 91 13 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 32 91 13 SOIL PREPARATION

PART 1 GENERAL

1.01 SUBMITTALS


1. Samples: Representative of stockpiled or imported topsoil. 2. Non-toxic tackifier.


1. Certified Topsoil Analysis Reports: a. Indicate quantities of materials necessary to bring topsoil into

compliance with textural/gradation requirements. b. Indicate quantity of lime, quantity and analysis of fertilizer, and

quantity and type of soil additive.


A. Perform Work specified in Section 31 10 00, Site Clearing, prior to performing Work specified under this section.

PART 2 PRODUCTS

2.01 TOPSOIL

A. General: Natural, friable, sandy loam, obtained from well-drained areas, free from objects larger than 1-1/2 inches maximum dimension, and free of subsoil, roots, grass, other foreign matter, hazardous or toxic substances, and deleterious material that may be harmful to plant growth or may hinder grading, planting, or maintenance.

B. Composition: In general accordance with ASTM D5268:

1. Gravel-Sized Fraction: Maximum 2 percent by weight retained on a No. 10 sieve.

2. Sand-Sized Fraction: Minimum 20 to 60 percent passing No. 10 sieve. 3. Silt and Clay-Sized Fraction: Minimum 35 to 70 percent.

C. Organic Matter: Minimum 1.5 percent by dry weight as determined in accordance with ASTM D2974.


SOIL PREPARATION PW/WBG/179201 32 91 13 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

D. pH: Range 5.0 to 7.0.

E. Textural Amendments: Amend as necessary to conform to required composition by incorporating sand, peat, manure, or sawdust.

F. Source: Import topsoil if onsite material is insufficient in quantity.

2.02 LIME

A. Composition: Ground limestone with not less than 85 percent total carbonates, ASTM C602.

B. Gradation:

1. Minimum 50 percent passing No. 100 sieve. 2. Minimum 90 percent passing No. 20 sieve. 3. Coarser material acceptable provided rates of application are increased

proportionately on basis of quantities passing No. 100 sieve.

2.03 SOIL ADDITIVES

A. Sawdust or Ground Bark:

1. Nontoxic, of uniform texture, and subject to slow decomposition when mixed with soil.

2. Nitrogen-treated, or if untreated mix with minimum 0.15 pound of ammonium nitrate or 0.25 pound of ammonium sulfate per cubic foot of loose material.

B. Peat:

1. Composition: Natural residue formed by decomposition of reeds, sedges, or mosses in a freshwater environment, free from lumps, roots, and stones. a. Organic Matter: Not less than 90 percent on a dry weight basis as

determined by ASTM D2974. b. Moisture Content: Maximum 65 percent by weight at time of

delivery.

C. Fertilizer:

1. Natural: a. Manure:

1) Well-rotted, stable or cattle manure, free from weed seed and refuse.


PW/WBG/179201 SOIL PREPARATION OCTOBER 2018 32 91 13 - 3 ©COPYRIGHT 2018 CH2M HILL

2) Maximum 50 percent sawdust or shavings by volume. 3) Age: Minimum 4 months; maximum 2 years.

2. Commercial: a. Commercial, uniform in composition, free-flowing, suitable for

application with equipment designed for that purpose. b. Contain the following minimum percentage of plant food by

weight: 1) Summer Mix:

a) Nitrogen: 20 percent. b) Phosphoric Acid: 10 percent. c) Potash: 10 percent.

2) Winter Mix: a) Nitrogen: 16 percent. b) Phosphoric Acid: 8 percent. c) Potash: 0 percent.

D. Sand: Fine Aggregate: Clean, coarse, well-graded, ASTM C33/C33M.


A. Topsoil Analysis/Testing: Performed by county or state soil testing service or approved certified independent testing laboratory.

PART 3 EXECUTION

3.01 SUBGRADE PREPARATION

A. Scarify subgrade to minimum depth of 6 inches where topsoil is to be placed.

B. Remove stones over 2-1/2 inches in any dimension, sticks, roots, rubbish, and other extraneous material.

C. Limit preparation to areas which will receive topsoil within 5 days after preparation.

3.02 TOPSOIL STOCKPILING

A. Topsoil shall be stockpiled on the same parcel from which it was excavated.

B. Contractor shall prevent loss of topsoil from wind erosion and shall apply a non-toxic tackifier as required. Topsoil to be stockpiled for more than one month shall be sprayed with a non-toxic tackifier.


SOIL PREPARATION PW/WBG/179201 32 91 13 - 4 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

3.03 TOPSOIL PLACEMENT

A. Do not place topsoil when subsoil or topsoil is frozen, excessively wet, or otherwise detrimental to the Work.

B. Topsoil shall be placed in the same parcel from which it was excavated.

C. Mix soil amendments, lime, and other soil additives, identified in analysis reports with topsoil before placement or spread on topsoil surface and mix thoroughly into entire depth of topsoil before planting or seeding. Delay mixing of fertilizer if planting or seeding will not occur within 3 days.

D. Place one-half of the total depth of topsoil and work into top 4 inches of subgrade soil to create a transition layer. Place remainder of topsoil to depth as shown or 6 inches where not shown where seeding and planting are scheduled.

E. Uniformly distribute to within 1/2 inch of final grades. Fine grade topsoil eliminating rough or low areas and maintaining levels, profiles, and contours of subgrade.

F. Remove stones exceeding 1-1/2-inch diameter, roots, sticks, debris, and foreign matter during and after topsoil placement.

G. Remove surplus subsoil and topsoil from Site. Grade stockpile area as necessary and place in condition acceptable for planting or seeding.

END OF SECTION


PW/WBG/179201 HYDROSEEDING OCTOBER 2018 32 92 00 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 32 92 00 HYDROSEEDING

PART 1 GENERAL

1.01 SUBMITTALS

A. Action Submittals: Product labels/data sheets.


1. Seed: Certification of seed analysis, germination rate, and inoculation: a. Certify that each lot of seed has been tested by a testing laboratory

certified in seed testing, within 6 months of date of delivery. Include with certification: 1) Name and address of laboratory. 2) Date of test. 3) Lot number for each seed specified. 4) Test Results: (i) name, (ii) percentages of purity and of

germination, and (iii) weed content for each kind of seed furnished.

b. Mixtures: Proportions of each kind of seed.

1.02 DELIVERY, STORAGE, AND PROTECTION

A. Seed:

1. Furnish in standard containers with seed name, lot number, net weight, percentages of purity, germination, and hard seed and maximum weed seed content, clearly marked for each container of seed.

2. Keep dry during storage.

B. Hydroseeding Mulch: Mark package of wood fiber mulch to show air dry weight.

1.03 WEATHER RESTRICTIONS

A. Hydroseeding shall be performed during a windless period. Soil shall not be worked when excessively dry or wet, and the Engineer reserves the right to stop any work taking place during a period when conditions are considered detrimental to soil structure or plant growth.


HYDROSEEDING PW/WBG/179201 32 92 00 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL


A. Complete Work specified in Section 32 93 00, Plants, and prepare topsoil as specified in Section 32 91 13, Soil Preparation, before starting Work of this section.

B. Complete Work under this section within 14 days following completion of soil preparation.

C. Notify Engineer at least 2 days in advance of:

1. Each material delivery. 2. Start of planting activity.

1.05 MAINTENANCE SERVICE

A. Contractor: Perform maintenance operations during maintenance period to include:

1. Reseed unsatisfactory areas or portions thereof immediately at the end of the maintenance period if a satisfactory stand has not been produced.

PART 2 PRODUCTS

2.01 FERTILIZER

A. Commercial, uniform in composition, free-flowing, suitable for application with equipment designed for that purpose. Minimum percentage of plant food by weight.

B. Mix:

1. N: 6 percent. 2. P: 24 percent. 3. K: 24 percent.

2.02 NATIVE SEED

A. Seed shall be premixed and packaged by a commercial seed supplier.

B. The seed shall be tagged and labeled in accordance with California Agricultural Code.



C. Supplier:

1. Pacific Coast Seed, Inc. 533 Hawthorne Place, Livermore, CA 94550, (925) 373-4417 (contact David Gilpin).

2. Or equal.

D. Native Seed Mix:

Lbs/Acre Species/Common Name

12 Bromus carinatus/California Brome

10 Elymus glaucus “Valley Blue Wildrye”

6 Hordeum brachyantherum/Meadow Barley

6 Elymus trachycaulus, Native Slender Wheatgrass

6 Lupinus succulentus, Arroyo Lupine

.5 Lasthenia californica, Dwarf Goldfields

1.5 Eschschoizia californica, Ca Poppy

2.03 HYDROSEEDING MULCH

A. Wood Cellulose Fiber Mulch:

1. Specially processed wood fiber containing no growth or germination inhibiting factors.

2. Dyed a suitable color to facilitate inspection of material placement. 3. Manufactured such that after addition and agitation in slurry tanks with

water, the material fibers will become uniformly suspended to form homogenous slurry.

4. When hydraulically sprayed on ground, material will allow absorption and percolation of moisture.

PART 3 EXECUTION

3.01 PREPARATION

A. Grade areas to smooth, even surface with loose, uniformly fine texture.

1. Roll and rake, remove ridges, fill depressions to meet finish grades. 2. Limit such Work to areas to be planted within immediate future. 3. Remove debris, and stones larger than 1-1/2-inch diameter, and other

objects that may interfere with planting and maintenance operations.


HYDROSEEDING PW/WBG/179201 32 92 00 - 4 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

B. Moisten prepared areas before planting if soil is dry. Water thoroughly and allow surface to dry off before seeding. Do not create muddy soil.

C. Restore prepared areas to specified condition if eroded or otherwise disturbed after preparation and before planting.

3.02 EQUIPMENT

A. Hydroseeding equipment shall have a built-in agitation system and operating capacity sufficient to agitate, suspend and homogeneously mix a slurry of water, fertilizer, fiber, seed and other additives.

B. Slurry distribution lines: Shall be large enough to prevent clogging and shall be equipped with a set of hydraulic spray nozzles which provide a continuous nonfluctuating discharge and uniform delivery of slurry in prescribed quantities without misses, waste or erosion.

C. Slurry tank: Shall have a minimum capacity of 1,000 gallons and shall be mounted on a traveling unit which may be drawn by a separate or self-propelled unit in order to properly place the slurry tank and spray nozzle for uniform distribution.

3.03 SLURRY PREPARATION

A. All preparation shall occur on site and materials shall be added in such a manner that they are uniformly blended into the mixture. Slurry shall be completely homogenous before application.

B. Agitation: With agitation system operating at half speed, water shall be added to the tank, and good circulation established. The mixture shall be agitated at 3/4 speed when the tank is half full.

C. Additives: Hydroseeding mulch shall not be added until the tank is at least one-third filled with water. Fertilizer and seed mix shall be added at the last practical moment. Total time from the addition of seed to seed discharge shall be less than four hours; if more than four hours, the remainder of the load shall be promptly discarded and removed from the site.

3.04 APPLICATION

A. The operator shall spray the areas with a uniform, visible coat using the green color of the wood pulp as a guide. The slurry shall be applied in a sweeping motion, so as to allow the fibers to build on each other until a good coat is achieved and the material is spread at the required rate per acre and covers the



Site completely. The finished treatment shall not have any observable “shadowing”.

3.05 APPLICATION RATES

A. The materials shall be mixed and applied in the approximate proportions:

Materials Per Acre

Hydroseeding Mulch 3,500 pounds

Seed Mix See Article Native Seed

Water As needed for application

3.06 CLEANUP

A. Prior to completion of all operations, Contractor shall remove, wash clean, or otherwise correct any unsightly overspray, trash, excess soil, other debris, or damage. All pavement shall be swept and washed clean, and cleanup operations performed in the general work area as needed to leave the entire area in neat, orderly condition.


A. After seeding is complete and on written notice from Contractor, Engineer will, within 15 days of receipt, determine if a satisfactory stand has been established.

B. If a satisfactory stand has not been established, Engineer will make another determination after written notice from Contractor following the next growing season.

END OF SECTION


PW/WBG/179201 PLANTS OCTOBER 2018 32 93 00 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 32 93 00 PLANTS

PART 1 GENERAL

1.01 DEFINITIONS

A. Measurement:

1. In size grading Balled and Burlapped (B & B), caliper takes precedence over height.

2. Take trunk caliper 6 inches above the ground level (up to and including 4-inch caliper size) and 12 inches above the ground level for larger trees.

3. Measure size of container-grown stock by height and width of plant. 4. Measure herbaceous perennials pot size, not top growth.

1.02 SUBMITTALS


1. Plant materials source list. 2. Product data on manufactured products specified.


1. Soil percolation test results. 2. Operation and Maintenance Data:

a. As specified in Section 01 78 23, Operation and Maintenance Data.

b. Instructions for storage, planting, care, and maintenance of each type of plant for 1-year period in climate and location of the Project.

3. Special guarantee.


A. Cover plants during shipment with a tarpaulin or other suitable covering to minimize drying.

B. Balled and Burlapped Plants: Wrap each ball firmly with burlap and securely bind with twine, cord, or wire for shipment and handling. Drum-lace balls with a diameter of 30 inches or more.


PLANTS PW/WBG/179201 32 93 00 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

C. As specified herein for transplanting.

1.04 SPECIAL GUARANTEE

A. Provide extended guarantee or warranty, with Owner named as beneficiary, in writing, as special guarantee. Special guarantee shall provide for removal and replacement with new plants those transplanted or newly planted plants found defective or to be dead or not in a vigorous, thriving condition during a period of 1 year after the date of Substantial Completion. Duties and obligations for correction or removal and replacement of defective Work as specified in Section 11 of the General Provisions.

B. Replace defective plants with new plants free of dead or dying branches and branch tips, and bearing foliage of a normal density, size, and color. Closely match new plants to adjacent specimens of the same species and meet requirements of this Specification.

C. Plant replacement plants that die during a season unfavorable for planting during first month of next favorable planting season.

D. Plants damaged or lost due to Project (or any part thereof) occupancy, vandalism, or acts of neglect by others are not subject to this special guarantee.

1.05 MAINTENANCE

A. Commence to maintain plant life immediately after planting and maintain until final acceptance of the Work, but in no case, less than 60 days after Substantial Completion of planting.

B. In accordance with accepted Submittal on care and maintenance of plants and as follows:

1. Maintain by watering, pruning, cultivating, and weeding as required for healthy growth. Restore planting saucers.

2. Tighten and repair stake and guy supports and reset trees and shrubs to proper grades or vertical position as required.

3. Restore or replace damaged wrappings. Spray as required to keep trees and shrubs free of insects and disease.

4. Remove guys, stakes, and other supports at end of maintenance service. 5. Maintenance includes temporary protection fences, barriers, and signs

as required for protection. 6. Coordinate watering to provide deep root watering to newly installed

trees.




A. Plant Deliveries: Notify Engineer at least 1 week in advance of each delivery.

B. Planting Season: Conduct planting during times of year that are normal for such work as determined by accepted local practice.

C. Plant trees and shrubs after final grades are established and before planting of lawns or grasses.

PART 2 PRODUCTS

2.01 PLANT MATERIALS

A. Provide quantity, size, genus, species, and variety of trees and shrubs indicated; comply with applicable requirements of AAN Z60.1.

B. Nomenclature (Names of Plants): In accordance with “Hortus Third”.

C. Quality and Size:

1. Nursery-grown, habit of growth normal for species. 2. Sound, healthy, vigorous, and free from insects, diseases, and injuries. 3. Equal to or exceeding measurements specified in plant list. Measure

plants before pruning with branches in normal position. 4. Root System of Container-Grown Plants: Well developed and well

distributed throughout the container, such that the roots visibly extend to the inside face of the growing container.

5. Perform necessary pruning at time of planting. 6. Sizes: Dimensional relationship requirements of AAN Z60.1 for kind

and type of plants required. 7. Balled and Burlapped Plants: Firm, intact ball of earth encompassing

enough of the fibrous and feeding root system to enable full plant recovery. a. Ball Size: AAN Z60.1.

8. Container-Grown Plants: Self-established root systems, sufficient to hold earth together after removal from container, without being root bound. a. Stock: Grown in delivery containers for at least 6 months but not

over 2 years. 9. Label each tree and shrub of each variety with securely attached

waterproof tag bearing legible designation of botanical and common name.



D. Plant List: On Drawings.

E. Replacement Shrubs and Trees: Same species, size, and quality as specified for plant being replaced, except existing trees larger than 4-inch caliper may be replaced with 4-inch caliper trees.

2.02 ANTIDESICCANT

A. Provide transpiration retarding material to be used where any plant material is moved during the growing season.

B. Products:

1. Foliguard. 2. Wiltpruf. 3. Or equal.

2.03 GUYING, STAKING, AND WRAPPING MATERIALS

A. Wood Stake: 2 inches by 2 inches by 8 feet.

B. Tree Ties: No. 4 chainlock tree ties as manufactured by Green Brothers, Ltd., or equal.

C. Guy Wires: Galvanized, 12-gauge, ductile steel.

D. Hose: Two-ply, reinforced rubber garden hose, not less than 1/2-inch diameter, new or used.

E. Turnbuckles: Zinc-coated, with 6-1/2 inch lengthwise opening, and at each end 3/8-inch diameter threaded openings fitted with screw eyes.

F. Wrapping Material: Heavy crepe paper.

1. Burlap: Of first quality, minimum 8 ounces in weight, not less than 6 inches nor more than 10 inches in width.

G. Deadmen: 6 inches by 6 inches by 3 feet long pressure treated timbers.

PART 3 EXECUTION

3.01 TRANSPLANTING

A. Remove existing plantings identified for transplant prior to beginning Work in area in accordance with standard nursery practices and as specified herein.



B. Nondormant Plants: Prior to digging, spray foliage with antidesiccant, as recommended by manufacturer.

C. Cover balls and containers of plants that cannot be planted immediately with moist soil or mulch.

D. Water plants as often as necessary to prevent drying until planted.

E. Do not remove container-grown stock from containers before time of planting.

F. Bare-Root Plants:

1. Dig up with least possible injury to fibrous root system. 2. Immediately upon removal from ground, cover roots with thick coating

of mud or wrap in wet straw, moss, or other suitable packing material for protection from drying until planted.

3. Plant or heel-in immediately upon relocation to temporary storage. Open and separate bundles of bare-root plants, and eliminate air pockets among roots as they are covered.

G. Replant each temporarily removed tree, shrub, or other plant only after construction activities are completed and applicable grading and topsoil replacement is completed in its vicinity. Replant trees, shrubs, and other plants in their original positions, unless otherwise shown or approved. Plant as specified for new plants.

H. Maintain transplanted materials in same manner as new trees and shrubs.

3.02 LOCATION OF PLANTS

A. Locate new planting or stake positions as shown, unless obstructions are encountered, in which case notify Engineer.

B. Locate no planting, except ground cover, closer than 18 inches to pavements, pedestrian pathways, and structures.

C. Request Engineer observe locations and adjust as necessary before planting begins.

3.03 PREPARATION

A. Planting Soil: Delay mixing of amendments and fertilizer if planting will not follow preparation of planting soil within 2 days. For pit and trench type backfill, mix planting soil prior to backfilling and stockpile at Site.



B. Plants: Place on undisturbed existing soil or well-compacted backfill.

C. Trees and Shrubs:

1. Pits, Beds, and Trenches: Excavate with vertical and scarified sides. 2. B & B Trees and Shrubs: Make excavations at least twice as wide as

root ball. 3. Container-Grown Stock: Excavate as specified for B & B stock, adjust

for size of container width and depth. 4. Bare-Root Trees: Excavate pits to a width to just accommodate roots

fully extended and depth to allow uppermost roots to be below original grade.

5. Fill excavations with water and allow to percolate out prior to planting.

D. Ground Cover Beds:

1. Mix amendments and fertilizer with top soil prior to placing or apply on surface of top soil and mix thoroughly before planting.

2. Scarify top soil to a depth of 4 to 6 inches. 3. Establish finish grading of soil. Rake areas to smooth and create

uniform texture and fill depressions. 4. Moisten.

3.04 PLANTING

A. Plant trees before planting surrounding smaller shrubs and ground covers. Adjust plants with most desirable side facing toward the prominent view (sidewalk, building, street).

B. B & B Plants: Place in pit by lifting and carrying by its ball (do not lift by branches or trunk). Lower into pit. Set straight and in pit center with tip of rootball 1 to 2 inches above adjacent finish grade.

C. Bare-Root Plants: Spread roots and set stock on cushion of planting soil mixture. Set straight in the pit center so that roots, when fully extended, will not touch walls of the planting pit and the uppermost root is just below finish grade. Cover roots of bare-root plants to the crown.

D. Container-Grown Plants: Remove containers, slash edges of rootballs from top to bottom at least 1-inch deep. Plant as for B & B plants.

E. Ground Covers: Dig planting holes through mulch with one of the following: hand trowel, shovel, bulb planter, or hoe. Split biodegradable pots or remove nonbiodegradable pots. Root systems of all potted plants shall be split or



crumbled. Plant so roots are surrounded by soil below the mulch. Set potted plants so pot top is even with existing grade.

3.05 BACKFILLING

A. Backfill with planting soil, except where existing soil is suitable according to top soil analysis.

B. B & B Plants:

1. Partially backfill pit to support plant. Remove burlap and binding from sides and tops of B & B plants, do not pull burlap from under balls.

2. When excavation is approximately 2/3 full, water thoroughly before placing remainder of backfill to eliminate air pockets even if it is raining. Finish backfilling pit sides.

3. Never cover top of rootball with soil. Form a saucer above existing grade, completely around the outer rim of the plant pit.

C. Bare-Root Plants:

1. Plumb before backfilling and maintain plumb while working backfill around roots and placing layers above roots.

2. Set original soil line of plant 1 inch to 2 inches above adjacent finish landscape grades. Spread out roots without tangling or turning up to surface. Cut injured roots cleanly; do not break.

3. Carefully work backfill around roots by hand; puddle with water until backfill layers are completely saturated.

3.06 GUYING, STAKING, AND WRAPPING

A. Support trees immediately after planting to maintain plumb position.

B. Guying: Support deciduous trees over 4 inches in caliper and all coniferous trees with three guys equally.

C. Staking: Support deciduous trees 4 inches in caliper or less with stakes spaced equally about each tree.

D. Wrapping: Spirally wrap trunks of deciduous trees from ground line to height of second branches, promptly after planting. Wrap neatly and snug. Hold material in place with raffia cord at top and bottom.



3.07 FERTILIZER

A. Add as top dressing depending on plant size, local customary practice, and manufacturer’s recommendation.

3.08 PRUNING AND REPAIR

A. Prune only after planting and in accordance with standard horticultural practice to preserve natural character of the plant. Perform in presence of Engineer. Remove all dead wood, suckers, and broken or badly bruised branches. Use only clean, sharp tools. Do not cut lead shoot.

3.09 WEED CONTROL

A. Maintain a weed-free condition within planting areas.

3.10 PROTECTION OF INSTALLED WORK

A. Protect planting areas and plants against damage for duration of maintenance period.

3.11 SUPPLEMENT

A. The supplement listed below, following “End of Section,” is a part of this Specification:

1. Schedule: Plant Listing.

END OF SECTION


PW/WBG/179201 PLANTS OCTOBER 2018 32 93 00 SUPPLEMENT- 1 ©COPYRIGHT 2018 CH2M HILL

Plant Listing

Quantity Size Genus Species Variety

150 Saplings Quercus Lobata Valley Oak

24 Saplings Fraxinus Latifolia Oregon Ash

250 Seedlings Rosa Californica CA Wild Rose

250 Seedlings Rubus Allegheniensis Allegheny Blackberry

10 Saplings Juglans Californica CA Black Walnut


PW/WBG/179201 CONVEYANCE PIPING—GENERAL OCTOBER 2018 33 05 01 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 33 05 01 CONVEYANCE PIPING—GENERAL

PART 1 GENERAL

1.01 SUBMITTALS


1. Detailed pipe fabrication drawings showing pipe details, special fittings and bends, dimensions, coatings, and other pertinent information.

2. Layout drawing showing location of each pipe section and each special length.

3. Pipe pressure class.


A. In accordance with manufacturer’s recommendations and as specified in individual Specification(s) following this section.

B. Marking at Plant: Mark each pipe and fitting at plant. Include date of manufacture, manufacturer’s identification, specification standard, diameter of pipe, dimension ratio, pipe class, pipe number for laying purposes, and other information required for type of pipe.

C. Pipe, specials, and fittings received at Project Site in damaged condition will not be accepted.

D. Gasket Storage: Store rubber gaskets in cool, well ventilated place, and do not expose to direct rays of sun. Do not allow contact with oils, fuels, petroleum, or solvents.

E. Store and support pipe securely to prevent accidental rolling and to avoid contact with mud, water, or other deleterious materials.

F. Handling:

1. Pipe shall be handled with proper equipment in a manner to prevent distortion or damage. Use of hooks, chains, wire ropes, or clamps that could damage pipe, damage coating or lining, or kink and bend pipe ends is not permitted.

2. Use heavy canvas, or nylon slings of suitable strength for lifting and supporting materials.


CONVEYANCE PIPING—GENERAL PW/WBG/179201 33 05 01 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

3. Lifting pipe during unloading or lifting into trench shall be done using two slings placed at quarter point of pipe section. Pipe may be lifted using one sling near center of pipe, provided pipe is guided to prevent uncontrolled swinging and no damage will result to pipe or harm to workers. Slings shall bear uniformly against pipe.

4. Pipe and fittings shall not be stored on rocks or gravel, or other hard material that might damage pipe. This includes storage area and along pipe trench.

G. Pipe shall not be stored on a given permanent easement of temporary construction easement for longer than 90 calendar days.

PART 2 PRODUCTS

2.01 PIPE

A. As specified in the individual Specification(s) following this section.

2.02 JOINTS

A. As specified in the individual Specification(s) following this section.

2.03 COUPLINGS

A. General:

1. Couplings shall be rated for appropriate operating pressure and hydrostatic test pressure.

2. Exposed, bolted, sleeve-type couplings shall be lined and coated with fusion bonded epoxy in accordance with AWWA C213.

3. Buried, bolted, sleeve-type couplings shall be lined and coated with fusion-bonded epoxy in accordance with AWWA C213.

B. For Pipe with Plain-Ends:

1. Bolted, sleeve-type coupling, in accordance with AWWA C219. a. Manufacturer of couplings shall observe same quality control

requirements as specified in AWWA C221 for fabrication of pipe expansion joints.

b. Unless thrust restraint is provided by other means, bolted, sleeve-type couplings shall be harnessed. Harness details shall be in accordance with requirements of appropriate reference standard or as shown on Drawings.

c. Certified Welding Inspector at coupling fabrication facility shall verify welders and welding procedures are qualified, procedures



are being followed, and quality assurance functions are being implemented.

d. Pipe Type to be Joined: As shown on the Drawings. e. Standard to Which Pipe is Manufactured: As specified in the

individual Specification(s) following this section. f. Pipe Ends Tolerance: Conform to Table 4 of AWWA C219. g. Pipe Outside Diameter, Including Coating: As shown on the

Drawings. h. Rated Working Pressure: To match pipe or greater. i. Test Pressure: To match pipe or greater. j. Operating Temperature Range: 65 degrees F to 80 degrees F. k. Inner Sleeve:

1) Length: In accordance with AWWA C219. 2) Thickness: In accordance with AWWA C219.

l. Additional Nondestructive Weld Evaluation: Dye penetrant test for all welds.

C. For Pipe with Flanged Ends:

1. Flanged coupling adapters, in accordance with AWWA C219. a. Pipe Type to be Joined: As shown on the Drawings. b. Standard to Which Pipe is Manufactured: Conforms to Table 4 of

AWWA C219. c. Pipe Ends Tolerance: Conform to Table 4 of AWWA C219. d. Rated Working Pressure: 100 psi minimum. e. Operating Temperature Range: 65 degrees F to 80 degrees F. f. Nondestructive Examination Requirements: Dye penetrant test for

all welds. 2. Dismantling joints for connecting flanged pipe shall be AWWA C219

compliant. Provide studs and nuts to seal gasket separate and independent from tie-bar restraint system.

D. Bolting Materials for Couplings: In accordance with the applicable AWWA standard.

2.04 SERVICE SADDLES

A. Double strap design rated for 150 psi minimum working pressure.

2.05 SLAB, FLOOR, WALL, AND ROOF PENETRATIONS

A. Modular Mechanical Seal:

1. Type: Interconnected synthetic rubber links shaped and sized to continuously fill annular space between pipe and wall sleeve opening.



2. Assemble interconnected rubber links with Type 316 stainless steel bolts, nuts, and pressure plates.

3. Size modular mechanical seals according to manufacturer’s instructions for the size of pipes shown to provide a watertight seal between pipe and wall sleeve opening.

4. Manufacturers and Products: a. Thunderline/LinkSeal, Div. of PSI, Houston, TX; Link Seal. b. Calpico, Inc., South San Francisco, California; Sealing Linx. c. Advance Products and Systems, Lafayette, Louisiana; Innerlynx.

B. Wall Sleeves:

1. Diameter, ends, and length shall be as shown on Drawings. 2. Shall include integral seep ring to minimize seepage between metal

sleeve and concrete.

C. If core drilling is required for penetrations of existing concrete walls or slabs, locations of drilling shall be determined by radiograph to avoid damage to reinforcing steel and conduits.

2.06 FLANGES, FLANGE GASKETS, AND BOLTING MATERIALS

A. As specified in individual specifications following this section.

B. Flanges, bolting materials, and flange gaskets for steel flanges shall conform to AWWA C207.

C. Flanges, bolting materials, and flange gaskets for ductile iron flanges shall conform to AWWA C110 and AWWA C115.

D. If the flanges are coated, provide two washers for each bolt on each side of the flange to minimize damage to the coating as the nuts are tightened. Provide bolts of the proper length to accommodate the washers.

2.07 FLANGE INSULATION KITS AND INSULATING COUPLINGS

A. As specified in Section 26 42 01, Pipe Bonding and Test Stations.

2.08 BALL JOINT ASSEMBLY

A. Cast Steel Ball Joint:

1. 15 degrees minimum articulation. 2. Grade 80-40 cast steel, in conformance with ASTM A148. 3. Provide stainless steel bolts and nuts.



4. Provide rubber gasket(s) as required for proper operation. 5. Working pressure rating 100 psi, minimum.

B. Protective Coatings:

1. Do not coat machined surfaces of ball joint. 2. Provide polyurethane coating on interior surface in accordance with

Section 09 90 00, Painting and Coating. 3. Provide polyurethane coating on exterior surface in accordance with

Section 09 90 00, Painting and Coating.

C. Manufacturers:

1. SPI/Mobile PulleyWorks. 2. Or equal.

2.09 FLANGED DUCKBILL DIFFUSERS

A. Duckbill-type elastomeric diffusers are to be all rubber and the flow operated check type with a flanged end connection. The port area shall contour down to a “duckbill” shape, which shall allow passage of flow in one direction only. The flange and flexible duckbill sleeve shall be one-piece rubber construction with nylon reinforcement.

B. Diffusers shall be a variable orifice providing a nonlinear jet velocity versus flow characteristic.

C. Furnish Type 304 stainless steel backup rings.

1. Red Valve Co., Inc., Carnegie, PA. 2. Or equal.

2.10 CONCRETE FOR THRUST BLOCKS

A. Thrust Block Concrete: As specified in Section 03 30 00, Cast-in-Place Concrete.

B. Reinforcing Steel: ASTM A615/A615M, Grade 60 deformed bars.

C. Welded Wire Fabric: ASTM A497/A497M.

D. Formwork: Plywood.

2.11 PIPE LOCATING TAPE




2.12 PIPE BEDDING AND PIPE ZONE MATERIAL


2.13 TRENCH STABILIZATION MATERIAL


PART 3 EXECUTION

3.01 GENERAL

A. Notify Engineer at least 2 weeks prior to field fabrication of pipe or fittings.

B. Furnish feeler gauges of proper size, type, and shape for use during installation for each type of pipe furnished.

C. Distributing Materials: Place materials along trench only as will be used each day, unless otherwise approved by Engineer. Placement of materials shall not be hazardous to traffic or to general public, obstruct access to adjacent property, or obstruct others working in area.

3.02 EXAMINATION

A. Verify size, material, joint types, elevation, and horizontal location of existing pipeline to be connected to new pipeline or new equipment.

B. Inspect size and location of structure penetrations to verify adequacy of wall pipes, sleeves, and other openings.

C. Damaged Coatings and Linings: Repair using coating and lining materials in accordance with manufacturer’s instructions, and as specified in individual Specification(s) following this section.

3.03 PREPARATION OF TRENCH

A. Prepare trench as specified in Section 31 23 16, Excavation.

B. Unless otherwise permitted by Engineer, maximum length of open trench shall not exceed 200 feet.



3.04 INSTALLATION

A. General:

1. Join pipe and fittings in accordance with manufacturer’s instructions, unless otherwise shown or specified.

2. Install individual pipe lengths in accordance with approved lay diagram. Misplaced pipe shall be removed and replaced.

3. Inspect pipe and fittings before installation, clean ends thoroughly, remove foreign matter and dirt from inside.

4. Flanged Joints: a. Install perpendicular to pipe centerline. b. Bolt Holes: Straddle vertical centerline, aligned with connecting

equipment flanges or as shown on Drawings. c. Use torque-limiting wrenches to provide uniform bearing and

proper bolt tightness. d. Flange Type: Use flat-faced flange when joining with flat-faced

ductile or cast iron flange. 5. Couplings:

a. Install in accordance with manufacturer’s written instructions. b. Before coupling, clean pipe holdback area of oil, scale, rust, and

dirt. c. Remove pipe coating, if necessary, to obtain smooth surface. Do

not remove pipe coating. If damaged, repair before joint is made. d. Clean gaskets before installation. e. If necessary, lubricate with gasket lubricant for installation on

pipe ends. f. Tighten coupling bolts progressively, drawing up bolts on

opposite sides gradually until bolts have uniform tightness.

B. Buried Pressure Pipe:

1. Concrete Encased or Embedded Pipe: Do not encase joints in concrete, unless specifically shown on Drawings.

2. Placement: a. Keep trench dry until pipe laying and joining is completed. b. Exercise care when lowering pipe into trench to prevent twisting

or damage to pipe. c. Measure for grade at pipe invert, not at top of pipe. d. Excavate trench bottom and sides of ample dimensions to permit

proper joining, welding, visual inspection, and testing of entire joint.

e. Prevent foreign material from entering pipe during placement.



f. Close and block open end of last laid pipe section when placement operations are not in progress and at close of day’s work.

g. In general, lay pipe upgrade with bell ends pointing in direction of laying.

h. Deflect pipe at joints for pipelines laid on a curve using no more than 75 percent of the manufacturer recommended deflection. If joint deflection of standard pipe lengths will not accommodate horizontal or vertical curves in alignment, provide: 1) Shorter pipe lengths. 2) Special mitered joints. 3) Standard or special fabricated bends.

i. Check gasket position with feeler gauge to assure proper seating. j. After joint has been made, check pipe alignment and grade. k. Place sufficient pipe zone material to secure pipe from movement

before next joint is installed. l. Prevent uplift and floating of pipe prior to backfilling.

3. Tolerances: a. Deflection From Horizontal Line: Maximum 2 inches. b. Deflection From Vertical Line: Maximum 1 inch. c. Joint Deflection: Maximum of 75 percent of manufacturer’s

recommendation. d. Horizontal position of pipe centerline on alignment around curves

maximum variation of 1 foot from position shown. 4. Disposal of Excess Excavated Material: As specified in

Section 31 23 16, Excavation.

3.05 BALL JOINT ASSEMBLY

A. Ball joint assembly shall be installed in accordance with manufacturer’s written installation and operation manual.

3.06 FLANGED DUCKBILL DIFFUSERS

A. Diffusers shall be installed in accordance with manufacturer’s written installation and operation manual.

B. Manufacturer’s authorized representative shall be available for customer service during installation and startup, and to train personnel in the operation and maintenance of the valve.

3.07 THRUST RESTRAINT

A. Location: Where shown on the Drawings and at pipeline tees, plugs, caps, bends, and locations where unbalanced forces exist.



B. Thrust Blocking:

1. Place only where shown on Drawings. 2. Quantity of Concrete: Sufficient to cover bearing area of pipe and

provide required soil bearing area as shown on Drawings. Concrete shall not encroach on to pipe joints.

3. Place blocking so pipe and fitting joints are accessible for repairs. 4. Place concrete in accordance with Section 03 30 00, Cast-in-Place

Concrete.

C. Thrust Ties:

1. Steel Pipe: Attach with lugs fabricated in accordance with details shown on Drawings.

2. Flanged Coupling Adapters: For exposed installations, install manufacturer’s anchor studs through the coupling sleeve or use dismantling joints.

3.08 CORROSION PROTECTION

A. Buried Pipe: As specified in the individual Specifications following this section.

B. Notify Engineer at least 3 days prior to start of surface preparation, coating application, and corrosion protection work.

3.09 PLACEMENT OF PIPE LOCATING TAPE

A. Place pipe locating tape in accordance with Section 31 23 23.15, Trench Backfill.

3.10 PIPE BEDDING AND ZONE MATERIAL

A. Place pipe bedding and pipe zone material in accordance with Section 31 23 23.15, Trench Backfill.


A. Pressure Leakage Testing: As specified in the individual Specification(s) following this section.

3.12 CLEANING

A. Following assembly and testing, and prior to final acceptance, flush pipelines with water at 2.5 fps minimum flushing velocity until foreign matter is removed. Dispose of water and flushed foreign matter.



B. If impractical to flush large diameter pipe at 2.5 fps, clean pipe in-place from inside by brushing and sweeping, then flush or blow line at lower velocity.

C. Remove accumulated debris through blowoffs 2 inches and larger or by removing spools, manway covers and valves from piping.

END OF SECTION


PW/WBG/179201 WELDED STEEL PIPE AND FITTINGS OCTOBER 2018 33 05 01.01 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 33 05 01.01 WELDED STEEL PIPE AND FITTINGS

PART 1 GENERAL

1.01 DEFINITIONS

A. Fittings: Including, but not limited to fittings, closure pieces, bends, reducers, tees, wyes, bifurcations, crosses, outlets, manifolds, nozzles, wall sleeves, bulkheads, and other piping and appurtenances fabricated from steel plate, sheet, or coils as required to provide the Work, complete. Fittings shall include piping above ground or inside structures.

B. Acronyms:

1. CJP: Complete Joint Penetration. 2. CWI: Certified Welding Inspector. 3. MT: Magnetic Particle Testing. 4. NDE: Nondestructive Examination. 5. NDT: Nondestructive Testing. 6. PJP: Partial Joint Penetration. 7. PQR: Procedure Qualification Record. 8. PT: Liquid Penetrant Testing. 9. RT: Radiographic Testing. 10. UT: Ultrasonic Testing. 11. VT: Visual Testing. 12. WPQ: Welder/Welding Operator Performance Qualification. 13. WPS: Welding Procedure Specification.

1.02 SUBMITTALS


1. Shop Drawings showing pipe layout. 2. Material list and steel reinforcement schedules for materials specified. 3. Fabrication Information:

a. Pipe and fitting details for temporary and permanent facilities indicating: 1) Cylinder thickness. 2) Manufacturing tolerances. 3) Maximum angular deflection limitations of field joints. 4) Closure sections and cutoffs for field length adjustment. 5) Bulkheads, including details for removal of test bulkheads

and repair of lining.


WELDED STEEL PIPE AND FITTINGS PW/WBG/179201 33 05 01.01 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

6) Weld lead outlets and plugs. 7) Stulling size, spacing, and layout.

b. Welded joint details including: 1) Butt joints. 2) Miter-cut ends for alignment conformance. 3) Lap joints. 4) Special thermal control joints required for control of

temperature stresses. 5) Butt strap joints.

4. Welding Data (Shop and Field Welding): a. Show on a weld map, complete information regarding base metal

specification designation location, type, size, and extent of welds with reference called out for WPS and NDE numbers in tail of welding symbol.

b. Distinguish between shop and field welds. c. Indicate, by welding symbols or sketches, details of welded joints

and preparation of base metal. Provide complete joint welding details showing bevels, groove angles, and root openings for all welds.

d. Welding and NDE symbols shall be in accordance with AWS A2.4.

e. Welding terms and definitions shall be in accordance with AWS A3.0M/A3.0.

f. Submit welding data together with Shop Drawings as a complete package.

5. Product data for the following: a. Welded Steel Pipe and Fittings:

1) Material data. 2) Chemical and physical test reports showing data consistent

with specified requirements for each heat of steel proposed for use.

b. Coatings and Linings: 1) Technical data sheets itemizing technical and performance

information that indicates compliance with this Specification.

2) Color chart, if applicable. 3) Manufacturer’s name, product number or name, and

thickness. c. Rubber Gasket Joint:

1) Details with dimensions and fabrication tolerances for both bell and spigot ends.

2) Materials. 3) Performance history or test data.




1. Certificates: a. Manufacturer’s Certificate of Compliance in accordance with

Section 01 43 33, Manufacturers’ Field Services. 2. Pipe Manufacturer’s written Quality Assurance/Control Plan. 3. Statements of Qualification:

a. Pipe manufacturer. b. Fittings fabricator. c. Contractor’s Shop Inspector. d. Contractor’s Field Inspector. e. Welders or Welding Operators:

1) Name of welder. 2) Welding procedures/positions for which welder is qualified

to weld. 3) Assigned certification stamp number. 4) Certification date. 5) Current certification status.

f. NDT Quality Control Personnel. 4. Procedures:

a. Shop and field welding information; at a minimum include complete welding code paper trail with linkage to Shop Drawings.

b. Welder Qualifications and Welding Procedure Specifications as specified below: 1) Provide complete joint dimensions and details showing

bevels, groove angles, root face, and root openings for all welds.

2) Notch-tough welding procedures required. For shop welding, address supplementary essential variables in addition to essential variables as indicated in ASME Section IX, QW-251.2. For field welding, heat-input, control PQR essential variables as indicated in AWS D1.1/D1.1M, Table 4.6 shall be included. For shop and field welding, provide heat-input table on WPSs for welder guidance.

3) PQRs for notch-tough welding shall document heat-input control by monitoring volts, amps, and travel speed or time-rate of change of weld metal volume as calculated by measuring change in electrode length over a period of time. Charpy V-notch tests shall be conducted on weld metal and heat affected zone. Test coupons shall be oriented transverse to final direction of rolling. Full size Charpy specimen test acceptance shall be same as base metal specified herein.

4) Written NDT procedures.



5) Current WPQ. 6) Written description of proposed sequencing of events or

special techniques such as: a) Controlling pipe wall temperature stress during

installation. b) Minimizing distortion of steel. c) Shop-Applied Cement-Mortar Lining: Include

description of machine to be used and list of similar projects where machine was used. Identify pipe size and total footage.

d) Monitoring pipeline temperatures during installation. c. Written weld repair procedures for the Work. d. Field coating application and repair. e. Field lining application and repair.

5. Reports: a. Source Quality Control Test Reports:

1) Hydrostatic testing. 2) Destructive weld testing. 3) Nondestructive weld testing. 4) Steel impact testing using Charpy V-notch method. 5) Letter from independent testing agency certifying pipe

furnished meets requirements of this Specification. b. Field Quality Control Test Reports:

1) Weld tests, including re-examination of repaired welds, on each weld joint for the following tests, as applicable: a) Visual Testing (VT). b) Radiographic Testing (RT). c) Ultrasonic Testing (UT). d) Magnetic Particle Testing (MT). e) Liquid Penetrant Testing (PT). f) Leak Testing (LT).

c. Cement-mortar lining compressive strength tests in accordance with AWWA C205.

d. Cement-mortar coating absorption tests in accordance with AWWA C205.

6. Field Testing Plan: Submit at least 15 days prior to testing and include following information at a minimum: a. Testing dates. b. Piping system and sections to be tested. c. Method of isolation. d. Method of conveying water from source to system being tested. e. Calculation of maximum allowable leakage for piping sections to

be tested.



7. Temperature Stress Control Plan: Submit at least 45 days prior to installing pipe and include at least the following information: a. Step by step installation procedures and sequencing to

demonstrate compliance with temperature control requirements, including: 1) Pipe installation. 2) Joint welding of standard joints and temperature control

joints. 3) Pipe bedding and backfill.

b. Methods to ensure compliance with procedures by installation personnel.

c. Equipment to be used to monitor pipe wall temperature. d. Time of day, climatic, or seasonal installation limits to be used to

achieve compliance with temperature control requirements. 8. Pipe manufacturer’s design engineer’s certification of training of

Contractor’s pipe installation crews.


A. Qualifications:

1. Pipe Manufacturer: a. Experienced in fabricating pipe of similar diameters, lengths, and

wall thickness required for the Work. b. Steel Pipe Fabricators Association (SPFA), Lloyd’s Registry

Certification, or ISO 9001:2000 Certification. c. Demonstrate current production capability for volume of work

required for Project. d. Experience shall include successful fabrication to AWWA C200

standards of at least 50,000 linear feet of 42-inch diameter or larger pipe, with wall thickness of 3/16 inches or greater, within past 5-year period.

e. Experience shall be applicable to fabrication plant facilities and personnel, not company or corporation that currently owns fabrication facility or employs personnel.

2. Fittings Fabricator: a. Experienced in fabricating fittings of similar diameters and wall

thickness required for the Work. b. Steel Pipe Fabricators Association (SPFA), Lloyd’s Registry

Certification, or ISO 9001:2000 Certification. c. Demonstrate current production capability for volume of work

required for this Project. d. Experience shall include successful fabrication to AWWA C200

and AWWA C208 standards of at least 50 fittings of 42-inch or



larger pipe, with wall thickness 3/16 inch or greater, within past 5-year period.

e. Experience shall be applicable to fabrication shop facilities and personnel, not company or corporation that currently owns fabrication facility or employs personnel.

3. Welders and Welding Operators: a. Shop Welders: In accordance with ASME BPVC SEC IX. b. Field Welders: In accordance with AWS D1.1/D1.1M.

4. Contractor’s Inspector for Shop and Field Welding: a. In accordance with AWS QC 1, with knowledge of welding code

for the Work. b. After receiving CWI qualification, at least one Shop CWI and one

Field CWI shall have 5 years’ minimum professional experience related to welding inspection similar to the Work. Other CWIs may work under the supervision of 5-year CWI, provided they have 1 year of related professional experience after receiving CWI qualification.

5. NDT Quality Control Personnel: a. In accordance with requirements of ASNT SNT-TC-1A, NDT

Level II. b. After receiving NDT qualification, at least one NDT person shall

have 5 years minimum professional experience related to NDT inspection similar to the Work. Other NDT personnel may work under the supervision of 5year NDT, provided they have 1 year of related professional experience after receiving NDT qualification.

B. Contractor’s Shop Inspector:

1. In accordance with AWWA C200. 2. Responsibilities:

a. Verify conformance to use of specified materials and their proper storage.

b. Monitor conformance to approved WPS. c. Monitor conformance to approved NDT procedure specifications. d. Monitor conformance of WPQ. e. Provide 100 percent visual inspection before, during, and after

shop welding. f. Coordinate NDT work and review test results. g. Maintain records and prepare report confirming results of

inspection and testing.

C. Contractor’s Field Inspector:

1. In accordance with AWWA C206 and AWS D1.1/D1.1M.



2. Responsibilities: a. Verify conformance to use of specified materials and their proper

storage. b. Monitor conformance to approved WPS. c. Monitor conformance to approved NDT procedure specifications. d. Monitor conformance of WPQ. e. Provide 100 percent VT before, during, and after field welding. f. Coordinate NDT work and review test results. g. Maintain records and prepare report confirming results of

inspection and testing.

D. Prefabrication Meeting: Hold prior to fabrication of pipe and fittings between representatives of Owner, Contractor, Engineer, and pipe fabricator to review following:

1. Project scope. 2. Submittal requirements. 3. Testing. 4. Inspection responsibilities. 5. Shop welding requirements. 6. Field welding requirements. 7. Shop and field coating and lining requirements. 8. Production and delivery schedule. 9. Other issues pertinent to the Work.

E. Inspection of Coating and Lining Application: Qualified manufacturer’s technical representative shall visit pipe coating and lining shop and Site at beginning of application process to verify proper workmanship associated with coating and lining application and as may be required to resolve shop or field problems, except for pipes exclusively lined and coated with cement mortar. Submit written report of visit to Engineer.

1.04 DELIVERY, HANDLING, AND STORAGE

A. Pipe Marking:

1. Legibly mark installation sequence number on pipe and fittings in accordance with piping layout. Standard pipe sections do not need sequence number labeled provided wall thickness is clearly marked.

2. Fittings shall be marked at each end with notation “TOP FIELD CENTERLINE”.

3. The word “TOP” shall be painted or marked on outside top spigot of each fitting.



4. Mark “TOP MATCH POINT” for compound bends in accordance with AWWA C208 so end rotations can be easily oriented in field.

B. Delivery:

1. Securely bulkhead or otherwise seal ends of pipe and fittings prior to loading at manufacturing site.

2. Pipe ends shall remain sealed until installation. 3. Damage to pipe and fittings, including linings and coatings, found upon

delivery to Site shall be repaired to Engineer’s satisfaction or removed from Site and replaced.

C. Storage:

1. Support pipe securely to prevent accidental rolling and to avoid contact with mud, water, or other deleterious materials.

2. Support on sand or earth berms free of rock exceeding 3 inches in diameter.


A. Notify Engineer in writing of the following:

1. Pipe Manufacturing: Not less than 14 days prior to starting. 2. Not less than 5 days prior to start of each of the following:

a. Welding. b. Coating application. c. Lining application. d. Shop hydrostatic testing.

PART 2 PRODUCTS

2.01 GENERAL

A. Pipe Manufacturer:

1. Manufacturing of steel pipe and fittings shall be under direction of one pipe Supplier.

2. Responsibility shall include, at minimum, coordinating work of other suppliers for fittings.

B. Pipe Size:

1. Unless shown otherwise for pipe over 30 inches in diameter, the diameter shown shall be considered finished inside diameter after lining.



2. For pipe 30 inches in diameter and less, diameter shown shall be in accordance with ASME B36.10M. a. Pipe size shall be nominal outside diameter for 14-inch diameter

pipe and larger. b. Pipe size shall be nominal inside diameter for 12-inch diameter

pipe and smaller.

C. Steel pipe and fittings shall be manufactured, tested, inspected, and marked to comply with AWWA C200 and additional requirements of these Contract Documents.

D. In lieu of collar reinforcement, pipe or fittings with outlets may be fabricated in their entirety of steel plate having thickness equal to sum of pipe wall plus required reinforcement.

2.02 PIPE BARREL

A. Steel: Provide steel coils for spiral welded steel pipe or steel plate for straight seam welded steel pipe in accordance with AWWA C200 and as follows:

1. Specified Minimum Yield Strength: 36,000 psi. 2. Specified Minimum Tensile Strength: 53,000 psi. 3. Minimum Elongation in 2-inch Gauge Length: 21 percent. 4. Steel Quality as follows:

a. Coils: Continuous cast process, fully-killed, fine grained practice conforming to physical, manufacturing and testing requirements of ASTM A1018/A1018M, SS Grade 36, Type 1.

b. Plate: 1) Fully-killed, conforming to ASTM A20/A20M, fine grained

practice conforming to physical, manufacturing and testing requirements of ASTM A516/A516M, Grade 70.

2) Steel Chemistry: Conform to ASTM A516/A516M, Grade 70. Steel plates that are 3/4-inch thick or greater shall be normalized.

5. Minimum nominal wall thickness as shown on Drawings. Maximum allowable thickness variation for plate, sheet, or coil shall be 0.010 inch less than ordered thickness.

2.03 FITTINGS

A. Fabrication:

1. Shop fabricate. No field fabrication will be allowed, unless approved by Engineer.



2. Fabricate from materials or straight pipe in conformance with specified requirements and dimensions of AWWA C208, unless otherwise indicated.

B. General:

a. Refer to ASME B36.10M for definitions of wall thickness for standard weight pipe and nominal pipe size (NPS).

b. Reinforce to withstand either internal pressures, both circumferential and longitudinal, or external loading conditions, whichever is greater.

c. Minimum Plate Thickness: The greater of adjacent mainline pipe, thickness shown, thickness calculated as hereinafter specified, or as shown in Table 1.

Table 1

Nominal Pipe Diameter (inches)

Pipe Manifolds Piping Above

Ground Piping in Structures

Bends Reducers

24 and Under Standard Weight Standard Weight

Over 24 See Drawings See Drawings

C. Bends, Unless Otherwise Indicated:

1. Minimum Radius: 2.5 times pipe diameter or as indicated on Drawings. 2. Minimum Bend Wall Thickness: Greater of Table 1 above or as

calculated for straight pipe under internal pressure multiplied by following bend stress intensities (tabulated below or calculated with the following bend stress intensity formula where “n” is the bend radius multiplier and SI=bend stress intensity). For “n” greater than, or equal to, 2.5 the stress intensity factor may be ignored as indicated in AWWA M11.

123

12

n

nSI

Bend Radius Multiplier “n”

AWWA M11 Bend Stress Intensity “SI”

1.0 1.67

1.5 1.33

2.0 1.22



3. Maximum Miter Angle: 11-1/4 degrees on each section resulting in a maximum deflection angle of 22.5 degrees per miter weld as recommended in AWWA C208.

4. Bevels: Vary bevels on miters to provide a constant weld groove angle. For 11-1/4-degree miter, (22.5-degree miter weld) bevels must vary from 18.75 degrees on OD of bend to 41.25 degrees on ID of bend to provide a constant 60-degree groove angle for CJP welding.

5. Complete joint penetration (CJP) welds on miter welds.

D. Outlets:

1. 24 Inches and Smaller: Fabricate from ASTM A53/A53M, Type E or S, Grade B, standard weight steel pipe.

2. Larger than 24 Inches: Fabricate from ASTM A106/A106M, Grade B, standard weight pipe.

3. Fabricate collar or wrapper reinforcement using same steel as specified for main pipe barrel.

E. Steel Butt-Weld Fittings:

1. 24 Inches and Smaller: In accordance with ASME B16.9 conforming to ASTM A234/A234M.

2. Standard weight. 3. Taper pipe wall at welds at 4:1 for connection to pipe of different wall

thickness. 4. Coordinate difference in diameter convention between fittings and

AWWA C200 and AWWA C208 pipe and fittings to provide complete piping system as shown.

2.04 RESTRAINED JOINTS

A. Shop Welded:

1. Fabricate in accordance with AWWA C200 as modified herein. 2. Complete joint penetration (CJP) butt joints shall be used for

longitudinal, girth, and spiral welds, unless otherwise indicated. 3. Lengths of pipe shall not be shop-joined using lap joints.

B. Preparation of Joints for Field Welding:

1. Butt Joint Welded: a. Plain ends beveled as required by AWWA C200 and Contractor’s

field WPS. b. Provide protection for factory beveled pipe ends so ends are not

damaged during transport.



2. Lap Joint Welded: a. Double fillet and single fillet lap joints in preparation for field

welding shall be in accordance with AWWA C200. b. For pipe 30 inches in diameter and larger, provide one of the

following: 1) Tack weld four metal tabs at equal intervals around inside

circumference of bell ends to indicate location at which spigot end has reached maximum penetration into bell. Remove stops after welding of joint.

2) Paint a 3/4-inch wide white stripe on outside circumference of spigot end of pipe. Side of stripe furthest from pipe end shall indicate location at which spigot end has reached maximum penetration into bell. Side of stripe closest to end of pipe will indicate limit of maximum joint pull.

c. Double welded lap joints and butt-strap joints shall be tapped and drilled for testing in accordance with AWWA C206.

C. Miter-End Cuts:

1. Welded Lap Joints: a. As shown on Drawings. b. Moderate deflections and long radius curves may be made using

miter-end cuts. c. Use only with rubber gasket joints or lap welded joints, unless

specifically approved in writing by Engineer. d. Maximum Total Allowable Angle: 3 degrees per pipe joint. e. Provide miter-cut that is cold expanded square with face of

miter-cut on bell ends only. f. Mitering of spigot ends will not be permitted.

D. Special Temperature Control Joint:

1. Provide a special 3-inch longer bell end (Special Temperature Control Joint) at a maximum spacing as indicated herein to account for movement on installed pipe as a result of temperature changes.

2. Minimum Special Temperature Control Joint length is as shown on Drawings.

2.05 FLANGES

A. In accordance with AWWA C207.



2.06 UNRESTRAINED JOINTS WITH RUBBER GASKET

A. General:

1. In accordance with AWWA C200. 2. Clearance between bell and spigot shall, when combined with gasket

groove configuration and gasket itself, provide watertight joints under operating conditions.

B. Rubber Gasket Carnegie Bell and Spigot:

1. Provide bell and spigot rings as sized pair. 2. Standard Spigot Shapes in Accordance with AWWA M11:

a. M3516 for pipe diameters less than 42 inches and maximum wall thickness of 3/8 inch.

b. M3818 for applications not suitable for standard shape M3516. c. M3818 may be substituted for standard shape M3516.

3. Weld bells and spigots to pipe cylinder using double fillet welded lap joint.

2.07 STULLING (STRUTTING)

A. Materials:

1. Shop-Lined Pipe: Wood stulls and wedges. 2. Unlined Pipe: Steel or wood.

B. Install stulling for pipe and fittings in accordance with approved submittal and as soon as practical after pipe is fabricated or, for shop-lined pipe, after lining has been applied.

C. Install stulling in manner that will not harm lining.

2.08 CEMENT-MORTAR COATING

A. General:

1. Notify Engineer at least 5 days prior to application of coating products. 2. Holdback of and coating from field-welded joints shall be as shown on

Drawings. 3. Unless otherwise indicated, coat exterior surfaces of pipe and fittings

passing through structure walls from center of wall or from wall flange to end of underground portion.



B. Shop-Applied:

1. Cement-mortar coating shall conform to AWWA C205. Thickness shall be 3/4 inch, minimum, except in the Old River, where there shall be a 3-inch cement mortar coating as shown on the Drawings.

2. Steel wire or ribbon mesh reinforcement shall be in accordance with AWWA C205.

3. Coating system for field joints shall be cement mortar in accordance with AWWA C205. Mortar shall be retained with suitable water-impermeable bands or heavy-duty diapers of sufficient strength to hold fresh mortar and resist rodding.

2.09 CEMENT-MORTAR LINING

A. General:

1. Notify Engineer at least 5 days prior to application of lining products. 2. Holdback of lining from field-welded joints shall be as shown on

Drawings.

B. Shop-Applied:

1. Applied centrifugally in conformance with AWWA C205. Thickness shall be 1/2 inch minimum.

2. Lining machine type that has been used successfully for similar work and approved by Engineer.

3. Maintain pipe in round condition during lining operation and thereafter by suitable bracing or strutting.

4. Provide polyethylene or other suitable bulkhead on ends of pipe and on special openings to prevent drying out of lining. Bulkheads shall be substantial enough to remain intact during shipping and storage until pipe is installed.

5. Pipe shall be left bare where field joints occur. 6. Ends of lining shall be left square and uniform. Feathered or uneven

edges will not be permitted.

2.10 CATHODIC PROTECTION

A. Provide as shown and as specified in Section 26 42 02, Galvanic Anode Cathodic Protection System.




A. Shop Hydrostatic Pressure Test: In accordance with AWWA C200 Section 5.2, except as follows:

1. General: Unless specified otherwise, testing of pipe and fittings shall be performed before lining and coating is applied.

2. Pipe: Maintain test pressure for minimum of 5 minutes. 3. Except as otherwise specified herein, no additional shop hydrostatic test

will be required on fittings fabricated from successfully tested straight pipe.

B. Joints, Lap-Welded:

1. Fit test minimum of 5 joints, selected by Engineer, of each pipe size used: a. Join pipe ends with proposed adjacent pipe end. b. Match-mark pipe ends. c. Record Actual Annular Space:

1) Maximum space at a point. 2) Minimum space at a point. 3) Space at 90-degree intervals; top, bottom, and spring line on

both sides.

C. Shop Nondestructive Testing:

1. Welds: 100 percent visually examined by Contractor’s Shop Inspector to criteria in ASME BPVC SEC VIII, Division 1.

2. CJP Welds: Spot radiographically or radioscopically examine pipe in accordance with ASME BPVC SEC VIII, Division 1, Paragraph UW-52. Welds that, in opinion of Engineer, cannot readily be radiographed, shall be ultrasonically examined in accordance with paragraph UW-53.

3. Fillet Welds: 100 percent examine using magnetic particle inspection method in accordance with ASME BPVC SEC VIII, Division 1, Appendix 6.

4. Air test collars and wrappers in accordance with AWWA C206.

D. Inspection of Pipe Fabrication Procedure: Select and provide independent testing agency to observe pipe fabrication. Agency staff shall have experience in observation of steel pipe fabrication in accordance with ASTM E329. Representative of agency shall be present full time while pipe is being fabricated and while protective coating and lining is applied. Provide a letter to Engineer certifying that pipe furnished meets requirements of this section.



PART 3 EXECUTION

3.01 INSTALLATION

A. General:

1. Joints and related work for field assembly of fittings shall conform to requirements for straight pipe, unless otherwise shown.

2. Inspect pipe and fittings before installation. Clean ends thoroughly, remove foreign matter and dirt from inside.

3. Make minor field adjustments by pulling standard joints. a. Maximum Allowable Angle: 75 percent of manufacturer’s

recommended or angle which results from 3/4-inch pull out from normal joint closure, whichever is less.

b. Maximum Allowable Gap: 1/8 inch between bell and spigot at weld location.

4. Horizontal deflections or fabricated angles shall fall on alignment, as shown within tolerances below.

5. Vertical deflections shall fall on alignment, and pipe angle point locations shall match those indicated on Drawings within tolerances below.

6. For field-welded joints, pipe 30 Inches in Diameter and Larger: a. Ensure maximum penetration of spigot end into bell end is

achieved through use of shop-welded tabs on inside circumference of bell end or by use of a paint stripe.

b. If welded metal tabs are used, remove tabs prior to welding inside of joint.

7. Stulling: a. Maintain stulling in place until pipe is completely backfilled and

compacted. b. If CLSM is used for backfill, the stulling shall be left in place

until the CLSM has achieved a minimum compressive strength of 50 psi as demonstrated by test cylinders of the product used for the backfill in the field.

c. Reinstall stulls that were temporarily removed to facilitate interior welding prior to backfilling.

8. Pipeline Alignment Tolerances: a. Plan: 2 inches. b. Elevation: 1 inch.

9. Pipe Deflection: After completion of backfilling and before acceptance of the Work, all pipes larger than 18 inches in diameter shall be tested for excessive deflection by measuring the actual inside vertical diameter. Deflection measurements will be made by the Engineer or by pulling a mandrel through pipe. Pipe diametral deflection shall not



exceed 2.25 percent of the nominal inside diameter measured in the vertical direction at any point in the pipe. Diametral deflection greater than 2.25 percent shall be corrected by the Contractor at no additional cost to the District.

B. Control of Temperature Stresses:

1. In accordance with AWWA C206, approved Temperature Stress Control Plan submittal, and this Specification.

2. To control temperature stresses, shade unbackfilled special temperature control joint area of pipe from direct rays of sun by use of properly supported awnings, umbrellas, tarpaulins or other suitable materials until pipe is backfilled at least 1 foot over top of pipe. The special temperature control joint area is defined as the entire length of pipe left exposed. Shading materials shall not rest directly on pipe, but shall be supported to allow air circulation around pipe. Shading of special temperature control joints is not required when ambient air temperature is below 70 degrees F.

3. Locate special temperature control joints at 300-foot intervals. 4. Install special temperature control joints as indicated on Drawings. 5. Design, furnish and install a pipeline temperature monitoring system

consisting of thermocouple temperature gauges to monitor temperature of steel pipe wall in trench. Gauges shall be located at top inside surface of pipe at intervals not exceeding 50 feet. Hand held portable temperature sensor devices may be used, provided temperature readings are taken at top of pipe at a frequency and spacing that demonstrates compliance with temperature control requirements.

6. Temperature Control Requirements: a. Prior to and during placement of pipe backfill, pipeline steel

temperature shall be at or below 90 degrees F. Monitor specified temperature and control for at least 3 hours after placement of pipe backfill. Provide supplemental cooling as required.

b. Place pipe backfill from a single heading starting at one special temperature control joint and proceed toward next special temperature control joint.

c. During period of pipe backfill placement, pipeline section that is partially backfilled shall be shaded as indicated in above. Temperature of partially backfilled pipe shall not be allowed to exceed 90 degrees F. Provide supplemental cooling as required.

d. Prior to welding special temperature control joints, pipeline extending 300 feet each direction from joint shall be maintained at or below 90 degrees F. Additionally, pipeline extending 300 feet each direction from joint shall be backfilled to at least 1 foot over top of pipe. Weld special temperature control joint at specified



temperature of 90 degrees or below. Begin and complete weld during coolest time interval of the 24-hour day. Use pipeline temperature monitoring system data to demonstrate to Engineer coolest interval of the day.

e. After field welding of special temperature control joint, pipe temperature for 150 feet in each direction shall be maintained below 90 degrees F for a minimum of 24 hours after special temperature control joint area has been backfilled to at least 1 foot over top of pipe.

3.02 WELDING

A. Perform welding only in presence of Contractor’s Field Inspector.

B. Conform to AWS D1.1/D1.1M, AWWA C206, approved welding procedures, and referenced welding codes. In case of conflict AWS D1.1/D1.1M shall govern.

C. Preheat and Interpass temperature requirements for unlisted base metals shall be determined according to AWS D1.1/D1.1M, Annex XI Guideline on Alternative Methods for Determining Preheat.

D. Rejectable weld defects shall be repaired or redone, and retested until sound weld metal has been deposited in accordance with appropriate welding codes.

3.03 REPAIR OF SHOP-APPLIED CEMENT-MORTAR COATINGS

A. Exterior surfaces of steel pipe and fittings shall be inspected upon delivery to Site and just prior to backfilling trench.

B. Repair of Cement Mortar Coating: Field repairs shall be made in accordance with AWWA C205.

3.04 COATING OF FIELD-WELDED JOINTS

A. Using Cement Mortar: Applied to joints in accordance with AWWA C205.

3.05 CEMENT-MORTAR LINING APPLICATION AT JOINTS

A. Cement-Mortar Lining: For pipe with shop-applied cement-mortar lining, place lining at joints in accordance with AWWA C205.


A. Apply to pipe as shown and as specified in Section 26 42 02, Galvanic Anode Cathodic Protection System.




A. Field Welding:

1. All welds, 100 percent inspection, shall be VT inspected by Contractor’s Field Inspector and marked to indicate acceptance or rejection.

2. Test butt strap double welded lap joint welds by pressurizing connection between the two fillet welds in accordance with AWWA C206. a. Apply air or other Engineer approved gas into connection between

the two fillet welds. b. Paint welds with soap solution. c. Mark leaks indicated by escaping gas bubbles. d. Close threaded openings with flush pipe plugs or by welding

them. 3. Inspect 100 percent of lap joint welds with PT or MT. 4. Weld Acceptance:

a. VT: Perform VT in accordance with AWS D1.1/D1.1M Paragraph 6.9, Visual Inspection, Statically Loaded Nontubular Connections.

b. PT or MT: 1) Perform on fillet and PJP groove welds in accordance with

AWS D1.1/D1.1M, Paragraph 6.10. 2) Acceptance shall be in accordance with VT standards

specified above. c. Remove in manner that permits proper and complete repair by

welding. d. Caulking or peening of defective welds is not permitted. e. Retest unsatisfactory welds.

B. Hydrostatic Testing:

1. Pipeline: a. General:

1) Notify Engineer in writing 5 days prior to testing. Perform testing in presence of Engineer.

2) Test newly installed pipelines. Using water as test medium, pipes shall successfully pass a leakage test prior to acceptance.

3) Furnish testing equipment and perform tests in manner satisfactory to Engineer. Testing equipment shall provide observable and accurate measurements of make-up water under specified conditions.



4) Isolate new pipelines that are connected to existing pipelines.

5) The new 42 inch pipeline shall be isolated and tested in the following three separate segments: a) Beginning of pipeline at Tracy WWTP to butterfly

valve in meter vault adjacent to Pond 5. b) Butterfly valve in meter vault adjacent to Pond 5 to

isolation valve just south of Paradise Cut. c) Butterfly valve just south of Paradise Cut crossing to

end of pipeline at Old River. 6) Conduct field hydrostatic test on buried piping after trench

has been completely backfilled. Testing may, as approved by Engineer, be done prior to placement of asphaltic concrete or roadway structural section.

7) Contractor may, if field conditions permit and as determined by Engineer, partially backfill trench and leave joints open for inspection and conduct an initial service leak test. Final field hydrostatic test shall not, however, be conducted until backfilling has been completed as specified above.

8) Supply of temporary water shall be as stated in Section 01 50 00, Temporary Facilities and Controls.

9) Dispose of water used in testing in accordance with federal, state, and local requirements.

b. Procedure: 1) Maximum filling velocity shall not exceed 0.25 foot per

second, calculated based on the full area of pipe. 2) Expel air from pipe system during filling. Expel air through

air release valve or through corporation stop installed at high points and other strategic points.

3) Test Pressure: 115 feet elevation. 4) Apply and maintain specified test pressure with hydraulic

force pump. Valve off piping system when test pressure is reached.

5) Maintain hydrostatic test pressure continuously for 2 hours minimum, adding additional make-up water only as necessary to restore test pressure.

6) Determine actual make-up water by measuring quantity of water necessary to maintain specified test pressure for duration of test.

7) If measured make-up water exceeds allowable or if leaks are visible, repair defective pipe section and repeat hydrostatic test.



c. Allowable Make-up Water: 1) For pipe with O-ring rubber gasket joints, allowable make-

up water shall not exceed 0.06 gallon(s) per inch of diameter per mile per 2 hours.

2) For pipe with welded or fused joints, allowable make-up water shall not exceed 0.0 gallons per inch of diameter per mile per 2 hours.

3) For pipe segments containing welded steel pipe, and another pipe material, allowable make-up water shall not exceed the the sum of the specified allowable make-up water for each pipe material.

END OF SECTION


PW/WBG/179201 DUCTILE IRON PIPE AND FITTINGS OCTOBER 2018 33 05 01.02 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 33 05 01.02 DUCTILE IRON PIPE AND FITTINGS

PART 1 GENERAL

1.01 SUBMITTALS


1. Shop Drawings: Marking plan and details of standard pipe section showing dimensions, pipe joints, fitting and special fitting pressure rating and thickness, size, coating and lining data.

2. Pipeline layout drawings showing the location of each pipe section, each special length, closure sections, location and angle of bends, outlets, locations of valves, and other special fittings.


1. Manufacturer’s Certificate of Compliance, in accordance with Section 01 43 33, Manufacturers’ Field Services, stating that inspections and specified tests have been made and that results thereby comply with requirements of Article Source Quality Control.

2. Manufacturer shall furnish sworn certificates that pipe and fittings have been manufactured, tested, and inspected in accordance with this and all applicable Specifications.

3. Field Hydrostatic Testing Plan: Submit at least 15 days prior to testing and at minimum, include the following: a. Testing dates. b. Piping systems and section(s) to be tested. c. Method of isolation. d. Method of conveying water from source to system being tested. e. Calculation of maximum allowable leakage for piping section(s)

to be tested. 4. Certifications of Calibration: Approved testing laboratory certificate if

pressure gauge for hydrostatic test has been previously used. If pressure gauge is new, no certificate is required.

5. Test documentation form and results.


A. Pipe manufacturer shall be ISO 9001 registered or provide the services of an independent inspection agency.


DUCTILE IRON PIPE AND FITTINGS PW/WBG/179201 33 05 01.02 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

B. Prior to start of manufacturing, manufacturer not meeting or having ISO registration requirements shall submit name of at least two independent inspection agencies for approval.

1. Independent inspection agency shall be responsible, on a daily basis, for sample monitoring of chemical and mechanical tests, sample visual inspection of quality assurance tests performed on in-process pipe and fittings, and sample visual and dimensional inspection on finished products.

PART 2 PRODUCTS

2.01 MATERIALS

A. General:

1. Ductile iron pipe shall be manufactured, lined, coated, and tested domestically in the United States of America.

2. Ductile iron fittings shall be manufactured, lined, coated, and tested domestically or for fittings produced outside of the United States of America, they shall be supplied by pipe manufacturer and verified stating fittings are compatible with the pipe.

3. Pipe manufacturer shall certify source manufacturing facility has been producing ductile iron pipe of the specified diameters, pressure, dimensions and standards for a period of not less than 10 years.

4. Ductile iron pipe and fitting shall be supplied by a single manufacturer. a. Mixing of components and sources is not permitted. b. Fitting from outside the United States of America shall be

produced in a facility with a minimum of 5 years’ documented experience manufacturing, coating, testing, and delivery of size and type specified to projects in the United States of America.

B. Pipe:

1. General: a. Pipe shall be new and recently manufactured. Refurbished pipe

shall not be provided. b. Lined and coated as specified.

2. Meet requirements of AWWA C150/A21.50, AWWA C151/A21.51, and AWWA C111/A21.11.

3. Centrifugally cast, grade 60-42-10 iron. 4. Pressure rating of pipe shall be 150 psi. 5. Pipe wall thickness of threaded pipe for a flanged pipe end shall be

minimum special thickness Class 53 in accordance with AWWA C115/A21.15.



C. Joints:

1. Push-On Joint: Rated at minimum working pressure equal to pipe material design.

2. Restrained Joint: a. Manufactured proprietary joint that mechanically restrains pipe to

adjoining pipe. b. Manufacturers and Products:

1) American Cast Iron Pipe; Flex-Ring, Field Flex-Ring, and Lok-Ring.

2) Pacific States Pipe; Thrust-Lock. 3) U.S. Pipe; TR Flex and HP Lok.

3. Use of set screws for restraint or field-lock gaskets shall not be allowed.

D. Fittings:

1. Fittings shall be new and recently manufactured. Refurbished fittings will not be accepted.

2. Mechanical, Push-On, Flanged, or Restrained Joint: In accordance with the following table:

Minimum Pressure Ratings for AWWA C110/A21.10 and C115/A21.15 Ductile Iron Fittings

Diameter (inches)

Rubber Gasket Joints (Push-on, Mechanical,

Restrained) (psi)

Flanged Joints (psi)

3 to 24 350 250

30 to 48 250 250

3. Rubber Gasket Joints Including Mechanical Joints, Push-On Joints, and Flanged Joints: In accordance with AWWA C111/A21.11.

4. Mechanical Joint Fittings: In accordance with AWWA C110/A21.10 and AWWA C153/A21.53.

5. See Note 57 on Drawing G-03 for additional fittings to be provided to Owner.

E. Welded Outlet: Only weld to pipe in manufacturer’s shop.

F. Lining: Pipe and fittings shall be cement-lined (double thickness) and asphaltic seal coated in accordance with AWWA C104/A21.4.



G. Coating: Asphaltic type, 1-mil thick, in accordance with AWWA C151/A21.51, AWWA C115/A21.15, AWWA C110/A21.10, and AWWA C153/A21.53.

H. Polyethylene Encasement:

1. Virgin polyethylene raw material conforming to requirements of ASTM D4976.

2. Elongation: 800 percent, minimum, in machine and transverse direction (ASTM D882).

3. Tensile Strength: 3,600 psi, minimum. 4. Dielectric Strength: 800V per mil-thickness, minimum. 5. Propagation Tear Resistance: 2,550-gram force (gf), minimum, in

machine and transverse direction (ASTM D1922). 6. Tube Form: Conform to AWWA C105/A21.5. 7. Film: 0.008 inch (8 mil) thick, minimum. 8. Number of Film Layers: Two.

I. Bolting:

1. Flanged Connection Bolts: Carbon steel, ASTM A307, Grade A hex bolts and ASTM A563, Grade A hex head nuts.

J. Gaskets:

1. Flat Faced Flange Gaskets: Rated for working pressure 150 psi to 250 psi, 1/8-inch thick, red rubber (SBR), hardness 80 (Shore A), rated to 200 degrees F, conforming to ASME B16.21, AWWA C207, and ASTM D1330, Grade 1 and Grade 2.


A. Factory Tests:

1. General: a. Tests shall be performed on pipe with metal thickness equal to

that specified. b. Only pipe that passes leak test shall be shipped.

2. Hydrostatic Proof Test: a. All Pipe: Perform at 500 psi for a minimum duration of

10 seconds. b. Pipe 30 Inches and Larger: Additionally, test to 75 percent of

minimum yield strength during test duration which shall not be less than 15 seconds.

c. Record each test cycle on a strip chart.



d. Each test cycle for 30 inch and larger pipe shall be marked by pipe number.

e. Inspect each pipe during testing for leaks. f. Pipe which shows evidence of leaks shall be scrapped. g. Repair welding of leaks is not permitted.

3. Perform a 15-psi air test on welded-on outlet pipe. 4. Pipe ends (spigot end, bell and socket) shall be gauged with suitable

gauges at sufficiently frequent intervals to ensure compliance to standard dimensions of AWWA C151/A21.51. a. In addition, each socket and spigot shall be inspected in a well

lighted area for injurious defects which could affect the joint performance.

b. Remove defects by cutting of pipe ends. c. Pipe with injurious defects in the bell shall be scrapped. d. Manufacturer shall have a recommended ovality tolerance for

pipes 18 inches inch and larger. e. Each end of each 18 inch and larger pipe shall be measured and

approved by manufacturer’s quality assurance inspector to meet tolerances.

5. Submit a certified inspection report from the independent agency of witnessed tests within 10 days of the inspection. a. Test results shall show restrained joints in the sizes specified have

been successfully tested to at least twice the specified pressure rating of the joint without leakage or failure.

PART 3 EXECUTION

3.01 EXAMINATION

A. Inspect pipe and fittings to ensure no cracked, broken, or otherwise defective materials are being used.

3.02 PREPARATION

A. Trench Grade:

1. When specified, grade bottom of trench by hand to specified line and grade with proper allowance for pipe thickness and pipe base. Trench bottom shall form a continuous and uniform bearing and support for pipe between bell holes.

2. Before laying each section of pipe, check grade and correct irregularities found. Grade may be disturbed for removal of lifting tackle.



B. Bell (Joint) Holes: At each joint, dig bell holes of ample dimensions in bottom of trench, and at sides where necessary, to permit joint to be made properly and to permit easy visual inspection of entire joint.

3.03 INSTALLATION

A. General:

1. Provide and use proper implements, tools, and facilities for safe and proper prosecution of the Work.

2. Lower pipe, fittings, and appurtenances into trench, piece by piece, by means of a crane, slings, or other suitable tools and equipment, in such a manner as to prevent damage to pipe materials, protective coatings and linings.

3. Do not drop or dump pipe materials into trench.

B. Cleaning Pipe and Fittings:

1. Remove lumps, blisters, and excess coal tar coating from bell and spigot ends of each pipe. Wire brush outside of spigot and inside of bell and wipe clean, dry, and free from oil and grease before pipe is laid.

2. Wipe ends of mechanical joint pipe and fittings and of rubber gasket joint pipe and fittings clean of dirt, grease, and foreign matter.

C. Laying Pipe:

1. Direction of Laying: Lay pipe with bell end facing in direction of laying. For lines on an appreciable slope, face bells upgrade at discretion of Engineer.

2. Mechanical Joint, Push-On Joint, and Restrained Joint Pipe: After first length of pipe is installed in trench, secure pipe in place with approved backfill material tamped under and along sides to prevent movement. Keep ends clear of backfill. After each section is jointed, place backfill as specified to prevent movement.

3. Take precautions necessary to prevent floating of pipe prior to completion of backfill operation.

4. When using movable trench shield, take necessary precautions to prevent pipe joints from pulling apart when moving shield ahead.

5. Do not allow foreign material to enter pipe while it is being placed in trench.

6. Close and block open end of last laid section of pipe to prevent entry of foreign material or creep of gasketed joints when laying operations are not in progress, at close of day’s work, or whenever workers are absent from job.



D. Joining Push-On Joint Pipe and Mechanical Joint Fittings:

1. Join pipe with push-on joints and mechanical joint fittings in accordance with manufacturer’s recommendations.

2. Provide special tools and devices, such as, special jacks, chokers, and similar items required for installation.

3. Lubricate pipe gaskets using lubricant furnished by pipe manufacturer. No substitutes will be permitted.

4. Clean ends of fittings of dirt, mud, and foreign matter by washing with water and scrubbing with a wire brush, after which, slip gland and gasket on plain end of pipe. If necessary, lubricate end of pipe to facilitate sliding gasket in place, then guide fitting onto spigot of pipe previously laid.

E. Cutting Pipe:

1. General: Cut pipe for inserting valves, fittings, or closure pieces in a neat and workmanlike manner without damaging pipe or lining and so as to leave a smooth end, at right angles to axis of pipe.

2. Pipe: Cut pipe with milling type cutter or saw. Do not flame cut. 3. Dressing Cut Ends: Dress cut end of mechanical joint pipe to remove

sharp edges or projections, which may damage rubber gasket. Dress cut ends of push-on joint pipe by beveling, as recommended by manufacturer.

F. Field Welding:

1. Use of field welded outlets will not be allowed. Welding for outlets shall be performed only in pipe manufacturer’s shop.

2. Field installed outlets may be installed with saddle approved by Engineer. Opening in pipe shall be machined cut and not with cutting torch.

3. Field welding of bars for restrained joint systems will not be allowed. Welding shall be performed in pipe manufacturer’s shop.

G. Line and Grade:

1. Minimum Pipe Cover: 4 feet, unless otherwise indicated. 2. No high points will be allowed between air valves. 3. Install air valves as shown and field verify intervening low points.

When field conditions warrant, exceptions may be made upon approval of Engineer.

4. Pipeline sections that are not installed to elevations shown or installed as approved by Engineer shall be reinstalled to proper elevation.



H. Thrust Restraint: Primary method of restraint shall be through use of restrained joint pipe. Thrust blocking shall be used where detailed on Drawings and as approved by Engineer.

I. Polyethylene Encasement:

1. Encase pipe, fittings, and valves where specified in accordance with AWWA C105/A21.5, Method A.

2. Cut polyethylene tube approximately 2 feet longer than pipe length. 3. Slip tube around pipe, centering to provide 1-foot overlap on each

adjacent section. 4. Pull encasement to take out slack and wrap snug around pipe. 5. Secure overlap in place and fold at quarter points of pipe length. 6. Wrap and tape encasement snug around fittings and valves. 7. Tape encasement to pipe every 2 feet along pipe.

J. Cathodic Protection, Joint Bonding, and Test Stations:

1. Cathodic protection shall conform to Section 26 42 02, Galvanic Anode Cathodic Protection System.

2. Joint bonds and test stations shall conform to Section 26 42 01, Pipe Bonding and Test Stations.

3.04 HYDROSTATIC TESTING

A. Pipeline Hydrostatic Test:

1. General: a. Notify Engineer in writing 5 days in advance of testing. Perform

testing in presence of Engineer. b. Test newly installed pipelines. Using water as test medium, pipes

shall successfully pass a leakage test prior to acceptance. c. Furnish testing equipment and perform tests in manner

satisfactory to Engineer. Testing equipment shall provide observable and accurate measurements of leakage under specified conditions.

d. Isolate new pipelines that are connected to existing pipelines. e. The new 42-inch pipeline shall be isolated and tested in the

following three separate segments: 1) Beginning of pipeline at Tracy WWTP to butterfly valve in

meter vault adjacent to Pond 5. 2) Butterfly valve in meter vault adjacent to Pond 5 to isolation

valve just south of Paradise Cut. 3) Butterfly valve just south of Paradise Cut crossing to end of

pipeline at Old River.



f. Conduct tests on entire pipeline after trench has been backfilled. Testing may be done prior to placement of asphaltic concrete or roadway structural section.

g. Contractor may, if field conditions permit and as determined by Engineer, partially backfill trench and leave joints open for inspection and conduct an initial service leak test. Hydrostatic test shall not, however, be conducted until backfilling has been completed.

h. Supply of temporary water shall be as stated in Section 01 50 00, Temporary Facilities and Controls.

i. Dispose of water used in testing. 2. Procedure:

a. Maximum filling velocity shall not exceed 0.25 foot per second, calculated based on the full area of pipe.

b. Expel air from pipe system during filling. Expel air through air release valve or through corporation stop installed at high points and other strategic points.

c. Test Pressure: 115 feet elevation. Apply and maintain specified test pressure with hydraulic force pump. Valve off piping system when test pressure is reached.

d. Maintain hydrostatic test pressure continuously for 2 hours minimum, adding additional make-up water only as necessary to restore test pressure.

e. Determine actual leakage by measuring quantity of water necessary to maintain specified test pressure for duration of test.

f. If measured leakage exceeds allowable leakage or if leaks are visible, repair defective pipe section and repeat hydrostatic test.

3. Allowable Make-up Water: For pipe with rubber gasket joints, allowable make-up water shall not exceed 0.06 gallon(s) per inch of diameter per mile per 2 hours.

END OF SECTION


PW/WBG/179201 BAR-WRAPPED CONCRETE OCTOBER 2018 CYLINDER PIPE AND FITTINGS ©COPYRIGHT 2018 CH2M HILL 33 05 01.04 - 1

SECTION 33 05 01.04 BAR-WRAPPED CONCRETE CYLINDER PIPE AND FITTINGS

PART 1 GENERAL

1.01 SYSTEM DESCRIPTION

A. Pipe shall be manufactured and inspected specifically for this Project, and shall not be taken from manufacturer’s inventory.

B. Design Requirements, General:

1. Design pipe in accordance with requirements of AWWA C303 and AWWA M9.

2. Working pressure is 50 psi. 3. Field Test Pressure: As specified in Article Field Quality Control. 4. External Live Loading Conditions: HS20 traffic load with 1.5 impact

factor, AASHTO Standard Specifications for Highway Bridges, as applicable. AREMA, Manual for Railway Engineering, Cooper E-80 railroad live load.

5. Earth Loading: a. Design pipe based on trench transition width, as defined by

AWWA M9. b. Design pipe for depth of cover as shown on Drawings. Design

pipe for a minimum depth of cover equal to 4 feet. c. Soil Unit Weight: 120 pounds per cubic foot. d. Design Modulus of Soil Reaction (E’): 1,500 psi.

6. Method of Bedding and Backfill: a. As shown on Drawings and as stated in Section 31 23 23.15,

Trench Backfill. b. Design Bedding Constant (“k”): 0.10. c. Design Deflection Lag Factor: 1.15.

7. Cement: Portland Cement Type I or II. 8. Minimum Water Temperature:

a. 65 degrees F. b. Pipe design shall include assumed pipe temperature at time of

installation. c. In no case shall assumed pipe installation temperature be less than

30 degrees F above minimum water temperature.


BAR-WRAPPED CONCRETE PW/WBG/179201 CYLINDER PIPE AND FITTINGS OCTOBER 2018 33 05 01.04 - 2 ©COPYRIGHT 2018 CH2M HILL

C. Design Requirements, Project-Specific:

1. Restrained Joint Types: a. The following are not allowed:

1) Welded filler rod. 2) Bell bolt-type harnesses.

2. Area of Cylinder Reinforcement: At least 60 percent of total steel area; cylinder plus bar reinforcement.

3. Under the combined effect of working pressure and surge pressure, average circumferential stress in steel cylinder and bar reinforcement of pipe shall not exceed values stated in AWWA C303, 24,000 psi.

4. Minimum Cylinder Thickness: 12-gauge. 5. Rubber Gasketed Joints: Gasketed Carnegie type bell and spigot. 6. Thermal Stress Control Joints: Located on all reaches of restrained joint

pipe in accordance with pipe designer’s recommendations.

1.02 SUBMITTALS


1. Parameters used for design including, but not limited to, earth loading, depth of cover, and internal pressures.

2. Detailed pipe fabrication or spool drawings showing typical pipe segments, special fittings and bends, joint details, dimensions, coatings, and other pertinent information.

3. Tabulated layout schedule in accordance with AWWA C303, showing location of each pipe section and each special length; number or otherwise designate laying sequence on each piece.

4. Dissimilar Buried Pipe Joints: Joint types and assembly drawings. 5. Rubber Gasket Joint: Material data. 6. Welding Data for Shop and Field Welding:

a. Show on a weld map, information regarding base metal specification designation location, type, size, and extent of welds with reference called out for WPS and NDE numbers in tail of welding symbol.

b. Distinguish between shop and field welds. c. Indicate, by welding symbols or sketches, details of welded joints

and preparation of base metal. Provide complete joint welding details showing bevels, groove angles, and root openings for all welds.

d. For pipe fittings, provide joint weld beveling diagram. Refer to AWS D1.1/D1.1M, Annex P Local Dihedral Angle that can be used to calculate bevels for weld joint details of intersecting pipes.



e. Welding and NDE symbols shall be in accordance with AWS A2.4.

f. Welding terms and definitions shall be in accordance with AWS A3.0.

g. Submit welding data together with Shop Drawings as a complete package.

7. Material for protecting interior of joints.


1. Manufacturer’s Certificate of Compliance in accordance with Section 01 43 33, Manufacturers’ Field Services, for the following: a. Materials meet requirements of AWWA C303. b. Pipe and fittings. c. Factory applied linings and coatings.

2. Steel Cylinder: a. Outside diameter. b. Thickness.

3. Diameter and spacing of bars. 4. Calculations:

a. Used to determine cylinder thickness, weld sizes, concrete thickness, bar size, and bar spacing.

b. Fittings and Specials: cylinder thickness, weld sizes, reinforcing. c. Signed and sealed by professional engineer registered in the State

of California. 5. Credentials and Statements of Qualification:

a. Pipe manufacturer. b. Weld Inspection and Testing Personnel. c. Certified Welding Inspector (CWI).

6. Pipe Manufacturer’s written Quality Assurance/Control Plan. 7. Welder Qualifications and Welding Procedure Specifications in

accordance with AWS D1.1/D1.1M. 8. Maximum angular deflection limitations of field joints. 9. Nondestructive testing (NDT) procedures. 10. Test Results: Concrete 28-day compressive strength. 11. Restrained Joint Thrust Restraint: Details including materials, sizes,

assembly ratings, pipe attachment methods, cylinder sizes, and weld sizes. In addition, provide one or both of the following to verify capacity of restrained joints: a. Design calculations signed and sealed by professional engineer in

the State of California. Calculations shall demonstrate load combinations can pass through all portions of joint (from cylinder to cylinder of adjacent pipe sections). Design stresses and analysis



used shall conform to these Specifications and be traceable to a recognized code or standard.

b. Proof-of-design test results for thrust joint assembly at loads equal to 1.5 times the greater of either maximum hydrostatic load or maximum thermally induced load. Proof-of-design test shall be conducted in accordance with the following requirements: 1) Tested unit circumferential loads (pounds per inch of

circumference) shall be equal to 1.5 times design case. 2) Thickness of tested pipe cylinder shall be equal to or thinner

than design case. 3) Diameter of pipe tested shall be 36 to 48 inch.

12. Joint details demonstrating proper clearances for field welding of inside or outside of pipe joint area.

13. Include calculations justifying need for or lack of need for thermal stress control joints. If thermal stress control joints are necessary, include location and details of joints. Also, include means and methods to be taken to reduce thermal stresses, such as welding thermal stress control joints in coolest part of day, and using backfill as insulation.

14. Rubber Gasket Joint: a. Details with dimensions and fabrication tolerances for both bell

and spigot ends. b. Performance history of at least 5 years at same or greater size and

pressure as largest pipe included in the Work or results of a testing program demonstrating joint performance at same or greater size as largest pipe included in the Work and 1.5 times highest pressure applied to pipe.

15. Letter from independent testing agency certifying pipe furnished meets requirements of this section.

16. Field Hydrostatic Testing Plan: Submit at least 15 days prior to testing and at minimum, include the following: a. Testing dates. b. Piping systems and section(s) to be tested. c. Method of isolation. d. Method of conveying water from source to system being tested. e. Calculation of maximum allowable leakage for piping section(s)

to be tested. f. Plan for disposal of test water.

17. Results of hydrostatic testing. 18. Certification of Calibration: Approved testing laboratory certificate if

pressure gauge for hydrostatic test has been previously used. If pressure gauge is new or if Owner is providing the gauge, no certificate is required.

19. Test report documentation.



20. Pipe manufacturer’s design engineer’s certification of training of Contractor’s pipe installation crews.


A. Qualifications:

1. Pipe Manufacturer: a. Meet at least one of the following requirements:

1) Member of STI/SPFA. 2) Obtained certification by Lloyd’s Register Group.

b. Obtained ISO 9001: 2008 Certification. c. Demonstrate current production capability for volume of work

required for this Project. 2. Pipe Manufacturer Experience: Applicable to fabrication plant facilities

and personnel, not company or corporation that currently owns fabrication facility or employs personnel. a. Experienced in fabricating pipe of similar diameters and wall

thickness required for the Work. b. Successful fabrication to AWWA C303 standards of at least

50,000 linear feet of 42-inch diameter or larger pipe within past 5-year period.

3. NDT Quality Control Personnel (Shop and Field): a. Certified in accordance with ASNT SNT-TC-1A Level II for

specified testing procedures. b. After receiving NDT qualification, minimum 5 years’ experience

with inspection and testing of welding and welded pipe and fittings similar to pipe and fittings required for Project.

4. Welder/Welding Operator (Shop and Field): a. Qualified before starting Work in accordance with ASME BPVC

Section IX, Article III. b. Qualified to perform groove welds in Positions 2G and 5G for

each welding process and pipe material specified. 5. Certified Welding Inspector (CWI) for both Shop and Field Welding:

a. Certified to AWS QC 1 and prior inspection experience using governing welding codes.

b. After receiving CWI qualification, at least one Shop CWI and one Field CWI shall have 5 years’ minimum professional experience related to welding inspection similar to the Work. Other CWIs may work under supervision of 5-year CWI, provided they have 1 year of related professional experience after receiving CWI qualification.



6. Fittings and Specials Fabricator: Experience shall be applicable to fabrication shop facilities and personnel, not company or corporation that currently owns fabrication facility or employs personnel. a. Experienced in fabricating fittings and specials of similar

diameters and wall thickness required for the Work. b. STI/SPFA or Lloyd’s Registry Certification. c. ISO 9001: 2008 Certification. d. Demonstrate current production capability for volume of work

required for this Project. e. Experience shall include successful fabrication to AWWA C303

standard of at least 25 fittings of 42 inch or larger pipe, with wall thickness 0.1046 inch or greater, within past 5-year period.


A. Packing and Shipping:

1. Ship with padded, curved and fitted bolsters, and padded tie downs. 2. Flanges: Securely attach metal, hardboard, or wood protectors over

entire gasket surface. 3. Cement Lining and Coating:

a. AWWA C205, Section 6. b. Enclose pipe ends with 10-mil polyethylene plastic wrap for

protection of cement-mortar lining during shipment. c. Keep plastic wrap on pipe until time of installation.

4. Stulling (Strutting): Design stulling for pipe, specials, and fittings such that over-deflection and damage is avoided during handling, storage, and installation, including backfill and compaction.

B. Cold Weather Storage: Elevate products to prevent coating from freezing to ground.

PART 2 PRODUCTS

2.01 MATERIALS

A. Pipe shall conform to requirements of AWWA C303 and AWWA M9, except as modified herein.

B. Joints:

1. Standard: Rubber gasketed Carnegie shape bell and spigot. Rolled groove bell and spigot in full conformance with requirements for joint rings in accordance with AWWA C303. Rolled groove joints may be an



integral part of cylinder, provided they provide full pressure rating capacity at all portions of joint.

2. Flanged: a. Steel ring in accordance with AWWA C207. b. Weld 6-inch long, 3/8-inch minimum thick steel cylinder section

to flange prior to flange face machining. c. Flange class to meet pressure rating of pipe or mating flange.

3. Restrained: By double lap welded joint meeting requirements of AWWA C200 and AWWA C206.

4. Plain End: a. 8 inches long or special pieces where mechanical couplings are

shown on Drawings. b. Prepare surfaces in accordance with manufacturer’s

recommendations and apply one coat of epoxy, 2 mils to 4 mils dry film thickness, of Amerlock 2.

C. Fittings:

1. In accordance with AWWA C303, AWWA M9, and herein. 2. Wall Thickness:

a. Refer to ASME B36.10M for definitions of wall thickness for standard weight pipe and nominal pipe size (NPS).

b. Reinforce to withstand either internal pressures, both circumferential and longitudinal, or external loading conditions, whichever is greater.

c. Minimum Plate Thickness: The greater of adjacent mainline pipe, thickness shown, thickness calculated as hereinafter specified, or as shown in Table 1.

Table 1

Nominal Pipe Diameter (inches)

Pipe Manifolds, Aboveground Piping, Piping in Structures

Elbows, Bends, Reducers

24 and Under Standard Weight Standard Weight

Over 24 1/4 inch 1/4 inch

3. Elbows, Unless Otherwise Indicated: a. Minimum Radius: 2.0 times pipe diameter or as indicated on

Drawings. b. Minimum Bend Wall Thickness: Greater of Table 1 above or as

calculated for straight pipe under internal pressure multiplied by



following bend stress intensities (tabulated below or calculated with following bend stress intensity formula where “n” is bend radius multiplier and SI=bend stress intensity.) For “n” greater than 2.5 stress intensity factor may be ignored as indicated in AWWA C208.

123

12

n

nSI

Bend Radius Multiplier “n” Bend Stress Intensity “SI”

1.0 1.67

1.5 1.33

2.0 1.22

D. Gaskets:

1. Standard Joints: In accordance with AWWA C303. 2. Flanged Joints: In accordance with AWWA C207.

E. Foam Grout Bands:

1. Fabric backing and steel strapping shall be of sufficient strength to hold fresh mortar.

2. Manufacturer: Mar-Mac Co.

F. Bolting: In accordance with AWWA C207.

G. Interior Joint Protection (Field Joint): Mortar mixture shall be in accordance with requirements of AWWA M9.


A. Owner and Owner’s designated representatives shall have full access to manufacturing facility during normal working hours.

B. CWI:

1. Present during shop welding. 2. Perform inspection prior to assembly, during assembly, during welding,

and after welding. 3. Duties include:

a. Verifying conformance of specified material and proper storage. b. Monitoring conformance with approved WPS.



c. Monitoring conformance of WPQ. d. Inspecting weld joint fit up prior to welding and providing in-

process inspection. e. Providing 100 percent visual inspection of welds. f. Coordinating nondestructive testing operations and reviewing test

results. g. Maintaining records and reports confirming results of inspection

and testing.

C. Fittings: Charpy V-notch tests in direction transverse to final rolling shall be performed in accordance with ASTM A370 on full size specimens of coupons taken from each plate. Acceptance shall be 25 foot-pounds at 30 degrees F.

D. Shop Nondestructive Testing:

1. Restrained Joint Pipe: In addition to 100 percent visual inspection of welds, perform the following nondestructive tests: a. Butt Joint Welds: Spot radiographically examine butt welds in

accordance with ASME BPVC Section VIII, Division 1, Paragraph UW-52.

b. Partial joint penetration, fillet welds, and offset lap welds as defined in AWWA C303, sometimes referred to as “crimp welds”: Examine 10 percent of these welds using magnetic particle inspection.

2. Unrestrained Joint Pipe: In addition to 100 percent visual inspection of welds, perform the following nondestructive tests: a. Butt Joint Welds: Inspect by hydrotesting. Spot radiographically

examine butt welds in accordance with ASME BPVC Section VIII, Division 1, Paragraph UW-52.

b. Partial joint penetration, fillet welds, and offset lap welds as defined in AWWA C303, sometimes referred to as “crimp welds”: Inspect by hydrotesting. Examine 10 percent of partial joint penetration or fillet welds using magnetic particle inspection.

3. Air test doubler pads in accordance with AWWA C206. 4. CJP welds including butt welds and groove welds that cannot be readily

radiographically examined shall be 100 percent ultrasonically examined in accordance with ASME BPVC Section VIII, Division 1.

E. Inspection of Pipe Fabrication Procedure:

1. Select and provide independent testing agency to observe pipe fabrication.

2. Agency staff shall have experience in observation of bar-wrapped concrete cylinder pipe fabrication in accordance with ASTM E329.



3. Representative of agency shall be present full time while pipe is being fabricated and while protective coating and lining is applied.

4. Provide letter to Engineer certifying pipe furnished meets requirements of this section.

PART 3 EXECUTION

3.01 EXAMINATION

A. Verify size, material, joint types, elevation, horizontal location, and pipe service of existing pipelines to be connected to new pipelines or new equipment.


3.02 PREPARATION

A. Damaged Coatings and Linings: Repair using original coating and lining materials in accordance with manufacturer’s instructions.

B. Leave interior bracing in place until pipe zone material has been placed and completely compacted.

C. Installation Training:

1. Prior to field installation, pipe manufacturer’s design engineer shall provide training to Contractor’s pipe installation crews describing assumptions used to design pipe that are dependent on Contractor’s installation methods.

2. Particular attention shall be paid to restrained joint installation, thermal stress control, and trench width if this specification allows pipe to be designed for trench widths less than transition width.

3. Provide documentation to Owner verifying training was provided.

3.03 INSTALLATION

A. General:

1. Join pipe and fittings in accordance with manufacturer’s instructions, unless otherwise shown or specified.

2. Inspect pipe and fittings before installation. Clean ends thoroughly; remove foreign matter and dirt from inside.



3. Make minor field adjustments by pulling standard joints. a. Maximum Allowable Angle: 75 percent of manufacturer’s

recommended or angle that results from 3/4-inch pull out from normal joint closure, whichever is less.

4. Horizontal deflections or fabricated angles shall fall on alignment, as shown within tolerances below.

5. Vertical deflections shall fall on alignment, and pipe angle point locations shall match those indicated on Drawings within tolerances below.

6. Stulling: a. Maintain stulling in place until pipe is completely backfilled and

compacted. b. Prior to backfilling, re-install stulls that were temporarily removed

to facilitate interior welding. 7. Pipeline Alignment Tolerances:

a. Plan: 2 inches. b. Elevation: 1 inch.

8. Submit Manufacturer’s Certificate of Proper Installation at completion of Project that contains at least the following: a. Installation personnel have been properly instructed. b. Installation personnel have employed proper pipe handling and

installation procedures. c. Written reports of each Site visit by manufacturer’s field service

representative.

B. Flanged Joints:

1. Install perpendicular to pipe centerline. 2. Bolt Holes: Straddle vertical centerline, align with connecting

equipment flanges or as shown. 3. Use torque-limiting wrenches to ensure uniform bearing and proper bolt

tightness. 4. Use flat-face flanges conforming to AWWA C207 when joining with

flat-faced flanges.

C. Interior Joints:

1. Pipe Less Than 24-inch Diameter: a. Portland cement mortar composed of one part cement to not more

than two parts fine aggregate with only sufficient water to form stiff mix.

b. Prior to assembly, install immediately behind joint area a suitable quantity of mortar to completely fill joint void area.



c. After assembly, trowel installed mortar into joint area using a “ball” pulled through joint area to spread mortar.

d. Metalizing of surfaces with zinc or other products is not an acceptable alternative.

2. Pipe 24-inch Diameter and Larger: a. After backfill has been placed at least to top of pipe zone, dampen

inside joint space with water or neat cement slurry and fill joint with portland cement mortar in accordance with AWWA M9.

b. Finished surface shall be dense troweled surface, free of projections or depressions, and shall be flush with interior surface of pipe.

c. Metalizing of surfaces with zinc or other products is not an acceptable alternative.

D. Exterior Joints: In accordance with AWWA M9.

E. Mortar Coating Repair: In accordance with AWWA C303.

F. Welding:

1. In accordance with AWWA C206. 2. Weld Identification: Mark each weld with symbol identifying welder. 3. Weld Inspection: 100 percent visual inspection by field CWI. 4. Alignment and Spacing: Align ends to be joined within existing

commercial tolerances on diameters, wall thicknesses, and out-of-roundness.

5. Carnegie Joints: Interior weld in accordance with Drawings and AWWA M9, Figure 9-24.

6. Tack Welds: Perform by qualified tack welder using same procedure as for completed weld, made with electrode similar or equivalent to that used for first weld pass.

G. Thrust Restraint:

1. Provide at tees, plugs, caps, bends, and other locations where shown and where unbalanced forces exist.

2. Type: Restrained joint, unless otherwise shown. 3. Anchoring of retainer glands or thrust ties with setscrews is

unacceptable.


A. As specified in Section 26 42 02, Galvanic Anode Cathodic Protection System.




A. Joints: Check each joint, including transition joints, as instructed by pipe manufacturer’s representative to verify proper joint installation.

B. Field Weld Inspection Criteria:

1. Unless otherwise specified, perform NDT of welds at frequency shown below.

2. Perform UT on CJP groove welds that cannot be readily radiographed. 3. If NDT discloses welding which does not comply with acceptance

criteria of Subparagraph Weld Acceptance, then entire weld segment shall be examined using same nondestructive examination (NDE) method (RT, UT, PT or MT): a. Fillet Welds and PJP Groove Welds: 10 percent random PT or

MT. b. All Welds: 100 percent VT.

4. Weld Acceptance: a. VT:

1) Structural Pipe and Tubing: AWS D1.1/D1.1M, Paragraph 6.9 and Table 6.1, Tubular Structures.

2) All Other Structural Steel: AWS D1.1/D1.1M, Paragraph 6.9, Visual Inspection, Statically Loaded Nontubular Connections.

b. PT or MT: 1) Perform on fillet and PJP groove welds in accordance with

AWS D1.1/D1.1M, Paragraph 6.10. 2) Acceptance shall be in accordance with VT standards

specified above.

C. Pipeline Hydrostatic Test:


testing in presence of Engineer. b. Test newly installed pipelines. Using water as test medium, pipes

shall successfully pass leakage test prior to acceptance. c. Furnish testing equipment. Testing equipment shall provide

observable and accurate measurements of leakage under specified conditions.

d. Isolate new pipelines that are connected to existing pipelines.



e. The new 42-inch pipeline shall be isolated and tested in the following three separate segments: 1) Beginning of pipeline at Tracy WWTP to butterfly valve in

meter valut adjacent to Pond 5. 2) Butterfly valve in meter vault adjacent to Pond 5 to isolation

valve just south of Paradise Cut. 3) Butterfly valve just south of Paradise Cut crossing to end of

pipeline at Old River. f. Conduct field hydrostatic test on buried piping after trench has

been completely backfilled. Testing may, as approved by Engineer, be done prior to placement of asphaltic concrete or roadway structural section.

g. Contractor may, if field conditions permit and as determined by Engineer, partially backfill trench and leave joints open for inspection and conduct an initial service leak test.

h. Do not conduct final field hydrostatic test until backfilling has been completed as specified above.

i. Supply of temporary water shall be as stated in Section 01 50 00, Temporary Facilities and Controls.

j. Dispose of water used in testing in accordance with federal, state, and local requirements.

2. Preparation: a. Install temporary thrust blocking or other restraint as necessary to

prevent movement of pipe and protect adjacent piping or equipment. Make necessary taps in piping prior to testing.

b. Wait 5 days minimum after concrete thrust blocking is installed to perform pressure tests. If high-early strength cement is used for thrust blocking, wait may be reduced to 2 days.

c. Prior to test, remove or suitably isolate appurtenant instruments or devices that could be damaged by pressure testing.

d. New Piping Connected to Existing Piping: Isolate new piping with grooved-end pipe caps, blind flanges, or other means acceptable to Engineer.

3. Procedure: a. Maximum filling velocity shall not exceed 0.25 foot per second,

calculated based on full area of pipe. b. Expel air from pipe system during filling. c. Test section may be filled with water and allowed to stand under

low pressure prior to testing. d. Test Pressure: 50 psi as measured at beginning of pipeline

alignment. e. Apply and maintain specified test pressure with hydraulic force

pump. Valve off piping system when test pressure is reached.



f. Maintain hydrostatic test pressure continuously for 2 hours minimum, adding additional make-up water only as necessary to restore test pressure.

g. Determine actual leakage by measuring quantity of water necessary to maintain specified test pressure for duration of test.

h. If measured leakage exceeds allowable leakage or if leaks are visible, repair defective pipe section and repeat hydrostatic test.

4. Allowable Make-up Water: a. For pipe with O-ring rubber gasket joints, allowable make-up

water shall not exceed 0.06 gallon(s) per inch of diameter per mile per 2 hours.

b. For pipe with welded or fused joints, allowable make-up water shall not exceed 0.0 gallons per inch of diameter per mile per 2 hours.

END OF SECTION


PW/WBG/179201 HIGH-DENSITY POLYETHYLENE (HDPE) OCTOBER 2018 PRESSURE PIPE AND FITTINGS ©COPYRIGHT 2018 CH2M HILL 33 05 01.10 - 1

SECTION 33 05 01.10 HIGH-DENSITY POLYETHYLENE (HDPE) PRESSURE PIPE AND FITTINGS

PART 1 GENERAL

1.01 TOM PAINE SLOUGH CROSSING BALLAST DESIGN REQUIREMENTS

A. Design ballast in accordance with requirements of Plastic Pipe Institute Handbook of Polyethylene Pipe, Second Edition, for Marine Installations and manufacturers recommendations.

B. Maximum Ballast Spacing: 10 feet.

1.02 SUBMITTALS


1. Shop Drawings: a. Catalog information confirming pipe, fittings, and other materials

conform to requirements of this section. b. Drawings of specific connection details.

2. Tom Paine Slough Crossing Pipeline Installation Plan: Submit pipeline installation plan where pipeline is in a wet or submerged trench condition. Plan shall include, but not be limited to, concrete ballast design and calculations. See Article Tom Paine Slough Crossing Ballast Design Requirements.


1. Manufacturer’s Certificate of Compliance, in accordance with Section 01 43 33, Manufacturers’ Field Services.

2. Infrared temperature gun product data. 3. Certificates of qualification for persons to be fusing HDPE pipe.

Experience, training record, and certificates of persons to be fusing HDPE pipe.

4. Information on manufacturer and model of machine to be used for fusion of HDPE pipe.

5. Testing Plan: Submit at least 15 days prior to testing and include the following as a minimum: a. Testing dates. b. Piping systems and section(s) to be tested. c. Method of isolation. d. Method of conveying water from source to system being tested.


HIGH-DENSITY POLYETHYLENE (HDPE) PW/WBG/179201 PRESSURE PIPE AND FITTINGS OCTOBER 2018 33 05 01.10 - 2 ©COPYRIGHT 2018 CH2M HILL

6. Certifications of Calibration: Approved testing laboratory certificate if pressure gauge for hydrostatic test has been previously used. If pressure gauge is new, no certificate is required.

7. Test report documentation. 8. Installation Plan following the Plastic Pipe Institute, ASTM F2620, and

manufacturer’s recommendations. Plan shall include, but not be limited to the following major components: a. Pipe and fitting storage. b. Pipe and fitting handling equipment. c. Proposed means to maintain required temperatures for fusing. d. Proposed means to shield the fusing area from wind, snow,

blowing dust, and rain. e. Proposed means to maintain uniform pipe wall temperature prior

to fusing. 9. Temperature Control Plan: Plan shall include means to reduce the

temperature of the pipe to the limit stated in Part 3 of this Specification. 10. Fusion parameters including recommended limits of criteria recorded by

data logger. 11. Fusion report for each joint, including information listed under Article

Field Quality Control. Submit joint reports, within 24 hours after fusion. 12. Gasket manufacturer’s table for recommended bolt torque and

tightening pattern.


A. Qualifications:

1. Pipe Manufacturer: Listed with Plastic Pipe Institute. 2. Experienced in fabricating pipe of similar diameters and wall thickness

required for the Work. 3. Successful fabrication of at least 10,000 linear feet of 42-inch diameter

or larger pipe within past 5-year period. 4. Persons fusing HDPE pipe shall have a current operator qualification

training certificate and wallet card showing the operator is qualified to operate the machine to be used on the Project and have a minimum of 2 year(s) of experience with fusing HDPE pipe and have received a minimum of 20 hours of training for fusing large-diameter HDPE pipe from pipe supplier or fusing equipment supplier.


A. Shipping: Do not cut, kink, or otherwise damage pipe during transportation.



B. Storage and Handling:

1. Pipe interiors are to be inspected and all debris removed, prior to storage.

2. Pipe shall not be stacked to prevent excessive deformation and have single rows in accordance with in AWWA Manual M55, Table 7-1.

3. Where necessary, because of ground conditions, store pipe on wooden sleepers, spaced suitably and of such widths as not to allow deformation of pipe at point of contact with sleeper or between supports.

4. Comply with the requirements of the approved Installation Plan. 5. Keep pipe shaded at all times from direct sunlight prior to fusion and

installation in trench. Shade material shall not be dark but a dense white fabric with high resistive tensile properties to prevent tearing from construction activities or windy conditions.

PART 2 PRODUCTS

2.01 MATERIALS

A. Pipe and Fittings:

1. Conform to requirements of AWWA C906. 2. Resin: Polyethylene resin shall meet or exceed requirements of

ASTM D3350 for PE 4710 material with cell classification of 445474C, or better. PE 4710 HDPE pipe and fittings shall be manufactured from bimodal resins. Pressure rating shall be based on hydrostatic design stress of 1000 psi at 73.4 degrees F.

3. Nominal SDR 26 and SDR 11 where shown on Drawings. 4. Outside Diameter Basis: IPS. 5. Pipe lengths, fittings, and flanged connections to be joined by thermal

butt-fusion shall be of a compatible resin mix for the fusion process. 6. Fittings:

a. Polyethylene fittings shall have same or higher-pressure rating as pipe.

b. Sizes 12 inches and Smaller: Molded and manufactured to the requirements of ASTM D3261, Standard Specification for Butt Heat Fusion Polyethylene (PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing.

c. Sizes Larger than 12inches: Thermal butt fused fabricated. d. Unless noted otherwise, provide fittings with a factory fused

4-foot long spool on each end to facilitate on-site fusion.



B. Backup Rings:

1. Convoluted for Flanged Connections: a. ASTM A240/A240M, Type 316 stainless steel b. Complete with one-piece, molded polyethylene flange adapters. c. Flanged Connections: Same or greater pressure rating as pipe.

2. Gaskets: Material, size, and thickness shall be as recommended by gasket manufacturer, and in accordance with PPI Technical Note 38. Gasket manufacturer shall provide a table with recommended bolt torque and tightening pattern.

C. Joints: Thermal butt-fusion or electrofusion, except where connecting to unions, valves, and equipment with flanged or threaded connections that may require future disassembly. Use appropriate transition fitting or adapter for all joints that are not thermal butt-fused or electro-fused.

D. Bolts, Nuts, Washers:

1. Bolt Materials: Type 316 stainless steel, ASTM A193/A193M, Grade B8M hex-head, carbide solution treated and strained hardened.

2. Bolt Fabrication: In accordance with ASME B18.2.1. 3. Nut Materials: Type 316 stainless steel, ASTM A194/A194M, Grade 8

hex-head. 4. Nut Fabrication: In accordance with ASME B18.2.2. 5. Washers: Type 316 stainless steel, same material as bolts In accordance

with ASME B18.21.1. 6. Thread Lubricant: Provide bolt manufacturer’s recommended lubricant

on bolt threads, nuts, the nut face and around the bolt hole.

E. Wall Anchor:

1. Material: Same as HDPE pipe. 2. Internal Diameter: Equal to adjacent pipe. 3. Shear Strength: Equal to or greater than tensile strength of adjacent

pipe. 4. Fabrication: Butt fusion. Extrusion bead welding is not allowed.

F. Electrofusion Flex Restraint:

1. Material: PE 4710 HDPE. 2. Method of Attachment: Electrofusion. 3. Designed for restraining movement of HDPE pipe.



4. Manufacturers: a. Central Plastics Company. b. Industrial Pipe Fittings, IPF-Plasson.

G. Electrofusion Couplings:

1. Material: PE 4710 HDPE. 2. Method of Attachment: Electrofusion. 3. Designed for coupling HDPE pipe. 4. Manufacturers:

a. Central Plastics Company. b. ISCO Industries.

H. Concrete Thrust Blocks and Collars: See Section 33 05 01, Conveyance Piping—General.

I. Products that restrain HDPE pipe with wedges, or clamps are not acceptable.

2.02 SERVICE CONDITIONS

A. Service: Conveyance of effluent from the City of Tracy Wastewater Treatment Plant.

PART 3 EXECUTION

3.01 INSTALLATION

A. General:

1. Install polyethylene pipe in conformance with AWWA M55, PPI TR-33, ASTM F2620, and pipe manufacturer’s recommendations.

2. Follow all requirements of approved Installation Plan where HDPE is to be installed in ambient temperatures less than 50 degrees F, in hot conditions, or in windy conditions.

3. Protect and install pipe in accordance with the Temperature Control Plan when contraction of the pipe length may cause damage to or pull out from structures.

B. Joining: Butt-fuse pipes and fittings in accordance with pipe manufacturer’s recommendations. Depending on Site conditions, perform butt-fusion joining in or outside of excavated trench.

1. If HDPE pipe surface temperature is above 80 degrees F as measured with infrared temperature gun, allow pipe to cool prior to making any connections to flanges, existing pipeline systems, or structures.



2. Connect HDPE pipe to auxiliary equipment such as valves, pumps, tanks, and other piping systems with flanged connections as follows: a. Polyethylene flange adapter, thermally butt-fused to end of pipe.

Flange “stub ends” are not allowed. b. Convoluted backing flange, as specified. c. Bolt and nut of sufficient length to show a minimum of three

complete threads when joint is made and tightened to manufacturer’s standard.

d. Follow requirements of PPI Technical Note 38 including mandatory 4-hour bolt re-torquing.

3. Special Precautions at Flanges: Support polyethylene pipe connected to heavy fittings, manholes, and rigid structures in such a manner that no subsequent relative movement between polyethylene pipe at flanged joint and rigid structures is possible.

4. Minimum Long-Term Field Bending Radius: 350 feet.

C. Placement in Trench:

1. Handle joined pipeline in such a manner that pipe is not damaged by dragging it over sharp and cutting objects.

2. Position slings for handling pipeline away from butt-fused joints. 3. Remove sections of damaged pipe and replace it with undamaged pipe.

Damaged pipe is defined as pipe with kinks or gouges exceeding 10 percent of pipe wall thickness.

4. Exercise care when lowering pipe into trench to prevent damage or twisting of pipe.

5. At flanges, valves, and connections, excavate out trench bottom sufficiently to ensure clearance between undisturbed trench bottom and flange, valve, or connection.


A. Joint Butt Fusion:

1. Measure and log each joint fusion by an electronic monitoring device (data logger) affixed to fusion machine. Data to be logged shall include the following and shall be capable of being retrieved electronically: a. Pipe size, dimensions, and wall thickness. b. Machine model and size. c. Operator identification. d. Job identification number. e. Weld number. f. Fusion, heating, and drag pressure settings. g. Heater plate temperature.



h. Time stamp showing when weld was performed. i. Heating and curing time of weld. j. Curing temperature readings and time stamps of readings. k. Error messages and warnings for out of range temperature or

pressure settings. 2. In addition to logged items above, the following shall be logged or

annotated on report: a. Location of joint being fused by pipeline station or by reference to

pipe Shop Drawing. b. Ambient temperature, wind speed, precipitation, and humidity. c. If internal bead was removed. d. Environmental actions taken (e.g. use of tarps, enclosures,

blankets, etc.) e. Type of HDPE and manufacturer.

B. Joint Weld Inspection:

1. Visually examine each joint in accordance with the guidelines in ASTM F2620. Remove and replace any joints not meeting the standard.

2. Mechanical Joint Testing: a. Provide additional piping for performing mechanical joint testing

as indicated herein. b. Pipe wall thickness 1-inch or less:

1) Test joints in accordance with the bend back testing provided in Appendix X4 of ASTM F2620.

c. Pipe wall thickness greater than 1-inch: 1) Test joints in accordance with the guided side bend testing

in accordance with ASME BPVC Section IX Article XXI-XXIV.

d. Specimens: Cut pipe 12 inches on each side of field made joint. Rejoin ends and proceed with Work.

e. Test Frequency: 1) SDR 26 HDPE:

a) First 1,000 Linear Feet: Two joints selected at random by Engineer.

b) Each Additional 5,000 Linear Feet: One joint selected at random by Engineer.

c) Each Test Failure: Two additional joints selected at random by Engineer.

2) SDR 11 HDPE: a) First two joints. b) One additional joint selected at random by Engineer.



c) Each Test Failure: Two additional joints selected at random by Engineer.

C. Pipeline Hydrostatic Test:


testing in presence of Engineer. b. Furnish testing equipment and perform tests in manner

satisfactory to Engineer. Testing equipment shall provide observable and accurate measurements of initial service leak and allowable make-up water volume under specified conditions.

c. Test newly installed pipelines. d. Isolate new pipelines that are connected to existing pipelines. e. Using water as test medium, pipes shall successfully pass a

hydrostatic test prior to acceptance. f. Conduct field hydrostatic test on buried piping after trench has

been completely backfilled. Testing may, as approved by Engineer, be done prior to placement of asphaltic concrete or roadway structural section.

g. Contractor may, if field conditions permit and as determined by Engineer, partially backfill trench and leave joints open for inspection and conduct initial service leak test. Final field hydrostatic test shall not be conducted until backfilling has been completed as specified above.

h. Supply of temporary water shall be as stated in Section 01 50 00, Temporary Facilities and Controls.

i. Dispose of water used in testing in accordance with federal, state, and local requirements.

2. Preparation: a. Install temporary thrust blocking or other restraint as necessary to

prevent movement of pipe and protect adjacent piping or equipment. Make necessary taps in piping prior to testing.

b. Wait 5 days minimum after concrete thrust blocking or designed thrust collars are installed to perform pressure tests. If high-early strength cement is used for thrust blocking, wait may be reduced to 2 days.

c. Prior to test, remove or suitably isolate appurtenant instruments or devices that could be damaged by pressure testing.

d. New Piping Connected to Existing Piping: Isolate new piping with grooved-end pipe caps, blind flanges, or other means as acceptable to Engineer.



3. Procedure: a. Test pressure shall be 50 psi as measured at location shown on

Drawings. b. Maximum filling velocity shall not exceed 0.25 feet per second,

calculated based on full area of the pipe. c. Expel air from pipe system during filling. d. Test procedure shall be in accordance with ASTM F2164.

1) Initial Expansion Phase: Add water as required to maintain test pressure for 4 hours.

2) Test Phase: Reduce pressure by 10 psi and start pressure test.

3) Test is successful if pressure says within 5 percent of initial value for 1 hour.

e. Depressurize test section and allow it to relax for at least 8 hours before retesting, if test is terminated because of leakage, equipment failure, or other reasons.

f. If there is leakage, repair defective pipe section and repeat hydrostatic test.

3.03 MANUFACTURER’S SERVICES

A. Provide pipe manufacturer’s representative at Site in accordance with Section 01 43 33, Manufacturers’ Field Services, for assistance during pipe joining operations and pipe installation.

END OF SECTION


PW/WBG/179201 AIR AND VACUUM RELEASE OCTOBER 2018 VALVE ASSEMBLIES ©COPYRIGHT 2018 CH2M HILL 33 12 16.29 - 1

SECTION 33 12 16.29 AIR AND VACUUM RELEASE VALVE ASSEMBLIES

PART 1 GENERAL

1.01 SUBMITTALS


1. Product data sheets for make and model. 2. Complete catalog information, descriptive literature, specifications, and

identification of materials of construction. 3. Maximum recommended test pressure; maximum and minimum

recommended working pressures of air valves, isolation valves, flanges, connecting piping, and fittings.

4. Recommended seating materials for specified operating pressures.


1. Manufacturers’ Instructions: a. Installation and testing of products specified. b. Pipeline tapping and service saddle installation.

2. Operation and maintenance data. 3. Affidavit of Compliance in accordance with AWWA C512 stating valve

and all materials used conform to applicable requirements of AWWA C512 and these Specifications, and tests specified have been performed and all requirements have been met.

PART 2 PRODUCTS

2.01 AIR VALVES

A. General:

1. Air release, air/vacuum, and combination air valves shall conform to AWWA C512.

2. Exterior of air valves shall be coated in accordance with Section 09 90 00, Painting and Coating.

3. Interior of air valves shall be coated in accordance with AWWA C550. 4. Air valves shall be factory tested in accordance with AWWA C512.


AIR AND VACUUM RELEASE PW/WBG/179201 VALVE ASSEMBLIES OCTOBER 2018 33 12 16.29 - 2 ©COPYRIGHT 2018 CH2M HILL

B. Rolling Seal Combination Air Valve 2 Inches to 8 Inches: Type V757 as specified in Section 40 27 02, Process Valves and Operators.

2.02 CONNECTION TO MAINLINE

A. Flanged Outlet or Fitting: Flange shall be as required to match drilling pattern of adjoining valve and suitable for test pressure and working pressure.

B. Service Saddle:

1. Stainless steel double straps. 2. Body: Ductile iron, nylon, or epoxy coated. 3. Bolts and Nuts: Type 304 stainless steel. 4. Comply with applicable portions of AWWA C800. 5. Manufacturers and Products:

a. Mueller; Series DR2S. b. Romac; Style 202S or 202N.

C. For steel pipe, connection to mainline may be flanged or threaded. Make threaded connections with welded, forged fittings in accordance with ASME Boiler and Pressure Code.

2.03 ISOLATION VALVES

A. As shown on the Drawings and as specified in Section 40 27 02, Process Valves and Operators.

B. Corporation Stop:

1. AWWA C800 type, with ends suitable for adjoining pipe. 2. Rated for minimum pressure of 150 psi.

2.04 PIPING BETWEEN MAINLINE AND AIR VALVE

A. Steel pipe conforming to Section 33 05 01.01, Welded Steel Pipe and Fittings. Coating shall conform to Section 09 90 00, Painting and Coating. Lining shall conform to Section 09 90 00, Painting and Coating.

B. Ductile iron pipe conforming to Section 33 05 01.02, Ductile Iron Pipe and Fittings.

2.05 VALVE VAULT

A. See Drawings.


PW/WBG/179201 AIR AND VACUUM RELEASE OCTOBER 2018 VALVE ASSEMBLIES ©COPYRIGHT 2018 CH2M HILL 33 12 16.29 - 3

2.06 ACCESSORIES

A. Insulation:

1. Cellular polystyrene, 1 inch thick. 2. Manufacturer and Product: Dow Chemical Co.; Styrofoam.

PART 3 EXECUTION

3.01 INSTALLATION

A. Valves:

1. In accordance with manufacturer’s printed instructions. 2. Orient valve in vault with easy access to operator. 3. Replace valves that drip or do not function properly.

B. Service Saddle:

1. Tap and install in accordance with manufacturer’s printed instructions. 2. Use adapters for size of line being tapped.

C. Valve Vault:

1. Place off center for access to operators. 2. Install so finished grade of top of vault conforms to slope and elevation

of adjacent ground.

D. Insulation:

1. Install within vault, above and around designated valve assemblies as required to protect valve from freezing.

2. Provide space for air passage to allow proper functioning of air valves. 3. Support insulation with clips anchored to manhole or vault wall.

3.02 TESTING AND INSPECTION

A. Air Valve:

1. May be either tested while testing pipelines, or as a separate step. 2. Isolation valves shall be in open position during pipeline test.

B. Isolation Valves: Test that valves open and close smoothly with operating pressure on one side and atmospheric pressure on the other.


AIR AND VACUUM RELEASE PW/WBG/179201 VALVE ASSEMBLIES OCTOBER 2018 33 12 16.29 - 4 ©COPYRIGHT 2018 CH2M HILL

C. Air and Vacuum Valves: Inspect valves as pipe is being filled to verify venting and seating is fully functional.

D. Verify leak-free performance during testing.

END OF SECTION


PW/WBG/179201 STORM DRAIN SANITARY SEWER OCTOBER 2018 AND DRAINAGE PIPING ©COPYRIGHT 2018 CH2M HILL 33 41 01 - 1

SECTION 33 41 01 STORM DRAIN SANITARY SEWER AND DRAINAGE PIPING

PART 1 GENERAL

1.01 SUBMITTALS

A. Informational Submittals: Manufacturer’s Certification of Compliance.

PART 2 PRODUCTS

2.01 PIPE AND FITTINGS

A. As specified in the Data Sheets following “End of Section.”

PART 3 EXECUTION

3.01 INSTALLATION OF PIPE, FITTINGS, AND APPURTENANCES

A. General:

1. Pipe laying shall proceed upgrade with spigot ends pointing in direction of flow.

2. Excavate bell holes at each joint to permit correct assembly and inspection of entire joint.

3. Pipe invert may deviate from line or grade up to 1/2 inch for line and 1/4 inch for grade, provided that finished pipe line will present a uniform bore, and such variation does not result in a level or reverse sloping invert, or less than minimum slope shown.

4. Pipe bedding shall form continuous and uniform bearing and support for pipe barrel between joints. Pipe shall not rest directly on bell or pipe joint.

5. Prevent entry of foreign material into gasketed joints. 6. Plug or close off pipes that are stubbed off for manhole, concrete

structure, or for connection by others, with temporary watertight plugs.

3.02 CLEANING

A. Prior to final acceptance and inspection of the system by Engineer, flush and clean all parts of the system. Remove all accumulated construction debris, rocks, gravel, sand, silt, and other foreign material from the system at or near the closest downstream access point. If necessary, use mechanical rodding or bucketing equipment.


STORM DRAIN SANITARY SEWER PW/WBG/179201 AND DRAINAGE PIPING OCTOBER 2018 33 41 01 - 2 ©COPYRIGHT 2018 CH2M HILL

B. Upon Engineer’s final inspection of the system, if any foreign matter is still present in the system, reflush and clean the sections and portions of the lines as required.

3.03 SUPPLEMENTS

A. Data Sheets.

Number Title

.01 Corrugated Metal

.03 Polyvinyl Chloride (PVC)

.04 Nonreinforced Concrete

.05 Reinforced Concrete

.07 Polyethylene (PE) Profile Wall

.08 Corrugated Polyethylene (CPE)

END OF SECTION


PW/WBG/179201 CORRUGATED METAL OCTOBER 2018 33 41 01.01 DATA SHEET - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 33 41 01.01 CORRUGATED METAL

Item Description

Pipe AASHTO M36M, Type I, galvanized.

Bituminous Coating AASHTO M190M, Type A.

Coupling Bands Manufacturer’s standard, with same protective coating as pipe.

Gaskets Manufacturer’s standard.

Source Quality Control In accordance with specified reference standard.

END OF SECTION


PW/WBG/179201 POLYVINYL CHLORIDE (PVC) OCTOBER 2018 33 41 01.03 DATA SHEET - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 33 41 01.03 POLYVINYL CHLORIDE (PVC)

Item Description

Pipe: 15-inch diameter and under

ASTM D3034: Standard dimension ratio less than 35, except that the cell classification shall be 12454-B or 12454-C as defined in ASTM D1784.

Pipe: 18- through 24-inch diameter

ASTM F679: Standard dimension ratio less than 35, except that the cell classification shall be 12454-C as defined in ASTM D1784.

Ribbed Profile Pipe: 18-through 36-inch diameter

ASTM F794: Minimum stiffness of 46 psi when tested in accordance with ASTM D2412, except that the cell classification shall be 12454-C as defined in ASTM D1784.

Joints ASTM D3212 rubber gasketed.

Gaskets ASTM F477. Lubricants: As approved by manufacturer.

Fittings PVC, gasketed. Provide plug when service piping is not required.

Plugs Removable. Removal shall provide a socket suitable for making a flexible jointed lateral connection or extension.

Source Quality Control Testing

In accordance with specified ASTM.

END OF SECTION


PW/WBG/179201 NONREINFORCED CONCRETE OCTOBER 2018 33 41 01.04 DATA SHEET - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 33 41 01.04 NONREINFORCED CONCRETE

Item Description

Class Nonreinforced Concrete, Class 3. Maximum Diameter 10 inches.

Cement ASTM C150, Type II, or

ASTM C150, Type I with maximum Tricalcium Aluminate 12 percent with fly ash, or

ASTM C595 Rev A, Type IP: Cement conforms to ASTM C150, with fly ash.

Minimum 564 pounds per cubic yard without fly ash.

Minimum 479 Pounds per Cubic Yard Plus Fly Ash: 85 pounds per cubic yard minimum, 160 pounds per cubic yard maximum.

Ratio: Water to Cementitious Materials

Not over 0.49.

Fly Ash ASTM C618, Class C or Class F, Tables 1 and 2 modified as follows:

Loss on Ignition: Maximum 3 percent.

Water Requirement: Maximum 100 percent of control or test cement fly ash mix in accordance with ASTM C1012.

Mix: Equal to or better than ASTM C150, Type II cement.

Test: ASTM C311 and ASTM C618.

Joints ASTM C443 Rev A rubber gasketed.

Rubber Gaskets ASTM C443 Rev A.

Tee Fittings Nonreinforced concrete, rubber gasketed, and fabricated by pipe manufacturer. Provide plug when service piping is not required.



NONREINFORCED CONCRETE PW/WBG/179201 33 41 01.04 DATA SHEET - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

SECTION 33 41 01.04 NONREINFORCED CONCRETE

Item Description


Load Bearing Ultimate: ASTM C14 modified as follows; one pipe per 100 lengths of pipe manufactured for all sizes. If pipe fails, two additional pipes shall be tested. If either of the two pipes fail, the entire 100 lengths will be rejected.

Permeability: ASTM C14 modified as follows; test 5 percent of each 100 lengths of pipe manufactured. If 20 percent of the group sampled fails, the entire 100 lengths will be rejected.

END OF SECTION


PW/WBG/179201 REINFORCED CONCRETE OCTOBER 2018 33 41 01.05 DATA SHEET - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 33 41 01.05 REINFORCED CONCRETE

Item Description

Pipe ASTM C76, Wall B, class as shown. Mark each joint with pipe class. Rotating packer or platform not allowed.

Cement ASTM C150, Type II, or

ASTM C150, Type I, with fly ash; maximum 12 percent Tricalcium Aluminate, or

ASTM C595 Rev A, Type IP, with fly ash; Cement: ASTM C150.

Minimum 564 pounds per cubic yard without fly ash.

Minimum 479 pounds per cubic yard with fly ash.

Ratio: Water to Cementitious Materials

Not over 0.49.

Fly Ash ASTM C618, Class C or Class F, Tables 1 and 2 modified as follows:

Loss on Ignition: Maximum 3 percent Water Requirement: Maximum 100 percent of control Ratio Percent CaO/Fe2O3: Maximum 1.5

or test cement fly ash mix in accordance with ASTM C1012. Mix: Equal to or better than ASTM C150, Type II cement.

85 pounds per cubic yard minimum, 160 pounds per cubic yard maximum.

Test: ASTM C311 and ASTM C618.

Joints ASTM C443 Rev A. Captive gasket in groove.

Rubber Gaskets ASTM C443.

Tee Fittings Reinforced concrete, rubber gasketed. Provide plug when service piping is not required.


Circumferential Reinforcement

Not closer than 1 inch to inside surface of pipe. Area of outer circular reinforcing cage not less than 75 percent of inner cage.


REINFORCED CONCRETE PW/WBG/179201 33 41 01.05 DATA SHEET - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

SECTION 33 41 01.05 REINFORCED CONCRETE

Item Description

Elliptical Reinforcement

Not allowed.


Load Bearing 0.01-inch Crack, Compressive Strength and Absorption: ASTM C76.

Load Bearing Ultimate: ASTM C76.

Permeability: ASTM C497.

Voids: Longitudinally sawcut one pipe from each 100 lengths of pipe manufactured in half with saw that will not damage the concrete or reinforcing steel. Inspect for voids adjacent to circumferential bars. Voids will be considered continuous if a 1/16-inch diameter pin can be inserted 1/4-inch deep. If voids exist adjacent to more than 10 percent of the circumferential bars, two additional pipes shall be tested. If either of the two pipes fail, the entire 100 lengths will be rejected.

END OF SECTION


PW/WBG/179201 POLYETHYLENE (PE) PROFILE WALL OCTOBER 2018 33 41 01.07 DATA SHEET - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 33 41 01.07 POLYETHYLENE (PE) PROFILE WALL

Item Description

Pipe ASTM F894.

Ring Stiffness Constant (RSC)

40.

Profile Open

Joints Plain ends for heat fusion joints.

Gaskets ASTM F477.

Fittings Manufacturer’s standard; same ring stiffness as adjacent pipe.

Source Quality Control ASTM F894.

Factory Testing Pipe lengths used for deflection testing shall be destroyed after testing.

END OF SECTION


PW/WBG/179201 CORRUGATED POLYETHYLENE (CPE) OCTOBER 2018 33 41 01.08 DATA SHEET - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 33 41 01.08 CORRUGATED POLYETHYLENE (CPE)

Item Description

Pipe AASHTO M252M (75 to 250-mm diameter). AASHTO M294M (300 to 900-mm diameter). AASHTO MP6 (1050 to 1200-mm diameter).

Pipe Stiffness (Minimum)

In accordance with specified AASHTO Specification.

Profile Type S and D.

Joints Plain ends for culvert.

Gaskets ASTM F477.

Fittings Manufacturer’s standard; same stiffness as adjacent pipe.

Source Quality Control In accordance with specified AASHTO Specification.

Factory Testing Pipe lengths used for deflection testing shall be destroyed after testing.

END OF SECTION


PW/WBG/179201 MARINE CONSTRUCTION OCTOBER 2018 35 01 01 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 35 01 01 MARINE CONSTRUCTION

PART 1 GENERAL

1.01 OVERVIEW

A. This Specification contains requirements for Work in the Old River (River).

1.02 WORK IN THE OLD RIVER

A. Unless otherwise indicated, Work in the River includes the installation and/or removal of all temporary or permanent equipment or materials.

B. Limits: Work within the River is defined as all areas north of the top of the southern River embankment.

C. References to right bank or left bank are orientated looking downstream.

D. The Contractor is responsible for complying with all requirements, including but not limited to approvals and permits issued by the following agencies: U.S. Army Corp of Engineers (USACE), the National Marine Fisheries Service (NMFS), the California Department of Fish and Game (DFG), the Regional Water Quality Control Board (RWQCB), the Central Valley Flood Protection Board (CVFPP), and the U.S. Coast Guard (USCG). Additionally, the Contractor is responsible for complying with the Mitigation and Monitoring Program prepared pursuant to the California Environmental Quality Act, as well as monitoring and reporting to both the Engineer and permitting agencies.

E. No construction activities that create or potentially create sediment runoff into the River shall occur until preventative measures have been approved and installed. Preventative measures include, but are not limited to, temporary sediment control systems, turbidity monitoring devices, and any other measures required by the approved Stormwater Pollution Prevention Plan (SWPPP) or by permit requirements.

F. Construction Timing:

1. Work within the River shall be limited to the period between June 1 and September 30.

2. No work shall be performed in the River that causes or might cause turbidity releases to the water, including but not limited to, excavation, backfill, or pipe laying, until after completion of the temporary river


MARINE CONSTRUCTION PW/WBG/179201 35 01 01 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

diversion and installation of turbidity monitoring devices. Engineer will approve both, in writing, prior to starting other work. Contractor is responsible for installing, maintaining, and modifying temporary turbidity control measures during the Work and complying with other Specification sections and permits related to this Work.

1.03 SITE CONDITIONS

A. River Flow Rate: River flow rates and water levels are subject to fluctuations. The Contractor is responsible for the safety and protection of the Work, at all times, regardless of river stage or flow rate.

B. The elevation of the existing riverbed surface, as shown on the Drawings, is approximate.

C. River stage (water surface elevation) at the Project Site and corresponding flow rates shown on the Drawings are approximations.

1.04 SUBMITTALS


1. Navigation Aids Plan: Submit a plan to Engineer a minimum of 45 calendar days prior to navigation aid placement. The plan shall include, but not be limited to the following: materials, workmanship, anchorage systems, location and schedule of all buoys, lights, and navigation aids to be deployed. Provide appropriate details of each device.

2. Hazardous Materials Containment Plan: a. Submit a minimum of 60 calendar days prior to commencing

in-river work. b. Contractor shall submit a Hazardous Materials Containment Plan

that includes the details of the preventative steps the Contractor shall take to prevent hazardous materials from spilling into the river or surrounding area. This plan shall also include the emergency actions the Contractor shall take in the event of a hazardous materials spill to contain and correct the spill and effects of the spill.



3. River Construction Plan: a. Contractor shall submit a River Construction Plan a minimum of

60 calendar days prior to Work in the river. The Construction Plan shall contain complete descriptive information, shop drawings, and supporting documentation relative to the Contractor’s proposed methods of construction in the river. At a minimum, the Construction Plan shall include the items listed below: 1) Location, method, sequence, schedule, and details for Work. 2) Methods and procedures for handling and supporting the

pipe during installation. 3) Work to be completed underwater by divers. 4) Schedule with dates describing specific activities and

durations. 5) At least five scaled plan views and cross-sections of

excavations, pipelines and structures. 6) List of major pieces of equipment. 7) Describe in detail a comprehensive program of daily

inspection, maintenance, repair, and safety of personnel that the Contractor shall implement in order to maintain the soundness and effectiveness of the temporary structures throughout the period of construction. Safety of personnel shall be the Contractor’s responsibility.

4. Temporary Work Trestle and Structures Plan: a. Submit a minimum of 60 calendar days prior to commencing

Work on any temporary work structure. b. Location, method, sequence, schedule, drawings and details for

installing and removing temporary work structures, including but not limit to, trestles, platforms, access ramps and sheet pile not included in other action submittals.

c. Trestle drawings and details shall be stamped and signed by a California registered engineer.

5. Temporary River Diversion Plan: a. Submit a minimum of 60 calendar days prior to commencing

Work on any temporary river diversion components. b. Location, method, sequence, schedule, drawings and details for

installing and removing the temporary river diversion.



6. Turbidity Control Plan: a. Submit a turbidity control plan a minimum of 60 calendar days

prior to work in the river. b. Include turbidity control measures, turbidity monitoring and

reporting procedures, and non-compliance contingency plan. 1) Measurement devices, sampling locations, sampling

frequency, sampling procedures, averaging methods, and reporting frequency. a) See supplement at End of Section.

2) Turbidity Control Barrier: Contractor may be required to install a turbidity control barrier in the river, downstream of the work, to limit turbidity releases. Contractor shall submit details and construction methods to describe the turbidity barrier. Include sufficient details, drawings, and supporting literature that demonstrates the construction method for installing and removing the barrier and descriptions of similar successful applications.

7. Excavation and Materials Handling Plan: a. Submit a minimum of 60 calendar days prior to excavation. b. Location, methods, sequence, and schedule for trench excavation

and backfill, including materials handling, stockpiling, and disposal. Include all areas beginning at top of embankment to the end of the diffuser pipes.

PART 2 PRODUCTS

2.01 NAVIGATION AIDS

A. Comply with all applicable local, state, and federal regulations, including:

1. U.S. Coast Guard (USCG) regulations and the USCG rules for Inland Navigation.

2. California Department of Boating and Waterways rules and regulations.



B. Provide and maintain lighted warning buoys upstream and downstream of Work areas in the River as shown on the Drawings. Buoys shall be spaced a maximum of 40 feet apart and be standard yellow with a quick flash (1 per second) amber light on top visible for 200 feet in all directions. Apply reflective tape to all buoys. Buoys shall be specifically designed for river deployment and capable of withstanding a high flow environment. Buoys shall be individually anchored to the river bottom and not connected to other buoys. Buoys shall state “KEEP OUT.”

C. Contractor shall install one sign 1,000 feet upstream and one sign 1,000 feet downstream of the Work. Signs shall be clearly readable from 300 feet, warning boaters of the hazard and indicating detour path. Signs shall be commercially made, 3/4-inch exterior plywood or better, with 8-inch minimum high black letters on orange background. Sign shall read “Warning - Boating Obstruction Ahead. Keep Left” (or Right, as applicable).

1. Engineer shall approve signs prior to posting.

2.02 TEMPORARY WORK STRUCTURES

A. Temporary work structures include, but are not limited to, trestles, platforms, barges, and other structures that are not included in other items.

B. Temporary work structures, unless otherwise specified, can be installed at Contractor’s option.

1. Safety and structural integrity of temporary work structures shall be the Contractor’s responsibility.

2. All temporary work structures located in the River requires lighting attached along the structures that are visible for 200 feet in all directions.

PART 3 EXECUTION

3.01 NAVIGATION AIDS

A. Navigation aids shall be placed as shown on the Drawings.

B. Navigation aids shall be installed prior to any Work in the River, and shall be maintained and effective throughout the duration of any Work in the River, including all times when temporary work structures and temporary river diversions are in place. Contractor shall inspect navigation aids twice per week and shall repair or replace damaged items within 48 hours of noting damage.



C. Navigation aids shall direct all boating traffic to the left bank of the river.

3.02 TURBIDITY MANAGEMENT

A. Turbidity monitoring devices and procedures shall be installed in the river and approved by the Engineer prior to any work in the river.

B. The Contractor shall control turbidity in the river from the construction:

1. If turbidity or settleable solids downstream from the Site exceed permitted compliance limits, the Contractor shall modify construction techniques and/or install a turbidity control barrier such that turbidity is within RWQCB compliance limits, in accordance with the Contract Documents, at no additional cost to the Owner. If initial measures to comply with turbidity requirements are not successful, the Contractor shall cease Work and implement such additional measures as are necessary to meet turbidity requirements. a. The turbidity control barrier shall be reliable and effective for all

river conditions while Work is being executed. b. Install the turbidity control barrier, as needed, in accordance with

manufacturer’s written recommendations at no additional cost to the Owner.

2. A reasonably sized opening in the turbidity barrier, approved by DFG, USACE, NMFS, and U.S. Fish and Wildlife Service (FWS), shall be maintained at all times to allow fish to move out of the Work area.

3. If a turbidity barrier effectively encloses a work area, as determined by DFG, USACE, NMFS, and FWS, the Contractor shall perform a fish rescue at no additional cost to the Owner. a. The fish rescue shall comply with environmental permit

requirements, including, but not limited to, requirements in Section 01 30 00, Environmental Mitigation and Compliance.

b. Coordinate with DFG, USACE, NMFS, and FWS personnel.

C. Turbidity Monitoring and Reporting:

1. The Contractor shall monitor turbidity in conformance with all environmental permits as specified in Section 01 45 00, Permits, Article Supplements. a. Inspection and Maintenance: Contractor shall inspect turbidity

monitoring devices twice per week and shall repair or replace damaged or missing items within 48 hours.



2. The Contractor shall monitor and report settleable solids in conformance with all environmental permits.

3. Contractor shall report turbidity and settleable solids measurements in conformance with all environmental permits, including but not limited to, the following: a. The units for reporting turbidity and turbidity increase shall be

NTU. b. The Contractor shall provide electronic turbidity readings to a

password-protected website using a real-time turbidity monitoring network system. 1) The custom website shall be accessible to the Owner,

Engineer, Construction Manager, and all resource agencies involved in Project approval.

2) Manually input background turbidity values to the website within 24 hours of each measurement.

3) Manually input settleable solids values to the website within 2 days of receiving the lab results.

c. The Contractor shall submit monthly turbidity and settleable solids measurements in electronic tables to both the Engineer and the RWQCB. The report shall include: 1) All water quality data, lab sample results, notices of

discharge, stormwater inspection reports and associated photos, as well as any other relevant information.

2) The average downstream turbidity value for each TMD. 3) The turbidity increase for each TMD.

d. Contractor shall contact the Engineer and verbally report permit violations within 1 hour of any violation.

e. Contractor shall prepare a written Notice of Discharge in accordance with the USACE Section 7 Consultation Letter of Likely to Not Adversely Affect under Section 01 30 00, Environmental Mitigation and Compliance, for water quality that exceeds compliance limits.

3.03 EXCAVATION

A. Excavation is unclassified. Remove material as needed to complete the Work, regardless of the nature of the material.

B. Temporary river diversion and the turbidity monitoring network shall be completely in place as specified herein, prior to and during excavation.

C. No side casting or stockpiling of excavated material is allowed in the River.



D. All excavated materials from the river shall be temporarily placed in a nearby storage area designated by the Engineer. Contractor shall be responsible for disposal of material excavated from river.

E. Contractor shall not sell, trade, or exchange in any way, native material that is excavated from the river.

3.04 PIPE INSTALLATION

A. Demonstrate that bottom of trench over width of pipe is within plus and minus 6 inches of specified grade.

3.05 PIPE BACKFILL

A. Place backfill in accordance with Section 31 23 23.15, Trench Backfill.

END OF SECTION


PW/WBG/179201 FABRICATED STAINLESS STEEL OCTOBER 2018 SLIDE GATE ©COPYRIGHT 2018 CH2M HILL 35 20 16.25 - 1

SECTION 35 20 16.25 FABRICATED STAINLESS STEEL SLIDE GATE

EQUIPMENT NUMBERS 05-SG-161 Slide Gate PART 1 GENERAL

1.01 DEFINITIONS

A. EPDM: Ethylene propylene diene monomer.

B. UHMWPE: Ultra high molecular weight polyethylene.

C. Non-Self-Contained: The arrangement of gate operator, supported by the structure or structural elements, such that operating thrust loads are applied to the structure or structural elements.

1.02 SUBMITTALS


1. Shop Drawings: a. Equipment Assembly: Make, model, horsepower, and weight

of each. b. Manufacturer’s catalog information, descriptive literature,

specifications, dimensional layouts, and identification of materials of construction.

c. Detailed electrical, structural and mechanical drawings showing equipment fabrications and interface with structure and other items. Include dimensions, size, and locations of connections to other work, and weights of associated equipment. Dimensional drawings shall be drawn to scale using standard US/Imperial units.

d. Gate opening and closing thrust forces that will be transmitted to support structure with operator at extreme positions and load.


FABRICATED STAINLESS STEEL PW/WBG/179201 SLIDE GATE OCTOBER 2018 35 20 16.25 - 2 ©COPYRIGHT 2018 CH2M HILL

e. Gate operator and stem calculations for each gate and service condition.

f. Functional description of internal and external instrumentation and controls to be supplied including list of parameters monitored, controlled, or alarmed.

g. Power and control wiring diagrams, including terminals and numbers.

h. Electric operator nameplate data and descriptive literature. i. Contractor-designed support and anchorage calculations as

specified in Section 01 61 00, Common Product Requirements.


1. Manufacturer’s Certificate of Compliance, in accordance with Section 01 43 33, Manufacturers’ Field Services.

2. Special shipping, storage and protection, and handling instructions. 3. Manufacturer’s installation instructions. 4. Routine maintenance requirements prior to plant startup. 5. Operation and Maintenance Data: As specified in Section 01 78 23,

Operation and Maintenance Data. 6. Manufacturer’s Certificate of Proper Installation in accordance with

Section 01 43 33, Manufacturers’ Field Services.

1.03 EXTRA MATERIALS

A. Furnish, tag, and box for shipment and storage following spare parts and special tools.

Item Quantity

Stem collars for gate stems One of each different size

Bronze lift nuts One of each different size

Special tools required to maintain or dismantle

One complete set

B. Delivery: In accordance with Section 01 61 00, Common Product Requirements.



PART 2 PRODUCTS

2.01 FABRICATED STAINLESS STEEL SLIDE GATES

A. General:

1. Unless otherwise specified, conform to AWWA C561. 2. Assembly Style:

a. Non-self-contained, rising stem, electrically actuated. b. See Drawings for installation configuration.

3. Mounting: Grout pad over a concrete wall. 4. Wall Opening: 20-inch ductile iron wall pipe. 5. Gate Opening: Coordinate size and anchorage with wall opening.

B. Performance Requirements:

1. Installed gate leakage shall not exceed 0.05 gallon per minute per foot of gate periphery at the specified operating head.

2. Design Operating Head: 10 feet.

C. Materials:

1. Frame, Guides, Slide, and Stem Guides: ASTM A240/A240M and ASTM A276, Type 316L stainless steel.

2. Stem and Couplings: ASTM A276, Type 316 stainless steel. 3. Seals: ASTM D1056, EPDM; ASTM D2000, resilient neoprene; or

ASTM D4020, UHMWPE. 4. Guide Liner: ASTM D4020, UHMWPE. 5. Fasteners: ASTM F593, ASTM F594, GR2, Type 316 stainless steel. 6. Lift Nut: ASTM B584, bronze. 7. Thrust Nut: ASTM A240/A240M or ASTM A194/A194M, Type 316,

stainless steel.

D. Frame:

1. Minimum material thickness of 1/4 inch. 2. Made of structural members or formed plate welded to form a rigid

one-piece frame. 3. Seating face of frame shall be machined or orientated at an angle to the

plane of the mounting flange to effect a wedging action upon closure. 4. Wedges necessary for meeting seating and unseating head conditions

and leakage requirements shall be stainless steel with UHMWPE seats.



5. Frame Invert: Furnish a resilient neoprene seal to function as a seating surface for the gate slide.

6. Join vertical guide frames and invert with factory welded corners. 7. Size guided slot to provide a minimum slide engagement of 1 inch on

each side.

E. Slide:

1. Consisting of a single flat plate, minimum thickness of 1/4 inch, reinforced with formed plates or structural members welded to slide to limit deflection.

2. Deflection shall not exceed 1/720th of gate width at maximum design head.

3. Machine to match frame.

F. Guide Liners:

1. UHMWPE, attached to slide or frame by means of studs, and of such length as to retain and support at least two thirds of the vertical height of the slide in the fully open position.

2. Adjustable by means of adjusting bolts.

G. Stems and Couplings:

1. Diameter as required to meet the design requirements and opening and closing thrust forces, 1 inch minimum.

2. Threads: Acme type with RMS surface roughness of 32 micro-inches or less on flanks. Extend threaded portion of stem 2 inches above operator when gate is in CLOSED position.

3. Connection: Designed to prevent rotation of thrust nut or thru-bolt that connects stem to slide. Thrust nut threaded and keyed or pinned to stem.

4. Couplings: a. Use when stems have more than one section. b. Same material as stem. c. Furnish with internal threads that transmit full thrust of stem. d. Hold in place on stem with bolts or keys and keyways. e. Same size and interchangeable.

5. Size so slenderness ratio of unsupported stem length (L) to radius of gyration (r) does not exceed 200.

6. Withstand in compression, without damage, thrust equal to at least 1.25 times output thrust of motor in stalled condition.



7. Bronze bushed stem guides, mounted on fabricated wall brackets, adjustable in two directions and spaced so that L/r ratio does not exceed 200.

8. Adjustable stop collar for CLOSED position. 9. Connect stems to slide with a yoke, bolted to stem and welded to slide.

H. Stem Covers:

1. Transparent plastic, vented pipe stem cover and cap. 2. OPEN/CLOSED designators and with 1-inch graduations on clear

mylar, pressure sensitive, adhesive tape, suitable for outdoor application.

I. Seals:

1. Specially molded shape secured to frame or slide, designed to remain in place during life of gate.

2. Shaped to produce a wide sealing area to form a flush invert. 3. Make top surface of seal flush with invert of gate opening. 4. Machine full length of bottom edge of slide accurately to make contact

with seal when slide is closed.

J. Manufacturers:

1. Fontaine-Aquanox. 2. Golden Harvest, Inc. 3. Mueller Water Products – Hydro Gate. 4. Whipps, Inc. 5. Or equal.

2.02 OPERATORS

A. General:

1. Components: Withstand a minimum of 250 percent of design torque or thrust at extreme operator positions without damage.

2. Gear train and gate stem sections shall produce a self-locking drive train.

3. Lift Nuts: Internally threaded with cut or cold-rolled Acme threads corresponding to stem threading.

4. Roller Bearings: Ball-thrust or tapered above and below lift nut to support both opening and closing thrusts.



a. Grease lubrication fittings for bearings. b. Input pinions with needle or ball bearings.

5. Lubrication: Furnish with an insert lubricator flange in lift, with a grease fitting for greasing stem threads below stem nut.

B. Electric Motor Operators:

1. Mounted to a 28-inch high stainless steel or aluminum pedestal, with totally enclosed weatherproof electric drive unit, and a totally enclosed gear box that operates a two-piece, bronze stem nut, which lifts gate stem.

2. Gears: Heat treated alloy steel, supported throughout by antifriction ball or roller bearings and grease lubricated.

3. Automatic double-acting geared limit switches and double-acting torque switches. a. Gear directly to the operating gear train and shall be “in step” at

all times, whether in motor or manual operation. b. Wire geared limit switches internally to stop the motor at the fully

OPEN and fully CLOSED positions. c. Wire torque switches internally so that, in the event of a

mechanical overload in either direction, the motor will be stopped. 4. Equip with side mounted handwheel for manual operation.

a. Include an automatic clutch to positively disengage the handwheel at any time the drive motor control is energized.

b. Design handwheel operator so that failure of the motorized gearing will not prevent hand operation of the gate.

5. Drive Unit: a. TENV, 480-volt, three-phase electric motor with integral

OPEN/STOP/CLOSE weatherproof pushbuttons, reversing controller, 480/120-volt control power transformer, space heaters in the limit switches and in the control compartments, mechanical dial type position indicator, and transparent plastic pipe stem cover and cap.

b. Furnish motor enclosure with drainage and breathing holes. c. Self-locking, with approximately 12 inches per minute gate travel

speed, and a rated running torque equal to 20 percent of the motor starting torque at a rated running time of 5 minutes, without exceeding the allowable NEMA temperature rise for the insulation class used.



6. Operation: Drive the gate to its fully OPEN or CLOSED position when the OPEN or CLOSED pushbutton is depressed momentarily. Motor shall stop in mid-travel when the STOP button is depressed.

7. Controls: a. Local OPEN/STOP/CLOSE pushbutton station. b. Auxiliary end of travel limit switches; OPEN and CLOSED

position switches shall be normally open contacts that close at the end position; contacts shall be dry and rated for 5 amps, 120V ac.

c. LOCAL/OFF/REMOTE weatherproof padlockable selector switch and provisions for remote OPEN/CLOSE operation; remote commands will be dry contact closures; motor operator shall impress the voltage required to read these contacts and shall go to the commanded position when in the REMOTE mode. Provide auxiliary contact which closes when LOCAL/OFF/REMOTE switch is in REMOTE position.

8. Manufacturers: a. AUMA Actuators, Inc. b. Flowserve Limitorque. c. Rotork Controls.

C. Identification Tagging Requirements:

1. For each gate operator, 1-1/2-inch minimum diameter, stainless steel or heavy brass tag, bearing gate tag number. Attach tag to operator by soldered split key ring so ring and tag cannot be removed. Use block type numbers and letters with 1/4-inch minimum high numbers and letters stamped on and filled with black enamel.

2. Gate nameplate shall be permanently attached to the gate frame, and shall include the manufacturer’s name, gate size, maximum working pressure, year of manufacture, and serial number.

2.03 APPURTENANCES

A. Anchor Bolts: ASTM A193/A193M, Type 316 stainless steel sized by equipment manufacturer, at least 1/2 inch in diameter or as shown and as specified in Section 05 50 00, Metal Fabrications.

B. Wedges: Adjustable wedges or pressure pads shall be provided as necessary to ensure gates meet specified leakage requirements. Such adjusting mechanisms shall prevent rotation and lateral motion of gates, and remain securely in place after adjustment.



2.04 SHOP/FACTORY FINISHING

A. Mechanically descale and passivate all weld burn and weld slag in accordance with ASTM A380 to provide uniform finish.

B. Factory prepare, prime, and finish coat other exposed metal surfaces in accordance with Section 09 90 00, Painting and Coating.


A. Factory Tests and Adjustments: Perform manufacturer’s standard tests on equipment.

PART 3 EXECUTION

3.01 INSTALLATION

A. In accordance with manufacturer’s written instructions and as specified.

B. Accurately place anchor bolts using templates furnished by manufacturer and as specified in Section 05 50 00, Metal Fabrications.

C. After gate and actuator have been properly aligned and secured, grout space between gate and wall with a poured, nonshrinking grout of the proper category, as specified in Section 03 62 00, Nonshrink Grouting.

D. Grease threads above stem nut prior to placing gate in operation.


A. Functional Tests: Conduct on each gate to verify proper operation of gate and operator.

B. Field Leakage Test:

1. Conduct on each gate in accordance with AWWA C561. 2. Perform under actual or approved simulated operating conditions. 3. Adjust, realign, or modify units and retest if necessary until satisfactory

operation is attained.




A. Manufacturer’s Representative: Present at Site or classroom designated by Owner, for minimum person-days listed below, travel time excluded:

1. 1/2 person-day for installation assistance and inspection. 2. 1/2 person-day for functional and performance testing and completion

of Manufacturer’s Certificate of Proper Installation. 3. 1/2 person-day for post-startup training of Owner’s personnel.

B. See Section 01 43 33, Manufacturers’ Field Services.

C. Provide manufacturer’s representative at Site in accordance with Section 01 43 33, Manufacturers’ Field Services, for installation assistance, inspection and certification of proper installation, equipment testing, startup assistance, and training of Owner’s personnel for specified component, subsystem, equipment, or system.

END OF SECTION


PW/WBG/179201 PIPING SUPPORT SYSTEMS OCTOBER 2018 40 05 15 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 40 05 15 PIPING SUPPORT SYSTEMS

PART 1 GENERAL

1.01 SUBMITTALS


1. Catalog information and drawings of piping support system, locating each support, sway brace, seismic brace, hanger, guide, component, and anchors. Identify support, hanger, guide, and anchor type by catalog number and Shop Drawing detail number.

2. Calculations for each type of pipe support, attachment and anchor. 3. Revisions to support systems resulting from changes in related piping

system layout or addition of flexible joints. 4. Seismic anchorage and bracing drawings and cut sheets, as required by

Section 01 88 15, Seismic Anchorage and Bracing.

B. Informational Submittals: Seismic anchorage and bracing calculations as required by Section 01 88 15, Seismic Anchorage and Bracing.

1.02 QUALIFICATIONS

A. Piping support systems shall be designed and Shop Drawings prepared and sealed by a Registered Professional Engineer in the State of California.

1.03 DESIGN REQUIREMENTS

A. General:

1. Piping Smaller than 30 Inches: Supports are shown to indicate specific type required for that pipe system (see Part 2).

2. Piping 30 Inches and Larger: Support systems have been designed for piping shown.

3. Meet requirements of MSS SP 58 and ASME B31.1 or as modified by this section.

B. Pipe Support Systems:

1. Design pipe support systems for gravity and thrust loads imposed by weight of pipes or required test pressures, including insulation and weight of fluid in pipes.


PIPING SUPPORT SYSTEMS PW/WBG/179201 40 05 15 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

2. Seismic loads in accordance with governing codes and as shown on Structural General Drawings.

3. Wind loads in accordance with governing codes and as shown on Structural General Drawings.

4. Maximum Support Spacing and Minimum Rod Size: In accordance MSS SP 58 Table 3 and Table 4.

C. Anchoring Devices: Design, size, and space support anchoring devices, including anchor bolts, inserts, and other devices used to anchor support, to withstand shear and pullout loads imposed by loading and spacing on each particular support.

D. Vertical Sway Bracing: 10-foot maximum centers or as shown.

PART 2 PRODUCTS

2.01 GENERAL

A. When specified items are not available, fabricate pipe supports of correct material and to general configuration indicated.

B. Special support and hanger details may be required for cases where standard catalog supports are not applicable.

C. Material: Galvanized steel or precoated steel.

2.02 WALL BRACKETS, SUPPORTS, AND GUIDES

A. Offset Pipe Clamp: Anvil Intl.; Figure 103, sizes 3/4 inch through 8 inches.

B. Channel Type:

1. Atkore-Unistrut. 2. Anvil Intl.; Anvil-Strut. 3. Eaton B-Line; Strut System.

2.03 PIPE SADDLES

A. Provide 90-degree to 120-degree pipe saddle for pipe 6 inches and larger with baseplates drilled for anchors bolts.

B. Saddle Supports, Pedestal Type:

1. Minimum standard weight pipe stanchion, saddle, and anchoring flange.



2. Adjustable Saddle: MSS SP 58, Type 38 without clamp. a. Anvil Intl.; Figure 264, sizes 2-1/2 inches through 36 inches with

Figure 62C base. b. Eaton B-Line; Figure B3092, sizes 3/4 inch through 36 inches

with Figure B3088S base.

2.04 FLANGE SUPPORTS

A. Flange Support with Adjustable Base: Sizes 2 inches through 24 inches, Standon; Model S89.

2.05 PIPE ANCHORS

A. Type: Anchor chair with U-bolt strap.

B. Manufacturer and Product: Eaton B-Line; Figure B3147A or Figure B3147B.

2.06 SEISMIC RESTRAINTS

A. Solid pipe bracing attachment to pipe clevis with clevis cross brace and angle rod reinforcement.

B. Manufacturers:

1. Mason Industries, Inc. 2. Eaton B-Line. 3. Anvil Intl.

2.07 ACCESSORIES

A. Anchor Bolts:

1. Size and Material: Sized by Contractor for required loads, and as specified in Section 05 50 00, Metal Fabrications.

B. Dielectric Barriers:

1. Plastic coated hangers, isolation cushion, or tape. 2. Manufacturer and Products:

a. Eaton B-Line; B1999 Vibra Cushion. b. Eaton B-Line; Iso Pipe, Isolation Tape.



PART 3 EXECUTION

3.01 INSTALLATION

A. General:

1. Install support systems in accordance with MSS SP 58, unless shown otherwise.

2. Support piping connections to equipment by pipe support and not by equipment.

3. Support large or heavy valves, fittings, and appurtenances independently of connected piping.

4. Support no pipe from pipe above it. 5. Support pipe at changes in direction or in elevation, adjacent to flexible

joints and couplings, and where shown. 6. Do not use adhesive anchors for attachment of supports to ceiling or

walls. 7. Do not install pipe supports and hangers in equipment access areas or

bridge crane runs. 8. Brace hanging pipes against horizontal movement by both longitudinal

and lateral sway bracing and to reduce movement after startup. 9. Install lateral supports for seismic loads at changes in direction. 10. Install pipe anchors where required to withstand expansion thrust loads

and to direct and control thermal expansion. 11. Repair mounting surfaces to original condition after attachments are

completed.

B. Standard Pipe Supports:

1. Horizontal Piping Supported from Walls: a. Single Pipes: Wall brackets, or attached to wall, or to wall

mounted framing with anchors. b. Stacked Piping: Wall mounted framing system and “J” hangers

acceptable for pipe smaller than 3 inch. c. Pipe clamp that resists axial movement of pipe through support is

not acceptable. Use pipe rollers supported from wall bracket. 2. Horizontal Piping Supported from Floors:

a. Saddle Supports: 1) Pedestal Type, elbow and flange. 2) Provide minimum 1-1/2-inch grout beneath baseplate.

b. Floor Mounted Channel Supports: 1) Use for pipe smaller than 3-inch running along floors and in

trenches at pipe elevations lower than can be accommodated using pedestal pipe supports.



2) Attach channel framing to floors with baseplate on minimum 1-1/2-inch nonshrink grout and with anchor bolts.

3) Attach pipe to channel with clips or pipe clamps. c. Concrete Cradles: Use for pipe larger than 3 inches along floor

and in trenches at pipe elevations lower than can be accommodated using stanchion type.

3. Vertical Pipe: Support with wall bracket and elbow support, or riser clamp on floor penetration.

C. Standard Attachments:

1. Existing Concrete Ceilings: Channel type support with minimum of two anchor points, concrete attachment plates or concrete anchors as limited below: a. Single point attachment to ceiling is allowed only for 3/4-inch rod

and smaller (8 inches and smaller pipe). b. Where there is vibration or bending considerations do not connect

a single pipe support hanger rod directly to a drilled concrete anchor (single point attachment) regardless of size.

2. Steel Beams: I-beam clamp or welded attachments. 3. Wooden Beams: Lag screws and angle clips to members not less than

2-1/2 inches thick. 4. Concrete Walls: Concrete inserts or brackets or clip angles with

concrete anchors. 5. Concrete Beams: Concrete inserts, or if inserts are not used attach to

vertical surface similar to concrete wall. Do not drill into beam bottom.

D. Saddles for Steel or Concrete Pipe: Provide 90 degree to 120 degree pipe saddle for pipe sizes 6 inches and larger when installed on top of steel or concrete beam or structure, pipe rack, trapeze, or where similar concentrated point supports would be encountered.

E. Accessories:

1. Dielectric Barrier: a. Provide between painted or galvanized carbon steel members and

copper or stainless steel pipe or between stainless steel supports and nonstainless steel ferrous metal piping.

b. Install rubber wrap between submerged metal pipe and oversized clamps.



3.02 FIELD FINISHING

A. Paint atmospheric exposed surfaces hot-dip galvanized steel components as specified in Section 09 90 00, Painting and Coating.

END OF SECTION


PW/WBG/179201 PROCESS PIPING—GENERAL OCTOBER 2018 40 27 00 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 40 27 00 PROCESS PIPING—GENERAL

PART 1 GENERAL

1.01 DESIGN REQUIREMENTS

A. Where pipe diameter, thickness, pressure class, pressure rating, or thrust restraint is not shown or specified, design piping system in accordance with the following:

1. Process Piping: ASME B31.3, normal fluid service unless otherwise specified.

2. Buried Piping: H20-S16 traffic load with 1.5 impact factor, AASHTO HB-17, as applicable.

3. Thrust Restraints: a. Design for test pressure shown in Piping Schedule located on the

Drawings. b. Allowable Soil Pressure: 1,000 pounds per square foot. c. Low Pressure Pipelines:

1) When bearing surface of the fitting against soil provides an area equal to or greater than area required for thrust restraint, concrete thrust blocks will not be required.

2) Determine bearing area for fittings without thrust blocks by projected area of 70 percent of internal diameter multiplied by chord length for fitting centerline curve.

1.02 SUBMITTALS


1. Shop Fabricated Piping: a. Detailed pipe fabrication or spool drawings showing special

fittings and bends, dimensions, coatings, and other pertinent information.

b. Layout drawing showing location of each pipe section and each special length; number or otherwise designate laying sequence on each piece.

2. Manufacturer’s catalog and submittal information for each pipe system to include pipe, fittings, linings, couplings, bolting, gaskets, lubricants, solvent cement, etc.

3. Dissimilar Buried Pipe Joints: Joint types and assembly drawings. 4. Pipe Corrosion Protection: Product data.


PROCESS PIPING—GENERAL PW/WBG/179201 40 27 00 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

5. Seismic anchorage and bracing drawings and cut sheets, as required by Section 01 88 15, Seismic Anchorage and Bracing.


A. In accordance with Section 01 61 00, Common Product Requirements, and:

1. Flanges: Securely attach metal, hardboard, or wood protectors over entire gasket surface.

2. Threaded or Socket Welding Ends: Fit with metal, wood, or plastic plugs or caps.

3. Linings and Coatings: Prevent excessive drying. 4. Cold Weather Storage: Locate products to prevent coating from freezing

to ground. 5. Handling: Use heavy canvas or nylon slings to lift pipe and fittings.

PART 2 PRODUCTS

2.01 PIPING

A. As specified on Piping Data Sheet(s) located at the end of this section as Supplement, and located on Drawings.

B. Diameters Shown: Nominal size.

2.02 JOINTS

A. Grooved End System:

1. Rigid type. 2. Use of flexible grooved joints will only be allowed where shown on

Drawings or with prior approval by Engineer. 3. Flanges: When required, furnish with grooved type flange adapters of

same manufacturer as grooved end couplings.

B. Flanged Joints:

1. Flat-faced, carbon steel, or alloy flanges when mating with flat-faced cast or ductile iron flanges.

2. Higher pressure rated flanges as required to mate with equipment when equipment flange is of higher pressure rating than required for piping.

C. Threaded Joints: NPT taper pipe threads in accordance with ASME B1.20.1.



D. Mechanical Joint Anchor Gland Follower:

1. Ductile iron anchor type, wedge action, with breakoff tightening bolts. Thrust rated to 250 psi minimum. Rated operating deflection not less than 2-1/2 degrees. UL and FMG approved.

2. Manufacturers and Products: a. EBAA Iron Inc.; Megalug. b. Romac Industries, Inc.; RomaGrip. c. Ford Meter Box Co.; Series 1400.

2.03 GASKET LUBRICANT

A. Lubricant shall be supplied by pipe manufacturer and no substitute or “or-equal” will be allowed.

2.04 PIPE CORROSION PROTECTION

A. Coatings: See Section 09 90 00, Painting and Coating, for details of coating requirements.

B. Heat Shrink Wrap:

1. Type: Cross-linked polyolefin wrap or sleeve with mastic sealant. 2. Manufacturer and Product: Raychem; WPC or TPS.

C. Polyethylene Encasement (Bagging):

1. Encasement Tube: Black polyethylene encasement tube, 8-mils minimum thickness, conforming to AWWA C105/A21.5, free of gels, streaks, pinholes, foreign matter, undispersed raw materials, and visible defects such as tears, blisters, and thinning at folds.

2. Securing Tape: Thermoplastic tape, 8-mils minimum thickness, 1-inch wide, pressure sensitive adhesive face capable of bonding to metal, bituminous coating, and polyethylene encasement tube.

D. Insulating Flanges, Couplings, and Unions:

1. Materials: a. In accordance with applicable piping material specified in Pipe

Data Sheet. Complete assembly shall have ASME B31.3 working pressure rating equal to or higher than that of joint and pipeline.

b. Galvanically compatible with piping. c. Resistant for intended exposure, operating temperatures, and

products in pipeline.



2. Union Type, 2 Inches and Smaller: a. Screwed or solder-joint. b. O-ring sealed with molded and bonded insulation to body.

3. Flange Type, 2-1/2 Inches and Larger: Flanged, complete with bolt insulators, dielectric gasket, bolts, and nuts. Bolt insulating sleeves shall be provided full length between insulating washers. Contractor shall be responsible for fit-up of all components of insulated flange assembly to provide a complete functioning installation. AWWA C207 steel flanges may be drilled oversize up to 1/8 inch to accommodate insulating sleeves. No less than minimum thread engagement in accordance with specified bolting standards will be permitted to accommodate thicknesses of all required washers, flanges and gasket.

4. Flange Insulating Kits: a. Gaskets: Full-face, Type E with elastomeric sealing element.

Sealing element shall be retained in a groove within retainer portion of gasket.

b. Insulating Sleeves: Full-length fiberglass reinforced epoxy (NEMA LI-1, G-10 grade).

c. Insulating Washers: Fiberglass-reinforced epoxy (NEMA LI-1, G-10 grade).

d. Steel Washers: Plated, hot-rolled steel 1/8-inch thick. 1) Provide two washers per bolt for flange diameters equal to

or less than 36-inch. 2) Provide four washers per bolt for flange diameters larger

than 36-inch. 5. Manufacturers and Products:

a. Dielectric Flanges and Unions: 1) EnPro GPT. 2) Advance Products and Systems.

b. Insulating Couplings: 1) Romac Industries, Inc.; Series IC400 or Series IC501. 2) Baker Coupling Company, Inc.; Series 216.

2.05 THRUST BLOCKS

A. Concrete: As specified in Section 03 30 00, Cast-in-Place Concrete.

2.06 FINISHES

A. Factory prepare, prime, and finish coat in accordance with Section 09 90 00, Painting and Coating.



2.07 IDENTIFICATION LABELS

A. Pipe Labels:

1. Labels: Self-adhesive tape, with separate directional flow arrow banding tape.

2. Material: Pressure sensitive vinyl. 3. Letters and Arrows: Black on OSHA safety yellow background. 4. Color Field and Letter Height: ASME A13.1. 5. Message: Piping system name as indicated on Piping Schedule. 6. Manufacturers and Products:

a. Brady Signmark; B-946 Self-Sticking Vinyl Pipe Markers and Directional Flow Arrow Tape.

b. Seton Identification Products; Opti-Code Markers and Arrows-On-A-Roll Tape.

PART 3 EXECUTION

3.01 EXAMINATION

A. Verify size, material, joint types, elevation, horizontal location, and pipe service of existing pipelines to be connected to new pipelines or new equipment.


3.02 PREPARATION

A. See Piping Schedule located on the Drawings, and Section 09 90 00, Painting and Coating, for additional requirements.

B. Inspect pipe and fittings before installation, clean ends thoroughly, and remove foreign matter and dirt from inside.

3.03 INSTALLATION—GENERAL

A. Join pipe and fittings in accordance with manufacturer’s instructions.

B. Remove foreign objects prior to assembly and installation.

C. Flanged Joints:

1. Install perpendicular to pipe centerline.



2. Bolt Holes: Straddle vertical centerlines, aligned with connecting equipment flanges or as shown.

3. Use torque-limiting wrenches to ensure uniform bearing and proper bolt tightness.

4. Plastic Flanges: Install annular ring filler gasket at joints of raised-face flange.

5. Grooved Joint Flange Adapters: Include stainless steel washer plates as required for mating to serrated faces and lined valves and equipment.

6. Raised-Face Flanges: Use flat-face flange when joining with flat-faced ductile or cast iron flange.

7. Verify compatibility of mating flange to adapter flange gasket prior to selecting grooved adapter flanging.

8. Flange fillers are to be avoided, but if necessary, may be used to make up for small angles up to 6 degrees and for filling gaps up to 2 inches between flanges. Stacked flange fillers shall not be used.

9. Threaded flanged joints shall be shop fabricated and delivered to Site with flanges in-place and properly faced.

10. Manufacturer: Same as pipe manufacturer or grooved joint flange adapter manufacturer.

D. Threaded and Coupled Joints:

1. Conform to ASME B1.20.1. 2. Produce sufficient thread length to ensure full engagement when

screwed home in fittings. 3. Countersink pipe ends, ream and clean chips and burrs after threading. 4. Make connections with not more than three threads exposed. 5. Lubricate male threads only with thread lubricant or tape as specified on

Piping Data Sheets.

E. Grooved-End Joints:

1. Piping shall be grooved in accordance with the manufacturer’s latest published instructions and shall be accurately cut with tools conforming to coupling manufacturer’s standards and to AWWA C606.

2. Install grooved joint couplings and gaskets in accordance with manufacturer’s latest published installation instructions.

F. Soldered Joints:

1. Use only solder specified for particular service. 2. Cut pipe ends square and remove fins and burrs. 3. After thoroughly cleaning pipe and fitting of oil and grease using

solvent and emery cloth, apply noncorrosive flux to the male end only.



4. Wipe excess solder from exterior of joint before hardened. 5. Before soldering, remove stems and washers from solder joint valves.

G. Pipe Connections at Concrete Structures: As specified in Article Piping Flexibility Provisions in Section 40 27 01, Process Piping Specialties.

H. PVC Piping:

1. Provide Schedule 80 threaded nipple where necessary to connect to threaded valve or fitting.

2. Use strap wrench for tightening threaded plastic joints. Do not overtighten fittings.

3. Do not thread Schedule 40 pipe.

I. Ductile Iron Piping:

1. Cutting Pipe: Cut pipe with milling type cutter, rolling pipe cutter, or abrasive blade cutter. Do not flame cut.

2. Dressing Cut Ends: a. General: As required for the type of joint to be made. b. Rubber Gasketed Joints: Remove sharp edges or projections. c. Push-On Joints: Bevel, as recommended by pipe manufacturer. d. Flexible Couplings, Flanged Coupling Adapters, and Grooved

End Pipe Couplings: As recommended by the coupling or adapter manufacturer.

3.04 INSTALLATION—EXPOSED PIPING

A. Piping Runs:

1. Parallel to building or column lines and perpendicular to floor, unless shown otherwise.

2. Piping upstream and downstream of flow measuring devices shall provide straight lengths as required for accurate flow measurement.

B. Supports: As specified in Section 40 05 15, Piping Support Systems.

C. Group piping wherever practical at common elevations; install to conserve building space and not interfere with use of space and other work.

D. Unions or Flanges: Provide at each piping connection to equipment or instrumentation on equipment side of each block valve to facilitate installation and removal.



E. Install piping so that no load or movement in excess of that stipulated by equipment manufacturer will be imposed upon equipment connection; install to allow for contraction and expansion without stressing pipe, joints, or connected equipment.

F. Piping Clearance, Unless Otherwise Shown:

1. Over Walkway and Stairs: Minimum of 7 feet 6 inches, measured from walking surface or stair tread to lowest extremity of piping system including flanges, valve bodies or mechanisms, insulation, or hanger/support systems.

2. Between Equipment or Equipment Piping and Adjacent Piping: Minimum 3 feet, measured from equipment extremity and extremity of piping system including flanges, valve bodies or mechanisms, insulation, or hanger/support systems.

3. From Adjacent Work: Minimum 1 inch from nearest extremity of completed piping system including flanges, valve bodies or mechanisms, insulation, or hanger/support systems.

4. Do not route piping in front of or to interfere with access ways, ladders, stairs, platforms, walkways, openings, doors, or windows.

5. Headroom in front of openings, doors, and windows shall not be less than the top of the opening.

6. Do not install piping containing liquids or liquid vapors in transformer vaults or electrical equipment rooms.

7. Do not route piping over, around, in front of, in back of, or below electrical equipment including controls, panels, switches, terminals, boxes, or other similar electrical work.

3.05 INSTALLATION—BURIED PIPE

A. Placement:

1. Keep trench dry until pipe laying and joining are completed. 2. Pipe Base and Pipe Zone: As specified in Section 31 23 23.15, Trench

Backfill. 3. Exercise care when lowering pipe into trench to prevent twisting or

damage to pipe. 4. Measure for grade at pipe invert, not at top of pipe. 5. Excavate trench bottom and sides of ample dimensions to permit visual

inspection and testing of entire flange, valve, or connection. 6. Prevent foreign material from entering pipe during placement. 7. Close and block open end of last laid pipe section when placement

operations are not in progress and at close of day’s work. 8. Lay pipe upgrade with bell ends pointing in direction of laying.



9. Install closure sections and adapters for gravity piping at locations where pipe laying changes direction.

10. Deflect pipe at joints for pipelines laid on a curve using unsymmetrical closure of spigot into bell. If joint deflection of standard pipe lengths will not accommodate horizontal or vertical curves in alignment, provide: a. Shorter pipe lengths. b. Special mitered joints. c. Standard or special fabricated bends.

11. After joint has been made, check pipe alignment and grade. 12. Place sufficient pipe zone material to secure pipe from movement

before next joint is installed. 13. Prevent uplift and floating of pipe prior to backfilling.

B. PVC Pipe Placement:

1. Lay pipe snaking from one side of trench to other. 2. Offset: As recommended by manufacturer for maximum temperature

variation between time of solvent welding and during operation. 3. Do not lay pipe when temperature is below 40 degrees F, or above

90 degrees F when exposed to direct sunlight. 4. Shield ends to be joined from direct sunlight prior to and during the

laying operation.

C. Tolerances:

1. Deflection from Horizontal Line, Except PVC: Maximum 2 inches. 2. Deflection From Vertical Grade: Maximum 1/4 inch. 3. Joint Deflection: Maximum of 75 percent of manufacturer’s

recommendation. 4. Horizontal position of pipe centerline on alignment around curves

maximum variation of 1.75 feet from position shown. 5. Pipe Cover: Minimum 3 feet, unless otherwise shown.

3.06 INSTALLATION—CONCRETE ENCASED

A. Provide reinforced concrete pipe encasement where shown on Drawings and where otherwise required. Some piping may be required to be concrete encased for pipe strength requirements that are included in the Specifications. Piping under and within the influence of buildings, utility trenches, vaults, slabs and other structures shall be concrete encased. See details on Drawings for encasement requirements.



B. Where concrete encased piping crosses structure construction and expansion joints, provide flexible piping joints to coincide with structure joints to prevent excessive pipe stress and breakage.

3.07 PIPE CORROSION PROTECTION

A. Ductile Iron Pipe:

1. Exposed: As specified in Section 09 90 00, Painting and Coating, and as shown in Piping Schedule located on the Drawings.

2. Buried: Wrap with polyethylene bagging. 3. Submerged or Embedded: Coat with epoxy as specified in

Section 09 90 00, Painting and Coating. If in potable water service, use NSF 61 approved epoxy.

B. Carbon Steel Pipe:

1. Exposed: As specified in Section 09 90 00, Painting and Coating. 2. Buried:

a. Pipe: Shop coat with epoxy as specified in Section 09 90 00, Painting and Coating.

b. Joints: Wrap with tape coating system in accordance with AWWA C209 and AWWA C214 with double outer wrap, or heat shrink wrap as specified herein.

3. Submerged or Embedded: Shop coat with epoxy as specified in Section 09 90 00, Painting and Coating.

C. PVC Pipe, Exposed: As specified in Section 09 90 00, Painting and Coating.

D. Piping Accessories:

1. Exposed: a. Field paint black and galvanized steel, brass, copper, and bronze

piping components as specified in Section 09 90 00, Painting and Coating, as applicable to base metal material.

b. Accessories include, but are not limited to, pipe hangers, supports, expansion joints, pipe guides, flexible couplings, vent and drain valves, and fasteners.

2. Buried: a. Ferrous Metal and Stainless Steel Components: Coat with epoxy

as specified in Section 09 90 00, Painting and Coating. b. Bolts, Nuts, and Similar Items: Coat with bituminous paint. c. Flexible Couplings, Grooved Couplings, and Similar Items: Wrap

with heat shrink wrap.



d. Buried Valves and Similar Elements on Wrapped Pipelines: Coat with bituminous paint and wrap entire valve in polyethylene encasement.

e. Cement-Coated Pipelines: Cement coat appurtenances same as pipe.

E. Polyethylene Encasement: Install in accordance with AWWA C105/A21.5 and manufacturer’s instructions.

F. Tape Coating System: Apply in accordance with AWWA C209 and AWWA C214.

G. Heat Shrink Wrap: Apply in accordance with manufacturer’s instructions to surfaces that are cleaned, prepared, and primed.

H. Insulating Flanges, Couplings, and Unions:

1. Applications: a. Dissimilar metal piping connections. b. Cathodically protected piping penetration to buildings and

watertight structures. c. Submerged to unsubmerged metallic piping connections. d. Connections to existing metallic pipe. e. Where required for electrically insulated connection.

2. Pipe Installation: a. Insulating joints connecting immersed piping to nonimmersed

piping shall be installed above maximum water surface elevation. b. Submerged carbon steel, ductile iron, or galvanized piping in

reinforced concrete shall be isolated from the concrete reinforcement steel.

c. Align and install insulating joints as shown on the Drawings and according to manufacturer’s recommendations. Bolt lubricants that contain graphite or other metallic or electrically conductive components that can interfere with the insulating capabilities of the completed flange shall not be used.

3.08 THRUST RESTRAINT

A. Location:

1. Buried Piping: Where shown and where required to restrain force developed at pipeline tees, plugs, caps, bends, and other locations where unbalanced forces exist because of hydrostatic testing and normal operating pressure.



2. Exposed Piping: At all joints in piping.

B. Mechanical Joint Valve Restraint in Proprietary Restrained Joint Piping: Install pipe joint manufacturer’s adapter gland follower and pipe end retainer, or mechanical joint anchor gland follower.

C. Thrust Blocking:

1. Place between undisturbed ground and fitting to be anchored. 2. Quantity of Concrete: Sufficient to cover bearing area on pipe and

provide required soil bearing area as shown. 3. Place blocking so that pipe and fitting joints will be accessible for

repairs. 4. Place concrete in accordance with Section 03 30 00, Cast-in-Place

Concrete.

3.09 SLAB, FLOOR, WALL, AND ROOF PENETRATIONS

A. Application and Installation: As specified in Section 40 27 01, Process Piping Specialties.

3.10 BRANCH CONNECTIONS

A. Do not install branch connections smaller than 1/2-inch nominal pipe size, including instrument connections, unless shown otherwise.

B. When line of lower pressure connects to a line of higher pressure, requirements of Piping Data Sheet for higher pressure rating prevails up to and including the first block valve in the line carrying the lower pressure, unless otherwise shown.

C. Threaded Pipe Tap Connections:

1. Ductile Iron Piping: Connect only with service saddle or at a tapping boss of a fitting, valve body, or equipment casting.

2. Welded Steel or Alloy Piping: Connect only with welded threadolet or half-coupling as specified on Piping Data Sheet.

3. Limitations: Threaded taps in pipe barrel are unacceptable.

3.11 VENTS AND DRAINS

A. Vents and drains at high and low points in piping required for completed system may or may not be shown. Install vents on high points and drains on low points of pipelines at all low and high point locations.



3.12 IDENTIFICATION LABELS

A. Pipe Labels:

1. Install where shown on Drawings. 2. Application: To pipe only after painting in vicinity is complete or as

approved by Engineer. 3. Installation: In accordance with manufacturer’s instructions.


A. Notify Engineer at least 3 days prior to start of any surface preparation or coating application work.

B. As specified in Section 09 90 00, Painting and Coating.

3.14 CLEANING

A. Following assembly and testing, and prior to final acceptance, flush pipelines (except as stated below) with water at 2.5 fps minimum flushing velocity until foreign matter is removed.

B. Insert cone strainers in flushing connections to attached equipment and leave in-place until cleaning is complete.

C. Remove accumulated debris through drains 2 inches and larger or by removing spools and valves from piping.

3.15 SUPPLEMENTS

A. The supplements listed below, following “End of Section,” are a part of this Specification:

1. Data Sheets.

Number Title

40 27 00.01 Cement-Lined Ductile Iron Pipe and Fittings

40 27 00.07 Galvanized Steel Pipe and Malleable Iron Fittings

40 27 00.10 Polyvinyl Chloride (PVC) Pipe and Fittings

END OF SECTION


PW/WBG/179201 CEMENT-LINED DUCTILE OCTOBER 2018 IRON PIPE AND FITTINGS ©COPYRIGHT 2018 CH2M HILL 40 27 00.01 DATA SHEET - 1

SECTION 40 27 00.01 CEMENT-LINED

DUCTILE IRON PIPE AND FITTINGS

Item Description

General Pipe manufacturer shall submit certification that source manufacturing facility has been producing ductile iron pipe of the specified diameters, dimensions, and standards for a period of not less than 10 years. Testing of pipe required by AWWA A21.51 shall be conducted in testing and laboratory facilities located in the USA and operating under USA laws and regulations. Pipe shall be handled during manufacture and shipped without nesting (without insertion of one pipe inside another).

Pipe Buried Liquid Service Using Restrained Mechanical or Proprietary Restrained Joints: AWWA C111/A21.11, and AWWA C151/A21.51, pressure class conforming to Table 5 and Table 7 for Type 4 trench, 250 psi minimum working pressure. Follower glands shall be ductile iron.

Exposed Pipe Using Grooved End and Flange Joints: AWWA C115/A21.15, thickness Class 53 minimum, 250 psi minimum working pressure.

Lining Cement Mortar: AWWA C104/A21.4.

Fittings Lined and coated same as pipe.

Mechanical: AWWA C110/A21.10, AWWA C111/A21.11, and AWWA C153/A21.53 ductile iron, 250 psi minimum working pressure. Follower glands shall be ductile iron.

Proprietary Restrained: AWWA C110/A21.10, AWWA C111/A21.11, and AWWA C153/A21.53, ductile iron, 250 psi minimum working pressure. Restraint shall be achieved with removable metal elements fitted between a welded bar on the pipe barrel and the inside of the joint bell or fitting sizes smaller than 16 inches may be mechanical joint, restrained by anchor gland followers, ductile iron anchor type, wedge action, with break-off tightening bolts. Assembled joints shall be rated for deflection in operation at rated pressure. Rated deflection shall be not less than 1-1/2 degrees for 36-inch and smaller pipe. Rated deflection shall be not less than 1/2 degree for 42-inch and larger pipe. McWane Ductile, American Cast Iron Pipe Co., U.S. Pipe. Restrained joints relying on metal teeth molded into the gasket to prevent joint separation under pressure will not be accepted.


CEMENT-LINED DUCTILE PW/WBG/179201 IRON PIPE AND FITTINGS OCTOBER 2018 40 27 00.01 DATA SHEET - 2 ©COPYRIGHT 2018 CH2M HILL



Item Description

Grooved End: AWWA C606 and AWWA C110/A21.10, ductile iron, 250 psi minimum working pressure; Victaulic.

Flange: AWWA C110/A21.10 ductile iron, faced and drilled, Class 125 flat face. Gray cast iron will not be allowed.

Joints Restrained Mechanical: 250 psi minimum working pressure.

Proprietary Restrained: 150 psi minimum working pressure. American Cast Iron Pipe Co., Flex-Ring or Lok-Ring; U.S. Pipe, TR Flex.

Grooved End: Rigid type radius cut conforming to AWWA C606, 250 psi minimum working pressure; Victaulic.

Flange: Class 125 flat face, ductile iron, threaded conforming to AWWA C115/A21.15. Gray cast iron will not be allowed.

Branch connections 3 inches and smaller, shall be made with service saddles as specified in Section 40 27 01, Process Piping Specialties.

Couplings Grooved End: 250 psi minimum working pressure, malleable iron per ASTM A47/A47M or ductile iron in accordance with ASTM A536; Victaulic.

Grooved End Adapter Flanges: 250 psi minimum working pressure, malleable iron per ASTM A47/A47M or ductile iron in accordance with ASTM A536; Victaulic.

Bolting Mechanical, Proprietary Restrained, and Grooved End Joints: Manufacturer’s standard.

Class 125 Flat-Faced Flange: ASTM A307, Grade A carbon steel hex head bolts, ASTM A563, Grade A carbon steel hex head nuts and ASTM F436/F436M hardened steel washers at nuts and bolt heads. Achieve 40 percent to 60 percent of bolt minimum yield stress.


PW/WBG/179201 CEMENT-LINED DUCTILE OCTOBER 2018 IRON PIPE AND FITTINGS ©COPYRIGHT 2018 CH2M HILL 40 27 00.01 DATA SHEET - 3



Item Description

Gaskets General: Gaskets in contact with potable water shall be NSF 61 certified.

Restrained Mechanical, and Proprietary Restrained Joints: Rubber conforming to AWWA C111/A21.11.

Grooved End Joints: Halogenated butyl conforming to ASTM D2000 and AWWA C606.

Flanged, Water, Sewage and Hot Air Services: 1/8-inch-thick, homogeneous black rubber (EPDM), hardness 60 (Shore A), rated to 275 degrees F, conforming to ASME B16.21 and ASTM D2000 4CA 415 A25 B35 C32 EA14 F19.

Full face for Class 125 flat-faced flanges, flat-ring type for Class 250 raised-face flanges. Blind flanges shall be gasketed covering entire inside face with gasket cemented to blind flange.

Gasket pressure rating to equal or exceed the system hydrostatic test pressure.

Joint Lubricant Manufacturer’s standard.

END OF SECTION


PW/WBG/179201 GALVANIZED STEEL PIPE OCTOBER 2018 AND MALLEABLE IRON FITTINGS ©COPYRIGHT 2018 CH2M HILL 40 27 00.07 DATA SHEET - 1

SECTION 40 27 00.07 GALVANIZED STEEL PIPE AND MALLEABLE IRON FITTINGS

Item Size Description

Pipe All Galvanized carbon steel, ASTM A106, Grade B seamless or ASTM A53, Grade B seamless or ERW.

Schedule 80.

Joints 2” & smaller Threaded or flanged at valves and equipment, or grooved end meeting requirements of AWWA C606.

2-1/2” & larger Flanged at valves and equipment, or grooved end meeting requirements of AWWA C606.

Fittings Threaded: 150- or 300-pound malleable iron, ASTM A197 or ASTM A47, dimensions in accordance with ASME B16.3.

Grooved End: Malleable iron ASTM A47 or ductile iron ASTM A536, 250 psi working pressure, grooved ends to accept couplings without field preparation. Victaulic; Anvil International, Inc., Gruvlok.

Branch Connections

2” & smaller Tee or reducing tee in conformance with Fittings above, galvanized 2,000-pound WOG threadolet or welding boss; galvanize after welding.

2-1/2” & larger Branch Same Size as Run: Grooved end tee in accordance with Fittings above. Branch One or More Sizes Smaller Than Run: grooved end reducing tee in accordance with Fittings above.

Flanges Galvanized forged carbon steel, ASTM A105/A105M, ASME B16.5 Class 150 or Class 300, threaded, 1/16-inch raised face.

Grooved end adapter flange, malleable iron ASTM A47 or ductile iron ASTM A536. Victaulic; Anvil International, Inc., Gruvlok.

Unions Threaded malleable iron, ASTM A197 or ASTM A47, 300-pound WOG, brass to iron seat, meeting the requirements of ASME B16.3.


GALVANIZED STEEL PIPE PW/WBG/179201 AND MALLEABLE IRON FITTINGS OCTOBER 2018 40 27 00.07 DATA SHEET - 2 ©COPYRIGHT 2018 CH2M HILL

SECTION 40 27 00.07 GALVANIZED STEEL PIPE AND MALLEABLE IRON FITTINGS


Couplings Grooved End: Rigid joint malleable iron, ASTM A47 or ductile iron, ASTM A536, 250 psi working pressure. Victaulic; Anvil International, Inc., Gruvlok.

Plugs Forged carbon steel, ASTM A181/A181M, Grade II, round head, threaded, galvanized.

Bolting Grooved End Couplings: Carbon steel, ASTM A183 bolts and nuts, 110,000 psi minimum tensile strength.

Flanges: Carbon steel ASTM A307, Grade A hex head bolts and ASTM A563, Grade A hex head nuts.

Gaskets All flanges Flanged, Water and Sewage Service: 1/8-inch thick, homogeneous black rubber (EPDM), hardness 60 (Shore A), rated to 250 degrees F continuous and conforming to ASME B16.21 and ASTM D1330, Steam Grade.

Blind flanges shall be gasketed covering entire inside face with gasket cemented to blind flange.

Grooved end couplings

EPDM or chlorinated butyl per ASTM D2000 for water, and air to 230 degrees F, dimensions conforming to AWWA C606.

Thread Lubricant

2” & smaller Teflon tape or joint compound that is insoluble in water.

END OF SECTION


PW/WBG/179201 POLYVINYL CHLORIDE (PVC) OCTOBER 2018 PIPE AND FITTINGS ©COPYRIGHT 2018 CH2M HILL 40 27 00.10 DATA SHEET - 1

SECTION 40 27 00.10 POLYVINYL CHLORIDE (PVC) PIPE AND FITTINGS


Pipe All Schedule 80 PVC: Type I, Grade I or Class 12454-B conforming to ASTM D1784 and ASTM D1785. Pipe shall be manufactured with titanium dioxide for ultraviolet protection.

Threaded Nipples: Schedule 80 PVC.

Fittings All Schedule to Match Pipe Above: ASTM D2466 and ASTM D2467 for socket weld type and Schedule 80 ASTM D2464 for threaded type. Fittings shall be manufactured with titanium dioxide for ultraviolet protection.

Joints All Solvent socket weld except where connection to threaded valves and equipment may require future disassembly.

Flanges All One-piece, molded hub type PVC flat face flange in accordance with Fittings above, ASME B16.1, Class 125 drilling

Bolting All Flat Face Mating Flange and In Corrosive Areas: ASTM A193/A193M, Type 316 stainless steel Grade B8M hex head bolts, ASTM A194/A194M Grade 8M hex head nuts and ASTM F436/F436M Type 3 alloy washers at nuts and bolt heads. Achieve 40 percent to 60 percent of bolt minimum yield stress.

With Raised Face Mating Flange: Carbon steel ASTM A307 Grade B square head bolts, ASTM A563 Grade A heavy hex head nuts and ASTM F436/F436M hardened steel washers at nuts and bolt heads. Achieve 40 percent to 60 percent of bolt minimum yield stress.


POLYVINYL CHLORIDE (PVC) PW/WBG/179201 PIPE AND FITTINGS OCTOBER 2018 40 27 00.10 DATA SHEET - 2 ©COPYRIGHT 2018 CH2M HILL

SECTION 40 27 00.10 POLYVINYL CHLORIDE (PVC) PIPE AND FITTINGS


Gaskets All Flat Face Mating Flange: Full faced 1/8-inch thick ethylene propylene (EPR) rubber.

Raised Face Mating Flange: Flat ring 1/8-inch ethylene propylene (EPR) rubber, with filler gasket between OD of raised face and flange OD to protect the flange from bolting moment.

Solvent Cement All Socket type joints shall be made employing solvent cement that meets or exceeds the requirements of ASTM D2564 and primer that meets or exceeds requirements of ASTM F656 and as recommended by pipe and fitting manufacturer.

Thread Lubricant All Teflon Tape.

END OF SECTION


PW/WBG/179201 STEEL CASING PIPE OCTOBER 2018 40 27 00.27 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 40 27 00.27 STEEL CASING PIPE

PART 1 GENERAL

1.01 WORK INCLUDED

A. This section provides the minimum requirements for steel casing pipe to be installed by the allowable tunneling method(s) identified in Section 02 40 00, Crossings, and in open cut cased installations. Steel casing pipe is required where shown on the Drawings.

1.02 SUBMITTALS

A. Action Submittals

1. Steel Casing Pipe for Tunneled Crossings: Furnish shop drawings illustrating the details of the casing pipe, grout/lubrication ports, joint details, joint seal system, and miscellaneous items to be furnished and fabricated for the pipe. Show dimensions, tolerances, wall thickness, properties and strengths, and other pertinent information. Submit to Construction Manager for acceptance by Engineer prior to fabrication.

2. Steel Casing Pipe for Open Cut Installations: Furnish Shop Drawings illustrating the details of the casing pipe, joint details, joint seal system, and miscellaneous items to be furnished and fabricated for the pipe. Show dimensions, tolerances, wall thickness, properties and strengths, and other pertinent information. Submit to Construction Manager for acceptance by Engineer prior to fabrication.

B. Informational Submittals: Design calculations demonstrating that the proposed jacking pipe is capable of supporting the maximum stresses to be imposed during jacking. The calculations shall take into account earth and hydrostatic loads, jacking forces, contact grouting pressures, external loads such as live loads due to traffic and rail, and any other loads that may be reasonably anticipated during jacking. All loads shall be shown and described.

1.03 DESIGN CRITERIA FOR TUNNELED CROSSINGS

A. Be fully responsible for the design of steel casing pipe that meets or exceeds the design requirements of this Specification and that is specifically designed for installation by tunneling methods.

B. Provide design of the casing pipe accounting for installation and service loads, including: (1) jacking loads; (2) external groundwater and earth loads;


STEEL CASING PIPE PW/WBG/179201 40 27 00.27 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

(3) practical consideration for handling, shipping, and other construction operations; (4) any other live or dead loads reasonably anticipated, including, but not limited to train loads. Provide design sealed and signed by a registered Professional Engineer licensed in the State of California.

C. Do not exceed the casing manufacturer’s allowable jacking capacity or 50 percent of the minimum steel yield stress, whichever is lower.

D. Provide steel casing pipe with a minimum wall thickness as shown on the Drawings and in accordance with UPRR requirements.

E. Provide steel casing pipe with inside diameters as shown on the Drawings. Install the required carrier pipe with casing spacers as required in Section 31 60 00, Installation of Carrier Pipe in Steel Casing.

F. Furnish steel casing pipe with lengths between 10 and 20 feet, depending on the installation requirements, available work and staging areas, shaft dimensions, as well as the shop practices of the pipe manufacturer.

G. Achieve steel casing pipe connections by complete joint penetration (CJP) field butt joint welding or a water-tight integral machine press-fit connection (Permalok). Field butt joint welding a square end piece of steel pipe to a 35-degree beveled end of steel pipe is acceptable unless otherwise specified. Install integral machined press-fit connections in accordance with the manufacturer’s installation procedures and recommendations.

H. Provide steel casing pipe with two grout/lubricant ports 20 degrees on either side of vertical centerline and one port at crown along the pipe at intervals of 10 feet or less. Attach flush ports and fittings to the pipe in a manner that will not materially affect the strength of the pipe or affect tunneling and jacking operations. Provide flush-mount plugs for sealing the fittings capable of withstanding external and internal pressures and loads without leaking.

I. Drilling grout holes through installed casing pipe will not be permitted. Thread grout ports to accept valve fittings and flush plugs.

1.04 DESIGN CRITERIA FOR OPEN CUT INSTALLATIONS

A. Be fully responsible for the design of steel casing pipe that meets or exceeds the design requirements of this Specification and that is specifically designed for installation by open cut installations.

B. Provide design of the casing pipe accounting for installation and service loads, including: (1) external groundwater and earth loads; (2) practical consideration or handling, shipping, and other construction operations; (3) any


PW/WBG/179201 STEEL CASING PIPE OCTOBER 2018 40 27 00.27 - 3 ©COPYRIGHT 2018 CH2M HILL

other live or dead loads reasonably anticipated, including, but not limited to, truck loads. Provide design sealed and signed by a registered Professional Engineer licensed in the State of California.

C. Provide steel casing pipe with inside diameters as shown on the Drawings. Install the required carrier pipe with casing spacers as required in Section 31 60 00, Installation of Carrier Pipe in Steel Casing.

D. Achieve steel casing pipe connections in accordance with Section 33 05 01 01, Welded Steel Pipe and Fittings.

PART 2 PRODUCTS

2.01 MATERIALS FOR TUNNELED CROSSINGS

A. Materials, Design, Fabrication, Handling, and Testing of Steel Casing Pipe: Conform to the requirements of ASTM A139, AWWA C200 and AWWA Manual M11 “Steel Pipe – A Guide for Design and Installation,” except as modified herein.

B. Steel Casing Pipe: New, smooth-wall, carbon steel pipe conforming to ASTM A139, Grade B.

C. Pemalok Steel Casing Pipe: New, smooth-wall, carbon steel pipe conforming to ASTM A515, Grade 60, or ASTM 572, Grade 42, with a watertight T7 joint profile.

D. Dimensional Tolerances: Bear sole responsibility for furnishing and installing steel casing pipe with dimensional tolerances in accordance with ASTM A139:

1. When pipe ends have to be field beveled for welding, bevel the ends on the outside to an angle of 35 degrees with a tolerance of plus or minus 2-1/2 degrees and with a width of root face 1/16 inch plus or minus 1/32 inch.

E. Prior to delivery of the pipe, furnish and install end/internal bracing as recommended by the manufacturer, for protection during shipping, storage, and installation.

2.02 MATERIALS FOR OPEN CUT INSTALLATIONS

A. Materials, Design, Fabrication, Handling, and Testing of Steel Casing Pipe: Conform to the requirements of Section 33 05 01.01, Welded Steel Pipe and Fittings.


STEEL CASING PIPE PW/WBG/179201 40 27 00.27 - 4 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

B. Lining and coating not required for casing pipe.

PART 3 EXECUTION

3.01 GENERAL

A. Installation for Tunneled Crossings:

1. Install steel casing pipe in accordance with the individual specification section identified for the allowable tunneling method in Section 02 40 00, Crossings.

2. Install carrier pipe inside steel casing pipe in accordance with Section 31 60 00, Installation of Carrier Pipe in Steel Casing.

B. Installation for Open Cut Installations:

1. Install steel casing pipe in accordance with Section 33 05 01 01, Welded Steel Pipe and Fittings.

2. Install carrier pipe inside steel casing pipe in accordance with Section 31 60 00, Installation of Carrier Pipe in Steel Casing.

END OF SECTION


PW/WBG/179201 PROCESS PIPING SPECIALTIES OCTOBER 2018 40 27 01 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 40 27 01 PROCESS PIPING SPECIALTIES

PART 1 GENERAL

1.01 SUBMITTALS

A. Action Submittals: Manufacturer’s data on materials, construction, end connections, ratings, overall lengths, and live lengths (as applicable).


1. Coupling Harness: a. Details, ratings, calculations and test reports for thrust restraints

relying on welded bars or rings. b. Weld procedure qualifications. c. Load proof-testing report of prototype restraint for any size

coupling.

C. Operation and Maintenance Data as specified in Section 01 78 23, Operation and Maintenance Data.

PART 2 PRODUCTS

2.01 GENERAL

A. Provide required piping specialty items, whether shown or not shown on Drawings, as required by applicable codes and standard industry practice.

B. Rubber ring joints, mechanical joints, flexible couplings, and proprietary restrained ductile iron pipe joints are considered flexible joints; welded, screwed, and flanged pipe joints are not considered flexible.

2.02 COUPLINGS

A. General:

1. Couplings shall be rated for working pressure not less than indicated in Piping Schedule for the service and not less than 150 psi.

2. Couplings shall be lined and coated with fusion-bonded epoxy in accordance with AWWA C213.

3. Unless thrust restraint is provided by other means, couplings shall be harnessed in accordance with requirements of AWWA Manual M11 or as shown on Drawings.


PROCESS PIPING SPECIALTIES PW/WBG/179201 40 27 01 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

4. Sleeve type couplings shall conform to AWWA C219 and shall be hydraulically expanded beyond minimum yield for accurate sizing and proofing of tensile strength.

B. Flexible Sleeve Type Coupling:

1. Manufacturers and Products: a. Steel Pipe:

1) Romac Industries, Inc.; Style 501. 2) Smith-Blair, Inc.; Style 411.

b. Ductile Iron Pipe: 1) Romac Industries, Inc.; Style 501. 2) Smith-Blair, Inc.; Style 441.

C. Transition Coupling for Steel Pipe:

1. Manufacturers and Products: a. Romac Industries, Inc.; Style RC501. b. Smith-Blair, Inc.; Style 413.

D. Flanged Coupling Adapter:

1. Manufacturers and Products: a. Steel Pipe:

1) Romac Industries, Inc.; Style FC400 or Style FCA501. 2) Smith-Blair, Inc.; Style 913.

b. Ductile Iron Pipe: 1) Romac Industries, Inc.; Style FC400 or Style FCA501. 2) Smith-Blair, Inc.; Style 912.

E. Restrained Flange Coupling Adapter:

1. Ductile iron or fabricated steel body, flange dimensions per ASME B16.1 Class 125, Buna-N gasket.

2. Pressure Rating: a. Minimum Working Pressure Rating: Not less than 150 psi. b. Safety Factor: Not less than two times working pressure and shall

be supported by manufacturer’s proof testing. 3. Thrust Restraint:

a. Provide hardened steel wedges that bear against and engage outer pipe surface, and allow articulation of pipe joint after assembly while wedges remain in their original setting position on pipe surface.



b. Products employing set screws that bear directly on pipe will not be acceptable.

4. Manufacturers and Products: a. Romac Industries, Inc.; RFCA. b. Smith Blair, Inc.; Model 911.

F. Dismantling Joints:

1. Dismantling joint shall consist of a self-contained flanged restrained joint fitting that allows for longitudinal adjustment.

2. Provide as a complete assembly consisting of flanged spigot piece, flange adapter, follower ring and bolts, tie bars, and Buna-N gasket.

3. Tie Bars: a. Minimum quantity shall be equal to one fourth the number of

flange bolt holes or four, whichever is greater. b. Diameter shall match that of corresponding flange bolts. c. Material: Steel threaded rod, rolled threads, ASTM A193,

Grade B7 or B7M. 4. Pressure Rating:

a. Minimum working pressure rating shall not be less than rating of the connecting flange.

b. Proof testing shall conform to requirements of AWWA C219 for bolted couplings.

5. Manufacturers and Products: a. Romac Industries, Inc.; DJ400. b. Smith Blair, Inc.; Model 975.

G. Exposed Metallic Piping Plain End Couplings:

1. Plain end pipe couplings shall be self-restrained against hydrostatic thrust forces equal to not less than two times the working pressure rating of the coupling.

2. Casing, bolts, and nuts shall be Type 304 or Type 316 stainless steel. The sealing sleeve shall be EPDM or NBR elastomer as best suited for the fluid service.

3. Manufacturers and Products: a. Straub Couplings, Grip-L or Metal Grip. b. Romac Industries, Inc.; Armor Lock.




A. Double-Strap Iron:

1. Pressure Rating: Capable of withstanding 150 psi internal pressure without leakage or over stressing.

2. Run Diameter: Compatible with outside diameter of pipe on which saddle is installed.

3. Taps: Iron pipe threads. 4. Materials:

a. Body: Malleable or ductile iron. b. Straps: Galvanized steel. c. Hex Nuts and Washers: Steel. d. Seal: Rubber.

5. Manufacturers and Products: a. Smith-Blair; Series 313 or 366. b. Romac Industries, Inc.; Series 202U.

B. Nylon-Coated Iron:

1. Pressure Rating: Capable of withstanding 150 psi internal pressure without leakage or over stressing.

2. Run Diameter: Compatible with outside diameter of pipe on which saddle is installed.

3. Materials: a. Body: Nylon-coated iron. b. Seal: Buna-N. c. Clamps and Nuts: Stainless steel.

4. Manufacturers and Products: a. Smith-Blair; Style 315 or 317. b. Romac Industries, Inc.; Series 202NSSU

2.04 OUTLET/TAPPING SADDLES

A. Materials:

1. Straps: Alloy steel with 3/4-inch threaded ends. 2. Seal: O-Ring SBR rubber gasket. 3. Compatible with ductile iron pipe.

B. Connection: As shown.

C. Pressure Rating: Capable of withstanding 250 psi internal pressure without leakage over stressing.



D. Manufacturer and Product: American Cast Iron Pipe Co.; Outlet/Tapping Saddle.

2.05 PIPE SLEEVES

A. Steel Pipe Sleeve:

1. Minimum Thickness: 1/2 inch. 2. Seep Ring:

a. Center steel flange for water stoppage on sleeves in exterior or water-bearing walls, 1/2-inch minimum thickness.

b. Outside Diameter: Unless otherwise shown, 3 inches greater than pipe sleeve outside diameter.

c. Continuously fillet weld on each side all around. 3. Factory Finish:

a. Galvanizing: 1) Hot-dip applied, meeting requirements of

ASTM A153/A153M. 2) Electroplated zinc or cadmium plating is unacceptable.

b. Shop Lining and Coating: Factory prepare, prime, and finish coat in accordance with Section 09 90 00, Painting and Coating.

2.06 SLAB, FLOOR, WALL AND ROOF PENETRATIONS

A. Ductile Iron Wall Pipe:

1. Diameter and Ends: Same as connecting ductile iron pipe. 2. Thickness: Equal to or greater than remainder of pipe in line. 3. Fittings: In accordance with applicable Pipe Data Sheet. 4. Thrust Collars:

a. Rated for thrust load developed at 250 psi. b. Safety Factor: 2, minimum. c. Material and Construction: Ductile iron or cast iron, cast integral

with wall pipe wherever possible, or thrust rated, welded attachment to wall pipe.

5. Manufacturers: a. American Cast Iron Pipe Co. b. U.S. Pipe Fabrication Co.

B. Steel or Stainless Steel Wall Pipe:

1. Same material and thickness as connecting pipe, except 1/2-inch minimum thickness.

2. Lining: Same as connecting pipe.



3. Thrust Collar: a. Outside Diameter: Unless otherwise shown, 3 inches greater than

outside diameter of wall pipe. b. Continuously fillet welded on each side all around.

2.07 MISCELLANEOUS SPECIALTIES

A. Strainers, Water Service, 2 Inches and Smaller:

1. Type: Bronze body, Y pattern, 200 psi nonshock rated, with screwed gasketed bronze cap.

2. Screen: Heavy-gauge Type 304 stainless steel or monel, 20 mesh. 3. Manufacturers and Products:

a. Armstrong International; Inc.; Model F. b. Mueller Steam Specialty; Model 351M.

B. Seal Water Hose:

1. 2-foot lengths of 3/8-inch hose with male NPT by union ends. 2. EPDM black cover and EPDM tube, reinforced with two textile braids. 3. Rated minimum working pressure of 200 psi. 4. Manufacturers:

a. Goodyear. b. Boston.

C. Pump Seal Water Sight Flow Indicators:

1. Bronze body, 3/8 inch, horizontal, ball action with tempered glass. 2. Rated 125 psi with NPT screwed ends. 3. Operate with a minimum flow of 0.25 gpm. 4. Manufacturers and Products:

a. Eugene Ernst Co.; Series E 57 4. b. Jacoby Tarbox Co.

PART 3 EXECUTION

3.01 GENERAL

A. Provide accessibility to piping specialties for control and maintenance.



3.02 PIPING FLEXIBILITY PROVISIONS

A. General:

1. Thrust restraint shall be provided as specified in Section 40 27 00, Process Piping—General.

2. Install flexible couplings to facilitate piping installation, in accordance with approved shop drawings.

B. Flexible Joints at Concrete Backfill or Encasement: Install within 18 inches or one-half pipe diameter, whichever is less, from the termination of any concrete backfill or concrete encasement.


A. Ferrous Metal Piping (except stainless steel): Double-strap iron.

B. Plastic Piping: Nylon-coated iron.

3.04 OUTLET/TAPPING SADDLE

A. Install in accordance with manufacturer’s written instructions.

3.05 COUPLINGS

A. General:

1. Install in accordance with manufacturer’s written instructions. 2. Before coupling, clean pipe holdback area of oil, scale, rust, and dirt. 3. Do not remove pipe coating. If damaged, repair before joint is made. 4. Application:

a. Metallic Piping Systems: Flexible couplings, transition couplings, and flanged coupling adapters.

b. Concrete Encased Couplings: Flexible coupling.

3.06 PIPE SLEEVES

A. Application:

1. As specified in Section 40 27 00, Process Piping—General. 2. Above Grade in Nonsubmerged Areas: Hot-dip galvanized after

fabrication. 3. Below Grade or in Submerged or Damp Environments: Shop-lined and

coated.



4. Alternatively, Molded Polyethylene Pipe Sleeve as specified may be applied.

B. Installation:

1. Support noninsulating type securely in formwork to prevent contact with reinforcing steel and tie-wires.

2. Caulk joint with specified sealant in non-submerged applications and seal below grade and submerged applications with wall penetration seal.

3.07 SLAB, FLOOR, WALL AND ROOF PENETRATIONS

A. Applications:

1. Watertight and Below Ground Penetrations: a. Wall pipes with thrust collars. b. Provide taps for stud bolts in flanges to be set flush with wall face.

2. Nonwatertight Penetrations: Pipe sleeves with seep ring. 3. Existing Walls: Rotary drilled holes.

B. Wall Pipe Installation:

1. Isolate embedded metallic piping from concrete reinforcement using coated pipe penetrations as specified in Section 09 90 00, Painting and Coating.

2. Support wall pipes securely by formwork to prevent contact with reinforcing steel and tie-wires.

END OF SECTION


PW/WBG/179201 PROCESS VALVES AND OPERATORS OCTOBER 2018 40 27 02 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 40 27 02 PROCESS VALVES AND OPERATORS

PART 1 GENERAL

1.01 SUBMITTALS


1. Shop Drawings: a. Product data sheets for each make and model. Indicate valve Type

Number, applicable Tag Number, and facility name/number or service where used.

b. Complete catalog information, descriptive literature, specifications, and identification of materials of construction.

c. Power and control wiring diagrams, including terminals and numbers.

d. For each power actuator provided, Manufacturer’s standard data sheet, with application specific features and options clearly identified.

e. Sizing calculations for open-close/throttle and modulating valves. f. Seismic anchorage and bracing drawings and cut sheets, as

required by Section 01 88 15, Seismic Anchorage and Bracing.


1. Seismic anchorage and bracing calculations as required by Section 01 88 15, Seismic Anchorage and Bracing.

2. Manufacturer’s Certificate of Compliance, in accordance with Section 01 43 33, Manufacturers’ Field Services for: a. Electric actuators; full compliance with AWWA C540. b. Butterfly valves; full compliance with AWWA C504.

3. Tests and inspection data. 4. Operation and Maintenance Data as specified in Section 01 78 23,

Operation and Maintenance Data. 5. Manufacturer’s Certificate of Proper Installation, in accordance with

Section 01 43 33, Manufacturers’ Field Services.


PROCESS VALVES AND OPERATORS PW/WBG/179201 40 27 02 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

PART 2 PRODUCTS

2.01 GENERAL

A. Valves to include operator, actuator, handwheel, chain wheel, extension stem, floor stand, operating nut, chain, wrench, and accessories to allow a complete operation from the intended operating level.

B. Valve to be suitable for intended service. Renewable parts not to be of a lower quality than specified.

C. Valve same size as adjoining pipe, unless otherwise called out on Drawings or in Supplements.

D. Valve ends to suit adjacent piping.

E. Resilient seated valves shall have no leakage (drip-tight) in either direction at valve rated design pressure. All other valves shall have no leakage (drip-tight) in either direction at valve rated design pressure, unless otherwise allowed for in this section or in stated valve standard.

F. Size operators and actuators to operate valve for the full range of pressures and velocities.

G. Valve to open by turning counterclockwise, unless otherwise specified.

H. Factory mount operator, actuator, and accessories.

2.02 SCHEDULE

A. Additional requirements relative to this section are shown on Electric Motor Actuator Schedule located at the end of this section.

2.03 MATERIALS

A. Bronze and brass valve components and accessories that have surfaces in contact with water to be alloys containing less than 16 percent zinc and 2 percent aluminum.

1. Approved alloys are of the following ASTM designations: B61, B62, B98/B98M (Alloy UNS No. C65100, C65500, or C66100), B139 (Alloy UNS No. C51000), B584 (Alloy UNS No. C90300 or C94700), B164, B194, and B127.

2. Stainless steel Alloy 18-8 may be substituted for bronze.



2.04 FACTORY FINISHING

A. Epoxy Lining and Coating:

1. Use where specified for individual valves described herein. 2. In accordance with AWWA C550 unless otherwise specified. 3. Either two-part liquid material or heat-activated (fusion) material except

only heat-activated material if specified as “fusion” or “fusion bonded” epoxy.

4. Minimum 7-mil dry film thickness except where limited by valve operating tolerances.

B. Exposed Valves: In accordance with Section 09 90 00, Painting and Coating.

2.05 VALVES

A. Gate Valves:

1. General: a. AWWA gate valves to be in full compliance with stated AWWA

standard and the following requirements: 1) Provide 2-inch operating nut and handwheel for AWWA

gate valves 12 inches and smaller. 2) Provide totally enclosed spur or bevel gear operator with

indicator for AWWA gate valves 14 inches and larger. 3) Provide Affidavit of Compliance in accordance with the

applicable AWWA standard for AWWA gate valves. 4) Mark AWWA gate valves with manufacturer’s name or

mark, year of valve casting, valve size, and working water pressure.

5) Repaired AWWA gate valves shall not be submitted or supplied.

6) Supply AWWA gate valves with stainless steel bolting. 7) AWWA C509 and AWWA C515 valves may be substituted

for each other. 2. Type V135 Resilient Seated Ductile Iron Gate Valve 3 Inches to

36 Inches: a. Ductile iron body, resilient seat, bronze stem and stem nut,

mechanical joint ends, nonrising stem, in accordance with AWWA C515, minimum design working water pressure 200 psig, full port, fusion epoxy coated inside and outside in accordance with AWWA C550.



b. Manufacturers and Products: 1) American Flow Control; Series 2500. 2) M&H; Style 7000 and C515 Large RW Valves.

B. Ball Valves:

1. Type V300 Ball Valve 3 Inches and Smaller for General Water and Air Service: a. Two-piece, standard port, NPT threaded ends, bronze body and

end piece, hard chrome-plated solid bronze or brass ball, RTFE seats and packing, blowout-proof stem, adjustable packing gland, zinc-coated steel hand lever operator with vinyl grip, rated 600-pound WOG, 150-pound SWP, complies with MSS SP-110.

b. Manufacturers and Products: 1) Threaded:

a) Conbraco Apollo; 70-100. b) Nibco; T-580-70.

2) Soldered: a) Conbraco Apollo; 70-200. b) Nibco; S-580-70.

2. Type V330 PVC Ball Valve 2 Inches and Smaller: a. Rated 150 psi at 73 degrees F, with ASTM D1784, Type I,

Grade 1 polyvinyl chloride body, ball, and stem, end entry, double union design, solvent-weld socket ends, elastomer seat, Viton or Teflon O-ring stem seals, to block flow in both directions.

b. Manufacturers and Products: 1) Nibco; Chemtrol Tru-Bloc. 2) ASAHI/America; Type 21. 3) Spears; True Union.

C. Plug Valves:

1. Type V400 Eccentric Plug Valve 2 Inches and Smaller: a. Nonlubricated type rated 175 psig CWP, drip-tight shutoff with

pressure from either direction, cast-iron or ductile iron body, threaded ends, lever operator, cast-iron plug with round or rectangular port, plug coated with Buna-N, stem bearing lubricated stainless steel or bronze, stem seal multiple V-rings, or U-cups with O-rings of nitrile rubber.

b. Provide epoxy lining and coating in compliance with AWWA C550.



c. Manufacturers and Products: 1) Pratt; Ballcentric. 2) DeZurik; Style PEC. 3) Milliken; Millcentric Series 613.

2. Type V405 Eccentric Plug Valve 3 Inches to 12 Inches: a. Nonlubricated type rated 175 psig CWP, drip-tight shutoff with

pressure from either direction, cast-iron body, exposed service flanged ends in accordance with ASME B16.1 or grooved ends in accordance with AWWA C606 for rigid joints, buried service mechanical joint ends, unless otherwise shown.

b. Plug cast iron with round or rectangular port of no less than 80 percent of connecting pipe area and coated with Buna-N, seats welded nickel, stem bearings lubricated stainless steel or bronze, stem seal multiple V-rings, or U-cups with O-rings of nitrile rubber, grit seals on both upper and lower bearings.

c. Provide epoxy lining and coating in compliance with AWWA C550.

d. Manual Operators: 1) 3-Inch to 4-Inch Valves: Wrench lever manual. 2) 6-Inch to 12-Inch Valves: Totally enclosed, geared, manual

operator with handwheel, 2-inch nut, or chain wheel. Size operator for 1.5 times the maximum operating shutoff pressure differential for direct and reverse pressure, whichever is higher. For buried service, provide completely sealed operator filled with heavy lubricant and 2-inch nut.

e. Manufacturers and Products: 1) Pratt; Ballcentric. 2) DeZurik; Style PEC. 3) Milliken; Millcentric Series 600.

3. Type V406 Eccentric Plug Valve 14 Inches to 20 Inches: a. Nonlubricated type rated 150 psig CWP, drip-tight shutoff with

pressure from either direction, cast-iron body, exposed service flanged ends in accordance with ASME B16.1 or grooved ends in accordance with AWWA C606 for rigid joints, buried service mechanical joints ends, unless otherwise shown, plug cast iron with round or rectangular port of no less than 80 percent of connecting pipe area and coated with Buna-N, seats welded nickel, stem bearings lubricated stainless steel or bronze, stem seal multiple V-rings or U-cups with O-rings of nitrile rubber, grit seals on both upper and lower bearings.

b. Totally enclosed, geared, manual operator with handwheel, 2-inch nut, or chain wheel. Size operator for 1.5 times maximum operating shutoff pressure differential for direct and reverse pressure, whichever is higher. For buried service, provide



completely sealed operator filled with heavy lubricant and 2-inch nut.

c. Provide epoxy lining and coating in compliance with AWWA C550.

d. Manufacturers and Products: 1) Pratt; Ballcentric. 2) DeZurik; Style PEC. 3) Milliken; Millcentric Series 600.

4. Type V464 Corporation Stop 1/2 Inch to 1 Inch: a. AWWA C800 type, tapered threaded inlet, except when

connecting to tapped fittings which require IPS tapered threads, outlet compression connection or IPS threads to suit connecting pipe, minimum rated working pressure 175 psi.

b. Manufacturers: 1) Mueller Co. 2) Ford Meter Box Co.

D. Butterfly Valves:

1. General: a. In full compliance with AWWA C504 and following

requirements: 1) Suitable for throttling operations and infrequent operation

after periods of inactivity. 2) Elastomer seats which are bonded or vulcanized to the body

shall have adhesive integrity of bond between seat and body assured by testing, with minimum 75-pound pull in accordance with ASTM D429, Method B.

3) Bubble-tight with rated pressure applied from either side. Test valves with pressure applied in both directions.

4) No travel stops for disc on interior of body. 5) Self-adjusting V-type or O-ring shaft seals. 6) Isolate metal-to-metal thrust bearing surfaces from

flowstream. 7) Provide traveling nut or worm gear actuator with

handwheel. Valve actuators to meet the requirements of AWWA C504.

8) Buried service operators shall withstand 450 foot-pounds of input torque at fully open and fully closed positions.

9) Provide linings and coatings in accordance with AWWA, unless otherwise indicated on the Drawings or specified herein.

10) Valves to be in full compliance with NSF 61.



b. Non-AWWA butterfly valves to meet the following actuator requirements: 1) For above ground installations, provide handle and notch

plate for valves 6 inches and smaller and heavy-duty, totally enclosed gearbox type operators with handwheel, position indicator and travel stops for valves 8 inches and larger, unless otherwise indicated on Drawings or specified herein.

2. Type V500 Butterfly Valve Water Works Service 3 Inches to 72 Inches: a. AWWA C504, Class 150B. b. Short body type, flanged ends. c. Cast-iron body, cast or ductile iron disc, Type 304 stainless steel

shafts, Buna-N rubber seat bonded or molded in body only, and stainless steel seating surface.

d. Provide epoxy lining and coating in compliance with AWWA C550.

e. Manufacturers and Products: 1) Pratt; Model 2FII or Triton XR-70. 2) DeZurik; AWWA Valve.

E. Check and Flap Valves:

1. Type V600 Check Valve 2 Inches and Smaller: a. All bronze, threaded cap, threaded or soldered ends, swing type

replaceable bronze disc, rated 125-pound SWP, 200-pound WOG. b. Manufacturers and Products:

1) Stockham; Figure B-319, threaded ends. 2) Milwaukee; Figure 509, threaded ends. 3) Stockham; Figure B-309, soldered ends. 4) Milwaukee; Figure 1509, soldered ends.

2. Type V634 Rubber Flapper Check Valve 2 Inches to 24 Inches: a. Iron body, ASME B16.1, Class 125 flanges, steel-reinforced

Buna-N flapper raised seating ring, rated 150-pound CWP. b. Provide epoxy interior coating in compliance with AWWA C550. c. Manufacturers and Products:

1) APCO; Series 100. 2) Val-Matic; “Swingflex.”

3. Type V694 Check Valve 4 Inch to 48 Inches: a. Elastomer type, flanged, round entry area to match pipe,

contoured duckbilled shaped exit, flat bottom and off-set bill design, curved bill for 18 inches and larger, valve open with approximately 2 inches of line pressure and return to CLOSED position under zero flow condition, rated for 50 psi minimum operating pressure; flanges steel backing flange type, drilled to ASME B16.1, Class 125, elastomer nylon-reinforced Buna-N.



b. Manufacturer and Product: Red Valve Co.; Tideflex Check Valve Series 35-1.

F. Self-Regulated Automatic Valves:

1. Type V742 Air and Vacuum Valve 1/2 Inch to 16 Inches For Vertical Turbine Service: a. 1/2 inch through 3 inches equipped with stainless steel diffuser

screen to break up solid water column before coming in contact with float, manufacturer’s standard double acting throttling device in outlet for throttling, NPT threaded inlet and outlet.

b. 4 inches and larger equipped with anti-slam device to throttle flow of water into air valve. Design anti-slam device to permit full, unrestricted flow of air into and out of air valve, but reduce flow area for water to approximately 10 percent. ASME B16.1 Class 125 flanged inlet and NPT threaded outlet.

c. Rated 150 psi working pressure, cast-iron or ductile iron body and cover, stainless steel float and trim, built and tested to AWWA C512.

d. Provide epoxy interior coating in compliance with AWWA C550. e. Manufacturers and Products:

1) APCO Valve and Primer Corp.; Series 141DAT to 146DAT or Series 1904 to 1916.

2) Val-Matic Valve; Series 100WS to 116WS. 2. Type V757 Rolling Seal Combination Air Valve 3/4 Inches to 8 Inches:

a. Uses rolling seal to allow smaller and larger amount of air to automatically exhaust under pressure and air to enter when vacuum occurs all in a single valve body.

b. 2 Inches and Smaller: 1) Design for working (seating) pressure range of 1 to 230 psi. 2) NPT inlet, reinforced nylon body, polypropylene drainage

elbow, foamed polypropylene float, and Buna-N O-ring. 3) Manufacturer and Product: ARI Valves; D-040.

c. 4 Inches and Larger: 1) Design for working (seating) pressure range of 3 to 230 psi. 2) Epoxy coated cast iron ASTM A48 body with

ASME B16.1, Class 125 flange inlet, EPDM rubber seal, stainless steel float, and BUNA-N, O-ring.

3) Manufacturer and Product: ARI Valves, D-060. 3. Type V758 Zero Pressure Seal Combination Air Valve 2 Inches to

12 Inches: a. Designed to allow smaller and larger amount of air to

automatically exhaust under pressure and air to enter when vacuum occurs all in a single valve body.



b. Designed for leak-free seal from 150 psi to 0 psi. c. Provide with flanged inlet, hooded outlet with stainless steel

insect screen, stainless steel body and trim, ultra-high-molecular-weight polyethylene float, and Viton O-rings.

d. Manufacturer and Product: International Valve; Vent-Tech SZG-C.

G. Miscellaneous Valves:

1. Type V940 Solenoid Valve 1/4 Inch to 2 Inches: a. Two-way internal pilot operated diaphragm type, brass body,

resilient seat suitable for air or water, solenoid coil molded epoxy, NEMA insulation Class F, 120 volts ac, 60 Hz, unless otherwise indicated. Solenoid enclosure NEMA 250, Type 4 unless otherwise indicated. Size and normal position CLOSED when de-energized.

b. Minimum operating pressure differential no greater than 5 psig, maximum operating pressure differential not less than 125 psig.

c. Manufacturers: 1) ASCO. 2) Parker-Skinner.

2.06 OPERATORS AND ACTUATORS

A. Manual Operators:

1. General: a. For AWWA valves, operator force not to exceed requirements of

the applicable valve standard. Provide gear reduction operator when force exceeds requirements.

b. For non-AWWA valves, operator force not to exceed applicable industry standard or 80 pounds, whichever is less, under any operating condition, including initial breakaway. Provide gear reduction operator when force exceeds requirements.

c. Operator self-locking type or equipped with self-locking device. d. Position indicator on quarter-turn valves. e. Worm and gear operators one-piece design, worm-gears of gear

bronze material. Worm of hardened alloy steel with thread ground and polished. Traveling nut type operator’s threaded steel reach rod with internally threaded bronze or ductile iron nut.

2. Specific Requirement: Manual operator for 42-inch butterfly valves shall provide slow closing. Operator shall require minimum of 136 turns to fully close the valve from 100 percent open position.



3. Exposed Operator: a. Galvanized and painted handwheel. b. Cranks on gear type operator. c. Chain wheel operator with tieback, extension stem, floor stand,

and other accessories to permit operation from normal operation level.

d. Valve handles to take a padlock, and wheels a chain and padlock. 4. Buried Operator:

a. Buried service operators on valves larger than 2-1/2 inches shall have a 2-inch AWWA operating nut. Buried operators on valves 2 inches and smaller shall have cross handle for operation by forked key. Enclose moving parts of valve and operator in housing to prevent contact with the soil.

b. Buried service operators to be grease packed and gasketed to withstand a submersion in water to 20 feet minimum.

c. Buried valves shall have extension stems, bonnets, and valve boxes.

B. Electric Motor Actuators:

1. General: a. Comply with latest version of AWWA C542. b. Size to 1-1/2 times required operating torque. Motor stall torque

not to exceed torque capacity of valve. c. Controls integral with the actuator and fully equipped as specified

in AWWA C542. d. Stem protection for rising stem valves.

2. Actuator Operation—General: a. Suitable for full 90-degree rotation of quarter-turn valves or for

use on multiturn valves, as applicable. b. Manual override handwheel. c. Valve position indication. d. Operate from FULL CLOSED to FULL OPEN positions or the

reverse in the number of seconds given in the Electric Motor Actuator Schedule.

3. Open-Close(O/C)/Throttling (T) Service: a. Size motors for one complete OPEN-CLOSE-OPEN cycle no less

than once every 10 minutes. b. Actuator suitable for throttling operation of valve at intermediate

positions. c. LOCAL-OFF-REMOTE Selector Switch, padlockable in each

position: 1) Integral OPEN-STOP-CLOSE momentary pushbuttons with

seal-in circuits to control valve in LOCAL position.



2) Remote OPEN-STOP-CLOSE momentary control dry contact inputs in REMOTE position. Integral seal-in circuits for remote OPEN and CLOSE commands; valve travel stops when remote STOP contact opens.

3) Auxiliary contact that closes in REMOTE position. d. OPEN and CLOSED indicating lights. e. Integral reversing motor starter with built-in overload protection. f. Valve shall remain in last position on loss of operator power.

4. Actuator Power Supply: a. 480 volts, three-phase, or 208 volts, three-phase as indicated. b. Control power transformer, 120-volt secondary.

5. Enclosure: a. As defined in NEMA 250, Type 4, unless otherwise indicated. b. Contain 120-volt space heaters, if required to prevent

condensation. 6. Limit Switch:

a. Single-pole, double-throw (SPDT) type, field adjustable, with contacts rated for 5 amps at 120 volts ac.

b. Each valve actuator to have a minimum of two auxiliary transfer contacts at end position, one for valve FULL OPEN and one for valve FULL CLOSED.

c. Housed in actuator control enclosure. 7. Manufacturers:

a. AUMA Actuators, Inc. b. Flowserve Limitorque. c. Rotork Controls.

2.07 ACCESSORIES

A. Tagging: 1-1/2-inch diameter heavy brass or stainless steel tag attached with No. 16 solid brass or stainless steel jack chain for each valve operator, bearing valve tag number shown on Electric Motor Actuator Schedule.

B. Limit Switch:

1. Factory installed NEMA 4X limit switch by actuator manufacturer. 2. SPST, rated at 5 amps, 120 volts ac.

C. Extension Bonnet for Valve Operator: Complete with enclosed stem, extension, support brackets, and accessories for valve and operator.

1. Manufacturers: a. Pratt. b. DeZurik.



PART 3 EXECUTION

3.01 INSTALLATION

A. Flange Ends:

1. Flanged valve bolt holes shall straddle vertical centerline of pipe. 2. Clean flanged faces, insert gasket and bolts, and tighten nuts

progressively and uniformly.

B. Screwed Ends:

1. Clean threads by wire brushing or swabbing. 2. Apply joint compound.

C. PVC Valves: Install using solvents approved for valve service conditions.

D. Valve Installation and Orientation:

1. General: a. Install valves so handles operate from fully open to fully closed

without encountering obstructions. b. Install valves in location for easy access for routine operation and

maintenance. c. Install valves per manufacturer’s recommendations.

2. Gate and Ball Valves: a. Install operating stem vertical when valve is installed in horizontal

runs of pipe having centerline elevations 4 feet 6 inches or less above finished floor, unless otherwise shown.

b. Install operating stem horizontal in horizontal runs of pipe having centerline elevations greater than 4 feet 6 inches above finish floor, unless otherwise shown.

3. Eccentric Plug Valves: a. Unless otherwise restricted or shown on Drawings, install valve as

follows: 1) Liquids with suspended solids service with horizontal flow:

Install valve with stem in horizontal position with plug up when valve is open. Install valve with seat end upstream (flow to produce unseating pressure).

2) Liquids with suspended solids service with vertical flow: Install valve with seat in highest portion of valve (seat up).

3) Clean Liquids and Gas Service: Install valve with seat end downstream of higher pressure when valve is closed (higher pressure forces plug into seat).



4. Butterfly Valves: a. Unless otherwise restricted or shown on Drawings, install valve a

minimum of 8 diameters downstream of a horizontal elbow or branch tee with shaft in horizontal position.

b. For vertical elbow or branch tee immediately upstream of valve, install valve with shaft in vertical position.

c. For horizontal elbow or branch tee immediately upstream of valve, install valve with shaft in horizontal position.

d. When installed immediately downstream of a swing check, install valve with shaft perpendicular to swing check shaft.

e. For free inlet or discharge into basins and tanks, install valve with shaft in vertical position.

5. Check Valves: a. Install valve in horizontal or vertical flow (up) flow piping only

for liquid services. b. Install valve in vertical flow (up) piping only for gas services. c. Install swing check valve with shaft in horizontal position.

E. Locate valve to provide accessibility for control and maintenance. Install access doors in finished walls and plaster ceilings for valve access.

F. Extension Stem for Operator: Where the depth of the valve operating nut is 3 feet or greater below finish grade, furnish an operating extension stem with 2-inch operating nut to bring operating nut to a point within 6 inches of finish grade.

G. Torque Tube: Where operator for quarter-turn valve is located on floor stand, furnish extension stem torque tube of a type properly sized for maximum torque capacity of valve.

H. Floor Box and Stem: Steel extension stem length shall locate operating nut in floor box.

I. Chain Wheel and Guide: Install chain wheel and guide assemblies or chain lever assemblies on manually operated valves over 6 feet 9 inches above finish floor. Install chain to within 3 feet 0 inch of finish floor. Where chains hang in normally traveled areas, use appropriate “L” type tie-back anchors. Install chains to within operator horizontal reach of 2 feet 6 inches maximum, measured from normal operator standing location or station.

3.02 TESTS AND INSPECTION

A. Valve may be either tested while testing pipelines, or as a separate step.



B. Test that valves open and close smoothly under operating pressure conditions. Test that two-way valves open and close smoothly under operating pressure conditions from both directions.

C. Inspect air and vacuum valves as pipe is being filled to verify venting and seating is fully functional.

D. Count and record number of turns to open and close valve; account for any discrepancies with manufacturer’s data.

E. Set, verify, and record set pressures for relief and regulating valves.

F. Automatic valves to be tested in conjunction with control system testing. Set opening and closing speeds, limit switches, as required or recommended by Engineer.

G. Test hydrostatic relief valve seating; record leakage. Adjust and retest to maximum leakage of 0.1 gpm per foot of seat periphery.

3.03 SUPPLEMENTS

A. The supplements listed below, following “End of Section,” is part of this Specification.

1. Electric Motor Actuator Schedule.

END OF SECTION


PW/WBG/179201 PROCESS VALVES AND OPERATORS OCTOBER 2018 40 27 02 SUPPLEMENT - 1 ©COPYRIGHT 2018 CH2M HILL

Electric Motor Actuator Schedule

Tag Number Valve Type

Valve Size

(inches) Process Fluid

Maximum Operating

Flow (gpm)

Maximum P (psi)

Actuator Power Supply

Travel Time (Seconds)

05-FV-141 V406 16 Stormwater 7,000 30 208V, 3-Phase 30

05-FV-151 V406 16 Stormwater 7,000 30 208V, 3-Phase 30

05-FV-171 V405 8 Pond Return 2,000 30 208V, 3-Phase 30

05-FV-181 V405 8 Pond Return 2,000 30 208V, 3-Phase 30

05-FV-211 V500 36 Plant Effluent 28,000 60 480V, 3-Phase 120 (Minimum)




PW/WBG/179201 INSTRUMENTATION AND CONTROL OCTOBER 2018 FOR PROCESS SYSTEMS ©COPYRIGHT 2018 CH2M HILL 40 90 01 - 1

SECTION 40 90 01 INSTRUMENTATION AND CONTROL FOR PROCESS SYSTEMS

1.01 SUMMARY

A. Work Includes:

1. Engineering, programming, furnishing, installing, calibrating, adjusting, testing, documenting, starting up, and Owner training for complete Process Instrumentation and Control System (PICS) for plant.

2. Major parts are: a. Primary elements, transmitters, and control devices. b. Stanchion-mounted control panel (CP-60). c. One Modicon M340 PLC system (PLC-60). d. New input/output modules in existing Modicon Quantum

programmable logic controller (PLC-07). e. Network interfaces to existing control systems.

3. Major work items include: a. Confirm interfacing wiring connections between new ASDs and

existing I/O points in existing TESCO Liquitronic programmable logic controller (RTU-40).

b. Program and test new alarms and shutdown logic in RTU-40. c. Install new I/O modules, terminal blocks, and wiring within

existing CP-07 (PLC-07). d. Provide and test I/O points associated with PLC-60. e. Program and test new alarms and logic in PLC-07, including

distributed I/O in DIO-60. f. Modifications and additions to plant SCADA HMI screens, tag

name database, alarm database, and Historian, using Owner’s standards.

B. Detailed Design: PICS as shown and specified includes functional and performance requirements and component specifications. Complete detailed PICS design.

1.02 DEFINITIONS

A. Abbreviations:

1. ASD: Adjustable Speed Drive. 2. CP: Control Panel. 3. DIO: Distributed I/O. 4. I/O: Input/Output. 5. LCP: Local Control Panel.


INSTRUMENTATION AND CONTROL PW/WBG/179201 FOR PROCESS SYSTEMS OCTOBER 2018 40 90 01 - 2 ©COPYRIGHT 2018 CH2M HILL

6. MCC: Motor Control Center. 7. PAT: Performance Acceptance Test. 8. PIC: Process Instrumentation and Control. 9. PLC: Programmable Logic Controller. 10. RTU: Remote Terminal Unit.

B. Rising/Falling: Terms used to define actions of discrete devices about their setpoints.

1. Rising: Contacts close when an increasing process variable rises through setpoint.

2. Falling: Contacts close when a decreasing process variable falls through setpoint.

C. Signal Types:

1. Analog Signals, Current Type: a. 4 mA to 20 mA dc signals conforming to ISA S50.1. b. Unless otherwise indicated for specific PICS Subsystem

components, use the following ISA 50.1 options: 1) Transmitter Type: Number 2, two-wire. 2) Transmitter Load Resistance Capacity: Class L. 3) Fully isolated transmitters and receivers.

2. Analog Signals, Voltage Type: 1 to 5 volts dc within panels where a common high precision dropping resistor is used.

3. Discrete signals, two-state logic signals using dc or 120V ac sources as indicated.

4. Pulse Frequency Signals: a. Direct current pulses whose repetition rate is linearly proportional

to process variable. b. Pulses generated by contact closures or solid state switches as

indicated. c. Power source less than 30V dc.

5. Special Signals: Other types of signals used to transmit analog and digital information between field elements, transmitters, receivers, controllers, and digital devices.

D. Instrument Tag Numbers:

1. A shorthand tag number notation is used in the Loop Specifications. For example: 60FIT161.

Notation Explanation

60 Facility/Unit process number.



Notation Explanation

FIT Equipment/ISA designator.

16 Loop number.

1 Unit number; number of same component types in a given loop; 1 and 2 in this example.

2. Facility/Unit Process Numbers are: a. 05 - Stormwater Pump Station and Emergency Storage Pond. b. 55 - Final Effluent Pump Station. c. 60 - Pond 5 Flowmeter Vault.

1.03 SUBMITTALS


1. General: a. Shop Drawings, full-scaled details, wiring diagrams, catalog cuts,

and descriptive literature. b. Identify proposed items and options. Identify installed spares and

other provisions for future work (for example, reserved panel space; unused components, wiring, and terminals).

c. Legends and Abbreviation Lists: Complete definition of symbols and abbreviations used on this Project (for example, engineering units, flow streams, instruments, structures, and other process items used in nameplates, legends, and data sheets).

2. Bill of Materials: List of required equipment. a. Group equipment items by enclosure and field, and within an

enclosure, as follows: 1) I&C Components: By component identification code. 2) Other Equipment: By equipment type.

b. Data Included: 1) Equipment tag number. 2) Description. 3) Manufacturer, complete model number, and all options not

defined by model number. 4) Quantity supplied. 5) Component identification code where applicable.

3. Catalog Cuts: I&C Components, Electrical Devices, and Mechanical Devices: a. Catalog information, mark to identify proposed items and options. b. Descriptive literature. c. External power and signal connections.



d. Scaled drawings showing exterior dimensions and locations of electrical and mechanical interfaces.

4. Component Data Sheets: Data sheets for I&C components. a. Format and Level of Detail: In accordance with ISA-S20. b. Include component type identification code and tag number on

data sheet. c. Specific features and configuration data for each component:

1) Location or service. 2) Manufacturer and complete model number. 3) Size and scale range. 4) Setpoints. 5) Materials of construction. 6) Options included.

d. Name, address, and telephone number of manufacturer’s local office, representative, distributor, or service facility.

5. Sizing and Selection Calculations: a. Primary Elements: Complete calculations plus process data used.

Example, for flow elements, minimum and maximum values, permanent head loss, and assumptions made.

b. Controlling, Computing and Function Generating Modules: Actual scaling factors with units and how they were computed.

6. Panel Construction Drawings: a. Scale Drawings: Show dimensions and location of panel mounted

devices, doors, louvers, and subpanels, internal and external. b. Panel Legend: List front of panel devices by tag numbers,

nameplate inscriptions, service legends, and annunciator inscriptions.

c. Bill of Materials: List devices mounted within panel that are not listed in panel legend. Include tag number, description, manufacturer, and model number.

d. Construction Details: NEMA rating, materials, material thickness, structural stiffeners and brackets, lifting lugs, mounting brackets and tabs, door hinges and latches, and welding and other connection callouts and details.

e. Construction Notes: Finishes, wire color schemes, wire ratings, wire and terminal block, numbering and labeling scheme.

7. Panel Control Diagrams: For discrete control and power circuits. a. Diagram Type: Ladder diagrams include devices, related to

discrete functions, that are mounted in or on the panel and that require electrical connections. Show unique rung numbers on left side of each rung.

b. Item Identification: Identify each item with attributes listed. 1) Wires: Wire number and color. Cable number if part of

multiconductor cable.



2) Terminals: Location (enclosure number, terminal junction box number, or MCC number), terminal strip number, and terminal block number.

3) Discrete Components: a) Tag number, terminal numbers, and location

(“FIELD”, enclosure number, or MCC number). b) Switching action (open or close on rising or falling

process variable), setpoint value and units, and process variable description (for example, Sump Level High).

4) Relay Coils: a) Tag number and its function. b) On right side of run where coil is located, list contact

location by ladder number and sheet number. Underline normally closed contacts.

5) Relay Contacts: Coil tag number, function, and coil location (ladder rung number and sheet number).

c. Show each circuit individually. No “tyPICSal” diagrams or “tyPICSal” wire lists will be permitted.

d. Ground wires, surge protectors, and connections. 8. Panel Wiring Diagrams: Show point-to-point and terminal-to-terminal

wiring within panel. 9. Loop Diagrams: Individual wiring diagram for each analog or pulse

frequency loop. a. Conform to the minimum requirements of ISA S5.4. b. Drawing Size: Individual 11-inch by 17-inch sheet for each loop. c. Divide each loop diagram into areas for panel face, back-of-panel,

and field. d. Show:

1) Terminal numbers, location of dc power supply, and location of common dropping resistors.

2) Switching contacts in analog loops and output contacts of analog devices. Reference specific control diagrams where functions of these contacts are shown.

3) Tabular summary on each diagram: a) Transmitting Instruments: Output capability. b) Receiving Instruments: Input impedance. c) Loop Wiring Impedance: Estimate based on wire sizes

and lengths shown. d) Total loop impedance. e) Reserve output capacity.

10. Installation Details: Include modifications or further details required to adequately define installation of I&C components.

11. List of spares, expendables, test equipment and tools.



12. Additional Equipment Recommended: List of, and descriptive literature for, additional spares, expendables, test equipment and tools recommended. Include unit prices and total costs as specified in Section 01 29 00, Payment Procedures.

B. Informational Submittals: For PICS equipment, provide Manufacturer’s Certificate of Proper Installation and readiness for operation.

1. Owner Training Plan. Reference Section 01 43 33, Manufacturers’ Field Services.

2. Operation and Maintenance (O&M) Manuals: In accordance with Section 01 78 23, Operation and Maintenance Data, unless otherwise specified in this section. a. Content and Format:

1) Complete sets O&M manuals. 2) Sufficient detail to allow operation, removal, installation,

adjustment, calibration, maintenance and purchasing replacements for each PICS component.

3) Final versions of Legend and Abbreviation Lists. 4) Manual format in accordance with Section 01 78 23,

Operation and Maintenance Data. b. Include:

1) Process and Instrumentation Diagrams: One reproducible copy of revised P&ID to reflect as-built PICS design.

2) Refer to paragraph Shop Drawings for the following items: a) Bill of Materials. b) Catalog Cuts. c) Component Data Sheets. d) Panel Control Diagrams. e) Panel Wiring Diagrams, one reproducible copy. f) Panel Plumbing Diagrams, one reproducible copy. g) Loop Diagrams, one reproducible copy. h) Interconnecting Wiring Diagrams, one reproducible

copy. i) Application Software Documentation.

3) Device O&M manuals for components, electrical devices, and mechanical devices include: a) Operations procedures. b) Installation requirements and procedures. c) Maintenance requirements and procedures. d) Troubleshooting procedures. e) Calibration procedures. f) Internal schematic and wiring diagrams.



g) Component Calibration Sheets from field quality control calibrations.

4) List of spares, expendables, test equipment and tools provided.

5) List of additional spares, expendables, test equipment and tools recommended.

3. Performance Acceptance Tests (PAT) Submittals: a. Preliminary Test Procedures: Outlines of proposed tests, forms,

and checklists. b. Final Test Procedures: Proposed test procedures, forms, and

checklists. c. Test Documentation: Copy of signed off test procedures when

tests are completed. 4. Software Programming Submittals:

a. Modifications to PLC-07 and RTU-40 programmable logic. Printout of entire logic will not be accepted. Provide printout showing only modified and new logic with detailed logic documentation.

b. Modified and new HMI screens, including examples of control popups.


A. Calibration Instruments: Each instrument used for calibrating PICS equipment shall bear the seal of a reputable laboratory certifying that instrument has been calibrated within the previous 12 months to a standard endorsed by the NIST.

B. Coordination Meetings:

1. In accordance with Section 01 31 13, Project Coordination. 2. Location: City of Tracy, Wastewater Treatment Plant. 3. Attended By: Engineer, Owner, and Contractor. 4. Minimum of one is required. Specific dates will be established in

Progress Schedule.


A. Provide Site and warehouse storage facilities for PICS equipment.

B. Prior to shipment, include corrosive-inhibitive vapor capsules in shipping containers, and related equipment as recommended by the capsule manufacturer.

C. Prior to installation, store items in dry indoor locations. Provide heating in storage areas for items subject to corrosion under damp conditions.



D. Cover panels and other elements that are exposed to dusty construction environments.

1.06 ENVIRONMENTAL REQUIREMENTS

A. Standard Environmental Requirements: Unless otherwise noted, design equipment for continuous operation in these environments:

1. Freestanding Panel and Consoles: a. Inside, Air Conditioned: NEMA 1. b. Inside: NEMA 12.

2. Smaller Panels and Assemblies (that are not Freestanding): a. Inside, Air Conditioned: NEMA 12. b. All Other Locations: NEMA 4X.

3. Field Elements: Outside.

B. Environmental Design Requirements: Following defines the types of environments referred to in the above.

1. Inside: a. Temperature: 20 to 110 degrees F. b. Relative Humidity: 10 to 100 percent. c. NEC Classification: Nonhazardous.

2. Outside: a. Temperature: Minus 20 to 120 degrees F. b. Relative Humidity: 10 to 100 percent, rain. c. NEC Classification: Nonhazardous.


A. Activity Completion: The following is a list of key activities and their completion criteria:

1. Shop Drawings: Reviewed and approved. 2. Quality Control Submittals: Reviewed and accepted. 3. Hardware Delivery: Hardware delivered to Site and inventoried by

Owner. 4. PAT: Completed and required test documentation accepted.

B. PICS Substantial Completion: When Engineer issues Certificate of Substantial Completion.

1. Prerequisites: a. All PICS Submittals have been completed. b. PICS has successfully completed PAT.



c. Owner training plan is on schedule. d. All spares, expendables, and test equipment have been delivered

to Owner.

C. PICS Acceptance: When Engineer issues a written notice of Final Payment and Acceptance.

1. Prerequisites: a. Certificate of Substantial Completion issued for PICS. b. Punch-list items completed. c. Final revisions to O&M manuals accepted. d. Maintenance service agreements for PICS accepted by Owner.

D. Prerequisite Activities and Lead Times: Do not start the following key Project activities until the prerequisite activities and lead times listed below have been completed and satisfied:

Activity Prerequisites and Lead Times

Submittal reviews by Engineer

Engineer acceptance of Submittal breakdown and schedule.

Hardware purchasing, fabrication, and assembly

Associated shop drawing Submittals completed.

Shipment Completion of PICS Shop Drawing Submittals and preliminary O&M manuals.

Owner Training Owner training plan completed

PAT Startup, Owner training, and PAT procedures completed; notice 4 weeks prior to start.

PART 2 PRODUCTS

2.01 GENERAL

A. PICS functions as shown on Drawings and as required for each loop. Furnish equipment items as required. Furnish all materials, equipment, and software, necessary to affect required system and loop performance.



B. First Named Manufacturer: PICS design is based on first named manufacturers of equipment and materials.

1. If an item is proposed from other than first named manufacturer, obtain approval from Engineer for such changes in accordance with Article Submittals.

2. If using proposed item requires other changes, provide work and equipment to implement these changes. Changes that may be required include, but are not limited to: different installation, wiring, raceway, enclosures, connections, isolators, intrinsically safe barriers, software, and accessories.

C. Like Equipment Items:

1. Use products of one manufacturer and of the same series or family of models to achieve standardization for appearance, operation, maintenance, spare parts, and manufacturer’s services.

2. Implement all same or similar functions in same or similar manner. For example, control logic, sequence controls, and display layouts.

2.02 LOOP SPECIFICATIONS

A. Location: Article Supplements.

B. Organization: By unit process and loop number.

C. Functional Requirements for Control Loops:

1. Shown on Drawings, in Panel Control Diagrams, and Process and Instrumentation Diagrams (P&ID). P&ID format and symbols are in accordance with ISA S5.1, except as specified or shown on Drawings.

2. Supplemented by Loop Specifications.

2.03 I&C COMPONENTS

A. Components for Each Loop: Major components for each loop are listed in Instrument List referenced in Article Supplements. Furnish all equipment that is necessary to achieve required loop performance.

B. Component Specifications: Generalized specifications for each type of component are located in Article Supplements.



2.04 NAMEPLATES AND TAGS

A. Panel Nameplates: Enclosure identification located on the enclosure face.

1. Location and Inscription: As shown. 2. Materials: Laminated plastic attached to panel with stainless steel

screws. 3. Letters: 1/2-inch white on black background, unless otherwise noted.

B. Component Nameplates—Panel Face: Component identification located on panel face under or near component.

1. Location and Inscription: As shown. 2. Materials: Laminated plastic attached to panel with stainless steel

screws. 3. Letters: 3/16-inch white on black background, unless otherwise noted.

C. Component Nameplates—Back of Panel: Component identification located on or near component inside of enclosure.

1. Inscription: Component tag number. 2. Materials: Adhesive backed, laminated plastic. 3. Letters: 3/16-inch white on black background, unless otherwise noted.

D. Legend Plates for Panel Mounted Pushbuttons, Lights, and Switches.

1. Inscription: Refer to: a. Table under paragraph Standard Pushbutton Colors and

Inscriptions. b. Table under paragraph Standard Light Colors and Inscriptions. c. P&IDs in Drawings.

2. Materials: Stainless steel, keyed legend plates. Secured to panel by mounting nut for pushbutton, light, or switch.

3. Letters: Black on gray or white background.

E. Service Legends: Component identification nameplate located on face of component.

1. Inscription: As shown. 2. Materials: Adhesive backed, laminated plastic. 3. Letters: 3/16-inch white on black background, unless otherwise noted.

F. Nametags: Component identification for field devices.

1. Inscription: Component tag number.



2. Materials: 16-gauge, Type 304 stainless steel. 3. Letters: 3/16-inch imposed. 4. Mounting: Affix to component with 16- or 18-gauge stainless steel wire

or stainless steel screws.

2.05 ELECTRICAL TRANSIENT PROTECTION

A. General:

1. Function: Protect elements of PICS against damage due to electrical transients induced in interconnecting lines by lightning and nearby electrical systems.

2. Implementation: Provide, install, coordinate, and inspect grounding of surge suppressors at: a. Connection of ac power to PICS equipment including panels,

consoles assembles, and field mounted analog transmitters and receivers.

b. At the field and panel, console, or assembly connection of signal circuits that have portions of the circuit extending outside of a protective building.

3. Construction: First-stage high energy metal oxide varistor and second-stage bipolar silicon avalanche device separated by series impedance. Includes grounding wire, stud, or terminal.

4. Response: 5 nanoseconds maximum. 5. Recovery: Automatic. 6. Temperature Range: Minus 20 degrees C to plus 85 degrees C.

B. Suppressors on 120V ac Power Supply Connections:

1. Occurrences: Tested and rated for a minimum of 50 occurrences of IEEE 587 Category B test waveform.

2. First-Stage Clamping Voltage: 350 volts or less. 3. Second-Stage Clamping Voltage: 210 volts or less. 4. Continuous Operation: Power supplies for one four-wire transmitter or

receiver, 5 amps minimum at 130V ac. 5. All Other Applications: 30 amps minimum at 130V ac. 6. For 120V ac Lines: EDCO HSP-121.

2.06 ELECTRICAL REQUIREMENTS

A. In accordance with Division 26, Electrical.

B. I&C and electrical components, terminals, wires, and enclosures: UL recognized or UL listed.



C. Wires within Enclosures:

1. ac Circuits: a. Type: 300-volt, Type MTW stranded copper. b. Size: For current to be carried, but not less than 16 AWG.

2. Analog Signal Circuits: a. Type: 300-volt stranded copper, twisted shielded pairs. b. Size: 18 AWG, minimum.

3. Other dc Circuits. a. Type: 300-volt, Type MTW stranded copper. b. Size: For current carried, but not less than 18 AWG.

4. Special Signal Circuits: Use manufacturer’s standard cables. 5. Wire Identification: Numbered and tagged at each termination.

a. Wire Tags: Machine printed, heat shrink. b. Manufacturers:

1) Brady PermaSleeve. 2) Tyco Electronics.

D. Wires entering or leaving enclosures, terminate and identify as follows:

1. Analog and discrete signal, terminate at numbered terminal blocks. 2. Special signals, terminated using manufacturer’s standard connectors. 3. Identify wiring in accordance with Section 26 05 05, Conductors.

E. Terminal Blocks for Enclosures:

1. Quantity: a. Accommodate present and spare indicated needs. b. Wire spare PLC I/O points to terminal blocks. c. One wire per terminal for field wires entering enclosures. d. Maximum of two wires per terminal for 18-WG wire for internal

enclosure wiring. e. Spare Terminals: 20 percent of all connected terminals, but not

less than 10 per terminal block. 2. General:

a. Connection Type: Screw compression clamp. b. Compression Clamp:

1) Complies with DIN-VDE 0611. 2) Hardened steel clamp with transversal groves that penetrate

wire strands providing a vibration-proof connection. 3) Guides strands of wire into terminal.

c. Screws: Hardened steel, captive and self-locking. d. Current Bar: Copper or treated brass.



e. Insulation: 1) Thermoplastic rated for minus 55 to plus 110 degree C. 2) Two funneled shaped inputs to facilitate wire entry.

f. Mounting: 1) Standard DIN rail. 2) Terminal block can be extracted from an assembly without

displacing adjacent blocks. 3) End Stops: Minimum of one at each end of rail.

g. Wire preparation: Stripping only permitted. h. Jumpers: Allow jumper installation without loss of space on

terminal or rail. i. Marking System:

1) Terminal number shown on both sides of terminal block 2) Allow use of preprinted and field marked tags. 3) Terminal strip numbers shown on end stops. 4) Mark terminal block and terminal strip numbers as shown

on Panel Control Diagrams and Loop Diagrams. 5) Fuse Marking for Fused Terminal Blocks: Fuse voltage and

amperage rating shown on top of terminal block. 3. Terminal Block, General-Purpose:

a. Rated Voltage: 600V ac. b. Rated Current: 30 amp. c. Wire Size: 22 AWG to 10 AWG. d. Rated Wire Size: 10 AWG. e. Color: Grey body. f. Spacing: 0.25 inch, maximum. g. Test Sockets: One screw test socket 0.079-inch diameter. h. Manufacturer and Product: Entrelec; Type M4/6.T.

4. Terminal Block, Ground: a. Wire Size: 22 AWG to 12 AWG. b. Rated Wire Size: 12 AWG. c. Color: Green and yellow body. d. Spacing: 0.25 inch, maximum. e. Grounding: Ground terminal blocks electrically grounded to the

mounting rail. f. Manufacturer and Product: Entrelec; Type M4/6.P.

5. Terminal Block, Blade Disconnect Switch: a. Rated Voltage: 600V ac. b. Rated Current: 10-amp. c. Wire Size: 22 AWG to 12 AWG. d. Rated Wire Size: 12 AWG. e. Color: Grey body, orange switch. f. Spacing: 0.25 inch, maximum. g. Manufacturer and Product: Entrelec; Type M4/6.SN.T.



6. Terminal Block, Fused, 24V dc: a. Rated Voltage: 600V dc. b. Rated Current: 16-amp. c. Wire Size: 22 AWG to 10 AWG. d. Rated Wire Size: 10 AWG. e. Color: Grey body. f. Fuse: 0.25 inch by 1.25 inches. g. Indication: LED diode 24V dc. h. Spacing: 0.512 inch, maximum. i. Manufacturer and Product: Entrelec; Type M10/13T.SFL.

7. Terminal Block, Fused, 120V ac: a. Rated Voltage: 600V ac. b. Rated Current: 16-amp. c. Wire Size: 22 AWG to 10 AWG. d. Rated Wire Size: 10 AWG. e. Color: Grey body. f. Fuse: 0.25 inch by 1.25 inches. g. Indication: Neon Lamp 110V ac. h. Leakage Current: 1.8 mA, maximum. i. Spacing: 0.512 inch, maximum j. Manufacturer and Product: Entrelec; Type M10/13T.SFL.

8. Terminal Block, Fused, 120V ac, High Current: a. Rated Voltage: 600V ac. b. Rated Current: 35 amps. c. Wire Size: 18 AWG to 8 AWG. d. Rated Wire Size: 8 AWG. e. Color: Grey. f. Fuse: 13/32 inch by 1.5 inches. g. Spacing: 0.95 inch, maximum. h. Manufacturer and Product: Entrelec; Type MB10/24.SF.

F. Grounding of Enclosures:

1. Furnish isolated copper grounding bus for signal and shield ground connections.

2. Bond ground bus at a common signal ground point in accordance with National Electrical Code requirements.

3. Single Point Ground for Each Analog Loop: a. Locate at dc power supply for loop. b. Use to ground wire shields for loop. c. Group and connect shields in following locations:

1) CP-07. 2) CP-60.

4. Ground terminal block rails to ground bus.



G. Power Distribution within Panels:

1. Feeder Circuits: a. One or more 120V ac, 60 Hz feeder circuits as shown on

Drawings. b. Make provisions for feeder circuit conduit entry. c. Furnish terminal board for termination of wires.

2. Power Panel: Furnish main circuit breaker and a circuit breaker on each individual branch circuit distributed from power panel. a. Locate to provide clear view of and access to breakers when door

is open. b. Breaker sizes: Coordinate such that fault in branch circuit will

blow only branch breaker but not trip the main breaker. 1) Branch Circuit Breaker: 15 amps at 250V ac.

c. Breaker Manufacturers and Products: Refer to Division 26, Electrical.

3. Circuit Wiring: P&IDs and Control Diagrams on Drawings show function only. Use following rules for actual circuit wiring: a. Devices on Single Circuit: 20, maximum. b. Multiple Units Performing Parallel Operations: To prevent failure

of any single branch circuit from shutting down entire operation, do not group all units on same branch circuit.

c. Branch Circuit Loading: 12 amperes continuous, maximum. d. Panel Lighting and Service Outlets: Put on separate 15-amp,

120V ac branch circuit. e. Provide 120V ac plugmold for panel components with line cords.

H. Signal Distribution:

1. Within Panels: 4 mA to 20 mA dc signals may be distributed as 1 to 5V dc.

2. Outside Panels: Isolated 4 mA to 20 mA dc only. 3. All signal wiring twisted in shielded pairs.

I. Relays:

1. General: a. Relay Mounting: Plug-in type socket. b. Relay Enclosure: Furnish dust cover. c. Socket Type: Screw terminal interface with wiring. d. Socket Mounting: Rail. e. Provide holddown clips.



2. Control Circuit Switching Relay, Nonlatching: a. Type: Compact general-purpose plug-in. b. Contact Arrangement: 3 Form C contacts. c. Contact Rating: 10A at 28V dc or 240V ac. d. Contact Material: Silver cadmium oxide alloy. e. Coil Voltage: As noted or shown. f. Coil Power: 1.8 watts (dc), 2.7VA (ac). g. Expected Mechanical Life: 10,000,000 operations. h. Expected Electrical Life at Rated Load: 100,000 operations. i. Indication Type: Neon or LED indicator lamp. j. Push to test button. k. Manufacturer and Product: Potter and Brumfield; Series KUP.

3. Control Circuit Switching Relay, Latching: a. Type: Dual coil mechanical latching relay. b. Contact Arrangement: 2 Form C contacts. c. Contact Rating: 10A at 28V dc or 120V ac. d. Contact Material: Silver cadmium oxide alloy. e. Coil Voltage: As noted or shown. f. Coil Power: 2.7 watts (dc), 5.3VA (ac). g. Expected Mechanical Life: 500,000 operations. h. Expected Electrical Life at Rated Load: 50,000 operations. i. Manufacturer and Product: Potter and Brumfield; Series KB/KBP.

4. Control Circuit Switching Relay, Time Delay: a. Type: Adjustable time delay relay. b. Contact Arrangement: 2 Form C contacts. c. Contact Rating: 10A at 240V ac.

1) Contact Material: Silver cadmium oxide alloy. d. Coil Voltage: As noted or shown. e. Operating Temperature: Minus 10 to 55 degrees C. f. Repeatability: Plus or minus 2 percent. g. Delay Time Range: Select range such that time delay setpoint fall

between 20 to 80 percent of range. h. Time Delay Setpoint: As noted or shown. i. Mode of Operation: As noted or shown. j. Adjustment Type: Integral potentiometer with knob external to

dust cover. k. Manufacturer and Products: Potter and Brumfield:

1) Series CB for 0.1 second to 100 minute delay time ranges. 2) Series CK for 0.1 to 120 second delay time ranges.

J. Power Supplies:

1. Furnish to power instruments requiring external dc power, including two-wire transmitters and dc relays.



2. Convert 120V ac, 60 Hz power to dc power of appropriate voltage(s) with sufficient voltage regulation and ripple control to assure that instruments being supplied can operate within their required tolerances.

3. Provide output over voltage and over current protective devices to: a. Protect instruments from damage due to power supply failure. b. Protect power supply from damage due to external failure.

4. Enclosures: NEMA 1 in accordance with NEMA 250. 5. Mount such that dissipated heat does not adversely affect other

components. 6. Fuses: For each dc supply line to each individual two-wire transmitter.

a. Type: Indicating. b. Mount so fuses can be easily seen and replaced.

K. Internal Panel Lights and Service Outlets for Smaller Panels:

1. Internal Panel Light: Switched 100-watt incandescent light. 2. Service Outlet: Breaker protected 120-volt, 15-amp, GFCI duplex

receptacle: 3. Required for CP-60.

L. Standard Pushbutton Colors and Inscriptions: Use following color code and inscriptions for pushbuttons, unless otherwise noted in Instrument List, Article Supplements.

1. Lettering Color: a. Black on white and yellow buttons. b. White on black, red, and green buttons.

M. Standard Light Colors and Inscriptions: Use following color code and inscriptions for service legends and lens colors for indicating lights, unless otherwise noted in Instrument List, Article Supplements.

Tag Function Inscription(s) Color

ON ON Green

OFF OFF Red

OPEN OPEN Green

CLOSED CLOSED Red


RESET RESET Black

EMERGENCY STOP EMERGENCY STOP Red




LOW LOW Amber

FAIL FAIL Amber

HIGH HIGH Red

1. Lettering Color: a. Black on white and amber lenses. b. White on red and green lenses.

2.07 MECHANICAL SYSTEMS

A. Test Tap:

1. Manufacturers and Products: a. Imperial Eastman; quick disconnect couplings No. 292 P and caps

No. 259 P. b. Crawford Fittings Co.; Swagelok quick connects Series QC4 and

caps QC4 DC. c. Parker; CPI Series precision quick couplings.

2.08 SPARE PARTS

Description Percent of Each

Type and Size Used No Less Than

Fuses 20 5 of each type

Indicating light bulb 20 10 of each type

Relays 20 5 of each type

Terminal Blocks 10 10 of each type

2.09 EXPENDABLES

Item Quantity

Corrosion-inhibiting vapor capsules Manufacturer’s recommended 2-year supply



2.10 FABRICATION

A. General:

1. Panels with external dimensions and instruments arrangement as shown on Drawings.

2. Panel Construction and Interior Wiring: In accordance with the National Electrical Code, state and local codes, NEMA, ANSI, UL, and ICECA.

3. Fabricate panels, install instruments, wire, and plumb, at the PICS factory.

4. Electrical Work: In accordance with Division 26, Electrical.

B. Factory Assembly: Assemble panels at the manufacturer’s factory. No fabrication other than correction of minor defects or minor transit damage shall be done on panels at Site.

C. UL Listing Mark for Enclosures: Mark stating “Listed Enclosed Industrial Control Panel” in accordance with UL 508A.

D. Wiring Within PICS Panels:

1. Restrain by plastic ties or ducts or metal raceways. 2. Hinge Wiring: Secure at each end so that bending or twisting will be

around longitudinal axis of wire. Protect bend area with sleeve. 3. Arrange wiring neatly, cut to proper length, and remove surplus wire. 4. Abrasion protection for wire bundles which pass through holes or across

edges of sheet metal. 5. Connections to Screw Type Terminals:

a. Locking-fork-tongue or ring-tongue lugs. b. Use manufacturer’s recommended tool with required sized anvil

to make crimp lug terminations. c. Wires terminated in a crimp lug, maximum of one. d. Lugs installed on a screw terminal, maximum of two.

6. Connections to Compression Clamp Type Terminals: a. Strip, prepare, and install wires in accordance with terminal

manufacturer’s recommendations. b. Wires installed in a compression screw and clamp, maximum of

one for field wires entering enclosure, otherwise maximum of two.

7. Splicing and tapping of wires, allowed only at device terminals or terminal blocks.

8. Terminate 24V dc and analog signal circuits on separate terminal block from ac circuit terminal blocks.



9. Separate analog and dc circuits by at least 6 inches from ac power and control wiring, except at unavoidable crossover points and at device terminations.

10. Arrange wiring to allow access for testing, removal, and maintenance of circuits and components.

11. Plastic Wire Ducts Fill: Do not exceed manufacturer’s recommendation.

E. Nonfreestanding Panel Construction:

1. Based on environmental design requirements required and referenced in Article Environmental Requirements, provide the following: a. For panels listed as inside, air conditioned:

1) Enclosure Type: NEMA 12 in accordance with NEMA 250. 2) Materials: Steel.

b. For all other panels: 1) Enclosure Type: NEMA 4X in accordance with NEMA 250. 2) Materials: Type 316 stainless steel.

2. Metal Thickness: 12-gauge, minimum. 3. Doors:

a. Rubber-gasketed with continuous hinge. b. Stainless steel lockable quick-release clamps.

4. Manufacturers: a. Hoffman Engineering Co. b. Rittal.

F. Factory Finishing:

1. Enclosures: a. Stainless Steel and Aluminum: Not painted. b. Nonmetallic Panels: Not painted. c. Steel Panels:

1) Sand panel and remove mill scale, rust, grease, and oil. 2) Fill imperfections and sand smooth. 3) Paint panel interior and exterior with one coat of epoxy

coating metal primer, two finish coats of two-component type epoxy enamel.

4) Sand surfaces lightly between coats. 5) Dry Film Thickness: 3 mils, minimum. 6) Color: Gray.

2. Manufacturer’s standard finish color, except where specific color is indicated. If manufacturer has no standard color, finish equipment with light gray color.



2.11 CORROSION PROTECTION

A. Corrosion-Inhibiting Vapor Capsule Manufacturers:

1. Northern Instruments; Model Zerust VC. 2. Hoffmann Engineering Co; Model A-HCI.


A. Scope: Inspect and test entire PICS to ensure it is ready for shipment, installation, and operation.

B. Location: Manufacturer’s factory or Engineer approved staging Site.

C. Test: Exercise and test all functions.

PART 3 EXECUTION

3.01 EXAMINATION

A. For equipment not provided by PICS, but that directly interfaces with the PICS, verify the following conditions:

1. Proper installation. 2. Calibration and adjustment of positioners and I/P transducers. 3. Correct control action. 4. Switch settings and dead bands. 5. Opening and closing speeds and travel stops. 6. Input and output signals.

3.02 INSTALLATION

A. Material and Equipment Installation: Retain a copy of manufacturers’ instructions at Site, available for review at all times.

B. Electrical Wiring: As specified in Division 26, Electrical.

C. Removal or Relocation of Materials and Equipment:

1. Remove from Site materials that were part of the existing facility but are no longer used, unless otherwise directed by Engineer to deliver to Owner.

2. Repair affected surfaces to conform to type, quality, and finish of surrounding surface.




A. Refer to Section 09 90 00, Painting and Coating.


A. Startup and Testing Team:

1. Thoroughly inspect installation, termination, and adjustment for components and systems.

2. Complete onsite tests. 3. Complete onsite training. 4. Provide startup assistance.

B. Operational Readiness Inspections and Calibrations: Prior to startup, inspect and test to ensure that entire PICS is ready for operation.

1. Loop/Component Inspections and Calibrations: a. Check PICS for proper installation, calibration, and adjustment on

a loop-by-loop and component-by-component basis. b. Prepare component calibration sheet for each active component

(except simple hand switches, lights, gauges, and similar items). 1) Project name. 2) Loop number. 3) Component tag number. 4) Component code number. 5) Manufacturer for elements. 6) Model number/serial number. 7) Summary of functional requirements, for example:

a) Indicators and recorders, scale and chart ranges. b) Transmitters/converters, input and output ranges. c) Computing elements’ function. d) Controllers, action (direct/reverse) and control modes

(PID). e) Switching elements, unit range, differential

(fixed/adjustable), reset (auto/manual). 8) Calibrations, for example:

a) Analog Devices: Actual inputs and outputs at 0, 10, 50, and 100 percent of span, rising and falling.

b) Discrete Devices: Actual trip points and reset points. c) Controllers: Mode settings (PID).

9) Space for comments. c. These inspections and calibrations will be spot checked by

Engineer.



2. Leak Test: In accordance with Division 33 specifications.

C. Performance Acceptance Tests (PAT): These are the activities that Section 01 91 14, Equipment Testing and Facility Startup, refers to as Performance Testing.

1. General: a. Test all PICS elements to demonstrate that PICS satisfies all

requirements. b. Test Format: Cause and effect.

1) Person conducting test initiates an input (cause). 2) Specific test requirement is satisfied if correct result (effect)

occurs. c. Procedures, Forms, and Checklists:

1) Conduct tests in accordance with, and documented on, Engineer accepted procedures, forms, and checklists.

2) Describe each test item to be performed. 3) Have space after each test item description for sign off by

appropriate party after satisfactory completion. d. Required Test Documentation: Test procedures, forms, and

checklists. All signed by Engineer and Contractor. e. Conducting Tests:

1) Provide special testing materials, equipment, and software. 2) Wherever possible, perform tests using actual process

variables, equipment, and data. 3) If it is not practical to test with real process variables,

equipment, and data, provide suitable means of simulation. 4) Define simulation techniques in test procedures.

f. Coordinate PICS testing with Owner and affected Subcontractors. 1) Contractor shall pay for all costs after second witnessing.

2. Test Requirements: a. Once facility has been started up and is operating, perform a

witnessed PAT on complete PICS to demonstrate that it is operating as required. Demonstrate each required function on a paragraph-by-paragraph and loop-by-loop basis.

b. Perform local and manual tests for each loop before proceeding to remote and automatic modes.

c. Where possible, verify test results using visual confirmation of process equipment and actual process variable. Unless otherwise directed, exercise and observe devices supplied by others, as needed to verify correct signals to and from such devices and to confirm overall system functionality. Test verification by means



of disconnecting wires or measuring signal levels is acceptable only where direct operation of plant equipment is not possible.

d. Make updated versions of documentation required for PAT available to Engineer at Site, both before and during tests.

e. Make one copy of O&M manuals available to Engineer at the Site both before and during testing.

f. Refer to referenced examples of PAT procedures and forms in Article Supplements.

3.05 TRAINING

A. General:

1. Provide an integrated training program to meet specific needs of Owner’s personnel.

2. Include training sessions, classroom and field, for managers, engineers, operators, and maintenance personnel.

3. Provide instruction on one working shift as needed to accommodate the Owner’s personnel schedule.

4. Owner reserves the right to make and reuse video tapes of training sessions.

B. Operations and Maintenance Training:

1. Include a review of O&M manuals and survey of spares, expendables, and test equipment.

2. Use equipment similar to that provided or currently owned by Owner. 3. Provide training suitable for instrument technicians with at least a

2-year associate engineering or technical degree, or equivalent education and experience in electronics or instrumentation.

C. Operations Training:

1. Training Session Duration: One 4-hour instructor day. 2. Number of Training Sessions: Two. 3. Location: Site. 4. Content: Conduct training on loop-by-loop basis.

a. Loop Functions: Understanding of loop functions, including interlocks for each loop.

b. Loop Operation: For example, adjusting process variable setpoints, AUTO/MANUAL control transfer, AUTO and MANUAL control, annunciator acknowledgement and resetting.

c. Interfaces with other control systems.



D. Maintenance Training:

1. Training Session Duration: One 4-hour instructor day. 2. Number of Training Sessions: Two. 3. Location: Project Site. 4. Content: Provide training for each type of component and function

provided. a. Loop Functions: Understanding details of each loop and how they

function. b. Component calibration. c. Adjustments: For example, controller tuning constants, current

switch trip points, and similar items. d. Troubleshooting and diagnosis for components. e. Replacing lamps, chart paper, fuses. f. Component removal and replacement. g. Periodic maintenance.

3.06 CLEANING/ADJUSTING

A. Repair affected surfaces to conform to type, quality, and finish of surrounding surface.

B. Cleaning:

1. Prior to closing system using tubing, clear tubing of interior moisture and debris.

2. Upon completion of Work, remove materials, scraps, and debris from interior and exterior of equipment.

3.07 PROTECTION

A. Protect enclosures and other equipment containing electrical, instrumentation and control devices, including spare parts, from corrosion through the use of corrosion-inhibiting vapor capsules.

B. Periodically replace capsules in accordance with capsule manufacturer’s recommendations. Replace capsules just prior to Final Payment and Acceptance.



3.08 SUPPLEMENTS

A. Supplements listed below, following “End of Section,” are part of this Specification.

1. Component Specifications. 2. Instrument List. 3. Loop Specifications. 4. PLC Input and Output List. 5. Sample Instrument Calibration Sheet: Provides detailed information on

each instrument (except simple hand switches, lights, and similar items). 6. Sample I&C Valve Adjustment Sheet: Each sheet shows detailed

information for installation, adjustment, and calibration of a given valve.

7. Sample Performance Acceptance Test Sheet: Describe the PAT for a given loop. The format is mostly free form. a. List the requirements of the loop. b. Briefly describe the test. c. Cite expected results. d. Provide space for check off by witness.

END OF SECTION


PW/WBG/179201 INSTRUMENTATION AND CONTROL OCTOBER 2018 FOR PROCESS SYSTEMS ©COPYRIGHT 2018 CH2M HILL 40 90 01 SUPPLEMENT 1 - 1

SUPPLEMENT 1 - COMPONENT SPECIFICATIONS

A. F4 Flow Element and Transmitter, Electromagnetic:

1. General: a. Function: Measure, indicate, and transmit the flow of a conductive

process liquid in a full pipe. b. Type:

1) Electromagnetic flowmeter, with operation based on Faraday’s Law, utilizing the pulsed dc type coil excitation principle with high impedance electrodes.

2) Full bore meter with magnetic field traversing entire flow-tube cross section.

3) Unacceptable are insert magmeters or multiple single point probes inserted into a spool piece.

c. Parts: Flow element, transmitter, interconnecting cables, and mounting hardware. Other parts as noted.

2. Service: a. Stream Fluid:

1) Wastewater Treatment Plant Effluent. 2) Suitable for liquids with a minimum conductivity of

5 microS/cm and for demineralized water with a minimum conductivity of 20 microS/cm.

3. Operating Temperature: a. Element:

1) Ambient: Minus 5 to 140 degrees F, typical, unless otherwise noted.

2) Process: Minus 5 to 140 degrees F, t typical, unless otherwise noted.

b. Transmitter: 1) Ambient: Minus 5 to 140 degrees F, typical, unless

otherwise noted. 2) Storage: 15 to 120 degrees F, typical, unless otherwise

noted. 4. Performance:

a. Flow Range: As noted. b. Accuracy: Plus or minus 0.5 percent of rate for all flows resulting

from pipe velocities of 2 to 30 feet per second. c. Turndown Ratio: Minimum of 10 to 1 when flow velocity at

minimum flow is at least 1 foot per second. 5. Features:

a. Zero stability feature to eliminate the need to stop flow to check zero alignment.

b. No obstructions to flow.


INSTRUMENTATION AND CONTROL PW/WBG/179201 FOR PROCESS SYSTEMS OCTOBER 2018 40 90 01 SUPPLEMENT 1 - 2 ©COPYRIGHT 2018 CH2M HILL

c. Very low pressure loss. d. Measures bidirectional flow.

6. Process Connection: a. Meter Size (diameter inches): As noted. b. Connection Type: 150-pound ANSI raised-face flanges;

AWWA C207, Table 2 Class D; or wafer style depending on meter size, unless otherwise noted.

c. Flange Material: Carbon steel, unless otherwise noted. 7. Power (Transmitter): 120V ac, 60 Hz, unless otherwise noted. 8. Element:

a. Meter Tube Material: Type 304 or 316 stainless steel, unless otherwise noted.

b. Liner Material: 1) Neoprene or polyurethane, unless otherwise noted. 2) For potable water service, must have appropriate approvals.

c. Liner Protectors: Covers (or grounding rings) on each end to protect liner during shipment.

d. Electrode Type: Flush or bullet nose as recommended by the manufacturer for the noted stream fluid.

e. Electrode Material: Type 316 stainless steel or Hastelloy C, unless otherwise noted.

f. Grounding Ring: 1) Required, unless otherwise noted. 2) Quantity: Two, unless otherwise noted. 3) Material: Type 316 stainless steel or Hastelloy C, unless

otherwise noted. g. Enclosure: NEMA 4X, minimum, unless otherwise noted. h. Submergence: Continuous (up to 10 feet depth), NEMA 6P/IP68.

9. Transmitter: a. Mounting: Stanchion, unless otherwise noted. b. Display: Required, unless otherwise noted.

1) Digital LCD display, indicating flow rate and total. 2) Bidirectional Flow Display: Required, unless otherwise

noted. a) Forward and reverse flow rate. b) Forward, reverse and net totalization.

c. Parameter Adjustments: By keypad or nonintrusive means. d. Enclosure: NEMA 4X, minimum, unless otherwise noted. e. Empty Pipe Detection: Drives display and outputs to zero when

empty pipe detected.



10. Signal Interface (at Transmitter): a. Analog Output:

1) Isolated 4 mA to 20 mA dc for load impedance from 0 ohm to at least 500 ohms minimum for 24V dc supply.

2) Supports Superimposed Digital HART Protocol: If noted. b. Discrete Outputs: Totalizer pulse.

11. Cables: a. Types: As recommended by manufacturer. b. Lengths: As required to accommodate device locations.

12. Built-in Diagnostic System: a. Features:

1) Field programmable electronics. 2) Self-diagnostics with troubleshooting codes. 3) Ability to program electronics with full scale flow,

engineering units, meter size, zero flow cutoff, desired signal damping, totalizer unit digit value, etc.

4) Initial flow tube calibration and subsequent calibration checks.

13. Factory Calibration: a. Calibrated in an ISO 9001 and NIST certified factory. b. Factory flow calibration system must be certified by volume or

weight certified calibration devices. c. Factory flow calibration system shall be able to maintain

calibration flow rate for at least 5 minutes for repeatability point checks.

d. Provide flow calibration documentation. 14. Cleaning Unit: Provide Cleaning Unit to be mounted with the

flowmeter. 15. Manufacturers:

a. Siemens Sitrans F M 5100W flowmeter with a MAG 5000 or 6000 signal converter and cleaning unit.

b. Or equal.

B. L18 Level Switch, Non-Mercury:

1. General a. Function: Actuate contact at preset liquid level. b. Type:

1) Direct-acting, stainless steel float with enclosed, encapsulated switch and integral cable.

2) Mercury free. c. Service (Liquid): Wastewater, unless otherwise noted.



d. Performance: 1) Setpoint: As noted. 2) Differential: 8 inches maximum. 3) Temperature: 32 degrees F (nonfreezing) to 160 degrees F.

e. Features: 1) Entire Assembly: Watertight and impact-resistant. 2) Float:

a) Material and Size: 5.5-inch diameter polymer-coated, Type 304 stainless steel float.

b) Buoyancy: 2 pounds. 3) Cable:

a) Length as noted or as necessary in accordance with mounting requirements.

b) Plastic-jacketed cable, oil-resistant, and suitable for continuous service.

4) Mounting: Pipe, unless otherwise noted. a) Pipe Mounting:

(1) Cable clamp, suitable for connection to 1 inch pipe.

(2) Pipe-to-wall bracket, suitable for connection to 1 inch pipe.

b) Anchor Mounting Kit: If noted. (1) 15-pound vinyl-coated cast-iron anchor. (2) 1/8 inch, Type 316 stainless steel wire rope. (3) Stainless steel cable clips.

5) Signal Interface: a) Switch Type: Magnetic reed. b) Switch Contacts:

(1) Isolated, rated at least 0.8 amp continuous at 120 V ac.

(2) Contact Type: N.O. SPST. 6) Manufacturers and Products:

a) Siemens Water Technologies; Model 9G-EF Direct Acting Float Switch

b) Contegra; Model FS90.

C. M43 Intrusion Switch:

1. General a. Function: Monitor intrusion of entry points such as doors,

overhead doors, pullboxes and handholes. b. Parts: Magnet, switch, and cabling.



2. Features: a. Type: Large magnet, surface-mount suitable for door, unless

otherwise noted. b. Cable: Armored, 36 inches long. c. Magnet and Switch Dimensions: Each, 2.6 inches long by

0.875 inches wide by 0.600 inches thick, nominal inches. d. Housing: Weather-resistant aluminum. e. Two holes on switch and magnet for fasteners.

3. Signal Interface: a. Contact Rating: 70VA ac/50 watts dc. b. Maximum Voltage: 150V ac/200V dc. c. Maximum Switching Current: 0.7-amp ac/1.0-amp dc. d. Maximum Carry Current: 2.5 amps.

4. Manufacturer and Product: George Risk Industries. a. George Risk Industries; Model 4402A. b. Or equal.

D. P4 Pressure Gauge:

1. General: a. Function: Local pressure indication. b. Type: Bourdon tube element.

2. Performance: a. Scale Range: As noted. b. Accuracy: Plus or minus 0.50 percent of full scale.

3. Features: a. Dial: 4-1/2 inch diameter. b. Pointer Vibration Reduction: Required, unless otherwise noted.

Use the following method. 1) Liquid filled gauge front, unless otherwise noted.

a) Glycerine fill, unless otherwise noted. c. Case Material: Black thermoplastic, unless otherwise noted. d. Materials of Wetted Parts (including element, socket/process

connection, throttling device (if specified) and secondary components): 1) Stainless steel, unless otherwise noted.

e. Pointer: Adjustable by removing ring and window. f. Window: Glass or acrylic, unless otherwise noted. g. Threaded reinforced polypropylene front ring. h. Case Type: Solid front with blow-out back.

4. Process Connection: a. Mounting: Lower stem, unless otherwise noted. b. Size: 1/2 inch MNPT, unless otherwise noted.



5. Accessories: a. Throttling Device: Required, unless otherwise noted.

1) Type suitable for the intended service. 2) Install in gauge socket bore.

6. Manufacturers and Products: a. Ashcroft; Duragauge Model 1279/Model, 1279 PLUS! b. Ametek U.S. Gauge; Solfrunt Model 19XX/1981 Advantatge.

1) WIKA, Type 2XX.34.

E. P7 Pressure Switch, Adjustable Dead Band:

1. General: a. Function: Monitor pressure, activate switch at setpoint, and

deactivate switch at reset point. b. Type:

2. Performance: a. Setpoint:

1) As noted. 2) Repeatability: Plus or minus 1 percent of range.

b. Reset Point: As noted. c. Range: The noted setpoint shall fall between 20 percent and

80 percent of the range. d. Deadband: Adjustable within nominally 25 percent and 85 percent

of range. e. Overpressure Proof Pressure:

1) Pressure psi Ranges: At least 400 percent of rated maximum static pressure.

2) Pressure Inches of Water Ranges: 20 psig. 3) Compound Range: 250 psig. 4) Vacuum Range: 250 psig.

f. Operating Temperature Range: 1) Dependent on actuator seal materials. 2) For BUNA-N seal, 0 degree F to 150 degrees F.

3. Features: a. Actuator Seal: BUNA-N, unless otherwise noted. b. Adjustable deadband. c. Mounting: Surface, unless otherwise noted.

4. Process Connection: a. 1/4-inch NPT female connections, unless otherwise noted. b. Materials:

1) Pressure psi Ranges: Type 316 stainless steel, unless otherwise noted.

2) Pressure Inches of Water Ranges: Epoxy coated carbon steel, unless otherwise noted.



5. Enclosure: NEMA 4X, unless otherwise noted. 6. Signal Interface:

a. Contact Type: 1) SPDT. 2) Rated for 10 amps minimum at 120V ac.

b. Hermetically Sealed Switch: If noted. 7. Manufacturers and Products:

a. Ashcroft; L or P Series. b. United Electric; J6 Series.

F. Y40 Uninterruptible Power Supply System:

1. General: a. Function: Provides isolated, regulated uninterrupted ac output

power during a complete or partial interruption of incoming line power. True online, double conversion.

b. Major Parts: Inverter, battery charger, sealed battery, and relay adapter board.

2. Performance: a. Capacity: As noted in Instrument List. b. Input Power:

1) 120V ac single-phase, 60 Hz, unless otherwise noted. 2) Connections: Manufacturer’s standard, unless otherwise

noted. c. Output Power:

1) 120V ac single-phase, 60 Hz, unless otherwise noted. 2) Connections: Manufacturer’s standard, unless otherwise

noted. d. On-line Efficiency: 89 to 92 percent minimum, unless otherwise

noted. e. Backup Runtime:

1) Full Load: 2.5 minutes minimum. 2) Half Load: 10 minutes minimum.

f. Continuous no-break power with no measurable transfer time. g. True Sine-Wave Output Voltage Total Harmonic Distortion

(THD): Plus or minus 6 percent or less. h. Input Voltage Range: 80 to 144 volts without using batteries. i. Output Voltage Regulation: Plus or minus 3 percent nominal. j. Operating Temperature: 0 degrees to 50 degrees C. k. Operating Relative Humidity: 1 to 95 percent without

condensation. l. Lightning and Surge Protection: Pass lightning standard

IEEE C62.41 Category B.



3. Features: a. Dry Contact Outputs: Normal open dry relay contacts to activate

on low battery, on battery, and shutdown conditions. 4. Manufacturer and Product:

a. SOLA HD SDU 850. b. Or equal.

G. Y50 Programmable Logic Controller and Distributed I/O Systems:

1. General: a. Provide a complete and fully functioning PLC system consisting

of the PLC major component items listed in the table below. Furnish all required ancillary devices and cables necessary to provide a functional system meeting the needs of the Project.

b. PLC hardware shall be Modicon M340 and Quantum to match existing PLC systems at the plant; no substitutions permitted.

Major PLC Component List

Item Model Number Description Comments

1 BMX P34 2020 Processor Module Qty 1 in PLC-60

2 BMX CPS 2010 Power Supply Qty 1 in PLC-60

3 BMX DDI 1602 16-Point Discrete Input Module

Qty 2 in PLC-60

4 BMX DDO 1602 16-Point Discrete Output Module

Qty 2 in PLC-60

5 BMX AMI 0800 16-Point Analog Input Module

Qty 1 in PLC-60

6 BMX XBP 0800 Back plane Qty 1 in PLC-60

7 140 DAI 540 00 16-Point Discrete Input Module

Qty 2 in spare slots 8 & 9 in PLC-07

8 140 DAO 842 10 16-Point Discrete Output Modules

Qty 1 in spare slot 10 in PLC-07

H. Y56 Industrial Ethernet Switch:

1. General: a. Function: Connect PICS to process control network. b. Type: Unmanaged. c. Parts: Switch with built-in copper Ethernet ports and fiber ports.



2. Service: a. Temperature: Minus 4 to 158 degrees F. b. Humidity: 10 to 95 percent, noncondensing. c. Vibration/Seismic: 50 g, 5 to 200, Triaxial. d. Shock: 200 g at 10 ms.

3. Performance: a. IEEE Compliance: Full 802.3. b. EMI Emissions and Safety: FCC Part 15A, UL 1604, Class 1,

Division 2, Groups A, B, C, D, T4A. 4. Features:

a. Number of Ports: 1) 10/100Base TX copper: Quantity six. 2) Mulitmode 100Base FX fiber optic: Quantity two.

b. Protocols: All standard IEEE 802.3. c. Port Type:

1) RJ45 copper connection; 10/100 Mbps auto-sensing. 2) Fiber connection; 100 Mbps. Type ST.

d. Full-Duplex Operation: Automatically switches from half-duplex to full-duplex when full-duplex capable devices are sensed on ports.

e. Mounting: DIN rail, panel or rack mountable. Provide DIN rail mounting unless otherwise noted.

5. Power: 10V to 30V dc. 6. Manufacturers and Products:

a. N-Tron; 508FX2. b. Or equal.

I. Y58 Fiber Patch Panel:

1. Function: Provides a secure place to terminate fiber optic cables. 2. Features:

a. Compartments: Two; one for fiber optic cable, one for jumpers to individual equipment.

b. Coil Former: Former to wind slack cable. Provides controlled long-radius bends.

c. Connectors: Minimum 12 ST connectors for entry and exit. d. Size: Maximum 18 inches by 12 inches by 4 inches. e. Construction: 1.5-millimeter steel with noncorrosive finish. f. Doors: Separate doors for cable and jumper terminations.

3. Manufacturer and Products: a. Corning; Model WCH-04P. b. Or equal.

END OF SUPPLEMENT 1



SUPPLEMENT 2 - INSTRUMENT LIST

Tag Number Comp Code Component Title Options P&ID

Inst. Detail Mech/Elec Panel Number

60-LSLL-160 L18 Level Switch, Float Setpoint:1’-6” above the wet well floor

NA 4091-248 SM-10 P3-LCP-160

60-LSH-191 L18 Level Switch, Float Setpoint: Elev 120.0 MSL I-03 4091-248 SM-04 SM-05 E-06

CP-60

60-YS-191 M43 Intrusion Switch Normally Closed I-03 E-06 CP-60

55-PI-150 55-PI-151 55-PI-152 55-PI-153

P4 Pressure Gauge Scale Range: 0 - 60 psi I-01 4091-304a SM-02 E-02

N/A

55-PSH-150 55-PSH-151 55-PSH-152 55-PSH-153

P7 Pressure Switch, Adjustable Deadband

Setpoint: 50 psi rising Reset: 45 psi falling Process Connection: 1/2 inch NPT

I-01 4091-304a SM-02 E-02

RTU-40

CP-60 NA Control Panel at Pond 5 Minimum Size: 46 x 30

NEMA Rating: 3R/12

Ventilated on thermostat control

I-04 E-06

60-FE-161 60-FIT-161

F4 Flow Element & Transmitter Range: 0 - 27,780 gpm 0 – 40.0 mgd

Totalizer Pulse: 1,000 gallon

Size: 36 inches

I-03 4091-222g SM-04 SM-05 E-06

CP-60



Tag Number Comp Code Component Title Options P&ID

Inst. Detail Mech/Elec Panel Number

05-FE-191 05-FIT-191

F4 Flow Element & Transmitter Range: 0 - 27,780 gpm 0 – 40.0 mgd

Totalizer Pulse: 1,000 gallon

Size: 36 inches

I-02 4091-222g SM-04 SM-05 E-06

CP-07

DIO-60 Y50 Distributed I/O See Major PLC Component List

I-03

I-04

CP-60

UPS-60 Y40 Uninterruptable Power Supply Capacity: 850 VA I-03 CP-60

Y56 Industrial Ethernet Switch Quantity 2 I-04 CP-60

Maintenance Bldg Janitor Closet

Y58 Fiber Patch Panel Quantity 2 I-04 CP-60

Maintenance Bldg Janitor Closet



SUPPLEMENT 3 - LOOP SPECIFICATIONS

GENERAL

Provide new and modify existing screen displays in the Wonderware Intouch v9.5 plant control system HMI using City standards. Update HMI tag database with equipment Input/Output as shown on PLC IO List. Update HMI Alarm database with alarm Inputs as shown on PLC IO List.

Modify all displays showing Final Effluent Pump Station pump order to reflect P150 and P151 relocations. Modify North Stormwater Pump Station displays to reflect new valves and gate. Provide a new display for Pond 5 Flowmeter Vault. Provide control pop-ups and setpoint displays as required.

A. Standard Analog Instrument Functions:

1. Functions: a. Monitor analog instrument value. b. Alarm on High and Low value. c. Alarm on Transducer failure, less than 3.8mA.

2. PLC Functions: a. Receive and scale analog instrument value. b. Provide operator adjustable High and Low alarm and clear

deadband (reset) setpoints. c. Provide operator adjustable Transducer alarm setpoints. d. Provide operator adjustable time delay to prevent nuisance alarm

notification. e. Provide alarm disable.

3. HMI Functions: a. Display analog instrument value. b. Display alarm status and alarm setpoint value. c. Provide operator control to adjust alarm setpoint value. d. Provide trend display of analog instrument value. e. Provide operator control for alarm disable.

B. Final Effluent Alarm Conditions:

1. Functions: Provide individual alarms and a common alarm for abnormal process conditions.

2. PLC Functions (create setpoints and alarms where not existing): a. Active Effluent Deox Analyzer (SO2) less than 0.5mg/l. b. Active Effluent Chlorine Analyzer less than 0.5mg/l. c. Active Effluent pH Analyzer less than 6.5 or 8.5pH. d. SO2 Water Champ Induction Mixer Failure (Dechlorination).



e. Cl2 Water Champ Induction Mixer Failure (w/time delay). f. Chlorine and/or Sulfer Dioxide Leak System Activated

(emergency angle valve shut off actuators are activated). 3. HMI Functions:

a. Display and annunciate alarm. b. Provide operator adjustable alarm and time delay setpoints. c. Provide operator control for alarm disable.

C. Final Effluent Pump Station Pressure Switches (55-PSH-150 to 55-PSH-153):

1. Functions: Monitor pump effluent pressure. 2. PLC Functions: Alarm and latch in when pressure switch becomes

active. Operator reset required to clear alarm. 3. HMI Functions:

a. Display pump discharge high pressure alarm. b. Provide operator control to clear high pressure alarm.

D. Final Effluent Pump Station Pumps (55-P-150 to 55-P-153):

1. Functions: Run pumps to maintain Operator adjustable level in the wetwell. Shut down pumps and limit operation during abnormal process conditions.

2. PLC Functions (existing, modify to include the following): a. Shutdown pumps in the event of a Final Effluent Alarm. b. Allow operator to restart pumps when the Final Effluent Alarm is

active only if the Final Effluent to Outfall Valve is fully closed and Final Effluent to ESP Valve is fully open.

c. Shutdown pumps when associated pressure alarm is active. d. Shutdown pumps and provide alarm if Final Effluent to Outfall

Valve is not fully open, and the Final Effluent to ESP Valve and Final Effluent to Pond 5 Valve are fully closed.

e. Allow operator or PLC to restart pumps when all alarms are clear. 3. HMI Functions (existing, modify as required below): Display alarm for

Final Effluent to Outfall Valve not fully open, and the Final Effluent to ESP Valve and Final Effluent to Pond 5 Valve are fully closed.

E. Emergency Storage Pond (05-FV-211):

1. Functions: Provide means of discharge to Emergency Storage Pond during abnormal process conditions.

2. PLC Functions: a. Open valve in the event of a Final Effluent Alarm or Effluent

Bypass Panic Button is pressed. b. Allow operator or PLC to close the valve when the alarm is clear.



c. Provide alarm if valve does not reach open/closed commanded position within 12 minutes.

3. HMI Functions: a. Display valve open/close/traveling status. b. Display valve SCADA auto/manual control status. c. Display valve local/remote control status. d. Display valve failure status. e. Provide operator SCADA auto/manual selection. f. Provide operator open/close control when in SCADA manual. g. Provide Effluent Bypass Panic Button.

F. Stormwater Pump Station and Emergency Storage Pond (05-FV-141, 05-FV-151, 05-SG-161, 05-FV-171, and 05-FV-181):

1. Functions: Provide operator selection of process flow. 2. PLC Functions:

a. There is no SCADA auto control. b. Allow operator to open or close each valve and gate. c. Alarm if neither pair (141 and 151, or 171 and 181) of valves is

fully open. d. Provide alarm if valve or gate does not reach open/closed

commanded position within 12 minutes. 3. HMI Functions:

a. Display valve and gate open/close/traveling status. b. Display valve and gate local/remote control status. c. Display valve and gate failure status. d. Display alarm condition if neither pair of valves is fully open. e. Provide operator open/close control of each valve/gate.

G. Pond 5 Flowmeter Vault (60-FIT-161, 60-FV-171, and 60-FV-181):

1. Functions: Provide Effluent Flow measurement, and flow selection to Outfall or Pond 5.

2. PLC Functions: a. Provide zero reading on Final Effluent to Outfall Flowmeter when

the Final Effluent to Outfall Valve is fully closed. b. Close the Final Effluent to Outfall Valve in the event of a Final

Effluent Alarm or Effluent Bypass Panic Button is pressed. c. Allow operator or PLC to open the Final Effluent to Outfall Valve

when the alarm is clear. d. Allow operator to open or close the Final Effluent to Pond 5

Valve. There is no automatic control of this valve. e. Provide alarm if valve does not reach open/closed commanded

position within 12 minutes.



3. HMI Functions: a. Display valve open/close/traveling status. b. Display valve SCADA auto/manual control status. c. Display valve local/remote control status. d. Display valve failure status. e. Provide operator SCADA auto/manual control. f. Provide operator open/close control when in SCADA manual.

H. Pond 5 Flowmeter Vault (60-LSH-191, and 60-YS-191):

1. Functions: Provide alarming for intrusion or if sump pump cannot maintain water discharge from vault.

2. PLC Functions: a. Provide alarm if any hatch is opened. b. Provide alarm if high level is detected in the vault.

3. HMI Functions: a. Display Intrusion alarm. b. Display High Level alarm.

END OF SUPPLEMENT 3



SUPPLEMENT 4 - PLC INPUT/OUT SUMMARY LISTS

Tag No. Description Active State

PLC-07 - DISCRETE INPUTS

05-HS-211 Final Effluent PS to ESP Valve in Remote Remote

05-ZSO-211 Final Effluent PS to ESP Valve Open Status Open

05-ZSC-211 Final Effluent PS to ESP Valve Closed Status Closed

05-HS-141 Stormwater PS to ESP Valve in Remote Remote

05-ZSO-141 Stormwater PS to ESP Valve Open Status Open

05-ZSC-141 Stormwater PS to ESP Valve Closed Status Closed

05-HS-151 Stormwater PS to Pond 1 Valve in Remote Remote

05-ZSO-151 Stormwater PS to Pond 1 Valve Open Status Open

05-ZSC-151 Stormwater PS to Pond 1 Valve Closed Status Closed

05-HS-161 ESP Return to Stormwater PS Gate in Remote Remote

05-ZSO-161 ESP Return to Stormwater PS Gate Open Status Open

05-ZSC-161 ESP Return to Stormwater PS Gate Closed Status Closed

05-HS-171 Pond 3 Return to Primary Influent Distribution Box Valve in Remote

Remote

05-ZSO-171 Pond 3 Return to Primary Influent Distribution Box Valve Open Status

Open

05-ZSC-171 Pond 3 Return to Primary Influent Distribution Box Valve Closed Status

Closed

05-HS-181 Pond 3 Return to ESP Valve in Remote Remote

05-ZSO-181 Pond 3 Return to ESP Valve Open Status Open

05-ZSC-181 Pond 3 Return to ESP Valve Closed Status Closed

PLC-07 - ANALOG INPUTS

05-FIT-191 Pond 3 Return to ESP Valve Closed Status Closed





PLC-07 - DISCRETE OUTPUTS

05-ZCO-211 Final Effluent PS to ESP Valve Open Command Open

05-ZCC-211 Final Effluent PS to ESP Valve Close Command Close

05-ZCO-141 Stormwater PS to ESP Valve Open Command Open

05-ZCC-141 Stormwater PS to ESP Valve Close Command Close

05-ZCO-151 Stormwater PS to Pond 1 Valve Open Command Open

05-ZCC-151 Stormwater PS to Pond 1 Valve Close Command Close

05-ZCO-161 ESP Return to Stormwater PS Gate Open Command Open

05-ZCC-161 ESP Return to Stormwater PS Gate Close Command Close

05-ZCO-171 Pond 3 Return to Primary Influent Distribution Box Valve Open Command

Open

05-ZCC-171 Pond 3 Return to Primary Influent Distribution Box Valve Close Command

Close

05-ZCO-181 Pond 3 Return to ESP Valve Open Command Open

05-ZCC-181 Pond 3 Return to ESP Valve Close Command Close

RTU-40 - DISCRETE INPUTS

55-PSH-150 Final Effluent Pump 1 Discharge Pressure High High




PLC-60 - DISCRETE INPUTS

60-JS-161 CP-60 Low Battery Low Battery

60-JS-162 CP-60 On Battery On Battery

60-JS-163 CP-60 Shutdown Shutdown

60-FQ-161 Final Effluent to Outfall Flow Total Pulse

60-HS-171 Final Effluent to Outfall Valve in Remote Remote

60-ZSO-171 Final Effluent to Outfall Valve Open Status Open





60-ZSC-171 Final Effluent to Outfall Valve Closed Status Closed

60-HS-181 Final Effluent to Pond 5 Valve in Remote Remote

60-ZSO-181 Final Effluent to Pond 5 Valve Open Status Open

60-ZSC-181 Final Effluent to Pond 5 Valve Closed Status Closed

60-LSH-191 Flowmeter Vault High Level Switch High

60-YS-191 Flowmeter Vault Intrusion Switches No Intrusion

PLC-60 - DISCRETE OUTPUTS

60-ZCO-171 Final Effluent to Outfall Valve Open Command Open

60-ZCC-171 Final Effluent to Outfall Valve Close Command Close

60-ZCO-181 Final Effluent to Pond 5 Valve Open Command Open

60-ZCC-181 Final Effluent to Pond 5 Valve Close Command Close

PLC-60 - ANALOG INPUTS

60-FIT-161 Final Effluent to Outfall Flow 0 – 27,780 gpm 0 – 40.0 mgd



CH2M HILL INSTRUMENT CALIBRATION SHEET Rev.06.05.92 COMPONENT MANUFACTURER PROJECT

Code: Name: Number: Name: Model: Name: Serial #:

FUNCTIONS RANGE VALUE UNITS COMPUTING FUNCTIONS? Y / N CONTROL? Y / N Indicate? Y / N Chart: Describe: Action? direct / reverse

Modes? P / I / D Record? Y / N Scale: SWITCH? Y / N

Unit Range: Transmit/ Input: Differential: fixed/adjustable Convert? Y / N Output: Reset? automatic / manual

ANALOG CALIBRATIONS DISCRETE CALIBRATIONS Note REQUIRED AS CALIBRATED REQUIRED AS CALIBRATED No.

Input Indicated Output Increasing Input Decreasing Input Number Trip Point Reset Pt. Trip Point Reset Pt. Indicated Output Indicated Output (note rising or falling) (note rising or falling) 1. 2. 3. 4. 5. 6. CONTROL MODE SETTINGS: P: I: D: 7. # NOTES: Component Calibrated and Ready for Startup By: Date: Tag No.:



CH2M HILL INSTRUMENT CALIBRATION SHEET Rev.06.05.92

EXAMPLE - ANALYZER/TRANSMITTER COMPONENT MANUFACTURER PROJECT

Code: A7 Name: Leeds & Northrup Number: WDC30715.B2 Name: pH Element & Analyzer/Transmitter Model: 12429-3-2-1-7 Name: UOSA AWT PHASE 3 Serial #: 11553322

FUNCTIONS RANGE VALUE UNITS COMPUTING FUNCTIONS? N CONTROL? N Indicate? Y Record? N

Chart: Describe: Action? direct / reverse Modes? P / I / D

Scale: 1-14 pH units SWITCH? N Unit Range:

Transmit/ Input: 1-14 pH units Differential: fixed/adjustable Convert? Y Output: 4-20 mA dc Reset? automatic / manual

ANALOG CALIBRATIONS DISCRETE CALIBRATIONS Note REQUIRED AS CALIBRATED REQUIRED AS CALIBRATED No

Input Indicated Output Increasing Input Decreasing Input Number Trip Point Reset Pt. Trip Point Reset Pt. Indicated Output Indicated Output (note rising or falling) (note rising or falling) 1.0 1.0 4.0 1.0 4.0 1.0 3.9 1. N.A. N.A. 2.3 2.3 5.6 2.2 5.5 2.3 5.6 2. 1. 7.5 7.5 12.0 7.5 11.9 7.5 12.0 3. 12.7 12.7 18.4 12.7 18.3 12.6 18.3 4. 14.0 14.0 20.0 14.0 20.0 14.0 20.0 5. 6. CONTROL MODE SETTINGS: P: N.A. I: D: 7. # NOTES: Component Calibrated and Ready for 1. Need to recheck low pH calibration solutions. Startup By: J.D. Sewell Date: Jun-6-92 Tag No.: AIT-12-6[pH]



CH2M HILL I&C VALVE ADJUSTMENT SHEET Rev.06.05.92

PARTS Project Name: Project Number:

Body Type: Mfr:

Size: Model:

Line Connection: Serial #:

Operator Type: Mfr:

Action: Model:

Travel: Serial #:

Positioner Input Signal: Mfr:

Action: Model:

Cam: Serial #:

Pilot Action: Mfr:

Solenoid Rating: Model:

Serial #:

I/P Input: Mfr:

Converter Output: Model:

Action: Serial #:

Position Settings: Mfr:

Switch Contacts: Model:

Serial #:

Power Type: Air Set Mfr:

Supply Potential: Model:

Serial #:

ADJUSTMENTS Initial Date VERIFICATION Initial Date

Air Set Valve Action

Positioner Installation

Position Switches Wire Connection

I/P Converter Tube Connection

Actual Speed

REMARKS: Valve Ready for Startup

By:

Date:

Tag No.:



CH2M HILL I&C VALVE ADJUSTMENT SHEET Rev.06.05.92 EXAMPLE

PARTS Project Name: SFO SEWPCP Project Number: SFO10145.G2

Body Type: Vee-Ball Mfr: Fisher Controls

Size: 4-inch Model: 1049763-2

Line Connection: 159 # ANSI Flanges Serial #: 1003220

Operator Type: Pneumatic Diaphragm Mfr: Fisher Controls

Action: Linear - Modulated Model: 4060D

Travel: 3-inch Serial #: 2007330

Positioner Input Signal: 3-15 psi Mfr: Fisher Controls

Action: Direct - air to open Model: 20472T

Cam: Equal percentage Serial #: 102010

Pilot Action: Mfr:

Solenoid Rating: None Model:

Serial #:

I/P Input: 4-20 mA dc Mfr: Taylor

Converter Output: 3-15 psi Model: 10-T-576-3

Action: Direct Serial #: 1057-330

Position Settings: Closed / Open 5 deg, rising Mfr: National Switch

Switch Contacts: Close / Close Model: 1049-67-3

Serial #: 156 &157

Power Type: Pneumatic Air Set Mfr: Air Products

Supply Potential: 40 psi Model: 3210D

Serial #: 1107063

ADJUSTMENTS Initial Date VERIFICATION Initial Date

Air Set JDS Jun-06-92 Valve Action JDS Jun-03-92

Positioner JDS Jun-06-92 Installation JDS Jun-03-92

Position Switches JDS Jun-06-92 Wire Connection JDS Jun-04-92

I/P Converter JDS Jun-07-92 Tube Connection JDS Jun-04-92

Actual Speed JDS Jun-07-92

REMARKS: Valve was initially installed backwards. Valve Ready for Startup

Observed to be correctly installed May-25-92 By: J.D. Sewell

Date: Jun-07-92

Tag No.: FCV-10-2-1



CH2M HILL PERFORMANCE ACCEPTANCE TEST SHEET Rev.06.05.92

Project Name: Project No.:

Demonstration Test(s): For each functional requirement of the loop: (a) List and number the requirement. (b) Briefly describe the demonstration test. (c) Cite the results that will verify the required performance. (d) Provide space for signoff.

Forms/Sheets Verified By Date Loop Accepted By Owner

Loop Status Report By:

Instrument Calibration Sheet Date:

I&C Valve Calibration Sheet

Performance Acceptance Test By Date

Performed

Witnessed Loop No.:



CH2M HILL PERFORMANCE ACCEPTANCE TEST SHEET Rev.06.05.92 EXAMPLE

Project Name: SFO SEWPCP Plant Expansion Project No.: SFO12345.C1

Demonstration Test(s): For each functional requirement of the loop: (a) List and number the requirement. (b) Briefly describe the demonstration test. (c) Cite the results that will verify the required performance. (d) Provide space for signoff.

1. MEASURE EFFLUENT FLOW

1.a With no flow, water level over weir should be zero and

FIT indicator should read zero. Jun-20-92 BDG

2. FLOW INDICATION AND TRANSMISSION TO LP & CCS

With flow, water level and FIT indicator should be related by expression

Q(MGD) = 429*H**(2/3) (H = height in inches of water over weir).

Vary H and observe that following.

2.a Reading of FIT indicator. Jun-6-92 BDG

2.b Reading is transmitted to FI on LP-521-1. Jun-6-92 BDG

2.c Reading is transmitted and displayed to CCS. Jun-6-92 BDG

H(measured) 0 5 10 15

Q(computed) 0 47.96 135.7 251.7

Q(FIT indicator) 0 48.1 137 253

Q(LI on LP-521-1) 0 48.2 138 254

Q(display by CFCS) 0 48.1 136.2 252.4

Forms/Sheets Verified By Date Loop Accepted By Owner

Loop Status Report J.D. Sewell May-18-92 By: J.D. Smith

Instrument Calibration Sheet J.D. Sewell May-18-92 Date: Jun-6-92

I&C Valve Calibration Sheet N.A.

Performance Acceptance Test By Date

Performed J. Blow MPSDC Co. Jun-6-92

Witnessed B.deGlanville Jun-6-92 Loop No.: 30-12


PW/WBG/179201 VERTICAL TURBINE PUMPS OCTOBER 2018 44 42 56.03 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 44 42 56.03 VERTICAL TURBINE PUMPS

EQUIPMENT NUMBERS

55-P-150 Effluent Pump

55-P-151 Effluent Pump

PART 1 GENERAL

1.01 DEFINITIONS

A. Terminology pertaining to pump performance and construction shall conform to the ratings and nomenclature of the Hydraulic Institute Standards.

1.02 SUBMITTALS


1. Make, model, weight, and horsepower of each equipment assembly. 2. Complete catalog information, descriptive literature, specifications, and

identification of materials of construction. 3. Performance data curves showing head, capacity, horsepower demand,

NPSH required, and pump efficiency over the entire operating range of the pump, from shutoff to maximum capacity. Indicate separately the head, capacity, horsepower demand, overall efficiency, and minimum submergence required at the design flow conditions.

4. Calculations: a. Torsional analysis for complete rotating assembly. Analysis report

shall include the specific items of API 610, Eleventh Edition, Part 6.9.2.10.

b. Lateral vibration analysis for discharge head motor assembly and for column pipe bowl assembly.

c. Seismic analysis for discharge head, equipment support and anchors, and column pipe bowl assembly.

5. Pump maximum downthrust or upthrust in pounds. 6. Detailed structural, mechanical, and electrical drawings showing

equipment dimensions, size and locations of connections and weights of components.

7. Assembly and installation drawings including shaft size, seal, coupling, bearings, anchor bolt plan, parts nomenclature, and materials of construction lists.


VERTICAL TURBINE PUMPS PW/WBG/179201 44 42 56.03 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

8. Baseplate drawings with leveling jackscrew details, anchor bolt and sleeve details, and minimum foundation installation and leveling requirements.

9. Power and control wiring diagrams, including terminals and numbers. 10. Complete motor nameplate data, as defined by NEMA, motor

manufacturer, including motor modifications. 11. Motor operational speed range for inverter duty motors. 12. Factory finish system. 13. Seismic anchorage and bracing drawings and cut sheets, as required by

Section 01 88 15, Seismic Anchorage and Bracing.


1. Seismic anchorage and bracing calculations as required by Section 01 88 15, Seismic Anchorage and Bracing.

2. Manufacturer’s Certification of Compliance that factory finish system is identical to requirements specified herein.

3. Special shipping, storage and protection, and handling instructions. 4. Manufacturer’s printed installation instructions. 5. Factory Functional and Performance Test Reports and Log: Factory test

data for each pump shall be submitted, reviewed, and approved by Engineer prior to shipment of equipment.

6. Suggested spare parts list to maintain equipment in service for a period of 1 year and 5 years. Include a list of special tools required for checking, testing, parts replacement, and maintenance with current price information.

7. List special tools, materials, and supplies furnished with equipment for use prior to and during startup and for future maintenance.

8. Operation and Maintenance Data: As specified in Section 01 78 23, Operation and Maintenance Data.

9. Manufacturer’s Certificate of Proper Installation, in accordance with Section 01 43 33, Manufacturers’ Field Services.

1.03 EXTRA MATERIALS

A. Furnish for this set of pumps:

1. Complete mechanical seal. 2. One complete set of special tools required to dismantle pump.



PART 2 PRODUCTS

2.01 GENERAL

A. See Section 26 29 23, Low-Voltage Adjustable Frequency Drive System, and Section 26 20 00, Low-Voltage AC Induction Motors.

B. Coordinate pump and motor requirements with adjustable speed drive manufacturer and be responsible for the following:

1. Torsional vibration of the rotating assembly and related stresses. 2. Motor thermal rating. 3. Structural design of pump and motor assembly. 4. Drive capacity for actual motor’s nameplate current rating being

supplied. 5. Minimum motor speed rating for required corresponding torque.

C. Lateral and Torsional Vibrations:

1. Pump and motor assembly shall have no natural frequencies within 20 percent of operating speed range.

2. Fundamental critical speed of rotating assembly shall be no less than 50 percent above the rated speed.

3. Pump manufacturer shall conduct an analysis of lateral and torsional vibration of pump and motor assembly. a. Excitation frequency range of the analysis shall include, but not

be limited to, number of motor poles and number of impeller vanes.

b. Perform detailed stress analysis for pump, coupling, motor system at each critical speed, and steady-state operating condition.

c. Stress analysis shall demonstrate that in no case shall maximum stress on pump, coupling and motor component exceed endurance limits of materials of construction.

2.02 SUPPLEMENTS

A. Some specific requirements are attached to this section as supplements.

2.03 SHAFT SEALS

A. Mechanical Seal Requirements:

1. Nonfretting type requiring no wearing sleeve for shaft. 2. Pump shaft shall be furnished with no reduction in size through seal

area.



3. Arrangement shall allow removal of seal without disturbing pump or driver.

4. Design such that dynamic O ring moves towards a clean surface as face wears and springs are not in pumped fluid.

5. Stationary seal face shall be spring loaded to provide self-aligning despite stuffing box misalignment.

6. Cartridge type mechanical seal: a. Single, balanced, flexible stator design. b. Capable of 600 psig service. c. O-ring secondary seals and setscrew drive with three-point

centering to ensure 0.003-inch maximum perpendicularity of rotary face to shaft.

d. Gland shall have flush port and be affixed to equipment with adjustable tabs to fit irregular bolt patterns.

e. Manufacturers and Products: 1) A.W. Chesterton Company; 155. 2) Crane; 1B.

7. Seal Materials: a. Metals:

1) Loaded Parts Over 0.060-inch Cross Section: Type 316 stainless steel minimum.

2) Thinner Parts (springs): Hastelloy C, Alloy 20, AMS5876 Elgiloy, or other alloy that is not vulnerable to chloride stress corrosion.

b. Elastomers: Fluorocarbon (Viton) preferred, unless seal manufacturer recommends ethylene propylene for service conditions.

c. Faces: 1) Homogeneous construction. Surface treatments and plated

faces are unacceptable. 2) Hard Face: Nickel-bound tungsten carbide. 3) Soft Face: Carbon-graphite, either Union Carbide 658RC or

Purecarbon P8412. 8. Seal Environmental Controls:

a. Pipe seal flush port drain to wetwell. Provide venting of seal chamber.

b. Material of Construction: Type 316 stainless steel. c. Connect mechanical seal to water pre-lube supply as indicated on

Drawings.



2.04 ACCESSORIES

A. Equipment Identification Plate: 16-gauge stainless steel with 1/4-inch die-stamped equipment tag number securely mounted in a readily visible location.

B. Lifting Lugs: Equipment weighing over 100 pounds.

C. Anchor Bolts: Type 316 stainless steel, sized by equipment manufacturer, and as specified in Section 05 50 00, Metal Fabrications.


A. General: Prepare and prime, and finish coat in accordance with Section 09 90 00, Painting and Coating.

B. Prepare sole plate bottom, bowl interior and exterior, inside and outside of column in accordance with SSPC SP-5 and factory line with 16 mils dry film thickness of Carboline 891 or equal.

C. Prepare head exterior, top of sole plate, and other exterior surfaces in accordance with SSPS SP-10 and factory coat with 4 mils dry film thickness of Carboline 891 or equal.


A. Factory Tests and Adjustments: Test all equipment actually furnished.

B. Factory Test Report: Include test data sheets, curve test results, performance test logs, certified correct by a registered professional engineer.

C. Functional Test: Manufacturer’s standard.

D. Performance Test:

1. Conduct on each pump at rated speed. 2. Perform under simulated operating conditions. 3. Test for a continuous 3-hour period without malfunction. 4. Test Log: Record the following:

a. Total head. b. Capacity. c. Horsepower requirements. d. Flow measured by factory instrumentation and storage volumes. e. Average distance from suction well water surface to pump

discharge centerline for duration of test.



f. Pump discharge pressure converted to feet of liquid pumped and corrected to pump discharge centerline.

g. Calculated velocity head at the discharge flange. h. Bowl head. i. Driving motor voltage and amperage measured for each phase.

5. Adjust, realign, or modify units and retest in accordance with Hydraulic Institute Standards if necessary.

E. Motor Test: Manufacturer standard.

F. Hydrostatic Tests: Pump casing(s) tested at 150 percent of shutoff head. Test pressure maintained for not less than 5 minutes.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install in accordance with manufacturer’s printed instructions and as follows.

B. Level sole plate by means of leveling screws bearing against 4-inch square by 1/4-inch thick stainless steel plates set in the pump foundation.

C. Adjust pump assemblies such that driving units are properly aligned, plumb, and level with driven units and interconnecting shafts and couplings. Do not compensate for misalignment by use of flexible couplings.

D. After pump and driver have been set in position and aligned, grout space between bottom of baseplate and concrete foundation with epoxy grout or Category III grout as specified in Section 03 62 00, Nonshrink Grouting.

E. Connect suction and discharge piping without imposing strain to pump flanges.

F. Anchor Bolts: Accurately place using equipment templates and as specified in Section 05 50 00, Metal Fabrications.


A. Functional Tests: Conduct on each pump and motor.

1. Alignment: Test complete assemblies for correct rotation, proper alignment and connection, and quiet operation.



2. Vibration Test: a. Test with unit installed and in normal operation, and discharging

to the connected piping systems at rates between low discharge head and high discharge head conditions specified, and with actual building structures and foundations provided. Unit shall not develop vibration exceeding 80 percent of the limits specified in HIS 9.6.4.

b. If unit exhibits vibration in excess of limits specified, adjust or modify as necessary. Unit that cannot be adjusted or modified to conform as specified shall be replaced.

3. Flow Output: Measured by plant instrumentation and storage volumes. 4. Test for continuous 3-hour period. 5. Test Report Requirements: In accordance with Hydraulic Institute

Standards for Vertical Pump Tests HIS 14.6. 6. Motor insulation resistance test in accordance with IEEC 43. 7. Measure and record motor voltage and current at each operating point.



1. 2 person-days for installation assistance and inspection. 2. 1 person-day for functional and performance testing and completion of

Manufacturer’s Certificate of Proper Installation. 3. 1/2 person-day for prestartup classroom or Site training. 4. 1/2 person-day for facility startup. 5. 1/2 person-day for post-startup training of Owner’s personnel. Training

shall not commence until an accepted detailed lesson plan for each training activity has been reviewed by Owner.

B. See Section 01 43 33, Manufacturers’ Field Services and Section 01 91 14, Equipment Testing and Facility Startup.

3.04 SUPPLEMENTS

A. The supplements listed below, following “End of Section,” are a part of this Specification.

1. Pump and Motor Data Sheet.

END OF SECTION


PW/WBG/179201 VERTICAL TURBINE PUMPS OCTOBER 2018 44 42 56.03 SUPPLEMENT - 1 ©COPYRIGHT 2018 CH2M HILL

VERTICAL TURBINE PUMP DATA SHEET, 44 42 56.03

Manufacturers and Product: (1) Cascade Pump Co.; Model Series 20MF (2) Fairbanks Nijhuis (3) Flowserve Corp. (4) Or equal

SERVICE CONDITIONS

Liquid Pumped: Plant Effluent

Pumping Temperature (Fahrenheit): Normal 60 Maximum 80 Minimum 40

Maximum NPSH Required (Ft. Absolute): 25

PERFORMANCE REQUIREMENTS

Rated Condition:

Maximum Pump Speed (rpm): 885 Capacity (US gpm): 8,415 Total Dynamic Head (ft): 25.3 Minimum Efficiency, Percent: 88

Low Head Condition:

Maximum Pump Speed (rpm): 885 Capacity (US gpm): 9,900 Total Dynamic Head (ft): 11.9 Minimum Efficiency, Percent: 70

High Head Condition:

Required Pump Speed (rpm): 885 Capacity (US gpm): 6,930 Total Dynamic Head (ft): 33.6 Minimum Efficiency, Percent: 83

Operating Flow Range at Maximum Speed:

Minimum: Not greater than 4,500 gpm Maximum: Not less than 10,500 gpm

Adjustable Speed (Y/N): Y

Maximum Noise Level, dBA at 3 Feet: 85

Number of Stages: 1


VERTICAL TURBINE PUMPS PW/WBG/179201 44 42 56.03 SUPPLEMENT - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

Minimum Diameter Solid Pump Can Pass (inches): 1.3

DESIGN AND MATERIALS

Pump Type: Open Line Shaft

Suction Bell: Cast Iron Suction Bell Bearing: High Lead Tin Bronze

Bowl: Cast Iron ASTM CL30 Bowl Wear Rings: Bronze ASTM B505, C93200

Suction Bell Bearings Lubrication: Food Grade Grease

Column: Steel

Column Connection Type: Flanged

Maximum Column Section Lengths (ft): 5

Casing Hydrostatic Test Pressure: 1.25 Times Shutoff Head

Line Shaft: Type 416 Stainless Steel, ASTM A582

Minimum Line Shafting Bearing Spacing (ft): 5

Line Shaft Bearings: High Lead Tin Bronze Line Shaft Lubrication: Product

Discharge Head: Size (inches): 20 Type: Flanged, ASME B16.5 Class 150 Material: Cast Iron, ASTM A536, Grade 60-40-18 Arrangement: Abovegrade Discharge Bearing: High Lead Tin Bronze

Impeller: Material: Bronze, ASTM B584, C83600 Impeller Shaft: Type 416 Stainless Steel, ASTM A582 Impeller Shaft Coupling: Type 416 Stainless Steel, ASTM A582 Wear Rings: Bronze, ASTM B505, C93200 Bearing: High Lead Tin Bronze Shaft Key: Type 416 Stainless Steel, ASTM A582 Dynamically Balanced: Y

Discharge Shaft Seal Type: Mechanical, as specified.

Coupling: Flanged, Adjustable Spacer Type, Steel, AISI 1020, Dynamically Balanced


PW/WBG/179201 VERTICAL TURBINE PUMPS OCTOBER 2018 44 42 56.03 SUPPLEMENT - 3 ©COPYRIGHT 2018 CH2M HILL

Sole Plate: Y

DRIVE MOTOR

General: In accordance with NEMA MG 1, and Section 26 20 00, Low-Voltage AC Induction Motors. Inverter Duty rated. Premium Efficient.

Horsepower: 75 Voltage: 460 Phase: 3

Synchronous Speed (rpm): 900

Service Factor: 1.15, sine wave, 1.0 on inverter power

Motor nameplate horsepower shall not be exceeded at any head-capacity point within the specified Operating Flow Range.

Temperature Rating: Continuous duty at 40 degrees C ambient

Enclosure: WP1

Non-Reverse Ratchet: None

Insulation: Class F with Class B rise

Mounting Type: Vertical, Coupled

ABMA 9 and ABMA 11, B-10 Motor Bearing Life (hrs): 100,000

REMARKS: Inverter duty motor; motor winding temperature switches; three normally closed switches wired in series. 120V motor space heater. Provide electrically isolated bearing and shaft grounding device. Motor shall be premium efficient in accordance with NEMA MG 1.


PW/WBG/179201 SUBMERSIBLE NON-CLOG PUMPS OCTOBER 2018 44 42 56.04 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 44 42 56.04 SUBMERSIBLE NON-CLOG PUMPS

EQUIPMENT IDENTIFICATION P3-P-160 Pond 3 Pump 1 P3-P-161 Pond 3 Pump 2

PART 1 GENERAL

1.01 DEFINITIONS

A. Terminology pertaining to pumping unit performance and construction shall conform to ratings and nomenclature of Hydraulic Institute Standards.

1.02 SUBMITTALS



identification of materials of construction, including cable seal details. 3. Performance data curves showing head, capacity, horsepower demand,

and pump efficiency over entire operating range of pump, from shutoff to maximum capacity. Indicate separately head, capacity, horsepower demand, overall efficiency, and minimum submergence required at guarantee point.

4. Power and control wiring diagrams, including terminals and numbers. 5. Motor protection module wiring diagram. 6. Motor data, in accordance with the requirements of Section 26 20 00,

Low-Voltage AC Induction Motors. 7. Factory-finish system. 8. L-10 bearing life calculations per ABMA. 9. Seismic anchorage and bracing drawings and cut sheets, as required by

Section 01 88 15, Anchorage and Bracing.


1. Seismic anchorage and bracing calculations as required by Section 01 88 15, Anchorage and Bracing.

2. Special shipping, storage and protection, and handling instructions. 3. Manufacturer’s printed installation instructions.


SUBMERSIBLE NON-CLOG PUMPS PW/WBG/179201 44 42 56.04 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

4. Manufacturer’s Certificate of Compliance, in accordance with Section 01 61 00, Common Product Requirements, certifying that factory finish system meets requirements specified herein.

5. Suggested spare parts list to maintain equipment in service for period of 1 year and 5 years. Include list of special tools required for checking, testing, parts replacement, and maintenance with current price information.


7. Operation and Maintenance Data as specified in Section 01 78 23, Operation and Maintenance Data.

8. Manufacturer’s Certificate of Proper Installation, in accordance with Section 01 43 33, Manufacturers’ Field Services.

PART 2 PRODUCTS

2.01 GENERAL

A. Submersible, vertical shaft, centrifugal nonclog type, suitable for pumping wastewater.

2.02 PERFORMANCE AND SERVICE CONDITIONS

A. Fluid: Wastewater treatment plant effluent.

B. Guarantee Point: 720 gpm at 35 feet total pump head.

C. Secondary Point: 420 gpm at 48 feet total pump head.

D. Drive: Constant speed.

2.03 MANUFACTURERS AND PRODUCTS

A. Xylem-Flygt; Model Series NP 3127 MT.

B. WILO USA LLC.

C. Fairbanks Nijhuis.

D. Or equal.



2.04 PUMP AND MOTOR ASSEMBLIES

A. General:

1. Equipment consists of pump complete with motor, submersible power and control cables, and pump lifting cable. As indicated on Drawings, provide pumps with guide rails, anchoring brackets, and base elbows.

2. Submersible, vertical shaft, centrifugal nonclog type, suitable for pumping wastewater.

3. Designed for continuous operation under submerged or partially submerged conditions, and intermittent operation when totally dry without damage to pump or motor.

B. Pump Design and Materials:

1. Motor and rotating parts shall be removable from motor end of pump. 2. Mating surfaces to be watertight and fitted with nitrile O-rings. 3. Pumps fitted with dynamically balanced, nonclog impellers designed to

pass course solids and stringy materials. 4. Casings, Volute, Impeller: Cast Iron ASTM A48, Class 35B. 5. Elastomers: Nitrile Rubber. 6. Fasteners: 300 series stainless steel. 7. Shaft Sealing System: Dual tandem-mounted mechanical seals

consisting of two independent seal assemblies. Each seal shall consist of one stationary and one positively driven rotating corrosion-resistant tungsten-carbide or silicon carbide ring. Each seal interface to be held in contact by its own spring system. Shaft sealing system shall operate in its own lubrication system and not rely on pumped media for lubrication. Provide drain and inspection plugs.

8. One-Piece Pump and Motor Shaft: Stainless steel, ASTM A479, S43100-T.

9. Base Elbows: Cast iron, ASTM A48, Class 35, 6-inch Class 125 discharge flange per ASME B16.1.

C. Motor:

1. Rated Power: 10 hp. 2. Voltage: 460 volt, three-phase. 3. Air filled, watertight, suitable for continuous submerged or partially

submerged operation to a depth of 65 feet, Factory Mutual rated. 4. Designed for continuous duty at full nameplate load while handling

pumped media of 104 degrees F, and capable of a minimum of 30 evenly spaced starts per hour. Design for intermittent operation when totally dry without damage to pump or motor.



5. Service Factor: 1.15. 6. Insulation: Class F. 7. Nameplate horsepower, excluding service factor, shall not be exceeded

at any head-capacity point on pump curve. 8. Thermal overload protection embedded in the stator lead coils,

factory-set. 9. Bearings shall be sealed and permanently grease lubricated, L-10 life of

50,000 hours minimum. Single deep-groove ball upper bearing, double row angular contact type lower bearing.

10. Provide a separate junction chamber sealed off from the stator housing containing a terminal board for connection of power and sensor leads. Terminal board shall use threaded compression type terminals.

11. Provide integral seal leakage sensor with leak detection circuit. The leakage chamber shall be located above the shaft seal and below the lower bearing.

12. Each motor power and control cable to be of sufficient length to reach the designated junction box with no splices. Cable shall have an outer jacket of oil resistant chloroprene rubber and be UL listed for Extra Hard Usage. Size in accordance with NEC requirements.

D. Cable Entry System:

1. Junction chamber and motor separated by stator lead sealing gland or terminal board that prevents foreign material entering through pump top.

2. Utilize cable with factory-installed sealing gland with nonshrink epoxy seal system.

3. O-ring compression seal between sealing gland and cable entry point shall also be acceptable.

E. Motor Protection Module: Provide pump with a motor protection module for remote mounting.

F. Lifting Arrangement:

1. Stainless steel chain, 2 feet minimum, and one “grip-eye.” 2. Attach chain permanently to pump and access platform with stainless

steel wire rope. 3. “Grip-eye” capable of being threaded over and engaging links of

stainless steel chain so pump and motor may be lifted with “grip-eye” and independent hoist.



G. Sliding Guide Bracket:

1. Integral part of pump unit. 2. Pump unit to be guided by no less than two stainless steel guide bars,

and pressed tightly against discharge connection elbow with metal-to-metal contact or through use of profile-type gasket, provided gasket is attached to pump’s flange and can be easily accessed for inspection when pump is lifted out of wetwell.

3. Provide with Type 316L stainless steel upper guide bar bracket, intermediate guide bar bracket(s), and cable holder hook brackets.

2.05 ACCESSORIES

A. Equipment Identification Plate: 16-gauge stainless steel with 1/4-inch die-stamped equipment tag number securely mounted in readily visible location.

B. Anchor Bolts: Type 316 stainless steel, sized by equipment manufacturer, and as specified in Section 05 50 00, Metal Fabrications. Coat in accordance with Section 09 90 00, Painting and Coating.


A. Manufacturer’s standard epoxy system for continuous submergence in corrosive water.


A. Perform manufacturer’s standard pump tests on each unit.

B. Submersible Motor Functional Test: In accordance with HIS 11.6.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install in accordance with manufacturer’s printed instructions.

B. Mount discharge elbows to floor slab with stainless steel anchor bolts.

C. Connect piping without imposing strain to flanges.

D. No portion of discharge elbow-mounted pumps shall bear directly on floor of sump.




A. Functional Test: Conduct on each pump.

1. Alignment: Test complete assemblies for correct rotation, proper alignment and connection, and quiet operation.

2. Flow Output: Measured by plant instrumentation and storage volumes. 3. Test for continuous 1-hour period.



1. 2 person-days for installation assistance and inspection. 2. 1 person-day for functional testing, training of Owner’s personnel, and

completion of Manufacturer’s Certificate of Proper Installation.

B. See Section 01 43 33, Manufacturers’ Field Services, and Section 01 91 14, Equipment Testing and Facility Startup.

END OF SECTION


PW/WBG/179201 SUBMERSIBLE SUMP PUMP OCTOBER 2018 44 42 56.18 - 1 ©COPYRIGHT 2018 CH2M HILL

SECTION 44 42 56.18 SUBMERSIBLE SUMP PUMP

EQUIPMENT NUMBER 60-P-191 Sump Pump PART 1 GENERAL

1.01 DEFINITIONS

A. Terminology pertaining to pumping unit performance and construction shall conform to the ratings and nomenclature of the Hydraulic Institute Standards.

1.02 SUBMITTALS

A. Shop Drawings:


identification of materials of construction. 3. Performance data curves showing head, capacity, and horsepower

demand over the entire operating range of the pump, from shutoff to maximum capacity. Indicate separately the head, capacity, and horsepower required at the guarantee point.

4. Power and control wiring diagrams, including terminals and numbers. 5. Complete motor nameplate data, as defined by NEMA, from motor

manufacturer, and including any motor modifications. 6. Factory finish system. 7. Assembly and installation drawings.

B. Quality Control Submittals:

1. Manufacturer's printed installation instructions. 2. Suggested spare parts list to maintain the equipment in service for a

period of 5 years. Include a list of special tools required for checking, testing, parts replacement, and maintenance with current price information.


4. Operation and maintenance manual.


SUBMERSIBLE SUMP PUMP PW/WBG/179201 44 42 56.18 - 2 OCTOBER 2018 ©COPYRIGHT 2018 CH2M HILL

PART 2 PRODUCTS

2.01 MANUFACTURERS AND PRODUCTS

A. Hydromatic Pump; Model SD50.

B. PACO Grundfos; Model PIP701C.

C. Or equal.

2.02 SERVICE CONDITIONS

A. Liquid Pumped: Plant effluent and/or rain water.

B. Pumping Temperature: 32 to 80 degrees F.

2.03 PERFORMANCE REQUIREMENTS

A. Rated Condition: Minimum 30 gpm at 20 feet TDH.

B. Minimum Shutoff Head: 29 feet.

C. Maximum Motor Speed: 1,750 rpm.

D. Maximum Horsepower: 0.5 (maximum) at any pumping head up to shutoff condition.

2.04 CONSTRUCTION DETAILS

A. Pump Configuration: Submersible, nonclog type, bottom suction, 1-1/2-inch minimum solids handling, NPT discharge connection.

B. Materials:

1. Motor Housing and Pump Casing: Cast iron. 2. Impeller: Cast iron; recessed vortex or semi-open nonclog design. 3. Shaft: Nickel plated steel or stainless steel. 4. Fasteners: Stainless steel.

C. Shaft Seal: Mechanical type, carbon/ceramic seal faces, all parts of corrosion resistant materials.

D. Motor:

1. Oil filled, 1/2-hp maximum, 115-volt, single-phase, 60 Hz, automatic reset thermal overload protection on motor windings.


PW/WBG/179201 SUBMERSIBLE SUMP PUMP OCTOBER 2018 44 42 56.18 - 3 ©COPYRIGHT 2018 CH2M HILL

2. Rated for at least 10 starts per hour. 3. Factory-wired 10-foot length submersible power cable with integral

float switch and “piggyback” plug.

2.05 ACCESSORIES

A. Equipment Identification Plate: 16-gauge stainless steel with 1/4-inch die-stamped equipment tag number securely mounted in a readily visible location.


A. Manufacturer's standard epoxy lining and coating.


A. Functional Test: Perform manufacturer's standard test on equipment.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install in accordance with manufacturer's printed instructions.


A. Functional Test: Test complete assembly for proper connection and quiet operation.

B. Performance Test: Confirm that flow output approximately matches the published performance curve.

END OF SECTION

VOLUME 3 STANDARD DETAILS

(BOUND SEPARATELY)

VOLUME 4 DRAWINGS

(BOUND SEPARATELY)

VOLUME 5 GEOTECHNICAL REPORTS

(BOUND SEPARATELY)

DESIGN CERTIFICATION - Tracy · 2018. 10. 24. · DESIGN CERTIFICATION The Plans and Technical...

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