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20-0218_CALPROMAX ENGINEERING, INC._Technical SpecificationsSAN JUAN HILLS GREENS 1 TS-TOC CORROSION PROTECTION SYSTEM CITY OF SAN JUAN CAPISTRANO CIP #17801 SAN JUAN HILLS GREENS CORROSION PROTECTION SYSTEM TABLE OF CONTENTS TECHNICAL SPECIFICATIONS Section Description 01010 Summary of Work 01015 General Provisions 01030 Measurement and Payment 01035 Mobilization and Demobilization 01045 Existing Facilities 01300 Submittals 01340 Shop Drawings and Materials Submittals 01400 Quality Control 01610 Transportation of Materials 01710 Clean-Up 02200 Structure Earthwork 02223 Trenching, Backfilling, and Compacting 03300 Concrete 03305 Concrete Paving 03462 Precast Concrete Vaults 09900 Painting and Coating 15089 Combination Air Release and Vacuum Relief Valve Assembly 16640 Cathodic Protection and Joint Bonding San Juan Hills Greens Corrosion Protection System, CIP 17801 THIS PAGE IS LEFT INTENTIONALLY BLANK SAN JUAN HILLS GREEN 2 Summary of the Work CORROSION PROTECTION SYSTEM 01010 SECTION 01010 SUMMARY OF THE WORK PART 1 - GENERAL A. WORK UNDER THIS CONTRACT AGREEMENT The Work to be performed under this Contract shall consist of furnishing all tools, equipment, materials, supplies, and manufactured articles; and furnishing all labor, transportation, and services, including fuel, power, water, and essential communications; and performing all work, or other operations required for the fulfillment of the Contract in strict compliance with the Contract Documents. The Work shall be complete, and all work, materials, and services not expressly indicated or called for in the Contract Documents which may be necessary for the complete and proper construction of the Work in good faith shall be provided by the CONTRACTOR as though originally so indicated, at no increase in cost to the OWNER. B. DESCRIPTION OF WORK The San Juan Hills Greens – Corrosion Protection System, as per plans and this specification, provides for the following: 1. Demolition of, but not limited to the following: a. Removal and replacement of sidewalk and asphalt paving if damaged. b. Removal and replacement of existing damaged 5/8-inch or 1-inch meter boxes with 1-inch meter boxes. c. Removal and replacement of existing damaged 2-inch meter boxes with 2- inch meter boxes. d. Removal and replacement in-kind of landscaping damaged in the course of construction. 2. Construction of, but not limited to, the following items: a. Construction of approximately 170 Sacrificial Anodes consisting of 2 – 60 pound magnesium anodes in 16-foot deep by 12-inch diameter anode well; and connection wire from said anodes to water system appurtenances including water service lines, air-vacuum reliefs, blow offs, and fire hydrant laterals. b. Testing and reporting the impressed current potential at all installed Sacrificial Anode installations. The Work is included in a single contract. The major components of the Work include all items shown on the drawings and specifications, to make the facilities complete and operational. C. PERMITS AND ENVIRONMENTAL MITIGATION SAN JUAN HILLS GREENS 3 Summary of the Work CORROSION PROTECTION SYSTEM 01010 1. The CONTRACTOR shall comply with the all construction requirements of the City of San Juan Capistrano. Bonding fees and inspection permit fees required by the City shall be paid by the CONTRACTOR and shall include: a. City of San Juan Capistrano Encroachment Permit (Cost $200 per permit); b. Business license as required by the City (Cost $65 plus $5 per employee). c. A haul route permit for disposal of spoils. d. Any other licenses required by the City or other Agencies. 2. Topography, Geology, Seismicity and Soils Mitigation. All earthwork activities shall conform to the California Building Code and Orange County erosion control measures. Slope hazard and erosion mitigation measures, as defined in the Orange County General Plan, shall be followed. 3. The CONTRACTOR shall adhere to all pertinent requirements of the City’s NPDES permit. Specifically the Contractor will adhere to the criteria for preparation of a water quality management plan, per the City’s checklist (Guidance for Determining when a WQMP is required), must follow the 2017 BMP Design Manual. A copy of which can be located at: https://cms.ocgov.com/gov/pw/watersheds/documents/wqmp/default.asp In particular: a) Sediments from areas disturbed by construction shall be retained on site using an effective combination of erosion and sediment controls to the maximum extent practicable and stockpiles of soil shall be properly contained to minimize sediment transport from the site to streets, drainage facilities or adjacent properties via runoff, vehicle tracking, or wind. b) Construction-related materials, wastes, spills or residues shall be retained on site to minimize transport from the site to streets, drainage facilities, or adjoining property by wind or runoff. c) Control spoils so no runoff comes in contact with them and could end up in a catch basin. d) Protect the nearest downstream catch basin with fiber rolls or filter fabric so no sediments enter the catch basin. e) No spoil should remain overnight on site. f) Site should be swept from all debris at end of day. SAN JUAN HILLS GREENS 4 Summary of the Work CORROSION PROTECTION SYSTEM 01010 D. CONSTRUCTION COORDINATION 1. In order that the Work shall be ready for use by the City, the work shall be completed within the time frame stated in the Notice Inviting Bids. 2. The CONTRACTOR shall cooperate fully with all utility forces of the OWNER or forces of other public or private agencies engaged in the project in form of relocation, altering, or otherwise rearranging of any facilities which interfere with the progress of the Work, and shall schedule the Work so as to minimize interference with said relocation, altering, or other rearranging of facilities. PARTS 2 AND 3 - PRODUCTS AND EXECUTION (Not applicable to this Section). PART 4 – PAYMENT Payment for the Work in this Section shall be included as part of the lump sum or unit prices bid for which such Work is appurtenant thereto, and no additional payment will be made specifically for the Work in this Section. END OF SECTION SAN JUAN HILLS GREENS 5 General Provisions CORROSION PROTECTION SYSTEM 01015 SECTION 01015 GENERAL PROVISIONS PART 1 - GENERAL A. DESCRIPTION This Section covers general provisions and requirements for the Work and is supplementary to the Conditions of the Contract. B. ORDER OF WORK 1. General. The work shall be carried on at such places on the project and also in such order or precedence as may be found necessary by the OWNER to expedite the completion of the project. After work has begun on any portion or designated part of the project, it shall be carried forward to final completion as rapidly as practicable. 2. Working Hours & Inspection. Per General Conditions. 3. Replacement of any concrete sidewalk, curb, or driveway removed in the course of the week will be made within 2 weeks of the initial removal. C. APPLICABLE CODES This article summarizes without limitation the laws and codes by which the Work has been designed and to which the CONTRACTOR shall conform in the prosecution of the Work. The CONTRACTOR shall make available for their use at the site, such copies of laws, regulations, or codes applicable to the Work as the City may request of him. 1. Laws and Regulations. As specified in Articles of the General Conditions. 2. Codes. a. California Building Code, latest edition, as amended by the latest Supplement. b. Title 8, Industrial Relations, California Administrative Code, Chapter 4, Division of Industrial Safety, Safety Orders. c. Title 19, Public Safety, California Administrative Code, State Fire Marshall. d. Title 24, California Administrative Code, Electrical Safety Orders. e. Local Plumbing Code. SAN JUAN HILLS GREENS 6 General Provisions CORROSION PROTECTION SYSTEM 01015 f. The National and Local Electrical Codes. g. National Fire Protection Association. h. State and Local Public Health Codes. i. California Environmental Quality Act. 3. Specifications. a. Standard Specifications, State of California Business and Transportation Agency, Department of Transportation, latest edition, referred to in the Contract Documents as State Standard Specifications. b. Standard Specifications for Public Works Construction, latest edition, complete with all subsequent editions of ERRATA and REVISED INDEX Supplements, adopted by Southern California Joint Committee of APWA-AGC. c. The City of San Juan Capistrano Standard Drawings, latest edition. d. Standard Specifications of the County of Orange. D. ABBREVIATIONS (AS APPLICABLE OR WHERE REFERENCED) This article summarizes without limitation the abbreviations and symbols used in the Contract Documents. Abbreviations used in the Contract Documents shall be interpreted according to their recognized and well-known technical or trade meanings; such abbreviations include, but are not limited to, the following: AASHTO American Association of State Highway and Transportation Officials ACI American Concrete Institute AISC American Institute of Steel Construction, Inc. AISI American Iron and Steel Institute ANSI American National Standards Institute APWA American Public Works Association ASCE American Society of Civil Engineers ASME American Society of Mechanical Engineers ASTM American Society of Testing and Materials AWS American Welding Society AWWA American Water Works Association CEQA California Environmental Quality Act CLFMI Chain Link Fencing Manufacturers Institute CS Commercial Standard, US Department of Commerce FedSpec Federal Specification HI Hydraulics Institute ICBO International Conference of Building Officials IEEE Institute of Electrical and Electronic Engineers SAN JUAN HILLS GREENS 7 General Provisions CORROSION PROTECTION SYSTEM 01015 IPCEA Insulated Power Cable Engineers Association MIL Military Specification (leading symbol) MSS Manufacturers Standardization Society of the Valve and Fittings Industry NEC National Electrical Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association OSHA Occupational Safety and Health Administration, US Department of Labor, as defined in the General Conditions PCA Portland Cement Association UBC Uniform Building Code UL Underwriter's Laboratories, Inc. PART 2 - PRODUCTS (Not applicable to this Section.) PART 3 - EXECUTION A. PROJECT MEETINGS 1. Attendees. Unless otherwise specified or required by the OWNER, the meetings shall be attended by the OWNER, the ENGINEER, and the CONTRACTOR and its Superintendent. Subcontractors may attend when involved in the matters to be discussed or resolved but only when requested by the OWNER. 2. Meeting Records. The Engineer will record minutes of each meeting and will furnish copies to the CONTRACTOR thereafter. If the CONTRACTOR does not submit written objection to the contents of such minutes within seven (7) days after presentation to it, it shall be understood and agreed that the CONTRACTOR accepts the minutes as a true and complete record of the meeting. 3. Meeting Schedule. The dates, times, and locations for the various meetings shall be agreed upon and recorded at the pre-construction conference. Thereafter, changes to the Schedule shall be by agreement between the OWNER and the CONTRACTOR, with appropriate written notice to all parties involved. 4. Weekly Safety Meetings. CONTRACTOR shall conduct weekly safety meetings and schedule such meetings in the Critical Path Schedule. To the extent practicable, it shall schedule the weekly safety meeting at a routine time and day from week to week, and provide all personnel at least 3 working days notice of any necessary changes to the meeting date and time. B. PRECONSTRUCTION CONFERENCE Prior to issuance of the Notice to Proceed, a pre-construction conference shall be held at the location, date, and time designated by the OWNER. In addition to the attendees named herein, the meeting shall be attended by the representatives of regulatory agencies having jurisdiction of the Project, if required, and such other persons the OWNER may designate. The CONTRACTOR shall submit its construction schedule and SAN JUAN HILLS GREENS 8 General Provisions CORROSION PROTECTION SYSTEM 01015 a breakdown of the bid items as a schedule of values acceptable to the OW NER, one week prior to the conference to allow time for review. 1. Execution and Submittal of Documents. At the pre-construction conference, unless otherwise agreed to by the OWNER the CONTRACTOR shall present to the OWNER the signed Contract Agreement, bonds, certificates of insurance and all other pre-construction documents required of it by the Contract Documents. 2. Agenda. In general, the matters to be discussed or resolved and the instructions and information to be furnished to or given by the CONTRACTOR at the pre- construction conference include: a. Project meeting schedule. b. Construction plans, progress schedule, schedule of values submitted by CONTRACTOR, and estimated monthly progress payments. c. Communication procedures between the parties. d. The names and titles of all persons authorized by the CONTRACTOR to represent and execute documents for him with samples of all authorized signatures. e. The names, addresses, and telephone numbers of all those authorized by the CONTRACTOR to act for him in emergencies. f. Construction permit requirements, procedures, and posting. g. Public Notice of starting Work. h. Procedures concerning the installation of Work on public or private property. i. Review of construction schedule as it pertains to the interfacing of work by others. j. Access and rights-of-way furnished by the City. k. Forms and procedures for CONTRACTOR's submittals. l. Change Order forms and procedures. m. Payment application forms and procedures and the revised progress schedule reports to accompany the applications. n. Designation of the CONTRACTOR's Safety Officer and his qualifications. o. Description and discussion of CONTRACTOR's proposed safety program. p. First-aid and medical facilities to be furnished by CONTRACTOR. SAN JUAN HILLS GREENS 9 General Provisions CORROSION PROTECTION SYSTEM 01015 q. CONTRACTOR's provisions for barricades, traffic control, utilities, sanitary facilities, and other temporary facilities and controls. r. Project sign for City if required by the Specifications. s. Inspector and his duties. t. Construction surveyor and initiation of surveying services, if necessary. u. Testing laboratory or agency, and testing procedures. v. Construction equipment and methods proposed by the CONTRACTOR. w. Procedures for payroll and labor cost reporting by the CONTRACTOR. x. Procedures to ensure nondiscrimination in employment on and for the Work. y. Permit and mitigation measures. z. Issuance of the Notice to Proceed. aa. Health and Safety Plan. ab. Haul Routes. ac. Other administrative and general matters as needed. C. PROGRESS MEETINGS The meetings shall be held in accordance with the agreed schedule as stated in Paragraph 3.1-C, of this Section. All matters bearing on the progress and performance of the Work since the preceding progress meeting shall be discussed and resolved, including without limitation any previously unresolved matters, deficiencies in the Work or the methods being employed for the Work, and problems, difficulties, or delays which may be encountered. D. REGULATORY AGENCIES When requested, the CONTRACTOR shall attend meetings held or required by the governmental regulatory agencies having jurisdiction of the Project. E. POSTCONSTRUCTION CONFERENCE A post-construction conference shall be held prior to final inspection of the Work to discuss and resolve all unsettled matters. The Bonds and insurance shall remain in force, and the other documents required to be submitted by the CONTRACTOR shall be reviewed and any deficiencies determined. Schedules and procedures for the final inspection process, and for the correction of defects and deficiencies, shall be discussed and agreed. SAN JUAN HILLS GREENS 10 General Provisions CORROSION PROTECTION SYSTEM 01015 F. TEMPORARY FACILITIES AND CONTROLS. 1. Requirements of Regulatory Agencies. Make all necessary arrangements, secure required permits, and pay all fees and charges required by public authorities where temporary facilities or controls are located on public property. The CONTRACTOR shall comply with the requirements of Orange County, City, or State laws and ordinances. 2. Working Areas. Drawings indicate the areas furnished or owned by OWNER for prosecution of the Work. All work shall be restricted to stay within those limits. The CONTRACTOR shall keep all areas clean, orderly, and free of hazards, and leave the areas in a clean and safe condition acceptable to OWNER, and relevant governing public authorities. 3. Construction Utilities. Water supplied by the OWNER will be supplied to the CONTRACTOR at construction water rates through a hydrant meter and approved backflow device. The CONTRACTOR, at its expense, shall furnish and install all temporary piping facilities or equipment required to convey the water from the OWNER’s delivery points to the locations where water is needed for testing purposes. The CONTRACTOR shall make application to the OWNER for temporary water connections and approved backflow devices. 4. Disposal. The CONTRACTOR shall dispose of excess spoils off site at a properly constructed and maintained disposal or recycling facility. All other construction debris shall be legally disposed of offsite. 5. Access to Work. The OWNER, its inspectors, agents, and other employees, shall at all times and for any purpose have access to the work and the premises used by the CONTRACTOR, and the CONTRACTOR shall provide safe and proper facilities therefor. 6. Preservation of Property. Due care shall be exercised to avoid damage to existing improvements, adjacent property, and trees and shrubbery that are not to be moved. Trees and shrubbery that are not to be removed, poles, fences, signs, property corners, all underground pipe and conduit, and other improvements within or near the work area shall be protected from injury or damage. If such objects, or improvements, are injured or damaged by reason of the CONTRACTOR's operations, they shall be replaced or restored, at the CONTRACTOR's sole expense, to a condition as good as, or better than, when the CONTRACTOR entered upon the work. 7. Survey Monuments. The CONTRACTOR shall not disturb any monuments or survey markers without permission from the OWNER, and he shall bear the expense of resetting any monuments or survey markers which may be disturbed without permission. The CONTRACTOR shall restore the monuments or survey markers disturbed or destroyed during contraction, under the direction of a California licensed land surveyor. The CONTRACTOR shall closely coordinate with the City during this Work. 8. Archaeological Findings. If the discovery of a potential archeological or historical resource occurs during construction, all work in the area of the archeological find SAN JUAN HILLS GREENS 11 General Provisions CORROSION PROTECTION SYSTEM 01015 shall stop and a qualified archeologist will be called in to evaluate the situation and make recommendations to the Cultural Resources Officer of the State of California. The Cultural Resources Officer will then determine what will be necessary for construction to proceed. Work outside the find area may continue. If work cannot continue elsewhere, then equipment must be completely shut down and contractor must have to delay work for several days, or fraction thereof, to allow the local Archaeologist the opportunity for the treatment and management of the archaeological materials. A line item is included in the contract for idle equipment in this event. 9. Observing Ordinances. The CONTRACTOR shall observe all the laws and ordinances of City, County or State, where applicable, in relation to the obstruction of streets and driveways, keeping open passageways and protecting the same where they are exposed and would be dangerous to travel. During the time that travel is allowed on the street or alley, it shall provide suitable access to adjoining private property. 10. The CONTRACTOR shall notify by printed notice in the format which has been approved by the OWNER, the occupants of all properties within the construction zone of any water line shut downs and limitations that will be created by the construction, a minimum of two working days in advance of the commencement of such construction. This notice shall be approved and signed by the OWNER, but prepared and distributed by the CONTRACTOR. 11. Traffic Control. The CONTRACTOR shall be aware that transportation of any heavy construction equipment and/or materials which requires the use of over - sized transport vehicles on State highways will require a Caltrans transportation permit. Such a permit may require that truck trips be limited to off-peak commute periods. The CONTRACTOR shall conduct its operations in such a manner as to provide reasonable access to the adjacent properties and shall have no greater length or quantity of work under construction than it can properly prosecute with a minimum of inconvenience to the public and other CONTRACTORs engaged on adjacent or related work. Safe temporary vehicular and pedestrian access to the affected properties and residences in the project area shall be maintained at all times during the construction of the project. Where driveways must be temporarily blocked during construction, the following restrictions shall apply:  No driveways shall be blocked between the end of work one day, and the beginning of work on the next business day. In the event the home owner requires passage across a blocked driveway CONTRACTOR will temporarily move equipment as required.  Where sites have more than one driveway, only one driveway at any one time may be blocked during construction.  Traffic control for work sites will be provided per the recommendations of the California Manual on Uniform Traffic Control Devices (CA MUTCD). SAN JUAN HILLS GREENS 12 General Provisions CORROSION PROTECTION SYSTEM 01015 The CONTRACTOR shall notify by printed notice, the occupants of all properties within the construction zone of any access, parking and circulation restrictions and limitations that will be created by the construction a minimum of two working days in advance of the commencement of construction. This notice shall be approved and signed by the OWNER, but prepared and distributed by the CONTRACTOR. G. PERMITS The CONTRACTOR shall comply with all permit requirements of the City and all other involved agencies, and all costs therefore shall be included in the prices bid. H. COOPERATION BETWEEN CONTRACTORS The CONTRACTOR is hereby notified that the OWNER may award contracts for other work in the project areas. Where two or more CONTRACTORs are employed on related or adjacent work, each shall conduct its operations in such a manner as not to cause unnecessary delay or hindrance to the other. Each CONTRACTOR shall be responsible to the other for all damage to work, person, or property, or for loss caused by failure to finish within the time specified for completion, at no additional cost to the OWNER. I. TAXES The CONTRACTOR shall be responsible for payment of and shall pay any and all taxes, which are applicable to the Work. J. AS-BUILT DRAWINGS The CONTRACTOR shall record the exact location, by dimension, and the exact depth, by elevation, of any each installed anode from a readily observable and determinate surface features. All information necessary to maintain and/or service any concealed work shall be noted on these record drawings. This data shall be legibly recorded in one set of bond prints to the satisfaction of the Engineer. Records shall be kept up-to-date and kept on-site with all entries checked by the Engineer before the work is buried or covered. All changes in or additions to the contract drawings shall be noted on the as-built prints. These drawings shall be delivered to the OWNER upon completion of the job. K. PRIVATE OWNERS' RELEASE CONTRACTOR shall provide to the OWNER a written release by the owner of any property used or damaged by CONTRACTOR in conjunction with the project prior to completion of the project stating that the property has been cleaned up, repaired or restored to its original condition. PART 4 - PAYMENT SAN JUAN HILLS GREENS 13 General Provisions CORROSION PROTECTION SYSTEM 01015 Payment per the General Conditions. END OF SECTION SAN JUAN HILLS GREENS 14 Measurement and Payment CORROSION PROTECTION SYSTEM 01030 SECTION 01030 MEASUREMENT AND PAYMENT PART 1 - GENERAL A. DESCRIPTION This Section summarizes requirements for prices to be submitted in the bids, defines work items, and describes measurement. B. PRICES REQUIRED In the appropriate places in the Bid Form, each Bidder shall quote unit prices and lump sum prices on the following items of Work in the units stated. Failure to quote on each price item may cause rejection of the Bidder's entire bid at the discretion of the OWNER. 1. Unbalanced Prices. Proposed prices which are so unbalanced as to be detrimental to the OWNER’s interest may be rejected or cause rejection of the Bidder's entire Bid, at the discretion of the OWNER. 2. Costs Included. Each proposed price shall cover all costs and charges including without limitation the costs of permits, sawcutting of all trench sections, 100% imported bedding, compacting in 8” lifts with no jetting or hydro-consolidation, material, labor, fabrication, delivery, installation or application, supervision, bond and insurance charges, overhead, profit, and taxes. Quoted prices shall be the exact amount per unit to be applied to the units of Work actually provided for the purpose of establishing the payment to the CONTRACTOR. 3. Duration of Prices. Quoted prices accepted by the OWNER shall be held good and in effect until the work is completed and accepted by the OWNER, unless modified by a Change Order. C. MEASUREMENT, PAYMENT, AND DEFINITIONS This Section defines the work items and the manner and method of measurement and payment for all items included in the Contract. Separate payments will not be made for any work under the Contract other than under the items in the Bid Schedule and payments provided for by approved Change Order. For all work specified and shown on the Drawings, it shall be the CONTRACTOR's responsibility to include those costs among the specified Bid Schedule items. In this respect, the cost of such items as safety provisions, submittals on materials and equipment, testing, clean-up, corrections through the Guaranty Period, and all related items required, shall be distributed by Bidders among the Bid items. The bid items reflect the actual payment for all labor, equipment, and materials to provide a complete work for the project. Any work required for the satisfactory completion of the project which is not itemized shall be considered incidental to the bid items. 1. Bid Item 1. Mobilization and Demobilization. (Total for this item shall not exceed 5% of Total Bid;) complete, shall be paid for as a lump sum item. SAN JUAN HILLS GREENS 15 Measurement and Payment CORROSION PROTECTION SYSTEM 01030 Such lump sum payment shall constitute full compensation for Mobilization and Demobilization. (Total for this item shall not exceed 5% of Total Bid; Mobilization shall not exceed 3%) complete. 2. Bid Item 2. City of San Juan Business License shall be paid for as a lump sum item. Such lump sum payment shall constitute full compensation for Applying for and Acquisition a License and Encroachment Permits, as required by State and Local Agencies; including but not limited to those listed in section 01010 (1) (C ) of these Specifications. 3. Bid Item 3. Sacrificial Anode per detail 1 on sheet CP-1, and connect to adjacent appurtenances per construction note C1, as detailed on the drawings and details. This item shall be paid for as a unit cost item. Such unit cost payment shall constitute full compensation for Sacrificial Anode and connections, where applicable. 4. Bid Item 4. Sacrificial Anode per detail 2 on sheet CP-2 and connect to adjacent appurtenance(s) per construction note C2, as detailed on the drawings and details. This item shall be paid for as a unit cost item. Such Unit cost payment shall constitute full compensation for Sacrificial Anode and connections, where applicable 5. Bid Item 5. Sacrificial Anode per detail 3 on sheet CP-3 and connect to adjacent appurtenance(s) per construction note C3, as detailed on the drawings and details. This item shall be paid for as a unit cost item. Such Unit cost payment shall constitute full compensation for Sacrificial Anode and connections, where applicable. 6. Bid Item 6. Sacrificial Anode per detail 4 on sheet CP-4 and connect to adjacent appurtenance(s) per construction note C4, as detailed on the drawings and details. This item shall be paid for as a unit cost item. Such Unit cost payment shall constitute full compensation for Sacrificial Anode and connections, where applicable. 7. Bid Item 7. Sacrificial Anode per detail 5 on sheet CP-5 and connect to adjacent appurtenance(s) per construction note C5, as detailed on the drawings and details. This item shall be paid for as a unit cost item. Such Unit cost payment shall constitute full compensation for Sacrificial Anode and connections, where applicable. SAN JUAN HILLS GREENS 16 Measurement and Payment CORROSION PROTECTION SYSTEM 01030 8. Bid Item 8. Sacrificial Anode per detail 7 on sheet CP-6 and connect to adjacent appurtenance(s) per construction note C6, as detailed on the drawings and details. This item shall be paid for as a unit cost item. Such Unit cost payment shall constitute full compensation for Sacrificial Anode and connections, where applicable. 9. Bid Item 9. Furnish all labor, materials and equipment for Replacement of Sidewalks caused to be removed in the course of construction Complete and Operational, shall be paid for per square foot concrete replaced. Such payment shall constitute full compensation for furnishing all labor, materials and equipment for Replacement of Sidewalks caused to be removed in the course of construction complete and operational. 10. Bid Item 10. Furnish all labor, materials and equipment to Install 1-inch Meter Boxes Complete and Operational, shall be paid for per unit. Such Unit cost payment shall constitute full compensation for furnishing all labor, materials and equipment to install 1” Meter Boxes complete and operational, including excavation, installation, backfill and compaction, complete and operational. 11. Bid Item 11. Furnish all labor, materials and equipment to Install 2-inch Meter Boxes Complete and Operational, shall be paid for per unit. Such Unit cost payment shall constitute full compensation for furnishing all labor, materials and equipment to install 1” Meter Boxes complete and operational, including excavation, installation, backfill and compaction, complete and operational. 12. Bid Item 12. Furnish all labor, materials and equipment for Installation of Replacement of Damage to Landscape Caused in the Course of Anode, Meter Box, and or Connection to the Line Installation, Complete, shall be paid for as a Lump Sum. Such lump sum payment shall constitute full compensation for furnishing all labor, materials and equipment for Installation of Replacement of Damage to Landscape Caused in the Course of Anode, Meter Box, and or Connection to the Line Installation, Complete, including excavation, trenching, installation, backfill and compaction, complete and operational. 13. Bid Item 13. Delay of work due to the discovery of artifacts, cultural deposits, of fossils per Section 01015.3.F.8, shall be paid on a unit basis. Such Unit cost payment shall constitute full compensation for any delay to work per Section 01015.3.F.8. 14. Bid Item 14. Furnish all labor, materials and equipment to install Dielectric Unions at copper services per section 16640.2.G, shall be paid per unit. SAN JUAN HILLS GREENS 17 Measurement and Payment CORROSION PROTECTION SYSTEM 01030 Such Unit cost shall constitute full compensation for furnishing all labor, materials and equipment for installation of Dielectric Unions at required locations. 15. Bid Item 15. Furnish all labor, materials and equipment to install 2-inch Traffic Rated Meter Boxes Complete and Operational, shall be paid for per unit. Such Unit cost payment shall constitute full compensation for furnishing all labor, materials and equipment to install 1” Traffic Rated Meter Boxes complete and operational, including excavation, installation, backfill and compaction, complete and operational. 16. Bid Item 16. Furnish all labor, materials and equipment to Install Traffic Rated 2- inch Meter Boxes Complete and Operational, shall be paid for per unit. Such Unit cost payment shall constitute full compensation for furnishing all labor, materials and equipment to install 1” Traffic Rated Meter Boxes complete and operational, including excavation, installation, backfill and compaction, complete and operational. D. WORK NOT LISTED IN THE SCHEDULE OF WORK ITEMS 1. The General Specifications and items in the Special Provisions, general requirements, and Specifications which are not listed in the schedule of work items of the bid are, in general, applicable to more than one listed work item, and no separate work item is provided therefore. Include the cost of Work not listed but necessary to complete the Project designated in the Contract Documents in the various listed work items on the bid. 2. The bid for the Work is intended to establish a total cost for the Work in its entirety. Should the CONTRACTOR feel that the cost for the Work has not been established by specific items in the bid, include the cost for that Work in some related bid item so that the bid reflects the total cost for completing the Work in its entirety. PART 2 - PRODUCTS (Not applicable to this section) PART 3 - EXECUTION (Not applicable to this section) END OF SECTION SAN JUAN HILLS GREENS 18 Mobilization and Demobilization CORROSION PROTECTION SYSTEM 01035 SECTION 01035 MOBILIZATION AND DEMOBILIZATION PART 1 - GENERAL A. DESCRIPTION This Section covers the requirements for mobilization and demobilization. The requirements specified in Conditions of the Contract and in Division 1 also form a part of this Section. 1. Work Included. Mobilization is the work preparatory to the construction of the San Juan Hills Greens – Sacrificial Anode Installation, and demobilization is the final cleanup of project work areas and removal of all equipment and temporary facilities provided by the CONTRACTOR. Mobilization includes execution of the contract; submittal of all required evidence of insurance; submittal of the Work Schedule, breakdown of lump sum bid items; submittal of the list of principal equipment proposed for use in the construction; the establishment of the CONTRACTOR's yard; the obtaining of all required permits; the established presence of the CONTRACTOR's Superintendent and/or Project Manager on-site; General Provisions; the beginning of the marshaling of major construction equipment and erection and service of temporary facilities. Demobilization includes all work at the end of construction to clean up the site and remove all equipment and temporary facilities as shown and specified. B. SUBMITTALS Prior to the payment for Mobilization, the CONTRACTOR shall submit the following documents to the ENGINEER for approval.  Certificate of Insurance  Work Schedule  Breakdown of Bid Items as schedule of values, and other items as requested by the OWNER  List of major equipment proposed for the construction  Copy of required permits  The resume of the Superintendent and/or On-Site Project Manager nominated for the project PART 2 - PRODUCTS (Not Applicable) PART 3 - EXECUTION Mobilization will be considered complete and eligible for payment when all submittals have been made and approved by the OWNER; the CONTRACTOR's field or offsite SAN JUAN HILLS GREENS 19 Mobilization and Demobilization CORROSION PROTECTION SYSTEM 01035 offices set up on site or offsite, the CONTRACTOR's storage yard established; the Superintendent is in residence in the CONTRACTOR's field office; the first piece of major equipment has been brought to the site, ready for work, and the set-up and an operational field office for the OWNER, ENGINEER, and/or Inspector. Demobilization will be considered complete when all the above listed facilities are removed and the project work areas have been cleaned up to the satisfaction of the OWNER. PART 4 - PAYMENT Payment for the Work in this Section shall be included as part of the lump sum or unit price bid for which such Work is appurtenant thereto and no additional payment will be made specifically for the Work in this Section. END OF SECTION SAN JUAN HILLS GREENS 20 Existing Facilities CORROSION PROTECTION SYSTEM 01045 SECTION 01045 EXISTING FACILITIES PART 1 - GENERAL A. DESCRIPTION This section includes requirements for connection to and abandonment of existing water facilities. B. RELATED WORK All related work specified elsewhere, or in other codes or standards, will be as last revised, unless a specific date of issuance is called out in opposition to later revision date(s). Other sections of the technical specifications, not referenced below, shall also apply to the extent required for proper performance of this work. 1. Trenching, Backfilling, and Compacting: 02223 C. CONDITION OF EXISTING FACILITIES The City does not warranty the condition, size, material, and location of existing facilities. D. LOCATION The contractor shall be responsible for potholing and verifying in advance the location of all existing pipelines as shown on the plans. Discrepancies shall be reported to the project engineer, prior to the fabrication of, or purchase of material affected by the discrepancy. E. PROTECTION OF EXISTING UTILITIES AND FACILITIES 1. The contractor shall be responsible for the care and protection of all existing sewer pipe, water pipe, gas mains, culverts, power or communications lines, side walks, curbs, pavement, or other facilities and structures that may be encountered in or near the area of the work. 2. It shall be the duty of the contractor to notify Underground Service Alert and each agency of jurisdiction and make arrangements for locating their facilities prior to beginning construction. 3. In the event of damage to any existing facilities during the progress of the work and of the failure of the contractor to exercise the proper precautions, the contractor will pay for the cost of all repairs and protection to said facilities. The contractor's work may be stopped until repair operations are complete. 4. Prior to the use SAN JUAN HILLS GREENS 21 Existing Facilities CORROSION PROTECTION SYSTEM 01045 F. PROTECTION OF LANDSCAPING 1. The contractor shall be responsible for the protection of all the trees, shrubs, fences, and other landscape items adjacent to or within the work area, unless directed to do otherwise on the plans. 2. In the event of damage to landscape items, the contractor shall replace the damaged items in a manner satisfactory to the City Representative and the property owner. 3. When the proposed pipeline is to be within planted or other improved areas in public or private easements, the contractor shall restore such areas to the original condition after completion of the work. This restoration shall include grading, a placement of 5 inches of good topsoil, new sod, and replacement of all landscape items indicated. G. PERMITS All work shall conform to the specifications and requirements of the State of California Department of Transportation, the Orange County PFRD, the city having jurisdiction, or the other affected agencies involved. The contractor shall keep a copy of all the required permits in the job site and comply with all the terms and conditions of said permits. PART 2 - MATERIALS A. GROUT Grout shall consist of Portland cement and water; or, of Portland cement, sand, and water. All grout mixtures shall contain 2% of bentonite by weight of the cement. Portland cement, water and sand shall conform to the applicable requirements of the concrete section (Section 03300), except that sand used shall be of such fineness that 100% will pass a standard 8-mesh sieve and at least 45%, by weight, will pass a standard 40-mesh sieve. B. BENTONITE Bentonite shall be a commercial-processed powdered bentonite, Wyoming type, such as Imacco-gel, Black Hills, or equal. All materials used in making the connection to the facilities shall conform to the applicable sections of these specifications. PART 3 - EXECUTION A. CONNECTION TO EXISTING WATER LINES 1. The contractor shall make all connections unless shown otherwise on the plans or specified herein. 2. The contractor shall furnish all and materials including furnishing all labor and equipment necessary to make the connections, all required excavation, backfill, pavement replacement, lights, and barricades, and may be required to include a SAN JUAN HILLS GREENS 22 Existing Facilities CORROSION PROTECTION SYSTEM 01045 water truck, high line hose, and fittings as part of this equipment for making the connections. In addition, the contractor shall assist the City in alleviating any hardship incurred during the shutdown for connections if required. The City Representative may require standby equipment or materials. 3. Not applicable. 4. Not applicable. B. Not applicable. PART 4 - PAYMENT Payment for the Work in this Section shall be included as part of the lump sum or unit price bid for which such Work is appurtenant thereto and no additional payment will be made specifically for the Work in this Section. END OF SECTION SAN JUAN HILLS GREENS 23 Submittals CORROSION PROTECTION SYSTEM 01300 SECTION 01300 SUBMITTALS PART 1 - GENERAL A. DESCRIPTION 1. Submittals of documents described in the Contract Documents, and hereinafter are required prior to, during and at the end of the construction period. The submittals shall conform to the requirements described in this Section and all referenced Sections or Articles. B PROCEDURE 1. Submittals within 10 days after the effective date of the Agreement: Submit the following items within 10 days after the Effective Date of the Agreement: a. Preliminary Construction Schedule: Prepare and submit in accordance with Section 01310, Construction Schedule. b. Preliminary Submittal Schedule: Prepare and submit schedule for the submittal of all Shop Drawings, product data and samples in accordance with Section 01340, Shop Drawing Procedures. Form is included in this Section. 2. Submittals within 10 days after the effective date of the Agreement: Submit the following items within 10 days after the Effective Date of the Agreement. a. Construction Schedule: Prepare and submit in accordance with Section 01310, Construction Schedule. b. Submittal Schedule: Prepare and submit schedule for the submittal of all Shop Drawings, product data and samples in accordance with Section 01340, Shop Drawing Procedures. Form is included in this Section. c. Monthly payment schedule. 3. Submittals Prior to Beginning The Work: Reference the Standard Form of Construction Agreement in the Contract Documents. 4. Submittals During Construction: During progress of the construction, make the following submittals in a timely manner to prevent any delay in the Work schedule: a. Updates to Construction Schedule: Provide an assessment of Work progress in relation to the Construction Schedule in accordance with Section 01310, Construction Schedule. b. Shop Drawings, Product Data and Samples: Submit Shop Drawings, product data and samples in accordance with Section 01340, Shop Drawing Procedures, and as required in various Sections of the Specifications. c. Progress Payments: Submit applications for partial payments as specified in the Construction Agreement. SAN JUAN HILLS GREENS 24 Submittals CORROSION PROTECTION SYSTEM 01300 d. Request for Information: The CONTRACTOR shall retain 1 copy and submit 3 copies to the PWD for response. Form is included in this Section. Submit a Request for Information when any of the following are required: 1. An interpretation of the Specifications. 2. Additional details. 3. Information not shown on the Drawings or in the Specifications. 4. Clarification of discrepancies. e. Change Orders: Forms are included in this Section. Whenever the City determines the need for a Change Order, the CONTRACTOR will receive a Request for Change Order Proposal Form, included in this Section. Upon receipt of a Request for Change Order Proposal Form or when the CONTRACTOR determines the need for a Change Order, the CONTRACTOR shall prepare and submit 3 copies of a Change Order Proposal in accordance with the Construction Agreement. The Change Order Proposal, included in this Section, must be in writing and must include sufficient information to assess the need for a change in the Work, the Contract time or the Contract amount. The Change Order Proposal must be approved by the CONTRACTOR, and PWD. When a Change Order Proposal is acceptable to the PWD, a Change Order will be prepared and executed. The CONTRACTOR is not authorized to begin Work on a Change Order until it is fully executed. Any Work done by the CONTRACTOR prior to execution of a Change Order is entirely at his own risk. f. CONTRACTOR’S Weekly Report: Use CONTRACTOR’s Form. Submit 1 copy of the CONTRACTOR’S Weekly Report. The CONTRACTOR and each Subcontractor shall prepare and submit a weekly report. The report shall contain, as a minimum, information on the location and description of the Work being performed, size, quantity and description of materials and equipment installed or delivered, coordination or scheduling concerns, requests for clarifications, and any discrepancies noted in the Contract Documents, or on the as-built conditions. The report shall also contain the CONTRACTOR’S daily workforce count by craft, general weather conditions, any Work performed other than during established working hours, and any other pertinent items relative to the Work and as required by the City. The report is due at the City’s office by 9:00 a.m. on the following Tuesday of each week, and shall be signed by a responsible member of the CONTRACTOR’S staff. g. Updates to Submittal Schedule: Submit 3 updated Shop Drawings, Product Data and Samples Submittal Schedule with each month’s Progress Payment Request. h. Construction Photographs: Not applicable. i. Operation and Maintenance Manuals and Lesson Plans: Not applicable. 5. Submittals at Interim Completion: Not applicable. 6. Submittals At Project Closeout: With a written Notice of Completion, submit the following items in the proper form as a condition of Final Acceptance of the Work: a. Guarantees, Warranties and Bonds: Submit as required in the Construction Agreement and listed in various Sections of the Specifications. SAN JUAN HILLS GREENS 25 Submittals CORROSION PROTECTION SYSTEM 01300 b. Survey notes. 7. Attachments: Not applicable. PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION (NOT USED) PART 4 - PAYMENT Payment for the Work in this Section shall be included as part of the lump sum or unit price bid for which such Work is appurtenant thereto and no additional payment will be made specifically for the Work in this Section. END OF SECTION SAN JUAN HILLS GREENS 26 Shop Drawings and Procedures CORROSION PROTECTION SYSTEM 01340 SECTION 01340 SHOP DRAWING PROCEDURES PART 1 - GENERAL A. DESCRIPTION 1. The submittal of Shop Drawings shall conform to requirements of Contract Documents and procedures described in this Section. A separate transmittal form shall be used for each specific item or class of material or equipment for which a submittal is required. Transmittal of Shop Drawings on various items using a single transmittal form shall be permitted only when the items taken together constitute a manufacturer's "package" or are so functionally related that expediency indicates review of the group or package as a whole. The item(s) to be supplied shall be highlighted clearly. 2. The term "Shop Drawing" as used herein shall be understood to include detailed design calculations, fabrication and installation drawings, lists, graphs, test data, operating instructions, and other items which shall include, but not are necessarily limited to: a. Drawings and/or catalog information and cuts. b. Specifications, parts list, suggested spare parts lists, and equipment drawings. c. Wiring diagrams of systems and equipment. d. Complete lubrication, maintenance and operation instructions, including initial startup instructions as described in Section 01731, Instruction of Operations and Maintenance Personnel. e. Applicable certifications. f. Anchor bolt templates, mounting instructions and mounting design calculations as required. g. Required maintenance operations to allow all installed equipment to remain idle for a period of time not to exceed 24 months. h. Other technical, installation, and maintenance data as applicable. i. Unloading and handling methods and storage requirements. j. Note, highlight, and explain proposed changes to the Contract Docu- ments. k. Paint submittal showing type of paint and the mils thickness of coating system used. The coating system shall be the approved system as submitted under Division 9, Finishes. l. Drawings showing CONTRACTOR field verifications illustrating all field dimensions. CONTRACTOR shall field verify all dimensions and existing materials shown on the Drawings. Any modifications required shall be at the CONTRACTOR'S expense. SAN JUAN HILLS GREENS 27 Shop Drawings and Procedures CORROSION PROTECTION SYSTEM 01340 3. Submittal Schedule: The CONTRACTOR, within ten (10) days after the Notice of Award Date, shall prepare and submit to the City a comprehensive Submittal Schedule. The CONTRACTOR shall identify on his Submittal Schedule all of the submittal items required by the Contract Documents governing his Work. The CONTRACTOR shall indicate, for each submittal item on his Submittal Schedule the following: a. Description and Transmittal Number; b. Reference to the applicable paragraph in the Contract Documents in chronological order that requires the submittal; c. The dates the CONTRACTOR proposes to furnish the submittals; d. The dates the materials, equipment, etc. are needed at the job site; and e. The date confirmation of compliance is needed by the CONTRACTOR (a minimum of 30 days from the date the City receives the shop drawing unless otherwise noted in the Contract Documents). f. Whether the submittal is for a deviation or an "equal" item. Complete submittals for all deviations or "equal" items shall be made to the City within 7 calendar days after the Notice of Award. Identification by the CONTRACTOR of deviations or "equal" items does not relieve the CON- TRACTOR of his responsibility to furnish equipment and materials that meet all the requirements of the Contract Documents. 4. In preparing his Submittal Schedule, the CONTRACTOR shall consider the nature and complexity of each submittal item and shall allow ample time for review, revision or correction. Submittals will normally be returned to the CONTRACTOR within 30 calendar days following receipt of the submittal. 5. The City will review the CONTRACTOR'S Submittal Schedule to determine its completeness and compatibility with the Progress Schedule. A Submittal Schedule which is incompatible with the Progress Schedule or a review schedule which places extraordinary manpower demands on the City will be sufficient reason(s) to reject the Submittal Schedule. It shall be understood that certain submittals will take longer than 30 days to review and that these particular submittals will be identified during the submittal, by the PWD to allow for very complex submittal reviews. The CONTRACTOR shall also identify submittals for which he anticipates long review periods. 6. The CONTRACTOR'S Submittal Schedule shall be consistent with the Progress Schedule. 7. City’s acceptance of the Submittal Schedule will be a precondition of the receipt of the first progress payment. B. PROCEDURES 1. All Shop Drawing submittals shall be accompanied by a shop drawing transmittal form. Any Shop Drawing submittal not accompanied by such a form, or where all applicable items on the form are not completed, will be returned for resubmittal. Ultimate responsibility for the accuracy and completeness of the information contained in the submittal shall remain with the CONTRACTOR. If data for more than one Section of the Specifications is submitted, a separate transmittal letter shall accompany the data submitted for each Section. A copy of all transmittal letters shall be sent to the City. SAN JUAN HILLS GREENS 28 Shop Drawings and Procedures CORROSION PROTECTION SYSTEM 01340 2. All letters of transmittal shall be submitted in duplicate. 3. At the beginning of each letter of transmittal, provide a reference heading indicating the following: 1. City’s Name 2. Project Name 3. Contract No. 4. Transmittal No. 5. Section No. 4. If a Shop Drawing deviates from the requirements of the Contract Documents, CONTRACTOR shall specifically note each variation in his letter of transmittal. 5. All Shop Drawings submitted for acceptance shall have a title block with complete identifying information satisfactory to City. 6. All Shop Drawings submitted shall bear the stamp of approval and signature of CONTRACTOR as evidence that they have been reviewed by CONTRACTOR. Submittals without this stamp of approval will not be reviewed by City and will be returned to CONTRACTOR. CONTRACTOR'S stamp shall contain the following minimum information: Project Name: CONTRACTOR'S Name: Date: ----------------Reference--------------- Item: Specifications: Section: Page No.: Para. No.: Drawing No.: of Location: Submittal No.: Approved By: SAN JUAN HILLS GREENS 29 Shop Drawings and Procedures CORROSION PROTECTION SYSTEM 01340 7. A number shall be assigned to each submittal by CONTRACTOR starting with No. 1 and thence numbered consecutively. Resubmittals shall be identified by the original submittal number followed by the suffix "A" for the first resubmittal, the suffix "B" for the second resubmittal, etc. 8. The CONTRACTOR shall initially submit to City a minimum of seven (7) copies of all submittals that are on 8-1/2-inch by 11-inch or smaller sheets, and one unfolded sepia and 6 prints made from that sepia for all submittals on sheets larger than 8-1/2-inch by 11-inch. 9. After PWD completes his review, Shop Drawings will be affixed with a stamp and marked with one of the following notations: a. No Objection. b. No Objection; Make Corrections Noted. c. Make Corrections Noted, Resubmit. d. Non-Conforming. e. Non-Conforming; Submit Conforming Submittal. f. Not Reviewed. g. For Information Only. 10. If a submittal is acceptable, it will be marked "No Objection" or "No Objection; Make Corrections Noted." Four (4) prints or copies of the submittal will be returned to CONTRACTOR. 11. Upon return of a submittal marked "No Objection" or "No Objection; Make Corrections Noted," CONTRACTOR may order, ship or fabricate the materials included on the submittal, provided it is in accordance with the corrections indicated. 12. If a Shop Drawing marked "No Objection; Make Corrections Noted" has extensive corrections or corrections affecting other Drawings or Work, City may require that CONTRACTOR make the corrections indicated thereon and resubmit the Shop Drawings for record purposes. Such Drawings will have the notation, "Make Corrections Noted, Resubmit." The corrected Shop Drawing shall be a pre-condition for payment for the work item of the Shop Drawing. 13. If a submittal is unacceptable, two (2) copies will be returned to CONTRACTOR with one of the following notations: g. "Non-Conforming, Submit Conforming Submittal" b. "Non-Conforming" 14. Upon return of a submittal marked "Non-Conforming; Submit Conforming Submittal," CONTRACTOR shall make the corrections indicated and repeat the initial approval procedure. The "Non-Conforming" notation is used to indicate material and/or equipment that is not acceptable. Upon return of a submittal so marked, CONTRACTOR shall repeat the initial approval procedure utilizing acceptable material and/or equipment. 15. Any related Work performed or equipment installed without a "No Objection" or "No Objection; Make Corrections Noted" Shop Drawing will be at the sole responsibility of the CONTRACTOR. SAN JUAN HILLS GREENS 30 Shop Drawings and Procedures CORROSION PROTECTION SYSTEM 01340 16. Shop Drawings shall be submitted well in advance of the need for the material or equipment for construction and with ample allowance for the time required to make delivery of material or equipment after data covering such is approved. CONTRACTOR shall assume the risk for all materials or equipment which are fabricated or delivered prior to the approval of Shop Drawings. Materials or equipment will not be included in periodic progress payments until approval thereof has been obtained in the specified manner. 17. City will review and process submittals within 30 calendar days following submittal receipt. 18. It is CONTRACTOR'S responsibility to review submittals made by his suppliers and subcontractors before transmitting them to PWD to assure proper coordination of the Work and to determine that each submittal is in accordance with his desires and that there is sufficient information about materials and equipment for PWD to determine compliance with the Contract Documents. Incomplete or inadequate submittals will be returned for revision without review. Each Shop Drawing shall clearly identify what is to be supplied. 19. CONTRACTOR shall furnish required submittals with complete information and accuracy in order to achieve required approval of an item within three submittals. All costs to City involved with subsequent submittals of Shop Drawings, Samples or other items requiring approval will be back charged to CONTRACTOR. Costs shall be determined as follows: C = (D.L.C. x 3.15) + (O.D.C. x 1.10) where: C = Cost for additional reviews D.L.C. = Direct Labor Cost (Hours spent on review x hourly rate of reviewer) O.D.C. = Other Direct Costs (travel, subsistence, etc.) In the event that CONTRACTOR requests a substitution for a previously approved item, all of City’s costs in the reviewing of the substitution will be back charged to CONTRACTOR, unless the need for such substitution is beyond the control of CONTRACTOR. 20. The City reserves the right to withhold monies, up to the limit identified in the Contract Documents, for Shop Drawing reviews beyond those described herein. 21. The City will implement, if requested by the CONTRACTOR, one (1) special Shop Drawing Review Meeting. The purpose of the meeting is to expedite Shop Drawing reviews for the equipment and materials required for the first document SAN JUAN HILLS GREENS 31 Shop Drawings and Procedures CORROSION PROTECTION SYSTEM 01340 of the Work. Requirements of this Section will not be waived but could be expedited. 22. Extension of contract time will not be granted because of CONTRACTOR’S substitutions, or because of the CONTRACTOR’S failure to make timely and correctly prepared and presented submittals with allowance for the checking and review periods. 23. The acceptance of submittals shall not relieve the CONTRACTOR of responsibility for any deviation from the requirements of the Contract Documents or for any revision in resubmittals unless the CONTRACTOR has given notice in writing of the deviation or revision at the time of submission or resubmission and written approval has been given to the specific deviation or revision. Acceptance of submittals shall not relieve the CONTRACTOR of responsibility for error or omissions in the submittal or for the accuracy of dimensions and quantities, the adequacy of connections and the proper and acceptable fitting, execution and completion of the Work. 24. No Work represented by required submittals shall be purchased or commenced until the applicable submittal has been accepted. Work shall conform to the approved submittals and all other requirements of the Contract Documents unless subsequently revised by an appropriate modification, in which case the CONTRACTOR shall prepare and submit revised submittals as may be required. 25. Within thirty (30) days of receiving A No Objection and or AN Objection; Make Corrections Noted of the submittal, the CONTRACTOR shall submit. C. SCHEDULE OF SUBMITTALS 1. A schedule of submittals shall be submitted to the ENGINEER via the CONSTRUCTION MANAGER within 7 calendar days after the date of receipt of the Notice To Proceed from the OWNER. Seven (7) copies of this schedule shall be submitted indicating the CONTRACTOR’S proposed schedule for submitting all submittals. Additionally, the schedule shall reflect the following information for each item. a. Description of Transmittal Number; b. Reference to the applicable paragraph in the Contract Documents in chronological order that requires the submittal; c. The dates the COTNRACTOR proposes to furnish the submittals; d. The dates the materials, equipment, etc. are needed at the job site; and e. The date confirmation of compliance is needed by the CONTRACTOR (a minimum of 14 days from the date the ENGINEER receives the shop drawing unless otherwise noted in the Contract Documents). f. Whether the submittal is for a deviation or an “equal” item, complete submittals of all deviations or “equal” items shall be made to the ENGINEER within 30 calendar days after the CONTRACTOR’S Submittal Schedule is approved by the ENGINEER. Identification by the CONTRACTOR of deviations or “equal” items does not relieve the CONTRACTOR of his responsibility to furnish equipment and materials that meet all the requirements of the plans and specifications. SAN JUAN HILLS GREENS 32 Shop Drawings and Procedures CORROSION PROTECTION SYSTEM 01340 2. In preparing the schedule, the CONTRACTOR shall coordinate it with the Progress Schedule and shall allow a minimum of 14 days for its processing and review by the CONSTRUCTION MANAGER/ENGINEER. Furnishing of the schedule shall not be interpreted as relieving the CONTRACTOR of his obligation to comply with all of the contract requirements for the items listed on the schedule. The CONTRACTOR shall review the listing at least every 30 days and take appropriate action to maintain an effective and updated system and a copy of the schedule shall be maintained at the job site. Seven (7) copies of the revised and/or updated submittal schedule shall be submitted to the ENGINEER at least every 30 days. The CONTRACTOR shall indicate on the schedule those submittals/re-submittals that were added or updated. Payment will not be made for any material or equipment which does not comply with contract requirements. Failure to submit revised and/or updated Submittal Schedule as described will result in suspension of the processing of monthly Progress Payments by the PWD until the revised and/or updated Submittal Schedule is received. 3. Updated shop drawing schedule submittals shall be numbered consecutively as 01341-101, 01341-102, and so on. Resubmittals shall be identified with alpha subscripts as specified in this Section. 4. Submittals shall not be accepted by the ENGINEER until the submittal schedule has been approved by the ENGINEER. D. SUBMITTAL LIST The following general list of submittals is provided for the convenience of the CONTRACTOR in preparing his Submittal Schedule. The CONTRACTOR shall be required to furnish all submittals required by the Contract Documents. Anodes, including Connection Wires from Anodes Splices Connections to Copper Lines Exothermic Weld System Vacuum Excavation Equipment Drill Equipment Disposal Plan PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION (NOT USED) PART 4 - PAYMENT Payment for the Work in this Section shall be included as part of the lump sum or unit price bid for which such W ork is appurtenant thereto and no additional payment will be made specifically for the Work in this Section. END OF SECTION SAN JUAN HILLS GREENS 33 Quality Control CORROSION PROTECTION SYSTEM 01400 SECTION 01400 QUALITY CONTROL PART 1 - GENERAL A. DESCRIPTION This Section covers quality control requirements supplementary to those of the Conditions of the Contract and other Sections of the Specifications. B. QUALITY ASSURANCE 1. Testing Laboratory Qualifications. Whether employed by the OWNER or CONTRACTOR, the Testing Laboratory shall be certified to conduct and perform testing services in the State and jurisdiction where the Work is located. All testing shall be performed under the direct supervision and control of a qualified registered professional engineer employed by the laboratory. 2. Foundation or Soils Engineer. The OWNER will employ and pay for the services of Civil Engineer registered in California specializing in Foundation or Soils Engineering to observe the specified portions of the Work and to supervise or perform testing pertaining to the observed Work. 3. Requirements of Regulatory Agencies. Refer to paragraphs 13.1.2, and 13.2.2 of Section 00700, "General Conditions." The Testing Laboratory will perform tests required by the ENGINEER at no cost to the CONTRACTOR. All other tests, inspections, permits, and approvals required by other regulatory agencies shall be furnished by the CONTRACTOR at its sole expense. 4. Source Quality Control. To the extent specified herein or in other Sections, the Testing Laboratory shall obtain samples of various materials at the source of supply and test the materials for compliance with the Contract Documents. The Testing Laboratory shall tag, seal, label, or otherwise suitably identify the bulk materials so sampled, and no such materials shall be used in the Work until the test reports are submitted to and approved by the ENGINEER. The applicable tests shall be repeated at the specified intervals, whenever the source of supply is changed, or whenever the characteristics of the materials change or vary in the opinion of the ENGINEER. 5. Factory Test Witnessing. To the extent specified or ordered by OWNER, the Testing Laboratory shall witness testing performed at the factory or supplier's test facility. Unless otherwise specified, the OWNER will pay the cost of factory test witnessing. 6. Inspection. Refer to paragraph 13.1 of Section 00700 "General Conditions." The CONTRACTOR shall give the ENGINEER not less than two (2) working days written notice whenever its operations require the services of more than one Inspector. To the extent specified, the Testing Laboratory shall furnish specially qualified inspectors for various field inspections. SAN JUAN HILLS GREENS 34 Quality Control CORROSION PROTECTION SYSTEM 01400 C. SUBMITTALS 1. Laboratory Test or Inspection Reports. Each report shall be signed and certified by the supervising engineer of the Testing Laboratory. Unless otherwise specified, the Testing Laboratory shall submit five (5) copies of each report to the ENGINEER. 2. Foundation or Soils Engineer's Reports. These reports shall be certified and submitted to the ENGINEER. A copy of each report will be furnished to the CONTRACTOR by the ENGINEER. 3. Schedule of Testing Laboratory Services. The CONTRACTOR shall submit a schedule giving the dates and duration that the Testing Laboratory shall perform testing services or furnish special inspections. After this, the CONTRACTOR shall give the ENGINEER and Testing Laboratory not less than ten (10) working days written notice of any change in the schedule. PART 2 - PRODUCTS (Not applicable to this Section) PART 3 - EXECUTION A SAMPLING Field samples will be selected and obtained by the Testing Laboratory or Inspector unless otherwise specified. B LABORATORY TEST PROCEDURES Testing shall conform to the requirements specified. If no procedure or test method is specified, testing shall comply with the material specification referenced unless otherwise directed by the ENGINEER. C CONTRACTOR FURNISHED ASSISTANCE When requested, CONTRACTOR shall furnish access, facilities, and labor assistance at the site as necessary for the duties to be performed by the Testing Laboratory and Inspector, including ladders, hoisting, temporary lighting, temporary water supply, and like services. D TEST SCHEDULE AND TEST COSTS The CONTRACTOR shall perform all certifying and testing requiring by the Contract Documents, other than what is scheduled in this Section, at its expense. The CONTRACTOR shall pay the OWNER, in accordance with Paragraph 13.1 of Section 00700, "General Conditions", any cost the OWNER incurs for tests when the tested material or equipment fails the test and for retesting caused by failure disclosed in previous tests. E TEST COSTS PAID BY OTHERS SAN JUAN HILLS GREENS 35 Quality Control CORROSION PROTECTION SYSTEM 01400 1. Making and testing concrete test cylinders. 2. Sampling and testing of Portland cement and concrete aggregates, field slump tests and air entrainment test. PART 4 - PAYMENT Payment for the Work in this Section shall be included as part of the lump sum or unit price bid for which such Work is appurtenant thereto and no additional payment will be made specifically for the Work in this Section. END OF SECTION SAN JUAN HILLS GREENS 36 Transportation & Handling of Materials CORROSION PROTECTION SYSTEM 01610 SECTION 01610 TRANSPORTATION AND HANDLING OF MATERIALS AND EQUIPMENT PART 1 - GENERAL A DESCRIPTION 1. CONTRACTOR shall make all arrangements for transportation, delivery, receiving and handling of products required for prosecution and completion of the Work. 2. Shipments of products to CONTRACTOR or Subcontractors shall be delivered to the Site only during regular working hours. Shipments shall be addressed and consigned to the proper party giving name of Project, street number and city. Shipments shall not be delivered to PWD except where otherwise directed. 3. If necessary to move stored products during construction, CONTRACTOR shall move them without any additional compensation. B PREPARATION FOR SHIPMENT 1. When practical, factory assemble products. Match mark or tag separate parts and assemblies to facilitate field assembly. Cover machined and unpainted parts that may be damaged by the elements with a strippable protective coating. 2. Package products to facilitate handling and protect from damage during shipping, handling, and storage. Mark or tag outside of each package or crate to indicate its purchase order number, bill of lading number, contents by name, PWD’s contract name and number, CONTRACTOR, equipment number, and approximate weight. Include complete packing lists and bills of materials with each shipment. 3. Protect products from exposure to the elements and keep thoroughly dry and dust free at all times. Protect surfaces against impact, abrasion, discoloration, or other damage. 4. Do not have products shipped until related Shop Drawings have been approved by City. C DELIVERY 1. Arrange deliveries of products in accordance with progress schedules and in ample time to facilitate inspection prior to installation. 2. Coordinate deliveries to avoid conflict with Work and conditions at Site and to accommodate the following: a. Work of other contractors or City. b. Limitations of storage space. c. Availability of equipment and personnel for handling products. d. City’s use of premises. SAN JUAN HILLS GREENS 37 Transportation & Handling of Materials CORROSION PROTECTION SYSTEM 01610 3. Have products delivered to Site in manufacturer's original, unopened, labeled containers. Keep City informed of delivery of all equipment to be incorporated in the Work. 4. Clearly mark partial deliveries of component parts of equipment to identify the equipment, to permit easy accumulation of parts and to facilitate assembly. 5. Immediately on delivery, inspect shipment to ensure: a. Product complies with requirements of Contract Documents and reviewed submittals. b. Quantities are correct. c. Containers and packages are intact and labels are legible. d. Products are properly protected and undamaged. 6. Promptly remove damaged products from the Site and expedite delivery of new, undamaged products. Remedy incomplete or lost products to provide that specified, so as not to delay progress of the Work. D PRODUCT HANDLING 1. Provide equipment and personnel necessary to handle products, including those provided by City, by methods to prevent soiling or damage to products or packaging. 2. Provide additional protection during handling as necessary to prevent scraping, marring or otherwise damaging products or surrounding surfaces. 3. Handle products by methods to prevent bending or overstressing. 4. Lift heavy components only at designated lifting points. 5. Handle products in a safe manner and as recommended by manufacturer to prevent damage. Do not drop, roll or skid products off delivery vehicles. Hand carry or use suitable materials handling equipment. PART 2 - PRODUCTS (NOT USED) PART 3 - EXECUTION (NOT USED) PART 4 - PAYMENT Payment for the Work in this Section shall be included as part of the lump sum or unit price bid for which such Work is appurtenant thereto and no additional payment will be made specifically for the Work in this Section. END OF SECTION SAN JUAN HILLS GREENS 38 Clean-Up CORROSION PROTECTION SYSTEM 01710 SECTION 01710 CLEAN-UP PART 1 - GENERAL A REMOVAL OF DEBRIS DURING CONSTRUCTION 1. During its progress, the work and the adjacent areas affected thereby shall be kept cleaned up and all rubbish, surplus materials and unneeded construction equipment shall be removed and all damage repaired. 2. Where material or debris has washed or flowed into or has been placed in watercourses, ditches, gutters, drains, catch basins, or elsewhere as a result of the CONTRACTOR's operations, such material or debris shall be entirely removed and disposed of during progress of the work, and the watercourses, ditches, gutters, drains, catch basins, and other facilities cleaned and kept in a neat, clean and functioning condition. 3. The Site is to be left broom-clean at the end of the day. All equipment, material, and supplies are to be moved to a predefined off-site storage location. B FINAL CLEANING 1. On or before the completion of the work, the CONTRACTOR shall, unless otherwise directed in writing by the OWNER's representative, tear down and remove all temporary buildings and structures built by it; shall remove all temporary works, tools and machinery or other construction equipment furnished by it; shall remove, acceptably disinfect, and cover all organic matter and material containing organic matter in, under and around privies, houses and other building used by it; shall remove all rubbish from any grounds which it has occupied; shall leave the roads and all parts of the premises and adjacent property affected by its operations in a neat and satisfactory condition; and shall remove all construction markings, paint and lines placed for the purpose of utility mark outs placed in the conduct of underground service alert process. 2. The CONTRACTOR shall restore or replace, subject to the approval of the OWNER, any property damaged by its work, equipment or employees, to a condition at least equal to that existing immediately prior to the beginning of operations. Suitable materials, equipment and methods shall be used for such restoration as approved by the OWNER, or as required elsewhere in these specifications. PART 2 - PRODUCTS (Not Applicable) PART 3 – EXECUTION (Not Applicable) PART 4 - PAYMENT SAN JUAN HILLS GREENS 39 Clean-Up CORROSION PROTECTION SYSTEM 01710 Payment for the Work in this Section shall be included as part of the lump sum or unit price bid for which such Work is appurtenant thereto and no additional payment will be made specifically for the Work in this Section. END OF SECTION SAN JUAN HILLS GREENS Structural Earthwork CORROSION PROTECTION SYSTEM 40 02200 SECTION 02200 STRUCTURAL EARTHWORK PART 1 - GENERAL A. Description This section includes excavation, backfilling, materials, testing, and shoring for structures. B. Related work All related work specified elsewhere, or in other codes or standards, will be as last revised, unless a specific date of issuance is called out in opposition to later revision date(s). Other sections of the technical specifications, not referenced below, shall also apply to the extent required for proper performance of this work. 1. Trenching, Backfilling, and Compacting: 02223 2. Concrete: 03300 C. Testing for Compaction Testing for compaction shall conform to Section 02223. D. Definition of Zones 1. Pavement and street zones shall be as specified in Section 02223. 2. Backfill zone is the backfill from the bottom of the structure excavation to the bottom of the street zone in paved areas or to the existing surface in unpaved areas. E. Permits All work shall conform to the specifications and requirements of the State of California Department of Transportation, the Orange County PFRD, the city having jurisdiction, or any other affected agencies involved. The contractor shall keep a SAN JUAN HILLS GREENS Structural Earthwork CORROSION PROTECTION SYSTEM 41 02200 copy of all the required permits in the job site and comply with all the terms and conditions of said permits. PART 2 - MATERIALS Native earth backfill, imported backfill material, granular material, imported sand, and crushed rock shall conform to the requirements of Section 02223. PART 3 - EXECUTION A. Compaction Requirements 1. Backfill in Street Zone: 90% relative compaction 2. Structural Backfill: 90% relative compaction 3. Gravel Base: 90% relative compaction 4. Adjacent to existing structures: 95% relative compaction B. Sidewalk, Pavement, and Curb Removal 1. Saw cut bituminous or concrete pavements regardless of their thickness, and curbs and sidewalks prior to excavation for the structure in accordance with the requirements of the City, or agency having jurisdiction. Curbs and sidewalks that are damaged in the course of construction are to be cut and removed and replaced from joint to joint 2. Haul removed pavement and concrete materials from the site to a proper disposal facility. These materials are not permitted for use as backfill. If the material to be removed exceeds 50 cubic yards, the contractor shall obtain a haul route permit from the City(s) having jurisdiction. C. De-watering 1. Provide and maintain means and devices to continuously remove and dispose of all water entering the excavation during construction of the structure and all backfill operations. 2. Dispose of the water in a manner to prevent damage to adjacent property and pipe trenches. 3. Do not allow water to rise in the excavation until backfilling around and above the structure is completed. 4. Reporting shall conform to the requirements of the City of San Juan Capistrano’s NPDES permit requirements. SAN JUAN HILLS GREENS Structural Earthwork CORROSION PROTECTION SYSTEM 42 02200 5. In no event shall the sewer system be used as a drain for de-watering. D. Structure Excavation 1. Structure excavation shall include the removal of all material of whatever nature necessary for the construction of structures and foundations in accordance with the plans and these specifications. 2. The sides of excavations for structures shall be sufficient to leave at least a 2-foot clearance, as measured from the extreme outside of formwork or the structure, as the case may be. 3. The contractor shall dispose of surplus material in accordance with Section 02223. E. Correction of Over Excavation 1. Where excavation is inadvertently carried below design depths, suitable provision shall be made by the contractor to adjust construction, as directed by the PWD Representative to meet requirements incurred by the deeper excavation. 2. No earth backfill will be permitted to correct over excavation beneath structures. 3. Over excavation shall be corrected by backfilling with crushed rock or concrete, as directed by the PWD Representative. F. Bracing 1. The contractor's design and installation of bracing and sheeting shall take the necessary precautions to be consistent with the rules, orders, and regulations of the State of California Construction Safety Orders. 2. Excavations shall be so braced, sheeted, and supported that they will be safe, such that the walls of the excavation will not slide or settle and all existing improvements of any kind, either on public or private property, will be fully protected from damage. 3. The sheeting, shoring, and bracing shall be arranged so as not to place any stress on portions of the completed work. SAN JUAN HILLS GREENS Structural Earthwork CORROSION PROTECTION SYSTEM 43 02200 4. Carefully remove sheeting, shoring, bracing, and timbering to prevent the caving or collapse of the excavation faces being supported. G. Backfill 1. After structures and foundations are in place, backfill shall be placed to the original ground line or to the limits designated on the plans. 2. No material shall be deposited against concrete structures until the concrete has reached a compressive strength of at least 3,000 pounds per square inch as tested per Section 03300. 3. Imported sand or granular material shall be placed in horizontal layers not exceeding 8 inches in depth. 4. Each layer of backfill material shall be moistened and thoroughly tamped, rolled, or otherwise compacted to the specified relative density. 5. Carefully operate compaction equipment near structures to prevent their displacement or damage. Structural fill is to be placed and compacted in uniform layers around all sides of the structure. H. Pavement Replacement Pavement replacement shall be in accordance with the requirements of the City or the agency having jurisdiction. I. Permits An Encroachment Permit from the City having jurisdiction is required prior to any work within City right-of-way. All traffic control and pavement replacement work shall be in accordance with the requirements of the permit and the City Inspector. A permit from OSHA is required of any excavation exceeding 5 feet. Follow all restrictions of the required permits form other agencies. END OF SECTION SAN JUAN HILLS GREENS 44 Trenching, Backfilling, and Compacting CORROSION PROTECTION SYSTEM 02223 SECTION 02223 TRENCHING, BACKFILLING, AND COMPACTING PART 1 - GENERAL A. DESCRIPTION This section includes materials, testing, and installation for trench excavation, backfilling, and compacting. B. RELATED WORK All related work specified elsewhere, or in other codes or standards, will be as last revised, unless a specific date of issuance is called out in opposition to later revision date(s). Other sections of the technical specifications, not referenced below, shall also apply to the extent required for proper performance of this work. C. TESTING FOR COMPACTION 1. Determine the density of soil in place by the use of a sand cone, drive tube, or nuclear tester. 2. Determine laboratory moisture-density relations of existing soils by ASTM D 1557. 3. Determine the relative density of cohesionless soils by ASTM D 2049. 4. Sample backfill materials by ASTM D 75. 5. Express "relative compaction" as the ratio, expressed as a percentage, of the in place dry density to the laboratory maximum dry density. 6. Compaction shall be deemed to comply with the specifications when no test falls below the specified relative compaction. 7. The Contractor shall secure the services of a qualified testing laboratory, acceptable to the City, and pay the costs of all testing work. Test results shall be furnished to the City Representative. D. PAVEMENT ZONE The pavement zone includes the asphalt concrete and aggregate base pavement section placed over the trench backfill. E. STREET ZONE The street zone is the top 18 inches of the trench in paved areas, or the depth determined by the jurisdictional agency. SAN JUAN HILLS GREENS 45 Trenching, Backfilling, and Compacting CORROSION PROTECTION SYSTEM 02223 F. TRENCH ZONE The trench zone includes the portion of the trench from the top of the pipe zone to the bottom of the street zone in paved areas or to the existing surface in unpaved areas. G. PIPE ZONE The pipe zone shall include the full width of trench from the bottom of the pipe or conduit to a horizontal level 12 inches above the top of the pipe. Where multiple pipes or conduits are placed in the same trench, the pipe zone shall extend from the bottom of the lowest pipes to a horizontal level 12 inches above the top of the highest or topmost pipe. H. PIPE BASE The pipe base shall be defined as a layer of material immediately below the bottom of the pipe or conduit and extending over the full trench width in which the pipe is bedded. Thickness of pipe base shall be a minimum of 4 inches, or as shown on the drawings or as described in these specifications for the particular type of pipe installed. I. SIDEWALK ZONE The sidewalk zone shall be defined as a layer of material immediately below the bottom of the existing sidewalk removed or immediately adjacent to on the landscaped area. Use clean compacted native material under Sidewalk, or as shown on the drawings or as described in these specifications. I. EXCESS EXCAVATED MATERIAL 1. The contractor shall make the necessary arrangements for and shall remove and dispose of all excess excavated material unless indicated differently in the special provisions for any job. Removed concrete must be sent to a recycling facility per the City has a recycling ordinance for Construction and Demolition material. 2. It is the intent of these specifications that all surplus spoils material not required for backfill be disposed of at a proper recycling or disposal site. 3. No excavated material shall be deposited on private property unless written the contractor thereof secures written permission from the owner. Before the PWD will accept the work, the contractor shall file a written release signed by all property owners with whom he has entered into agreements for disposing excess excavated material, absolving the PWD from any liability connected therewith. 4. The contractor shall obtain a haul route permit from the city having jurisdiction. J. SAFETY 1. All excavations shall be performed, protected, and supported as required for safety and in the manner set forth in the operation rules, orders, and regulations prescribed by the Division of Industrial Safety of the State of California. SAN JUAN HILLS GREENS 46 Trenching, Backfilling, and Compacting CORROSION PROTECTION SYSTEM 02223 2. Barriers shall be placed at each end of all excavations and at such places as may be necessary along excavations to warn all pedestrians and vehicular traffic of such excavations. Lights shall also be placed along excavations from sunset each day to sunrise of the next day until such excavation is entirely refilled. 3. No trench or excavation shall remain open during non-working hours. The trench or excavation shall be covered with steel plates, spiked in place, or secured with temporary A.C. pavement around the edges, or backfilled. K. ACCESS Unobstructed access must be provided to all driveways, water valves, hydrants, or other property or facilities that require routine use. L. BLASTING Not applicable. M. PERMITS All work shall conform to the specifications and requirements of the State of California Department of Transportation, the Orange County PFRD, the city having jurisdiction, or and other agencies involved. The contractor shall keep a copy of all the required permits in the job site and comply with all the terms and conditions of said permits. PART 2 - MATERIALS A. NATIVE EARTH BACKFILL 1. The use of native earth as backfill material will require the approval of the City Representative in all cases. 2. Native earth backfill, acceptable for use, shall be fine-grained material free from roots, debris, and rocks with a maximum dimension not larger than 1-inch. 3. Native backfill shall not be used in the pipe zone. B. IMPORTED BACKFILL MATERIAL 1. Whenever the excavated material is not suitable for backfill, the contractor shall arrange for and furnish suitable imported backfill material that is capable of attaining the required relative density. 2. The contractor shall dispose of the excess trench excavation as specified in the preceding section. Backfilling with imported material shall be done in accordance with the methods described herein. C. GRANULAR MATERIAL SAN JUAN HILLS GREENS 47 Trenching, Backfilling, and Compacting CORROSION PROTECTION SYSTEM 02223 Granular material shall be defined as soil having a minimum sand equivalent of 30 as determined in accordance with State of California, CALTRANS, Test "California 217," with not more than 20% passing a 200-mesh sieve. D. IMPORTED SAND Imported sand shall have a minimum sand equivalent of 30 per State of California, CALTRANS, Test "California 217" with 100% passing a 3/8-inch sieve and not more than 20% passing a 200-mesh sieve. Certification that the sand meets this requirement shall be provided. E. CRUSHED ROCK AND GRAVEL 1. Crushed rock shall be the product of crushing rock or gravel. Fifty percent of the particles retained on a 3/8-inch sieve shall have their entire surface area composed of faces resulting from fracture due to mechanical crushing. Not over 5% shall be particles that show no faces resulting from crushing. Less than 10% of the particles that pass the 3/8-inch sieve and are retained on the No. 4 sieve shall be weatherworn particles. Gravel shall not be added to crushed rock. 2. Gravel shall be defined as particles that show no evidence of mechanical crushing, are fully weatherworn, and are rounded. For pipe bedding, where gravel is specified, crushed rock may be substituted or added. 3. Where crushed rock or gravel is specified in the bedding details on the plans, the material shall have the following gradations: 3/4-Inch 1½-Inch 1-Inch Max Crushed Max Gravel Max Gravel Rock Sieve Size % Passing % Passing % Passing 2" 100 1½" 90 - 100 100 1" 20 - 55 90 - 100 100 3/4" 0 - 15 60 - 80 90 - 100 1/2" - - 30 - 60 3/8" 0 - 5 0 - 15 0 - 20 No. 4 - 0 - 5 0 - 5 No. 8 - - - 4. Unless otherwise specified, 3/4-inch-maximum crushed rock shall be used for pipes with inside diameters of 30 inches and less. F. SAND-CEMENT SLURRY Sand-cement slurry shall consist of two sacks (188 pounds) of Portland cement per cubic yard of sand and sufficient moisture for workability. SAN JUAN HILLS GREENS 48 Trenching, Backfilling, and Compacting CORROSION PROTECTION SYSTEM 02223 PART 3 - EXECUTION A. COMPACTION REQUIREMENTS 1. The CONTRACTOR shall engage the services of a qualified soils engineering firm to determine the relative compaction of the trench backfill. 2. If the backfill fails to meet the specified relative compaction requirements, the contractor shall rework the backfill until the requirements are met. The contractor shall make all necessary excavations for density tests as directed by the City Representative. Orange County PFRD, city having jurisdiction, or CALTRANS compaction requirements shall prevail in all public roads. 3. Compaction tests shall be performed at random depths and at 200-foot intervals, or every 10th site as appropriate and as directed by the City Representative. 4. Unless otherwise shown on the drawings or otherwise described in the specifications for the particular type of pipe installed, relative compaction in pipe trenches shall be as described below: a. Pipe zone and pipe base: 90% relative compaction b. Trench zone not beneath paving: 90% relative compaction. c. Trench zone to street zone in paved areas: 90% relative compaction. d. Street zone in paved areas: per agency requirements. The most stringent agency requirements shall prevail. e. Rock refill material for foundation stabilization: 90% relative density. f. Rock refill for over excavation: 90% relative density. B. MATERIAL REPLACEMENT Removal and replacement of any trench and backfill material that does not meet the specifications shall be the contractor's responsibility. C. CLEARING AND GRUBBING 1. Areas where work is to be performed shall be cleared of all trees, shrubs, rubbish, and other objectionable material of any kind which, if left in place, would interfere with the proper performance or completion of the contemplated work, would impair its subsequent use, or would form obstructions therein. 2. Organic material from clearing and grubbing operations will not be incorporated in the trench backfill. 3. Organic material from clearing and grubbing operations will be disposed of at a proper waste disposal facility. D. SIDEWALK, PAVEMENT, AND CURB REMOVAL 1. Saw cut bituminous or concrete pavements regardless of their thickness, and curbs and sidewalks prior to excavation for the structure in accordance with the SAN JUAN HILLS GREENS 49 Trenching, Backfilling, and Compacting CORROSION PROTECTION SYSTEM 02223 requirements of the City, or the agency having jurisdiction. Saw cut, remove and replace from joint to joint all curbs and sidewalks damaged in the course of construction. 2. Haul removed pavement and concrete materials from the site, to a proper disposal facility. These materials are not permitted for use as trench backfill. If the material to be removed exceeds 50 cubic yards, the contractor shall obtain a haul route permit from the City(s) having jurisdiction. E. TRENCHING AND TUNNELING 1. Excavation for pipe, fittings, and appurtenances shall be open trench to the depth and in the direction necessary for the proper installation of the facilities as shown on the plans. 2. Trench banks shall be kept as near to vertical as possible and shall be properly braced and sheeted. 3. Tunneling will not be permitted. 4. The use of a jack and bore or hydraulic ram may be employed. F. BRACING 1. The contractor's design and installation of bracing and shoring shall be consistent with the rules, orders, and regulations of the State of California Construction Safety Orders. 2. Excavations shall be so braced, sheeted, and supported that they will be safe such that the walls of the excavation will not slide or settle and all existing improvements of any kind, either on public or private property, will be fully protected from damage. 3. The sheeting, shoring, and bracing shall be arranged so as not to place any stress on portions of the completed work until the general construction thereof has proceeded far enough to provide ample strength. 4. Care shall be exercised in the drawing or removal of sheeting, shoring, bracing, and timbering to prevent the caving or collapse of the excavation faces being supported. G. TRENCH WIDTHS 1. Excavation and trenching shall be true to line so that a clear space of not more than 8 inches or less than 6 inches in width is provided on each side of the largest outside diameter of the pipe in place measured at a point 12 inches above the top of the pipe. For the purpose of this article, the largest outside diameter shall be the outside diameter of the bell on bell and spigot pipe or the pipe collar. 2. Where the trench width, measured at a point 12 inches above the top of the bell of the pipe, is wider than the maximum set forth above, the trench area around the SAN JUAN HILLS GREENS 50 Trenching, Backfilling, and Compacting CORROSION PROTECTION SYSTEM 02223 pipe shall be backfilled with crushed rock, Class B concrete, or slurry to form a cradle for the pipe as shown on the Drawing W -8 at the discretion of the PWD Representative. Concrete or slurry shall not be poured directly against the pipe. H. LENGTH OF OPEN TRENCH Within developed areas, the length of open trench may be restricted as determined by the encroachment permit from the city or the agency having jurisdiction. I. GRADE 1. Excavate the trench to the lines and grades shown on the drawings with allowance for pipe thickness and for pipe base or special bedding. 2. The trench bottom shall be graded to provide a smooth firm, and stable foundation that is free from rocks and other obstructions and shall be at a reasonably uniform grade. J. CORRECTION OF OVER EXCAVATION 1. Where excavation is inadvertently carried below the design trench depth, suitable provision shall be made by the contractor to adjust the excavation, as directed by the PWD Representative, to meet requirements incurred by the deeper excavation. 2. Over excavations shall be corrected by backfilling with approved graded crushed rock or gravel and shall be compacted to provide a firm and unyielding subgrade or foundation, as directed by the PWD Representative. K. DE-WATERING 1. The contractor shall provide and maintain at all times during construction ample means and devices with which to promptly remove and properly dispose of all water from any source entering the excavations or other parts of the work. De- watering shall be done by methods that will ensure a dry excavation and preservation of the final lines and grades of the bottoms of excavations. De- watering methods may include well points, sump points, suitable rock or gravel placed below the required bedding for drainage and pumping, temporary pipelines, and other means, all subject to the approval of the PWD Representative. 2. In no event shall the sewer, or storm drain system be used as drains for de- watering the construction trenches. 3. De-watering shall commence when groundwater is first encountered and shall be continuous until such times as water can be allowed to rise. No concrete shall be poured in water, nor shall water be allowed to rise around the concrete or mortar until it has set at least eight hours. L. FOUNDATION STABILIZATION 1. Whenever the trench bottom does not afford a sufficiently solid and stable base to support the pipe or appurtenances, the contractor shall excavate to a depth below SAN JUAN HILLS GREENS 51 Trenching, Backfilling, and Compacting CORROSION PROTECTION SYSTEM 02223 the design trench bottom, as directed by the PWD Representative, and the trench bottom shall be backfilled with 3/4-inch rock and compacted to provide uniform support and a firm foundation. 2. Where rock is encountered, it shall be removed below grade and the trench shall be backfilled with graded gravel or crushed rock to provide a compacted foundation cushion with a minimum allowable thickness of 4 inches under the pipe foundation plane. 3. If excessively wet, soft, spongy, unstable, or similarly unsuitable material is encountered at the surface upon which the bedding material is to be placed, the unsuitable material shall be removed to a depth as determined in the field by the PWD Representative and replaced by crushed rock. M. EXCAVATED MATERIAL 1. All excavated material shall not be stockpiled in a manner that will create an unsafe work area or obstruct sidewalks or driveways. Gutters shall be kept clear or other satisfactory measures shall be taken to maintain street or other drainage. 2. In confined work areas, the contractor may be required to stockpile the excavated material off-site, as determined by the project permits. N. PLACING PIPE BASE 1. Place the specified thickness of pipe base material over the full width of trench and compact the material to the specified relative density. Grade the top of the pipe base ahead of the pipe to provide firm, uniform support along the full length of pipe. 2. Excavate bell holes at each joint to permit assembly and inspection of the entire joint. O. PLACING MOUNDS TO SUPPORT PIPE 1. As an alternate to placing imported sand pipe base material, the pipe may be supported on mounds of imported sand. 2. The mounds shall be of imported sand and extend the full trench width. The mounds shall provide a minimum of 6 inches of contact with the pipe. 3. The pipe shall be supported to maintain its design line and grade. 4. The mounds shall be located 2½ feet from the coupling of the pipe. P. BACKFILLING WITHIN PIPE ZONE 1. Backfill the pipe zone per the detailed piping specification for the particular type of pipe and per the following: SAN JUAN HILLS GREENS 52 Trenching, Backfilling, and Compacting CORROSION PROTECTION SYSTEM 02223 2. After pipe has been bedded, place pipe zone material simultaneously on both sides of the pipe, keeping the level of backfill the same on each side. Carefully place the material around the pipe so that the pipe barrel is completely supported and that no voids or un-compacted areas are left beneath the pipe. Use particular care in placing material on the underside of the pipe to prevent lateral movement during subsequent backfilling. 3. Compact material placed within 12 inches of the outer surface of the pipe by hand tamping only. Q. BACKFILL WITHIN TRENCH ZONE 1. Compact the trench zone per the detailed piping specification for the particular type of pipe and per the following: 2. Push the backfill material carefully onto the backfill previously placed in the pipe zone. Do not permit free fall of the material until at least 2 feet of cover is provided over the top of the pipe. Do not drop sharp, heavy pieces of material directly onto the pipe or the tamped material around the pipe. 3. The remaining portion of the trench to the street zone or ground surface, as the case may be, shall be backfilled, compacted and/or consolidated by approved methods to obtain the specified relative compaction. a. Where densities are required which cannot be attained by water densified backfill the Engineer may authorize the use of impact, free fall or “Stomping” type equipment to supplement the densification of the backfill. The backfill shall be placed in horizontal layers of such depths as are considered proper for the type of compacting equipment being used in relation to the backfill material being placed. Each layer shall be evenly spread, properly moistened, and compacted to the specified relative density. The contractor shall repair or replace any pipe, fittings, manholes, or structures as directed by the PWD Representative damaged by the contractor's operations. b. Consolidation of backfill performed by flooding, or jetting shall not be allowed. R. BACKFILL WITHIN STREET ZONE 1. The street zone within roadbed areas shall be compacted using approved hand, pneumatic, or mechanical type tampers to obtain the required relative compaction. 2. All work shall be done in accordance with the requirements and to the satisfaction of the city or the agency having jurisdiction. 3. Flooding and jetting will not be permitted in this Zone. S. SIDEWALK, PAVEMENT, AND CURB REPLACEMENT SAN JUAN HILLS GREENS 53 Trenching, Backfilling, and Compacting CORROSION PROTECTION SYSTEM 02223 Replace bituminous and concrete pavement, curbs, and sidewalks damaged or removed during construction in accordance with the requirements of the city or the agency having jurisdiction. PART 4 - PAYMENT Payment for the Work in this Section shall be included as part of the lump sum or unit price bid for which such Work is appurtenant thereto and no additional payment will be made specifically for the Work in this Section. END OF SECTION SAN JUAN HILLS GREENS 54 Concrete CORROSION PROTECTION SYSTEM 03300 SECTION 03300 CONCRETE PART 1 - GENERAL A. DESCRIPTION This section describes concrete materials, mixing, placement, form work, reinforcement and curing. B. RELATED WORK All related work specified elsewhere, or in other codes or standards, will be as last revised, unless a specific date of issuance is called out in opposition to later revision date(s). Other sections of the technical specifications, not referenced below, shall also apply to the extent required for proper performance of this work. 1. Structure Excavation: 02200 PART 2 - MATERIALS A. CONCRETE 1. All Portland cement concrete shall conform to the provisions of Section 90 of the "State Specifications" except as herein modified. 2. Portland cement concrete shall be composed of Portland cement, fine aggregate, coarse aggregate, and water proportioned and mixed to produce a smooth dense workable mixture. It can be of the ready-mix variety as produced by any reliable ready-mix concrete firm. 3. Portland cement, including Portland cement used in precast products, shall be Type II conforming to ASTM C 150. 4. Concrete mix design shall conform with ASTM C 94. Use classes of concrete as described in the following table. SAN JUAN HILLS GREENS 55 Concrete CORROSION PROTECTION SYSTEM 03300 Minimum 28-Day Compressive Cement Content Class Type of Work Strength (in psi) A Concrete for all 3,000 reinforced structures, piers, vaults, and sidewalks B Concrete for anchors, 2,000 thrust blocks, encase- ments, slope protection cutoff walls, cradles and miscellaneous unreinforced concrete B. REINFORCING STEEL 1. Reinforcement shall conform to ASTM A 615, Grade 40. 2. Fabricate reinforcing steel in accordance with the current edition of the Manual of Standard Practice, published by the Concrete Reinforcing Steel Institute. Bend reinforcing steel cold. 3. Deliver reinforcing steel to the site bundled and tagged with identifying tags. C. WELDED WIRE FABRIC Welded wire fabric shall conform to ASTM 185. D. TIE WIRE Tie wire shall be 16-gage minimum, black, soft annealed. E. BAR SUPPORTS Bar supports in beams and slabs exposed to view after form stripping shall be galvanized or plastic coated. Use concrete supports for reinforcing in concrete placed on grade. F. FORMS 1. Forms shall be accurately constructed of clean lumber and shall be of sufficient strength and rigidity to hold the concrete and to withstand the necessary pressure and tamping without deflection from the prescribed lines. 2. The surface of forms against which concrete is placed shall be smooth and free from irregularities, dents, sags, or holes. The surface shall leave uniform form marks conforming to the general lines of the structure. SAN JUAN HILLS GREENS 56 Concrete CORROSION PROTECTION SYSTEM 03300 PART 3 - EXECUTION A. EXCAVATION Excavation for structures shall be in accordance with Section 02200. B. FORM WORK 1. The contractor shall notify the City Representative a minimum of one working day before the placement of concrete to enable the City Representative to check the form lines, grades, and other required items for approval before placement of concrete. 2. Unless otherwise indicated on the plans, all exposed sharp edges shall be chamfered with at least 3/4 - by 3/4-inch triangular fillets. 3. Before placing concrete; the form surface shall be clean and coated with form oil of high penetrating qualities. C. REINFORCEMENT 1. Place reinforcing steel in accordance with the current edition of Recommended Practice for Placing Reinforcing Bars, published by the Concrete Reinforcing Steel Institute. 2. All reinforcing steel shall be of the required sizes and shapes and placed where shown on the drawings or prescribed by the PWD Representative. 3. Do not straighten or rebend reinforcing steel in a manner that will injure the material. Do not use bars with bends not shown on the drawings. 4. All bars shall be free from rust, scale, oil, or any other coating which would reduce or destroy the bond between concrete and steel. 5. Position reinforcement steel in accordance with the drawings and secure by using annealed wire ties or clips at intersections and support by concrete or metal supports, spacers, or metal hangers. Do not place metal clips or supports in contact with the forms. Bend tie wires away from the forms in order to provide the specified concrete coverage. Bars additional to those shown on the drawings, which may be found necessary or desirable by the Contractor for the purpose of securing reinforcement in position, shall be provided and paid for by the Contractor. 6. Place reinforcement a minimum of 2 inches clear of any metal pipe or fittings. 7. The reinforcement shall be so secured in position that it will not be displaced during the placement of concrete. 8. All reinforcing steel and wire mesh shall be completely encased in concrete. SAN JUAN HILLS GREENS 57 Concrete CORROSION PROTECTION SYSTEM 03300 9. Secure reinforcing dowels in place prior to placing concrete. Do not press dowels into the concrete after the concrete has been placed. 10. Minimum lap for all reinforcement shall be 20 bar diameters. 11. Place additional reinforcement around the pipe or opening as indicated in the drawings. 12. Wire mesh reinforcement is to be rolled flat before being placed in the form. Support and tie wire mesh to prevent movement during concrete placement. 13. Extend welded wire fabric to within 2 inches of the edges of the slab. Lap splices at least 1-1/2 courses of the fabric and a minimum of 6 inches. Tie laps and splices securely at ends and at least every 24 inches with 16-gage black annealed steel wire. Pull the fabric into position as the concrete is placed by means of hooks, and work concrete under the steel to ensure that it is at the proper distance above the bottom of the slab. D. EMBEDDED ITEMS All embedded bolts, dowels, anchors, and other embedded items shall be held correctly in place in the forms before concrete is placed. E. MIXING AND PLACING CONCRETE 1. Concrete, either commercial of on-site ready mix or batch mixed, shall be placed in the forms before taking its initial set. 2. No concrete shall be placed in water except with permission of the City Representative. 3. As the concrete is placed in the forms, or in excavations to be filled with concrete, it shall be thoroughly settled and compacted throughout the entire layer by internal vibration and tamping bars. 4. All concrete surfaces upon which or against which the concrete is to be placed, and to which new concrete is to adhere, shall be roughened, thoroughly cleaned, wet, and grouted before the concrete is deposited. F. CONCRETE FINISHING 1. Immediately upon the removal of forms, all voids shall be neatly filled with cement mortar. 2. The surfaces of concrete to be permanently exposed to view must be smooth, free from projections, and thoroughly filled with mortar. 3. Exposed surfaces of concrete not finished against forms, such as horizontal or sloping surfaces, shall be screened to a uniform surface and worked with suitable tools to a smooth mortar finish. SAN JUAN HILLS GREENS 58 Concrete CORROSION PROTECTION SYSTEM 03300 G. PROTECTION AND CURING OF CONCRETE The contractor shall protect all concrete against damage. Exposed surfaces of new concrete shall be protected from the direct rays of the sun and from frost by being kept damp for at least two weeks after the concrete has been placed, or by using the "Hunt White Coverage" process or approved equal. H. BACKFILL Backfill around structures shall be in accordance with Section 02200. END OF SECTION SAN JUAN HILLS GREENS 59 Concrete Paving CORROSION PROTECTION SYSTEM 03305 SECTION 03305 CONCRETE PAVING PART 1 - GENERAL A DESCRIPTION Contractor shall provide all tools, equipment, materials, labor and services for furnishing, placing, finishing and curing concrete to the grades and dimensions shown on the Contract Drawings and as specified herein. Where any permit requirements exceed the requirements of this Section, the permit requirements shall govern. B SYSTEM The Work of this Section shall include the construction of cast in place and precast concrete for site improvements, specified herein, or shown on the Contract Drawings. Earthwork is included Section 02350 of these specifications. C STANDARD SPECIFICATION Except as supplemented or specifically modified herein or shown otherwise on the Contract Drawings, the entire work under this Section shall be in compliance with the provisions in the applicable Sections of the Edition that was in effect on the date that the Contract Drawings were signed and sealed by the Design Engineer and includes all Supplement(s) of the Standard Specifications for Public Works Construction (SSPWC) also known as the “Green Book”. In case of conflict between any requirements set forth in this Section, the Contract Drawings and any provisions of the foregoing Standard Specifications the requirements shown on the Contract Drawings shall govern over the requirements set forth herein and the requirements set forth herein shall govern over the SSPWC. D SUBMITTALS Contractor shall submit Certificates of Compliance, signed by the manufacture for concrete mix design, including aggregate, cement, fly ash and reinforcing steel. Contractor shall submit additional supporting data upon request of the Engineer. PART 2 – MATERIALS A CONCRETE MATERIALS Conform to the applicable portions of Section 201 of the SSPWC except as modified herein: Certificates of compliance, signed by the manufacture, shall be furnished for all cement and fly ash. Supporting data shall be furnished upon request of the Engineer. SAN JUAN HILLS GREENS 60 Concrete Paving CORROSION PROTECTION SYSTEM 03305 1. Unless otherwise shown on the Contract Drawings, mix design shall be 520- C- 3250 2. Portland Cement shall be Type II low alkali Portland cement conforming to ASTM C 150. 3. Type F fly ash shall conform to SSPWC 201-1.2.5 (b) and shall not exceed 20 %, by weight, of the total cementitious material. Type C fly ash shall not be allowed. 4. Water-cementitious ratio shall not exceed 0.45. 5. Maximum slump shall not exceed 4-inches for formed concrete and 5-inches for flat work. 6. Membrane curing compound shall be Type 1-D – Clear or translucent with fugitive dye. 7. Calcium Chloride shall not be allowed. B TRANSIT MIXED CONCRETE CERTIFICATION 1. The manufacture of the concrete shall furnish to the purchaser with each batch of concrete before unloading at the job-site, a delivery ticket on which is printed, stamped or written information concerning the concrete mix as follows: a. Name of ready-mix batch plant. b. Serial number of delivery ticket. c. Date and truck number. d. Name of Contractor. e. Work site name and location. f. Mix design or designation. g. Quantity of grout. h. Time and date of batching (time of first mixing of cement and aggregates). i. Type and brand of cement. j. Type, brand and weight of admixtures. k. Amount of cement (weight in pounds per cubic yard). l. Quantity of water (gallons) including moisture in aggregates. m. Space for water added at job-site (gallons) and name/initials of person authorizing the added water. 2. Not furnishing the above information shall be grounds for rejecting the grout mix. C REINFORCEMENT Conform to the applicable portions of Section 201 of the SSPWC except as modified herein: 1. Reinforcing bars shall be Grade 60 steel conforming to ASTM A 615. 2. Welded Wire Mesh shall conform to ASTM A 185. Wire gauge and dimensions shall be as shown on the Contact Drawings. D CONCRETE FORMS Conform to applicable portions of Sections 303 and 303 of the SSPWC and the Local Agency standards except as modified herein: SAN JUAN HILLS GREENS 61 Concrete Paving CORROSION PROTECTION SYSTEM 03305 1. All reinforced concrete structures shall have both inside and outside forms and shall conform to Section 303-1.3. 2. Curbs Walks, Gutters, Cross Gutters, Alley Intersections, Access Ramps and Driveways shall conform to Section 303-5.2 and the Local Agency Standards. In cases of conflict the Local Agency Standards shall prevail. E CRUSHED ROCK Crushed Rock shall be 1 Inch (25 mm) in conformance with Section 200-1.2 Table 200- 1.2 (A) of the SSPWC PART 3 - EXECUTION A GENERAL All concrete work shall conform to the applicable portions of Section of 303, the Contract Drawings and Local Agency Requirements. 1. Concrete shall be delivered to the work site in Transit Mixers (Transit mix concrete trucks) in accordance with Section 201-1.4.3 of the SSPWC. Certified weigh master certificates shall be delivered with each transit mix truck. Hand mixing (1 cy or less) will be permitted in accordance with Section 201-1.4.4 of the SSPWC. B REINFORCING STEEL Reinforcing steel shall be placed in accordance with the Contract drawings and Section 303-1.7 of the SSPWC. C CONCRETE STRUCTURES 1. Structural concrete shall be placed in accordance with the Contract drawings and Section303-1.8 of the SSPWC. 2. Compacted crushed rock (6-inch thick minimum) shall be placed as base material under all structures unless shown otherwise on the Contract Drawings. 3. Surface finish shall be in accordance with Section 303-1.9 of the SSPWC. 4. All concrete shall be cured by water or membrane compound methods in accordance with Section 303-1.10 of the SSPWC. D CONCRETE CURBS, WALKS, GUTTERS, CROSS GUTTERS, ALLEY INTERSECTIONS, ACCESS RAMPS AND DRIVEWAYS 1. Concrete curbs, walks, gutters, cross gutters, alley intersections access ramps and driveways shall be constructed in accordance with the Contract Drawings, Local Agency Requirements and Section 303.5 of the SSPWC. In case of conflicts, the Local Agency Standards shall prevail. 2. Minimum thickness of walks shall be 4-inch nominal. SAN JUAN HILLS GREENS 62 Concrete Paving CORROSION PROTECTION SYSTEM 03305 3. Concrete finish shall conform to Section 303-5.5 of the SSPWC. In case of conflicts, the Local Agency Standards shall prevail. END OF SECTION SAN JUAN HILLS GREENS 63 Precast Vaults and Meter Boxes CORROSION PROTECTION SYSTEM 03462 SECTION 03462 PRECAST CONCRETE VAULTS, AND METER BOXES PART 1 - GENERAL A. DESCRIPTION This section includes the materials, manufacture, and installation of precast concrete vaults. B. RELATED WORK All related work specified elsewhere, or in other codes or standards, will be as last revised, unless a specific date of issuance is called out in opposition to later revision date(s). Other sections of the technical specifications, not referenced below, shall also apply to the extent required for proper performance of this work. 1) Structure Earthwork: 02200 2) Concrete: 03300 C. APPROVED MANUFACTURERS 1. Precast Vaults Brooks Products, Inc. Best Concrete Products Associated Concrete Products 2. Meter Boxes Eisel Enterprises, Inc. Brooks Products, Inc. 3. Joint Sealing Compound Quikseal manufactured by Associated Concrete Products 4. Waterproofing Grace Dehydratine 4 D. FRAMES AND COVERS All precast sections shall be provided with fabricated aluminum or steel frames and covers as specified or shown on the drawings and shall be built up so that the cover is flush with the surrounding surface unless otherwise specified on the drawings or by the PWD Representative in the field. E. METER BOXES 1. Precast concrete meter boxes shall be furnished and installed by the contractor unless noted otherwise. SAN JUAN HILLS GREENS 64 Precast Vaults and Meter Boxes CORROSION PROTECTION SYSTEM 03462 2. Sizes shall be as specified on the standard drawings for the various sizes and types of services. 3. Any meter boxes to be requested for review as an equal must have identical lid and inside box dimensions. PART 2 - MATERIALS A. PRECAST CONCRETE VAULT 1. Precast concrete vaults and covers shall be manufactured in a plant especially designed for that purpose and shall conform to the shapes and dimensions indicated on the plans. 2. Design loads shall consist of dead load, live load, impact, and in addition, loads due to water table and any other loads that may be imposed upon the structure. Live loads shall be for HS 20 per AASHTO standard specifications for highway bridges. Design wheel load shall be 16 kips. The live load shall be that which produces the maximum shears and bending moments in the structure. 3. The manufacture shall certify that the precast vault is fabricated to withstand the soil and loading conditions. B. METER BOX COVERS 1. All meter box covers shall be furnished with rectangular reading lids. 2. Concrete meter box covers shall be installed only in non-traffic locations. 3. Meter box covers within roadways or driveways shall be steel diamond plate designed to withstand highway loading. C. VAULT FRAMES AND COVERS 1. Vault frames and covers shall be fabricated stainless steel or aluminum. 2. Covers shall be fabricated with supports to resist deflection. 3. All covers shall be hinged. Covers shall have hydraulic assists. 4. All covers shall be equipped with a hold-open mechanism. 5. All covers shall be equipped with a flush locking devices. 7. All vaults located within roadways or driveways shall have traffic covers. Vaults in all other locations shall have parkway covers unless specified otherwise by the PWD Representative. 8. A 6" by 12" hinged reading lid shall be positioned over a meter in a vault. D. JOINT SEALING COMPOUND The joint sealing compound shall be a permanently flexible plastic material complying in every detail to Federal Specification SS S-00210 (GSA-FSS) dated July 26, 1965. "Quickseal", or equal. SAN JUAN HILLS GREENS 65 Precast Vaults and Meter Boxes CORROSION PROTECTION SYSTEM 03462 E. WATERPROOFING Waterproofing shall be formulated to comply with Federal Specification SS-A-701. PART 3 - EXECUTION A. EARTHWORK 1. Excavation and backfill for precast concrete vaults shall be in accordance with Section 02200 and the requirements herein. 2. The Contractor shall prepare an excavation large enough to accommodate the structure and permit grouting of openings and backfilling operations. 3. The bottom of the structure shall be placed on 12 inches of compacted, crushed rock sub-base, graded level and to the proper elevation as shown on the plans. B. INSTALLATION 1. Openings or "knockouts" in precast concrete vaults shall be located as shown on the drawings and shall be sized sufficiently to permit passage of the largest dimension of pipe and/or coupling flange. Upon completion of installation, all voids or openings in the vault walls around pipes shall be filled with 3,000-psi concrete or mortar, using an approved epoxy for bonding concrete surfaces. 2. After the structure and all appurtenances are in place and approved, backfill shall be placed to the original ground line or to the limits designated on the plans. 3. All joints between precast concrete vault sections shall be made watertight. The sealing compound shall be installed according to the manufacturer's recommendations to provide a watertight joint that remains impermeable throughout the design life of the structure. 4. Frames and covers shall be built up so that the cover is flush with the surrounding surface unless otherwise specified on the drawings or by the PWD Representative in the field. The contractor is responsible for placing the cover at the proper elevation where paving is to be installed and shall make all necessary adjustments so that the cover meets these requirements. 5. Waterproofing shall be applied to the exterior walls of all buried vaults in accordance with the manufacturer's instructions. Protection shall be placed over the waterproofing to prevent damage. C. METER BOXES 1. Boxes shall be set true to line and to the grade of the top of the curb, sidewalk, or surrounding graded area. 2. Meter boxes are not to be set until the developer has completed fine grading for landscape grading. SAN JUAN HILLS GREENS 66 Precast Vaults and Meter Boxes CORROSION PROTECTION SYSTEM 03462 3. Retaining walls may be required around meter boxes installed on slopes as determined by the PWD Representative. END OF SECTION SAN JUAN HILLS GREENS 67 Painting and Coating CORROSION PROTECTION SYSTEM 09900 SECTION 09900 PAINTING AND COATING PART 1 - GENERAL A. Description This section includes the materials and application of painting and coating systems for buried and exposed surfaces. All articles to be painted or coated will be painted or coated in the place of manufacture, unless field painting and coating is absolutely necessary. The PWD Representative will make the determination. In the event that the paint or coating is damaged in the field, it will be touched up in the same manner as the original paint or coating applied in the place of manufacture. B. Related Work Described Elsewhere All related work, or in other codes or standards, will be as last revised, unless a specific date of issuance is called out in opposition to later revision date(s). Other sections of the technical specifications, not referenced below, shall also apply to the extent required for proper performance of this work. 1. Ductile-Iron Pipe and Fittings: 15056 2. Manual Valves: 15100 3. Fire Hydrants: 15139 4. Domestic and Recycled water Facilities Identification: 15151 C. Approved Manufacturers and Materials 1. Inorganic Zinc Primer Carboline 621 Tnemec – Zinc 90-97 Devoe Catha-Coat 302H 2. Alkyd Enamel Carboline Subsil 30 HS Tnemec Hi-Build Tnemec-Gloss 2H Ameron Amercoat 5401 HSA Devoe Devguard 4308 SAN JUAN HILLS GREENS 68 Painting and Coating CORROSION PROTECTION SYSTEM 09900 3. Epoxy Paint Carboline Glamorglaze 202 Tnemec Hi-Build 66 Epoxoline Devoe Bar – Rust 233H Ameron Amercoat 351 4. Bituminous Mastic Minnesota Mining and Manufacturing EC 244 Carboline Kop-Coat Bitumastic 300M 5. Polyurethanes Carboline 133HB Tnemec Hi-Build Epoxoline 69 Devoe Devthane 389 Ameron Amercoat 450HS D. Paint Schedule Aboveground or exposed facilities shall be color coded to differentiate recycled water facilities from domestic water facilities. 1. Domestic water System a. Piping and Structures: Safety Blue Carboline S150 Tnemec SC06 Devoe 9800 Ameron BL-6 b. Valve Box Lids and PWD Fire Hydrants: OSHA Safety Yellow Carboline 6666 Tnemec SC01 Devoe 9400 Ameron YE-3 c. Private Fire System: Safety Red Carboline 5555 Tnemec SC09 Devoe 9000 Ameron RD-2 2. Recycled Irrigation Water Facilities: Safety Purple Devoe 9600 Tnemec SC08 SAN JUAN HILLS GREENS 69 Painting and Coating CORROSION PROTECTION SYSTEM 09900 E. Permits All work shall conform to the specifications and requirements of the State of California Department of Transportation, the Orange County PFRD, the city having jurisdiction, or and other agencies involved. The contractor shall keep a copy of all the required permits in the job site and comply with all the terms and conditions of said permits. PART 2 - MATERIALS A. Primer 1. All primer shall contain not less that 63% solids by volume. B. Alkyd Enamel 1. All enamels shall be silicone-alkyd based. 2. All enamels shall be lead-free. 3. All enamels shall be high gloss industrial type intended for use on exterior metal surfaces. 4. All enamels shall contain not less than 60% solids. C. Bituminous Mastic 1. Bituminous mastic shall be coal-tar pitch based. 2. Bituminous mastic shall have a minimum of 70% solids by volume. D. Epoxy Paint 1. Epoxy shall be a colored polyamide cured epoxy with not less than 70% solids by volume. 2. All coatings and pigments to be used in the water passages of domestic water service components and appurtenances shall have National Sanitation foundation (NSF) or Underwriters Laboratory (UL) approval for use with domestic water. NSF and / or UL approved coatings acceptable for use in contact with domestic water are: SAN JUAN HILLS GREENS 70 Painting and Coating CORROSION PROTECTION SYSTEM 09900 a. Devoe Bar-Rust 233H b. Tnemec Pota-Pox Series 20 c. Carboline Super Hi-Guard 891 PART 3 - EXECUTION A. Surface Preparation 1. Do not sandblast or prepare more surface area than can be coated in one day. Remove all sharp edges, burrs, and weld spatter. Do not sandblast epoxy-coated pipe that has already been factory coated. 2. Surface preparation shall conform to the SSPC specifications as described below: Solvent Cleaning SP-1 Hand Tool Cleaning SP-2 Power Tool Cleaning SP-3 White Metal Blast Cleaning SP-5 Commercial Blast Cleaning SP-6 Brush-Off Blast Cleaning SP-7 Near-White Blast Cleaning SP-10 3. Wherever the words "solvent cleaning," "hand tool cleaning," "wire brushing," or "blast cleaning" or similar words are used in these specifications or in paint manufacturer's specifications, they shall be understood to refer to the applicable SSPC (Steel Structure Painting Council, Surface Preparation Specifications, ANSI A159.1) specifications listed above. B. Painting Systems 1. All materials of a specified painting system, including primer, intermediate, and finish coats, shall be produced by the same manufacturer. Thinners, cleaners, driers, and other additives shall be as recommended by the paint manufacturer for the particular coating system. 2. Deliver all paints to the job site in the original, unopened containers. C. Surfaces Not To Be Coated The following surfaces shall not be painted and shall be protected during the painting of adjacent areas: SAN JUAN HILLS GREENS 71 Painting and Coating CORROSION PROTECTION SYSTEM 09900 1. Mortar-coated pipe and fittings. 2. Stainless steel. 3. Metal letters. 4. Nameplates. 5. Grease fittings. 6. Brass and copper, submerged. 7. Buried pipe, unless specifically required in the piping specifications. 8. Bronze meters and strainers. D. Protection of Surfaces Not To Be Painted Remove, mask, or otherwise protect hardware, lighting fixtures, switch plates, aluminum surfaces, machined surfaces, couplings, shafts, bearings, nameplates on machinery, and other surfaces not intended to be painted. Provide drop cloths to prevent paint materials from falling on or marring adjacent surfaces. Protect working parts of mechanical and electrical equipment from damage during surface preparation and painting process. Mask openings in motors to prevent paint and other materials from entering the motors. E. Field Touch Up of Manufacturer-Applied Prime Coats Surfaces that are primed at the place of manufacture shall receive a field touch-up of inorganic zinc primer to cover all scratches or abraded areas. F. Alkyd Enamel 1. The following items shall be painted using an alkyd enamel system: a. All aboveground or exposed piping and all piping in vaults. b. Fire hydrants. c. Valve box lids. d. Air release valves. e. Meter box reading lids for all recycled water services. f. Steel meter vault covers for all services 3 inches and larger. g. All exposed metalwork as directed by the PWD Representative. 2. Surface Preparation: a. All rust, mill scale, or weld splatter shall be removed by sandblasting or power tool cleaning. b. All unpainted surfaces shall be solvent cleaned in accordance with SP-1. SAN JUAN HILLS GREENS 72 Painting and Coating CORROSION PROTECTION SYSTEM 09900 c. All abraded or scratched enamel coatings shall be sanded smooth or receive power tool cleaning per SP-3. d. All failures in the existing coating shall be sandblasted in accordance with SP-6. e. All existing surfaces to be repainted shall be Solvent cleaned in accordance with SP-1. 3. All unpainted or damaged surfaces shall be coated with primer to a dry-film thickness of not less than 2 mils. 4. The finish coats shall be two or more coats of alkyd enamel applied to a dry-film thickness of 3 mils each, providing a total painted dry film thickness of not less than 5 mils. G. Bituminous Mastic 1. Buried metal (flanges, Teflon coated nuts and bolts, flexible couplings, exposed reinforcing steel, etc.) shall be coated with a minimum of 20 mils of bituminous mastic. 2. All surfaces coated with bituminous mastic shall be covered with 8 mil polyethylene wrap per Section 15056. H. Epoxy Coating All items requiring epoxy coating to be coated with factory applied fusion bonded 100% pure powder epoxy. However, where, in the Engineer’s opinion, because of the nature of the item being coated it would be impossible to use the fusion bonded powder method without causing damage to the item, the use of a liquid epoxy, factory applied by the manufactured of the item being coated, will be permitted. The use of liquid epoxy other than those specified herein, including the equipment manufacturer’s proprietary coating systems, must be reviewed and approved by the Engineer prior to use. 1. Only those metal surfaces specifically called out shall be epoxy coated. 2. Epoxy lining and coating of valves shall be per AWWA C550 and Section 15100 Manual Valves. 3. Surfaces to be epoxy coated shall be sandblasted to SP-10 requirements. 4. Sandblasted surfaces shall be coated with inorganic zinc primer to a dry film thickness of not less than 3 mils. 5. Apply two coats of epoxy paint (4 mils each) to the primed surface. The manufacturer's recommended drying time between coats shall be followed. SAN JUAN HILLS GREENS 73 Painting and Coating CORROSION PROTECTION SYSTEM 09900 6. Prepare multiple-component coatings using all of the contents of the container for each component as packaged by the paint manufacturer. Do not use partial batches. Do not use multiple-component coatings that have been mixed beyond their pot life. Provide small quantity kits for touch up painting and for painting other small areas. Mix only the components specified and furnished by the paint manufacturer. Do not intermix additional components for reasons of color or otherwise, even within the same generic type of coating. I. Dry-Film Thickness Testing 1. Measure coating thickness specified for metal surfaces with a magnetic-type dry-film thickness gage. Test the finish coat (except zinc primer and galvanizing) for holidays and discontinuities with an electrical holiday detector, low-voltage, wet-sponge type. The Contractor shall provide measuring equipment. Provide detector as manufactured by Tinker and Rasor or K-D Bird Dog. Provide dry-film thickness gage as manufactured by Mikrotest or Elcometer. Check each coat for the correct dry-film thickness. Do not measure within eight hours after application of the coating. 2. If the item has an improper finish color or insufficient film thickness, the surface shall be cleaned and top coated with the specified paint material to obtain the specified color and coverage. Visible areas of chipped, peeled, or abraded paint shall then be primed and finish coated in accordance with the specifications. Work shall be free of runs, bridges, shiners, laps, or other imperfections. 3. The epoxy lining of all valves will be inspected and tested by a PWD representative prior to valve installation. The contractor shall notify the PWD seven days prior to valve installation to arrange for inspection. END OF SECTION SAN JUAN HILLS GREENS 74 Combo Air and Vacuum Release Assembly CORROSION PROTECTION SYSTEM 15089 SECTION 15089 COMBINATION AIR RELEASE AND VACUUM RELIEF VALVE ASSEMBLY PART 1 - GENERAL A. Description This section includes materials and installation of combination air and vacuum valves. Air release and vacuum relief assemblies to be provide and installed per AWWA C 512, unless noted otherwise in this section. B. Application 1. Air release and vacuum relief valves shall be installed at high points in continuous lines 10-inches and larger or as shown on the plans. 2. If the profile changes during construction from that shown on the drawings, the air and vacuum release valves shall be installed at the high points in lines as constructed. 3. The installation shall be complete as shown on Standard Drawing W -16. C. Related work All related work specified elsewhere, or in other codes or standards, will be as last revised, unless a specific date of issuance is called out in opposition to later revision date(s). Other sections of the technical specifications, not referenced below, shall also apply to the extent required for proper performance of this work. 1. Concrete: 03300 2. Painting and Coating: 09900 3. Hydrostatic Testing of Pressure Pipelines: 15042 4. Copper, Brass and Bronze Pipe, Fittings and Appurtenances: 15057 5. Manual Valves: 15100 D. Approved Manufacturers SAN JUAN HILLS GREENS 75 Combo Air and Vacuum Release Assembly CORROSION PROTECTION SYSTEM 15089 1. APCO Model 143C, and 145C 1. Val-Matic 2. Pipeline Products Company. E. Air Release Valve Criteria 1. Air release shall be sized to accommodate the release of the maximum amount of entrained air that could be released in the system, as a function of the maximum differential in temperature and pressure which could result in air entrainment, or 2% of the volume of water passing through the system; whichever is greater. F. Vacuum Relief Criteria 1. The vacuum relief shall be sized to accommodate 200% of the normal flow. PART 2 - MATERIALS A. Combination Air and Vacuum Relief 1. Materials of construction for combination air and vacuum relief valves shall be as described below: Item Material Specification Body and Cover Cast iron Ductile iron Float, Lever, Poppet Stainless steel ANSI Type 316 (ASTM A240 or A276) Seat Rubber Buna-N 2. Coat exterior of valves with one coat of primer and two coats of finish paint at the place of manufacture, applied per Section 09900. 3. Coat interior of valves with epoxy at the place of manufacture in accordance with Section 09900. B. Steel Vented Pipe Vertical Cover 1. The steel vented pipe vertical cover shall be manufactured from 12-gauge steel or approved equal. C. Service Piping SAN JUAN HILLS GREENS 76 Combo Air and Vacuum Release Assembly CORROSION PROTECTION SYSTEM 15089 Water service piping utilized in the installation of the combination air and vacuum relief valve shall be Type K copper with bronze accessories per Section 15057. D. PVC Pipe PVC pipe nipple shall be Class C900 or C905 as described in Section 15064, Schedule 80. PART 3 - EXECUTION A. Location 1. Air release valve assemblies and combination air and vacuum valves shall be installed at each point in the pipeline as shown on the drawings or as specified by the PWD Representative. 2. The tap for the air valves shall be made in a level section of pipe no closer than 18 inches to a bell, coupling, joint, or fitting. 3. The center of the PVC sleeve shall be, except as otherwise approved by the PWD Representative, located as shown on Standard Drawing W-16 as described below: a. Where concrete curb or asphalt concrete (AC) berm exists or is to be constructed, and the sidewalk is next to the property line; 2 feet 1 inch back of the face of the curb. b. Where 6-foot wide or narrower sidewalk is to be installed or exist next to the curb; 10 inches back of sidewalk edge. Where there is insufficient Public Right-of-Way behind of the sidewalk, an easement will be required. c. Where there is no curb or berm, the location shall be designated by the PWD Representative. B. Installation 1. Air release assemblies and combination air and vacuum valves shall be installed in accordance with Standard Drawing W -16. 2. The tap and piping shall be installed per Section 15057. 3. The concrete pad and support shall be constructed per Section 03300. SAN JUAN HILLS GREENS 77 Combo Air and Vacuum Release Assembly CORROSION PROTECTION SYSTEM 15089 3. Clean threaded joints by wire brushing or swabbing. Apply Teflon joint compound or Teflon tape to pipe threads before installing threaded valves. Joints shall be watertight. 5. The air and vacuum relief valve and the steel vented pipe cover shall be painted in accordance with Section 09900. The final coat of paint shall be applied immediately prior to the final inspection. 6. A bronze ball valve with handle shall be installed on the copper service line above the concrete slab. 7. A PVC nipple shall be installed between the shutoff valve and the air release valve. C. Valve Pressure Testing 1. Test valves at the same time that the connecting pipelines are pressure tested. See Section 15042 for pressure testing requirements. 2. Protect or isolate any parts with a pressure rating is less than the test pressure. END OF SECTION SAN JUAN HILLS GREENS 78 Cathodic Protection and Joint Bonding CORROSION PROTECTION SYSTEM 16640 SECTION 16640 CATHODIC PROTECTION AND JOINT BONDING PART 1 - GENERAL A. Description This section includes materials, testing, and installation of cathodic protection equipment including magnesium anodes, wiring, bonding, test stations, dielectric union (separation), thermite welds, and other equipment. The work shall include the provision of all materials, equipment and app aratus not specifically mentioned herein or noted on the plans, but which are obviously necessary to complete the work specified. B. Related Work Specified Elsewhere 1. Trenching, Backfilling, and Compacting: 02223. 2. Painting and Coating: 09900. 3. Concrete: 03300 C. Submittals 1. Submit shop drawings in accordance with the General Conditions. 2. Submit manufacturer's catalog data on anodes, wires, test stations, Pipe clamps, and thermite welds. 3. Following completion of the cathodic prote ction installations, but prior to final restoration, the City’s hired CONSULTANT shall submit a testing report including elelctrical continuity and cathodic protection potential and current data on all installed anode and connections. The report needs to i nclude findings and conclusions for approval to the ENGINEER. D. References Where referred to in these specs the following referenced specifications apply: American Society of Testing and Materials (ASTM) National Electrical Manufacturers Association (NEMA) Industrial Cable Engineers Association (ICEA) American Water Works Association (AWWA) SAN JUAN HILLS GREENS 79 Cathodic Protection and Joint Bonding CORROSION PROTECTION SYSTEM 16640 National Association of Corrosion Engineers (NACE) American National Standards Institute (ANSI) PART 2 - MATERIALS All materials shall conform to the requirements set forth herein or as designated on the drawings, unless otherwise specified. All materials must be new, free from defects, and shall be of the best commercial quality for the purpose specified. All necessary items and accessories not shown on t he drawings or specified herein, but which are required to fully carry out the specified intent of the work, shall be furnished by the CONTRACTOR without additional cost to the OWNER. A. Magnesium Anodes Anodes used shall be prepackaged, high potential, cast magnesium. The anode sizes and chemical composition listed as below: Chemical Composition Element Content % Al : 0.010 Mn : 0.50 to 1.30 Cu : 0.02 max Ni : 0.001 max Fe : 0.03 max Other : 0.05 each or 0.3 max total Magnesium : Remainder Dimension Length : 60 in. Height : 4 in. Width : 4 in. Pre packed dimension Length : 64 in. Height : 6.75 in. Anode Lead wire Size : # 8 AWG Length : 20 ft (minimum) Insulation : HMWPE Color : Black Weight Bare : 60 lbs Packaged : 130 lbs SAN JUAN HILLS GREENS 80 Cathodic Protection and Joint Bonding CORROSION PROTECTION SYSTEM 16640 The anodes shall be factory assembled with a chemical backfill in a water permeable cloth sack. The chemical backfill shall be a mixture consisting of 75% gypsum, 20% bentonite, and 5% sodium sulfate. The anode shall be supplied with a factory installed lead wire, type HMWPE. The anode wire shall be of sufficient length to reach appropriate Meter Box, Air Vacuum, Fire Hydrant or valves without splicing. Bentonite Bentonite shall be a commercial-processed powdered bentonite, Wyoming type, such as Imacco-gel, Black Hills, or equal. All materials used in making the connection to the facilities shall conform to the applicable sections of these specifications. Open Circuit Potential The open circuit potential of all anodes, buried in the soil, shall be between -1.55 and -1.75 Volts DC versus a copper-copper sulfate reference electrode. Anode Manufacturers Corrpro, Model # 60S4 Galvotec Corrosion Services, model # GA –MG-60-HP Northtown Company, Model # H-MG-60-HP Or approved equal. B. Wires All wires shall be stranded copper with HMWPE insulation suitable for direct burial in corrosive soil and water, conforming to UL83 and ASTM standards B3 or B8. HMWPE insulation shall conform to ASTM D1248 type1, class c, grade 5. Anode lead wire : No. 8 AWG HMWPE (Black) Test lead wire : No. 8 AWG HMWPE (White) Bonding Wire : No. 8 AWG HMWPE (White) Wire Manufacturer: Kalas Manufacturing Incorporated Or approved equal. C. Anode to Pipe Connection Anode to pipe connection at all meter station, air vacuums and Valves shall be done using pipe clamp as shown in the drawing. Clamp to be brass with brass screws and swivel to allow installation with out removing screws. Clamp size to match nominal size of copper pipeline. Clamp Manufacturer: Northtown Company, Model CPGC-1, CPGC-2 SAN JUAN HILLS GREENS 81 Cathodic Protection and Joint Bonding CORROSION PROTECTION SYSTEM 16640 Or approved equal. Anode to pipe connection at all Fire Hydrants shall be done by Thermite welding as shown in the drawing. Thermit weld manufacturer: ThermOweld, Erico Or approved Equal. D. Cathodic Test Stations Flush-Mounted Type: Test station shall be precast concrete with a cast iron cover marked "CP Test" designed to withstand H -20 traffic loads. Provide a five-lead terminal board for Type II test stations with 3/4 inch clearance between terminals. Terminal studs and nuts shall be nickel-plated brass. Test station shall be Brooks Products IRT or Christy G5 valve box or equal. Provide a 0.01-ohm shunt in each test station. Shunts shall be as manufactured by Holloway, M. C. Miller Company, Cott Manufacturing, or equal. Test station boxes mounted in unpaved area shall be mounted in a 24 - inch square by 4- inch thick concrete pad. Test station wiring shall be No. 8 AWG single conductor, stranded copper, with white 600-volt HMWPE insulation. E. Bonding Wires Bonding wires shall be No. 8 AWG single-conductor, stranded copper, with 600-volt HMWPE insulation. F. Thermite-Weld Caps Thermite-weld caps shall be high-density polyethylene plastic, 10 mils (minimum) thick, as manufactured by Royston Laboratories or equal. Cap shall have a 100% solids mastic-filled dome and a tunnel portion to contain the lead wire from the thermite weld connection. Use Roybond 747 primer or equal. G. Dielectric Separation (Union) All Dielectric union for 1” or 2” copper pipe shall be accordance with the latest ANSI ASTM and ASME material specification. SAN JUAN HILLS GREENS 82 Cathodic Protection and Joint Bonding CORROSION PROTECTION SYSTEM 16640 CONTRACTOR must get approval from ENGINEER for dielectric union manufacturer. PART 3 - EXECUTION All materials, workmanship and installation shall conform to all requirements of the legally constituted authority having jurisdiction. These authorities include, but are not limited to, the latest revision of the National Electric Code, General Construction Safety Orders of the Industrial Accident Commission; and all other applicable State, County, or City codes and regulations. Nothing in the drawings or specifications is to be constructed to permit work not conforming to these regulations and codes. Where larger size or better grade materials than required by these regulations and codes are specified, the specifications and drawings shall have precedence. All materials and equipment to be used in construction shall be stored in such a manner to be protected from detrimental effects from the elements. If actual storage cannot be provided, materials and equipment shall be stacked well above ground level and protected from the elements with tarps, allowing for adequate ventilation to prevent buildup of moisture condensation. The CONTRACTOR shall be responsible for clean-up and removal of all debris, extra material, and equipment utilized for installation of the cathodic protection system. A. Magnesium Anodes Anodes shall be installed at the locations and in the manner indicated on the drawings. Anodes shall not be carried, suspended, or lowered by means of anode lead wires. Damaged anodes shall be replaced by the contractor at his sole expense. Protective plastic or paper covering shall be removed before anodes are installed. Anode shall be installed as per manufacturer instruction in native soil and shall be backfilled with bentonite free of rocks, clods, vegetation and debris of any type. Anodes shall be backfilled with six inch lifts of native soil, each lift compacted sufficiently and tightly, taking care to cause no punctures or damage to cloth bag, anode backfill material, anode lead wire or the anode itself. Install each prepackaged anode in a hole larger than the prepackaged anode diameter as noted on plans or per the manufactures installation instructions. Auger may be done manually or using air vacuum method depends upon soil condition. Excavation within the first 4 feet, must be either by hand digging or use of an air-knife. Anode lead wire shall run to the point of connection at the end of t he pipe run in the meter box. Provide minimum 1 ft slack in the wire, and coil it in the meter box. At air releases valve and blow off valve, the anode lead wire shall run through under the concrete pad and clamped to the copper pipe. At blowoffs and manua l SAN JUAN HILLS GREENS 83 Cathodic Protection and Joint Bonding CORROSION PROTECTION SYSTEM 16640 air releases, coil anode lead wire in the valve box and clamp to the copper pipe. Care must be taken to ensure that no damage occurs to wires and insulation. After backfill is level with the top of the anode, pour a minimum of 10 gallons of water onto the anode to completely saturate the backfill. Place and tamp bentonite in annular space between anode bag and hole wall. Place either bentonite or native soil compacted to 90% between anode bags and on top of anodes. If anode location is in sidewalk, patch hole created by 12” diameter core per section 03300, minimizing damage to the rest of the sidewalk. If anode location is in resident lawn, care will be exercised not to damage the resident’s lawn and to restore the soil surface after the work (auger hole) to its original state. B. Wires Wires buried in the ground shall be laid straight and without kinks. Direct buried wire shall have a minimum cover of 18-inches. Each wire run shall be continuous in length and free of joints or splices. Care shall be exercised during installation to avoid punctures, cuts, and similar damage to insulation. Any damage to insulation will require replacement of the entire cable length. At the discretion of the on site City Inspector, splices may be made using a 3M-82-A1 splice kit. In no case will the use of a splice kit be allowed to the wire within 10 feet of the anode bag. Backfill surrounding the wires shall be native soil free of foreign materials. Plastic cable warning tape shall be placed in the backfill twelve inches directly above the wire runs. Fill annular space created by tunneling with grout. Provide minimum 1- foot separation between anode lead wires and any other utility. C. Anode to Pipe Connection Anode to Pipe connection shall be done using clamp for all meter station, air vacuums and Valves as shown in the drawings. Anode to pipe connection at all Fire Hydrants shall be done using thermite welding as shown in drawing. Remove any existing coating on the pipe by making a 3 -inch-square window in the coating. File or grind the exposed metal surface to produce a bright metal finish, equivalent to SSPC SP-10. Make weld and test per Standard Drawing. SAN JUAN HILLS GREENS 84 Cathodic Protection and Joint Bonding CORROSION PROTECTION SYSTEM 16640 D. Coating Over Thermite-Weld Connection After completing the thermite-weld connection between the wire and the pipe, coat the connection with primer and thermite weld cap. E. Bonding If anodes installed for a cluster of pipes, Bond all pipes using no. 8 HMWPE wire as shown in the drawings. All service meter pipe, Air- vacuum pipe and Blow offs pipe can bonded using pipe clamp and fire hydrant can be bonded using thermite weld. F. Installation of Cathodic Test Stations Provide test stations at as shown in Drawings. Install a flush-mounted type with the top flush with the ground or pavement . Coil the wire in slack loops to compensate for settlement near the cathodic test station. PART 4 - TESTING After installation of the cathodic protection facilities at each location, the system shall be tested under the direct supervision of a NACE I nternational certified cathodic protection specialist or registered corrosion engineer hired by the City to assure conformance with the specifications. A minimum of a 5 day notice shall be given to the ENGINEER prior to scheduling the energizing and testing of the systems. A report on the first 10 installation shall be submitted no later than 7 days after the installation of the first 10 sites. 1. A final report on all the installations, containing the results of testing shall be submitted no later than 30 days following completion of field testing. A. Cathodic Protection System Testing shall include a determination of proper operation and adequacy of anodes and anode to pipe connections. Prior to introducing cathodic protection current or connecting the anode, static potentials with reference to Cu/Cuso4 reference electrode shall be obtained and recorded. The open circuit potential of each sacrificial Mg anode with reference to Cu/Cuso4 reference electrode shall be obtained and recorded. A high impedance voltmeter shall be used to measure and record the potential. After connecting the anodes, potentials and anode currents shall also be documented. The piping shall be protected at an acceptable cathodic protection criterion per NACE International standard SP-0169 (latest edition). SAN JUAN HILLS GREENS 85 Cathodic Protection and Joint Bonding CORROSION PROTECTION SYSTEM 16640 A report containing the results of testing shall be submitted no later than 30 days following completion of field testing. B. Dielectric separation (union) Dielectric union installation test: Test all dielectric union m ust be tested using Mc miller make 601 insulation checker, or approved equal, for acceptance. END OF SECTION