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HomeMy WebLinkAbout2008-213 (5)Indian River County Purchasing Division 180027 th Street Vero Beach, FL 32960 Phone (772) 567-8000 Fax (772) 770=5140 Ext. 1416 Date. Project Name: Bid Number: Bid Opening Date: THE BI ADDENDUM NO. 3 March 17, 2008 Wabasso Beach Park Restoration 2008032 March 26, 2008 at 2:00 pm TE HAS B TO MARCH This Addendum is in Response to REQUESTS FOR INFORMATION (RFI) and consisting of 2 pages. ****************This Addendum MUST be returned with your bid***************** All Bids must be received by the Purchasing Division office located at 1800 27ths Street, Vero Beach, FL 32960, prior to the Date and Time shown above. Late bids will be returned unopened. Company Name Name: (Type / Printed) Authorized Signature: Telephone: Title: Date: Fax: TO PROSPECTIVE BIDDERS AND OTHERS CONCERNED: This ADDENDUM and all other ADDENDUMS are intended to clarify, correct, or change the Bidding Requirements and/or the Contract Documents. Therefore, ent .All ADDENDUMS are hereby made a part of hey hereby supersede anything to the contrary in and s e Bidding Requirements or Contract Doc hall be attached to the subject Bidding Requirements and Contract Documents. F:\Public Works\Cliff Suthard\Wabasso Beach Park\A Construction Bid Documents\Bid Documents as of 2-6-2008\Hddendum #1 #2. #3. #49 & #5\Addendum #3.doc Page 1 of 2 3.03 into existing water bodies, must be installed, constructed or, in case of vegetative buffers, protected from disturbance, as a first step in the land alteration process. E. Working in or Crossing Waterways or Water Bodies: Land alteration and construction shall be minimized in both permanent and intermittent waterways and the immediately adjacent buffer of 25 feet from top of bank of the waterways and the buffer area whenever possible, and barriers shall be used to prevent access. Where in channel work cannot be avoided, precautions must be taken to stabilize the work area during land alteration, development and/or construction to minimize erosion. If the channel and buffer area are disturbed during land alteration, they must be stabilized within three (3) calendar days after the in channel work is completed. Silt curtains or other filter/siltation reduction devices must be installed on the downstream side of the in channel alteration activity to eliminate impacts due to increased turbidity. Whenever stream crossings are required, properly sized temporary culverts shall be provided by the Contractor and removed when construction completed. The area of the crossing shall be restored to a condition as nearly as possible equal to that which existed prior to any construction activity. F. Swales, Ditches and Channels: All swales, ditches and channel leading from the site shall be sodded within three (3) days of excavation. All other interior swales, etc., including detention areas will be sodded prior to substantial completion. G. Underground Utility Construction: The construction of underground utility lines and other structures shall be done in accordance with the following standards: 1. No more than 100 lineal feet of trench shall be open at any time; 2. Wherever consistent with safety and space consideration, excavated material shall be cast to the uphill side of trenches. Trench material shall not be cast into or onto the slope of any stream, channel, road ditch or waterway. PERFORMANCE A. Maintenance: All erosion and siltation control devices shall be checked regularly, especially after each rainfall and will be cleaned out and/or repaired as required. B. Compliance: Failure to comply with the aforementioned requirements may result in a fine and/or more stringent enforcement procedures such as, but not limited to, issuance of a "Stop Work Order". END OF SECTION 02270 - 2 02270 — Erosion Control SECTION 02302 EXCAVATION AND FILL PART 1 - GENERAL 1.01 REFERENCES The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. A. AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) 1. ASTM C 33(1999; Rev. A) Concrete Aggregates 2. ASTM C 136(1996; Rev. A) Sieve Analysis of Fine and Coarse Aggregates 3. ASTM D 698(1991; R 1998) Laboratory Compaction Characteristics of Soil Using Standard Effort (129400 ft-lbf/ft (600 kN-m/m)) 4. ASTM D 1140(1997) Amount of Material in Soils Finer Than the No. 200 (75 - Micrometer) Sieve 5. ASTM D 1556(1990; R 1996) Density and Unit Weight of Soil in Place by the Sand -Cone Method 6, ASTM D 1557(1991; R 1998) Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft (2,700 kN-m/m)) 7. ASTM D 2321(1989; R 1995) Underground Installation of Thermoplastic Pipe for Sewers and Other Gravity -Flow Applications 8, ASTM D 2487(1998) Classification of Soils for Engineering Purposes (Unified Soil Classification System) 9, ASTM D 2922(1996) Density of Soil and Soil -Aggregate in Place by Nuclear Methods (Shallow Depth) 10. ASTM D 3017(1996) Water Content of Soil and Rock in Place by. Nuclear Methods (Shallow Depth) 11. ASTM D 4318(1998) Liquid Limit, Plastic Limit, and Plasticity Index of Soils B. AMERICAN WATER WORKS ASSOCIATION (AWWA) 1 1.02 DEFINITIONS AWWA C600(1999) Appurtenances A. Hard Materials Installation of Ductile -Iron Water Mains and their 02302=1 02302 - Excavation and Fill 1.03 J�V Weathered rock, dense consolidated deposits, or conglomerate materials which are not included in the definition of "rock" but which usually require the use of heavy excavation equipment, ripper teeth, or jack hammers for removal. B. Rock Solid homogeneous interlocking crystalline material with firmly cemented, laminated, or foliated masses or conglomerate deposits, neither of which can be removed without systematic drilling and blasting, drilling and the use of expansion jacks or feather wedges, or the use of backhoe -mounted pneumatic hole punchers or rock breakers; also large boulders, buried masonry, or concrete other than pavement exceeding 1/2 cubic yard in volume Removal of hard material will not be considered rock excavation because of intermittent drilling and blasting that is performed merely to increase production. C. Cohesive Materials Materials ASTM D 2487 classified as GC, SC, ML, CL, MH, and CH. Materials classified as GM and SM will be identified as cohesive only when the fines have a plasticity index greater than zero. D. Cohesionless Materials Materials ASTM D 2487 classified as GW, GP, SW, and SP. Materials classified as GM and SM will be identified as cohesionless only when the fines have a plasticity index of zero. SUBMITTALS A. The following Test Reports are to be obtained and paid for by Contractor 1. Fill and backfill optimum density test where specified 2. Select material optimum density and gradation tests 3. Compaction density tests where specified 4. In-place density tests where specified DELIVERY, STORAGE AND HANDLING OF MATERIALS Perform in a manner to prevent contamination or segregation of materials. PART 2 -PRODUCTS 2.01 SOIL MATERIALS Free of debris, roots, wood, scrap material, vegetation, refuse, soft unsound particles, and deleterious or objectionable materials. Unless specified otherwise, the maximum particle diameter shall be one- half the lift thickness at the intended location. A. Common Fill Common shall consist of sandy -loam, sand, gravel, soft shale, or crushed stone. The Engineer shall be the sole judge of what constitutes suitable and unsuitable material for backfill from "on-site excavations." 02302 — Excavation and Fill 02302 - 2 B. Select Material Select Fill shall consist of uniform, clean, free draining sand or sand and shell containing less than 5% fines passing a No. 200 sieve. Laboratory test results of this fill shall be submitted to the Engineer for his approval. C. Topsoil Natural, friable soil representative of productive, well -drained soils in the area, free of. subsoil; stumps; rocks larger than 1 inch diameter; brush; weeds; toxic substances; and other material detrimental to plant growth. Amend topsoil pH range to obtain a pH of 5.5 to 7. PART 3 - EXECUTION OF WORK 3.01 SURFACE PREPARATION A. Clearing and Grubbing Unless indicated otherwise, remove trees, stumps, logs, shrubs, and brush within the clearing limits. Remove stumps entirely. Grub out matted roots and roots over 3 inches in diameter to at least 24 inches below existing surface. B. Stripping Strip existing topsoil to a minimum depth of 6 inches without contamination by subsoil material. Remove all existing topsoil with organic roots and materials. Stockpile topsoil separately from other excavated material and locate convenient to areas for soils exchange. C. Unsuitable Material All cleared, grubbed and demolished material deemed unsuitable shall be stockpiled on-site by the Contractor for disposal by soils exchange with material over excavated from the proposed stormwater management tract(s). D. Disposal In all areas where excavation is to be done, all earth, rock, muck and other materials shall be removed and separated as to suitable and unsuitable material for backfill as defined herein. The Contractor shall temporarily stockpile all unsuitable fill and backfill material for later disposal by soils exchange from suitable material to be over excavated from the on-site stormwater management lakes. The stockpiled material shall be piled in an orderly manner so as not to endanger the work or obstruct roadways or drainage within the designated job site location. All unsuitable material shall be disposed of by over excavating an equal volume of suitable material from the stormwater management lakes and subsequently filling the over excavated volume with the unsuitable material. All over excavated material shall be utilized and spread on the project site. Hazardous or waste materials shall not be used in the unsuitable material to be exchanged. Waste, brush, refuse, stumps, roots, timber, etc. shall be removed from the site and disposed of in an approved manner. 02302 - 3 02302 — Excavation and Fill E. Removal of Muck, Rock and Other Unsuitable Material All muck, rock , clay, marl, gravel, boulders, heterogeneous fill material and any other organic or unsuitable "materials of excavation" encountered under pavement areas, structures and utilities shall be excavated and removed. Also any "unforeseen obstacles" such as buried trees or timbers, abandoned utilities, metal objects, concrete masses, or any other type of debris encountered shall be removed. All areas under proposed pavements or structures, which are indicated by testing to have more than trace amounts of silt and/or clay within the top several feet of existing grade shall be "proof rolled" using a vibratory compactor. Should the existing material continuously yield or "pump" during the proof rolling, the Engineer shall be notified and a determination made as to the amount of stripping needed to accomplish a stabilized foundation. Stripping shall be accomplished to clean in-place sand or other suitable material as approved by the Engineer. Removal of unsuitable material within areas which are to receive footings, slabs or other foundations shall be completed for the full area under such structures and to ten feet minimum outside the maximum perimeter. Where pavement is to be placed, said removal shall include all area under the surface and extend to the outside of any shoulders, under any sidewalks and bike paths, or as directed by the Engineer. All roots, stumps, logs, limbs, timbers, boulders, or any material which is not suitable for backfill material shall be removed from the site promptly and excavated and disposed of by the Contractor at his expense. Removal of all "materials of excavation" and "unforeseen obstacles" will be paid for under the heading of "Excavation and Hauling". 3.02 PROTECTION A. In Sheeting and Bracing Where excavations may endanger workmen, existing structures, utilities or other facilities, it shall be the Contractor's responsibility to immediately install and maintain adequate sheeting and bracing per OSHA specifications in order to protect said facility. No work shall proceed in such excavations until the sheeting and bracing has been properly and completely installed. The sheeting thus installed shall be removed as the work progresses or, at the discretion of the Engineer, be cut off below finished grade and left in place. Sheeting and bracing may be either steel or wood at the option of the Contractor. Sheeting and bracing shall be installed in a manner that will allow for removal without injuring or endangering workmen, the work, adjacent structures, and the like. Voids caused by withdrawal of sheeting shall be promptly and completely filled with sand and compacted to a degree equal to the surrounding soil. Drainage and Dewatering Provide for the collection and disposal of surface and subsurface water encountered during construction. 02302 — Excavation and Fill 02302 - 4 1. Drainage So that construction operations progress successfully, completely drain construction site during periods of construction to keep soil materials sufficiently dry. The Contractor shall establish/construct storm drainage features (ponds/basins) at the earliest stages of site development, and throughout construction grade the construction area to provide positive surface water runoff away from the construction activity and/or provide temporary ditches, swales, and other drainage features and equipment as required to maintain dry soils. When unsuitable working platforms for equipment operation and unsuitable soil support for subsequent construction features develop, remove unsuitable material and provide new soil material as specified herein. It is the responsibility of the Contractor to assess the soil and ground water conditions presented by the plans and specifications and to employ necessary measures to permit construction to proceed. 2. Dewatering All water encountered during excavation shall be promptly and completely removed to a depth below the exposed excavation surface sufficient to provide a dry working surface. The excavation shall be kept dry until the work to be built or placed therein has been completed as specified. Dewatering shall be done in a manner that will not cause sloughing or caving of the excavation walls. Water from said dewatering shall be disposed of in a manner as will not result in violations of State water quality standards in receiving waters, nor cause injury to public health nor to public or private property, nor to the work completed or in progress. Any and all damage caused by dewatering shall be promptly repaired by the Contractor at no cost to the Owner. The receiving point for water from said operation shall be approved by the applicable regulatory agency and the Engineer. The Contractor is responsible for obtaining all required permits and any other approval necessary. C. Underground Utilities Location of the existing utilities indicated on the Drawings are approximate only. The Contractor shall physically verify the location and elevation of the existing utilities indicated prior to starting construction. The Contractor shall contact Sunshine One Call at 1-800-432-4770, 48 hours prior to commencement of excavation for assistance in locating existing utilities. D. Machinery and Equipment Movement of construction machinery and equipment over pipes during construction shall be at the Contractor's risk. Repair, or remove and provide new pipe for existing or newly installed pipe that has been displaced or damaged. 3.03 EXCAVATION Excavate to contours, elevation, and dimensions indicated. Reuse excavated materials that meet the specified requirements for the material type required at the intended location. Keep excavations free from water. Excavate soil disturbed or weakened by Contractor's operations, soils softened or made unsuitable for subsequent construction due to exposure to weather. Refill with common fill and compact to 95 percent of ASTM D 1557 maximum density. Unless specified otherwise, refill excavations cut below indicated depth with common fill and compact to 95 percent of ASTM D 1557 maximum density. 02302 = 5 02302 — Excavation and Fill 3.04 A. Pipe Trenches Excavate trenches to uniform width, sufficiently wide to provide ample working room and a minimum of 9 to 12 inches of clearance on both sides of the pipe or conduit. Grade bottom of trenches to provide uniform support for each section of pipe after pipe bedding placement. B. Excavate trenches to depth indicated or required to establish indicated slope and invert elevations and to support bottom of pipe or conduit on undisturbed soil. 1. Where rock is encountered, cavy excavation 6 inches below required elevation and backfill with a 6 -inch layer of tamped sand or gravel prior to installation of pipe. 2. For pipes or conduit less than 6 inches in nominal size, and for flat-bottomed, multiple - duct conduit units, do not excavate beyond indicated depths. Hand -excavate bottom cut to accurate elevations and support pipe or conduit on undisturbed soil. 3. For pipes and equipment 6 inches or larger in nominal size, shape bottom of trench to fit bottom of pipe for 90 degrees (bottom 1/4 of the circumference). Fill depressions with tamped sand backfill. At each pipe joint, dig bell holes to relieve pipe bell of loads and to ensure continuous bearing of pipe barrel on bearing surface. FILLING AND BACKFILLING Fill and backfill to contours, elevations, and dimensions indicated. Compact each lift before placing overlaying lift. B. Unsuitable Material Replacement Fill material shall be placed and spread evenly in layers not to exceed twelve inches before compaction. All fill material shall be free from vegetable matter, wood, and other deleterious substances, and shall not contain rocks or clods having a diameter of more than three inches. B. Pre -fill Compaction Should the pre -fill surface elevation be below that required for the base of proposed building foundations or paving subgrade, the areas within road rights -of -ways, under parking areas, and the areas under and within five feet of proposed buildings shall be precompacted. This precompaction shall be performed equally on existing ground and on surfaces which have been excavated to remove unsuitable material. The top one foot of said areas shall be compacted to a minimum density of 95% of maximum as determined by AASHTO T-180. The maximum spacing between density tests shall be 150 feet. B. Compaction Backfill material shall be compacted to 95% of maximum density per AASHTO T-180. Equipment suitable and adequate for uniform compaction to the specified density shall be used for backfill operations subject to the approval of the Engineer. All compaction equipment shall be in good working order and any worn or defective equipment shall be immediately replaced or repaired. 02302 - 6 02302 — Excavation and Fill B. Soil Stability and Compaction Control The Contractor shall arrange to have sufficient soil tests made by an independent testing laboratory selected by the Engineer to demonstrate conformance of his work with the stability and compaction levels required by these specifications. Compaction tests shall be taken at intervals listed herein or as deemed necessary by the Engineer. Any proposed alternative test methods to those specified herein must be approved by the Engineer prior to testing. At the request of the Engineer, the Contractor shall provide such documentation of a proposed alternative test method as the Engineer may require to evaluate the method for approval. In no case shall the Contractor proceed with construction on compacted material until the tests prove satisfactory and approval is given by the Engineer. In general, at least one test for maximum dry density/optimum moisture content shall be performed on a representative sample of each inherently different material to be used for compacted backfill or embankment fill. For material of uniform composition and textural class, a minimum of one test per 200 cu. yd. of material shall be performed at the point of use. Tests for in-place density (percent compaction) shall be taken at locations designated by the Engineer. The Contractor shall have density tests taken in four (4) separate locations. Each location shall be tested in lifts not to exceed 12 -inches in thickness. E. Trench Backfilling Backfill as rapidly as construction, testing, and acceptance of work permits. Place and compact backfill under structures and paved areas in 12 inch lifts to top of trench and in 6 inch lifts to one foot over pipe outside structures and paved areas. 1. Bedding Requirements Except as specified otherwise in the individual piping section, provide bedding for buried piping in accordance with AWWA C600, Type 4, except as specified herein. Backfill to top of pipe shall be compacted to 95 percent of ASTM D 698 maximum density. Plastic piping shall have bedding to spring line of pipe. Provide ASTM D 2321 materials as follows: Class I: Angular, 0.25 to 1.5 inches, graded stone, including a number of fill materials that have regional significance such as coral, slag, cinders, crushed stone, and crushed shells. Class 11: Coarse sands and gravels with maximum particle size of 1.5 inches, including various graded sands and gravels containing small percentages of fines, generally granular and noncohesive, either wet or dry. Soil Types GW, GP, SW, and SP are included in this class as specified in ASTM D 2487, 3.05 COMPACTION Expressed as a percentage of maximum density. Determine in-place density of existing subgrade; if required density exists, no compaction of existing subgrade will be required. 02302 = 7 02302 - Excavation and Fill 3.06 3.07 A. General Site Backfill Compact underneath areas designated for vegetation and areas outside the 5 foot line from existing or proposed structures to a minimum 95 percent of maximum density per ASTM D 1557, B. Backfill Under Pavements and Around Structures Compact underneath areas designated for surface pavements and around proposed structures to a minimum 98 percent of maximum density per ASTM D 1557, FINISH OPERATIONS A. Grading Finish grades as indicated on the plans to within two inches. In areas where sodding is required, finished soil grade shall be set 3 -inches below the plan elevation to compensate for sod thickness.. For existing grades that will remain but which were disturbed by Contractor's operations, grade as directed. B. Protection of Surfaces Protect newly graded areas from traffic, erosion, and settlements that may occur. Repair or reestablish damaged grades, elevations, or slopes. DISPOSITION OF SURPLUS MATERIAL The Contractor may temporarily stockpile all unsuitable fill and backfill material for later disposal. The stockpiled material shall be piled in an orderly manner so as not to endanger the work or obstruct roadways or drainage within the designated job site location. All unsuitable material shall be disposed of by hauling off-site by the Contractor to a suitable disposal location. Waste, brush, refuse, stumps, roots, timber, etc. shall be removed from the site and disposed of in an approved manner. Excess suitable backfill material is the property of the Owner. The Owner shall determine the ultimate disposition of the material and may require the Contractor to relocate (haul) the material to a site within a 10 mile drive of the project site at no additional cost to the Owner. END OF SECTION 02302 = 8 02302 — Excavation and Fill SECTION 02400 DIRECTIONAL BORE CROSSINGS 1. GENERAL A. Scope The work to be performed under this item shall include the furnishing of all H.D.P.E. pipe and fittings for the job, equipment and labor required for the joining and installation of the pipe as herein described and as shown on the Plans. The CONTRACTOR shall perform all pipe work, directional drilling, backpulling and related work required for the construction of the directional bore in accordance with the provisions set forth under the applicable items of this Section. B. References Standards applicable in this Specification shall be: 1) American Society of Testing and Materials (ASTM) a) ASTM D 2657 — Practice for Heat -Joining of Polyolefin Pipe and Fittings b) ASTM D 3261 — Standard Specification for Butt Fusion Polyethylene (PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing c) ASTM D 3350 — Standard Specification for Polyethylene Plastics Pipe and Fittings Material d) ASTM F 714 — Standard Specification for Polyethylene (PE) Plastic Pipe (SDR - PR) Based on Outside Diameter e) ASTM F 1962 — Use of Maxi -Horizontal Directional Drilling for Placement of Polyethylene Pipe or Conduit Under Obstacles, Including River Crossings 2) Plastics Pipe Institute a) Plastic Pipe Institute Technical Report TR — 3, Policies and Procedures for Develogi:ng Recommended Hydrostatic Design Stresses for Thermo-Dlastic Pipe Materials b) Plastic Pipe Institute, TR -31, "Underground Installation of Polyolefin Pipe c) Plastics Pipe Institute, Handbook of Polyethylene Pipe, Chapter on Polyethylene Joining Procedures, Washington, DC. 3) American Association of State Highway and Transportation Officials a) AASHTO T-180 Density Relations of Soils using a 10 lb. Rammer and an 18 - inch drop 02400 -1 02400 — Directional Bore Crossings C. 4) American Water Works Association (AWWA) a) AWWA C906 — Polyethylene (PE) Pressure Pipe and Fittings, 4 in. through 63 in., for water distribution Quality Assurance 1) Quality All materials shall be new and properly manufactured, and shall conform to the requirements of any referenced standards. All materials shall be standard first -grade quality produced by expert workmen and be intended for the use for which they are offered. Materials which, in the opinion of the ENGINEER, are inferior or of a lower grade than indicated, specified or required will not be acceptable. 2) Source Limitations To the greatest extent possible for each unit of Work, the CONTRACTOR shall provide products, materials, or equipment of a singular generic kind from a single source. 3) Compatibility of Options Where more than one choice is available as options for CONTRACTOR'S selection of a product, material, or equipment, the CONTRACTOR shall select an option, which is compatible with other products and materials already selected. Compatibility is a basic general requirement of product/material selections. 4) CONTRACTOR/INSTALLER (C/I) Qualifications For a C/I to be considered as an acceptable C/I, the C/I must have had at least three (3) years active experience in the commercial installation of directional bored polyethylene pipe and must have installed a minimum of 10,000 linear feet or 20 sections of successful large diameter (12" or greater) polyethylene pipe installations in the United States. To be acceptable, the C/I shall hold an active CERTIFIED or REGISTERED UNDERGROUND UTILITIES CONTRACTOR LICENSE with the State of Florida Department of Professional Regulation Construction Industry Licensing Board. A copy of the CERTIFIED UNDERGROUND UTILITIES CONTRACTOR LICENSE shall be submitted prior to excavation. 5) Right of Rejection The ENGINEER or the OWNER, shall have the right, at all times and places, to reject any articles or materials to be furnished hereunder which, in any respect, fail to meet the requirements of the Contract Documents, regardless of whether the defects in such articles or materials are detected at the point of manufacture or after. completion of the Work at the site. 02400 — Directional Bore Crossings 02400 - 2 The CONTRACTOR shall promptly remove rejected articles or materials from the site of the Work after notification of rejection. All costs of removal and replacement of rejected articles or materials as specified herein shall be borne by the CONTRACTOR. D. Submittals 1) Along with the required bid and contract submittals, the CONTRACTOR shall submit to the ENGINEER, for review and approval, the items a and b as listed below: a) Five (5) sets of the manufacturer's shop drawings, catalog cut sheets, technical data, installation requirements and recommended methods, and recommended repair methods. Upori approval by the ENGINEER, the manufacturer's recommendations shall become the basis for acceptance or rejection of actual methods of installation used in the work. b) Certification of the manufacturer's compliance with the specified standards and specifications for all materials. The CONTRACTOR shall not permit any materials to be brought onto the job site prior to obtaining approval from the ENGINEER. No pipe shall be delivered without prior notification to the ENGINEER. Each pipe section shall be subject to inspection by the ENGINEER immediately before it is installed. Any pipe section judged to be defective may be rejected. E. Safety The CONTRACTOR shall cant' out his operations in strict accordance with all OSHA and manufacturer's safety requirements. Particular attention is drawn to those safety requirements involving working with hazardous/combustible material, (if needed), working in traffic areas, entering confined spaces, and operating heavy machinery. F. Warranty In addition to the CONTRACTOR'S one-year warranty, the pipe shall be certified by the manufacturer for specified material properties for this particular job. The manufacturer warrants the pipe to be free from defects in raw materials for one year from the date of acceptance. During the warranty period, any defects that affect the integrity or strength of the pipe shall be repaired at the CONTRACTOR'S expense in a manner mutually agreed by the OWNER and the CONTRACTOR. 2. MATERIALS A. High Density Polyethylene Pipe (H.D.P.E.) Pipe shall be new, unused, sections of polyethylene pipe having a nominal density of 0.955. The polyethylene resin used to manufacture the pipe shall have a "Plastic Pipe Institute" 02400 - Directional Bore Crossings 02400=3 3. material designation of PE 3408, with an ASTM D3350 cell classification of 34544C. The pipe shall be black in color, containing approximately 2 percent U.V. stabilizer. The pipe shall be co -extruded with a color coded sheath or have three (3) sets of colored lines at the 120° quadrants. The pipe shall be designed for a working pressure of 160 psi. Pipe shall be extruded to the minimum wall thickness described in AWWA C906 for DRI 1. Pipe outside dimensions shall meet that of ductile iron pipe size (D.I.P.S.). Pipe shall be provided in nominal 40 foot long sections. During the extrusion process, the HDPE pipe shall be continuously marked with durable printing including the following information: 1) Nominal Size 2) Dimension Ratio 3) Manufacturer Name and Product Series 4) Cell Class 5) ASTM Basis 6) Pipe Test Category 7) Plant Identification 8) Production Date B. Fittings HDPE fittings shall be in accordance with ASTM D 3261 and shall be manufactured by injection molding, a combination of extrusion and machining, or fabricated from HDPE pipe conforming to this specification. The fittings shall be designed for a working pressure of 160 psi. The fittings shall be manufactured from the same resin type and cell classification as the pipe itself. The fittings shall be homogeneous throughout and free from cracks, holes foreign inclusions, voids, or other injurious defects. All fittings shall be constructed to have a minimum D.R. 11 sidewall thickness, with a D.I.P.S. outside diameter. C. Joints Sections of polyethylene pipe shall be joined at the job site by the butt fusion process into one continuous length. The joining process shall be the heat fusion method and shall be performed in strict accordance with the pipe manufacturer's recommendations. The heat fusion equipment used in the joining procedures should be capable of meeting all conditions recommended by the pipe manufacturer. EXECUTION OF WORK Installation of the polyethylene pipeline shall be conducted using "medi" — HDD or "maxi" — HDD equipment of intermediate size and capabilities. 'The installation guidelines and practices governing this installation shall follow that of the "maxi" — HDD category rather than "mini" — HDD practices. A. Preparation 1) Clearing — The CONTRACTOR shall perform all clearing necessary, where applicable for the proper installation of the pipe at the locations shown on the drawings. Plantings, shrubbery, trees, utility poles or structures subject to damage 02400 - 4 02400 — Directional Bore Crossings resulting from the excavation shall be transplanted, relocated, braced, shored or otherwise protected and preserved unless otherwise directed by the Engineer. 2) Delivery and Receiving Pipe — The pipe shall be delivered no more than 5 working days prior to joining and installation. Pipe and fittings may be stored in the right-of- way, adjacent to the boring path in the right-of-way only when they may be maintained outside the roadway "clear zone" as determined by F.D.O.T. standards. Appropriate unloading and handling equipment of adequate capacity must be used to unload the truck. Safe handling and operating procedures must be observed. Pipe and fittings must not be rolled or pushed off the truck. When using a forklift, or forklift attachments on equipment such as articulated loaders or bucket loaders, lifting capacity must be adequate at the load center on the forks. Forklift equipment must be rated for the maximum lifting capacity at a distance from the back of the forks. Lifting equipment such as cranes, extension boom cranes, and side boom tractors, should be hooked to wide web choker slings that are secured around the load. Only wide web slings should be used. Wire rope slings and chains can damage components and shall not be used. Spreader bars shall be used when lifting pipe longer than 20" Individual pipes may be stacked in rows. Pipes shall be laid straight, not crossing over or entangled with each other. The base row must be blocked to prevent sideways movement or shifting. The pipe sections shall be stacked no higher than 2 rows. B. Joining, Pive and Stub -End 1) Joining and stringing of the pipe shall be accomplished in one continuous operation. The joining shall begin promptly at the beginning of the work day and continue until completed. Pipe joining and directional boring shall be the only on-site operation allowed to continue beyond 5:00 P.M. The CONTRACTOR shall have all traffic control devices, lane closures and signage in place and ready for use prior to start- up. 2) Joining shall be accomplished using a hydraulically operated, microprocessor controlled heat fusing machine, specifically designed to handle the project pipe O.D. The operator shall have had a minimum 3 years experience in the process of operating H.D.P.E. butt -fusion machines capable of joining at least 8 -inch diameter pipe. 3) Joining shall generally follow these procedures: a) Securing Each component that is to be fused must be held in position so that it will not move unless a clamping device moves it. 02400 — Directional Bore Crossings 02400 - 5 b) Face The component ends must be faced to establish clean, parallel mating surfaces. The equipment shall incorporate a rotating planer block in its facer to accomplish this goal. Facing shall be continued until a minimal distance exists between the fixed and movable jaws of the machine and the facer is locked firmly and squarely between the jaws. This operation shall provide for a perfectly square face, perpendicular to the pipe centerline on each component end and with no detectable gap. c) Alignment The pipe profiles must be rounded and aligned with each other to minimize mismatch (high -low) of the pipe walls. This shall be accomplished by adjusting the clamping jaws until the outside diameters of the pipe ends match. The jaws must not be loosened or the pipe may slip during fusion. d) Melting Ends of the components shall be heated to the pipe manufacturer's recommended temperature, interface pressure, and time duration. By doing so, the heat will penetrate into the pipe ends and a molten "bead" of material will form at the pipe ends. Heating tools, which simultaneously heat both pipe ends, shall be used to accomplish this operation. These heating tools shall be furnished with thermocouples to measure internal heater temperature so that the operator can monitor the temperature before each joint is made. The heater faces, which come into contact with the pipe, shall be coated by the manufacturer to prevent molten plastic from sticking to the heater faces. e) Joinin¢ After the pipe ends have been heated for the proper time and to the proper temperature, the heater tool shall be removed and the molten pipe ends shall be brought together with sufficient pressure to properly mix the pipe materials and form a homogeneous joint. The pipe manufacturer's instructions may specify either interface pressure or bead size of molten material as a guide for a proper joint. f) Holding The molten joint must be held immobile under pressure until cooled adequately to develop strength. The proper cooling times for the joint are: material, pipe - diameter, and wall -thickness dependent; and shall be as recommended by the pipe manufacturer. C. Strinains of Pipe and Trace Wire The CONTRACTOR shall have appropriate rollers and a winch/cable system adequately sized to pull the joined pipe sections into the proper position for installation. 02400 — Directional Bore Crossings 02400 - 6 Where possible, the entire length of polyethylene pipe to be installed shall be joined and strung beyond the entrance of the bore path. hi no case shall the ingress and/or egress, to public or private property be completely blocked. Should the stringing of an entire section of pipe block such ingress and/or egress, the section of pipe shall be segmented in maximum lengths beyond the entrance of the bore path. Once strung out for insertion into the bore hole, the trace wire specified for all piping shall be laid along the top of the pipe segment and taped to the pipe along its entire length. There shall be no discontinuity in the trace wire, and where a splice is needed, it shall be prepared prior to beginning the pipe back pull. D. Separation and Clearance 1) The bore depth shall equal or exceed 10 times the bore size under F.D.O.T. pavements. 2) When installed outside of pavement, the off set parallel to the pavement edge must be at least 3 'h times the bore size clearance from vitrified clay pipe sanitary sewer and any gas main. 3) Bore installations shall maintain at least 3 '/2 times the bore size clearance from vitrified clay pipe sanitary sewer and any gas main. 4) Bore installations shall maintain at least 18 -inches of separation between any sewer line crossings. E. Directional Boring Boring of the pipeline hole shall follow applicable sections of the recommended standards of ASTM F 1962 "Use of Maxi -Horizontal Directional Drilling for Placement of P.E. Pipe or Conduit Under Obstacles, Including River Crossings". The CONTRACTOR shall have adequately sized boring/pullback equipment, self-contained drilling fluid recycling system equipment and a properly trained crew with classroom and field experienced personnel manning the primary job positions. 1) Machine Size & Capability — The size and capacity of the drilling equipment must be compatible with the thrust and torque required to perform the drilling, reaming, and pipe pullback operations. The estimated forces applied to the pipe_ may be considered a minimum equipment requirement. The CONTRACTOR'S equipment shall be capable of drilling through consolidated or loose sands and clay as well as cemented layers of lime rock (commonly known as "cap rock") that may vary from loose fragments to 2 or 3 foot thick sections. The CONTRACTOR'S equipment must include a self-contained, mobile slurry system, capable of pumping and recycling the drilling fluid. Cuttings from the drilling process shall be hauled and disposed of by the CONTRACTOR. Should the County desire the cuttings for fill, the CONTRACTOR shall haul the material to the desired disposal site. The disposal site shall be within a 10 mile drive from the furthest bore location. All drilling fluid, mud, clay, etc. shall be hauled and disposed of by the CONTRACTOR at an acceptable disposal site. 02400 = 7 L 02400 - Directional Bore Crossings F 2) Drill Unit Positioning — The drill rig unit shall be positioned within the right-of-way or Owner's property to provide the desired bore route and pipe depth. Proper equipment anchoring is especially important for the existing sandy soils. 3) Drill Rods — The drill rods should be as least as strong as the equipment capability. The drill rod capabilities shall also be compatible with the planned bore route with respect to cumulative fatigue stresses. . 4) Drilling Fluid Usage — Drilling fluid shall be used to provide lubrication during the pilot boring, reaming and pullback operations to reduce the required torque and thrust of pullback loads. In addition, the drilling fluid shall stabilize the bore hole, cool the drill head (and internal circuitry), and remove cuttings and spoils. The crew must be trained in the proper use of drilling fluids and the appropriate types for various ground conditions. The Engineer shall be notified if excessive drilling fluid pressures or volumes are noticed. 5) Location and Tracking — In order to maintain the actual bore along the planned path, the pilot bore must be carefully tracked, and path confirmation established at least once each 15 ft interval. For paths with horizontal and vertical turns, or in critical areas including the vicinity of other obstacles, shorter intervals of 10 ft shall be used. Any misdirection of the drill head shall be corrected immediately. 6) Back Reaming — Where necessary, back reaming shall be performed to produce a hole size sufficiently large to readily install the pipe. Back reaming shall allow the bore hole to be created in stages, reducing the required torque and thrust loads at the machine. Back reaming operations shall help ensure that the capability of the machine is not exceeded due to the combined forces of increasing the hole diameter while pulling the pipe. Appropriate cutters and compactors compatible with the soil conditions shall be employed including proper usage of drilling fluid. Back reaming shall be used to reduce the possibility of voids or surface heaving or settlement, including unanticipated drilling fluid appearances. Hole diameter increments should be restricted to approximately 10 -inches or less during a single pass. The final hole diameter shall be 20% but in no case larger than 50% greater than the outer diameter of the pipe to provide clearance for pipe grips, allow spoils flow, and reduce the required loads during the pipe pullback operation. During back reaming, additional drill roads must be available at the pilot bore exit that are connected to a swivel at the rear of the reamer and pulled into the hole to maintain the path. Pipe Pullback 1) Gripping of Pipe — Due to the distance of the operation and the high pullback loads generated, secure gripping procedures must be used. Basket -type or internal only grips will not be allowed. The gripping method selected must allow the full tensile rating of the pipe to be developed. Appropriate types may include an internal/external clamping or bolting device, or a fused PE pipe adapter with a built- in pulling eye. In the latter case, a smaller diameter section of the adapter may serve as a breakaway link protecting the main section of pipe. 2) Swivel — A swivel is required between the reamer or compactor preceding the pipe to prevent the transmission of torsional loads to the pipe. The rating of the swivel 02400 — Directional Bore Crossings 02400 - 8 should be larger than the lower of the pull force capability of the drill rig or the total strengths of the pipe to be installed, but not excessively greater. 3) Breakaway Link — In general, the recorded pulling forces as indicated at the drill rig will exceed the tensions experienced by the pipe or conduit throughout most of the pullback process. It is recommended that individual breakaway links be provided between the main swivel and the grip at the pipe, to ensure that the pipelines are installed within allowable load levels. Broken links will require removal of the pipe from the entry end. If a breakaway swivel is used as the breakaway link, and not specifically designed for direct exposure with soil, this item should be cleaned well after each application. The use of such a breakaway swivel does not eliminate the need for the main swivel described earlier. 4) Handling the Pipe — Extreme care must be exercised when handling the pipe to ensure that it is not subject to excessively sharp bends which may cause a kink or other damage to the pipe. Particular areas of concern typically include the pipe entry and exit points. It is important to minimize bending of the pipe as it enters the bore hole, and to ensure low friction on the portion of the pipe outside the hole. This may be accomplished by the use of appropriate lifting equipment and roller stands to reduce friction. Due to the potentially high tensile load at the pipe exit, it is especially important to avoid sharp bends at this point. G. As -Built Drawings and Information A record of the actual as -built bore path, including plan and profile views and vertical and horizontal deviations, indicating the relation to the planned path, must be submitted to the Engineer. Any information obtained during the initial bore regarding soil characteristics, etc. should be added. The experiences gained during the initial bore may be used to provide guidance for the backreaming operating, as well as for subsequent operations in the project area. Additional information should also be included, such as steering or correction commands, drilling fluid usage, and the type of drill head being used. Regarding the reaming and pullback operations, the pipe insertion velocity, duration, type and size of reamers (cutters or compactors), final bore hole size, drilling fluid usage, and required pullback forces should be recorded. H. Connection to Upstream and Downstream Piping Where the directional bored pipe is joined to bell and spigot, mechanical, or other types of unrestrained joints, the forces caused by shortening of the polyethylene pipe when under pressure must be counteracted per AWWA Technical Bulletin No. 8. The joint between the polyethylene pipe and any push type connection shall be mechanically restrained as well as the appropriate number of upstream and downstream joints as indicated on the Drawings. I. Completion and Cleanup 1) Pipe Cut -Off and Cleanup — The pipe shall be allowed to achieve mechanical and thermal equilibrium with its surroundings prior to cutting at either end. Premature cutting of the pipe may allow the ends to shrink back into the hole. The pipe may be cut after it has been verified that there has been insignificant movement at the pipe entry end and negligible residual tensile load at the drill rig end. If the bore ends are 02400 - 9 02400 — Directional Bore Crossings to remain in place for more than 48 hours prior to final connection and burial, the pipe ends shall be cut off above grade, and an appropriate plug shall be installed after thorough cleaning of the pipeline. 2) Pipe Cleaning — The CONTRACTOR shall utilize a hydraulic cleaning and vactor truck to remove all cuttings and drilling fluid from the pipe. 3) Site Cleanup — After inspection and approval by the Owner or his representative, the surface area disturbed by construction of this project must be restored to its original condition. The site must be cleaned of equipment, tools, and spoils. All drilling fluid must be cleaned from the site or its vicinity and properly disposed of. 4) Disposal — Pipe cuttings shall be disposed of by the CONTRACTOR at a solid waste disposal site or other disposal area, acceptable to the Owner. END OF SECTION 02400 - Directional Bore Crossings ;6'Z41111 [% I L SECTION 02440 CONCRETE DRIVEWAYS, CURBS, SLABS ON GRADE AND SIDEWALKS PART 1 -- GENERAL 1.01 SUMMARY A. Provide all labor, materials, equipment and transportation required for the construction of the concrete driveway, curbs, slabs on grade, and walks to the lines and grades as shown on the Drawings and specified herein. 1.02 QUALITY ASSURANCE A. Testing and inspections: See Section 02752. B. Materials and methods shall comply with the standards indicated. C. Obtain concrete from a plant currently certified to comply with approval of requirements of the Concrete Materials Engineering Council, or the Florida Department of Transportation, or the Check List for Plant Certification of the National Ready Mixed Concrete Association. 1.03 SUBMITTALS The following shall be submitted to the Engineer: A. Concrete mix design. B. Product literature for joint sealer, joint filler and curing compound. C. Product literature for synthetic fiber reinforcement. D. Concrete cylinder strength test results. E. Slump test results. F. Ready mixed concrete: Provide delivery tickets orweigh master's certificate perASTM C- 94, including weights of cement and each size of aggregate. Amount of water in aggregate, and amount of water added at the plant. Write in amount of water added on the job. PART 2 ==PRODUCTS 2.01 MATERIALS A. Concrete: Concrete for slabs on grade, walks, driveway, and curbs shall be structural Class I that conforms to the requirements of FDOT Standard Specifications for Road and Bridge Construction, 2007, Section 346, Portland Cement Concrete, with 28 -day compressive strength of 3000 psi unless shown otherwise on the Drawings. 02440=1 02440 — Concrete Driveways, etc... Be Admixtures are permitted in accordance with FDOT Standard Specifications for Road and Bridge Construction, 2007, Section 346-2.5. Co Except where shown on the plans, slabs on grade, and walks shall be reinforced with Fibermesh, as manufactured by SI Concrete Systems, or approved equal. D. Use forms of either wood or metal with a depth equal to the Plan dimensions forthe depth of concrete being deposited against them, as shown on the construction drawings. Forms shall be straight, free from warp or bends, and of sufficient strength when staked to resist the pressure of the concrete without deviation from line and grade. Clean the forms each time they are used, and oil or saturate with water prior to placing the concrete. E. Preformed Joint Filler: Preformed joint filler shall be nonextruding and resilient bituminous type and shall conform to the requirements of Section 932-1, FDOT Standard Specifications for Road and Bridge Construction, 2007. F. Joint Sealer: Joint sealer shall conform to the requirements of Section 932-1.2, FDOT Standard Specifications for Road and Bridge Construction, 2007, G. Membrane Curing Compound: Membrane curing compound shall conform to the requirements of Section 925.2, FDOT Standard Specifications for Road and Bridge Construction, 2007, PART 3 -- EXECUTION 3.01 PREPARATION A. The foundation shall be excavated or backfilled to the required depth. Compact the foundation material upon which the slabs on grade or sidewalk is to be set to, at least 98 percent of the maximum density as determined by AASHTO T-180 or 100 percent of the maximum density as determined by AASHTO T-99,, with an even surface, true to line, grade and cross section, and soaking wet at the concrete is placed. Be Forms: Set the forms straight, free from wrap or bends, and true to line and grade. C. Slipforming: The slipforming method will be allowed, provided that an acceptable finished product, true to line, grade, and cross section is consistently produced. 3.02 MIXING CONCRETE A. Concrete shall be mixed in accordance with FDOT Standard Specifications for Road and Bridge Construction, 2007, Section 346-7. 3.03 INSTALLATION A. Placing Concrete: 02440-2 02440 — Concrete Driveways, etc... J 1. The concrete shall be distributed on the subgrade to such depth that, when it is consolidated and finished, the thickness required by the Drawings will be obtained at all points and the surface will at no point be below the grade specified for the finished surface. The concrete shall be deposited on the subgrade in a manner which will require as little rehandling as possible. Placing of the concrete shall be continuous between transverse joints, without the use of intermediate bulkheads. 2. Concrete shall be thoroughly consolidated against and along the faces of all forms by means of vibrators. Vibrators (if needed) shall not be permitted to come in contact with the subgrade or a side form. Vibration at any one location shall not continue so long as to produce puddling or the accumulation of excessive grout on the surface. In no case shall the vibrator be operated longer than 15 seconds in any one location. B. Striking -Off, Consolidating And Finishing Concrete: 1. Immediately after the placing, the concrete shall be struck off, consolidated and finished, to produce a finished product conforming to the cross section, width and surface finish required by the Drawings and Specifications. 2. After the concrete has sufficiently set a minimum of 12 hours, the Contractor shall remove the forms and shall backfill the space on each side. The earth shall be compacted and graded in satisfactory manner without damage to the concrete work. Honeycombs shall be filled with sand cement mortar. Plastering will not be allowed on the face of the curb. Rejected curb, curb and gutter or valley gutter shall be removed and replaced without additional compensation. Co Final Finish: As soon as the water sheen has disappeared and just before the concrete becomes nonplastic, a light broom finish shall be given to the surfaces, except curbs. D. Joints: Joints shall be constructed where shown on the DRAWINGS. 1. Transverse Construction Joints: Transverse construction joints shall be constructed at the end of all pours and at other locations where the pouring operations are stopped for as long as 30 minutes. Construction joints, however, shall not be placed within ten feet of any other transverse joint or of either end of a section of curb. If sufficient concrete has not been placed to form a slab at least ten feet long, the excess concrete, back to the last preceding joint, shall be removed. The joints shall be the full depth of the pavement and shall be formed by placing a wood or metal bulkhead accurately and securely in place, in a plane perpendicular to the profile and center line of the pavement. 2. Transverse Contraction Joints: Transverse contraction joints shall be constructed along curbs, slabs on grade, and walks at the intervals specified in 3.03 D4 below, where shown on the DRAWINGS, and shall consist of planes of weakness created by sawing the surface of the pavement or tooling the joint. a. It shall be the Contractor's responsibility to see that the sawing equipment does not damage the curb, slabs on grade, or walk and to saw the transverse contraction joints as soon as the concrete has hardened to the degree that tearing and raveling are not excessive and within a maximum time of 12 hours after the pour. If, at any time, uncontrolled cracking occurs, the Contractor will be required to replace the affected sections and modify his methods. 02440=3 02440 — Concrete Driveways, etc... L 3. Transverse Expansion Joints: One half-inch expansion joints shall be formed by placing preformed joint filler topped with joint sealant at the ends of each radius return, around all structures, and at intervals specified in 3.03 D4 below and as shown on the DRAWINGS. 4. Spacing of transverse contraction and expansion joints. Walk,Slab Width Contraction Joint Expansion Joint Spacinq Spacing 4' 4' 40' 5' 5' 40' 6' 6' 42' 8' 8' 40' 10' 10' 40' Provide isolation joints between slabs on grade and sidewalks adjacent to fixed objects including curbs, inlets, etc. E. Finishing 1. Strike off the concrete by means of a wood or metal screed used perpendicular to the forms in order to obtain the required grade, and remove surplus water and laitance. 2. Broom -finish the concrete surface. The surface variations shall not be more than 1/4 inch under a 10400t straight edge. Carefully finish the edge of the slabs on grade and sidewalk with an edging tool having a radius of 1/2 inch. F. Curing: 1. After the finishing operations have been completed and as soon as the concrete has hardened sufficiently that marring of the surface will not occur, the entire surface and the edges of the newly placed concrete shall be covered and cured with membrane curing compound. 2. Curing compound shall be uniformly applied to the surfaces to be cured, in a single coat, continuous film, at the rate of one gallon to not more than 200 square feet, by a mechanical sprayer. 3. Curing compound shall not be applied during periods of rainfall. Curing compound shall not be applied to the inside faces of joints to be sealed. Should the film become damaged from any cause within the required curing period, the damaged portions shall be repaired immediately with additional compound. Upon removal of side forms the sides of the slabs exposed shall immediately be coated to provide a curing treatment equal to that provided for the surface. G. Backfilling and Compacting: After the concrete has set sufficiently, refill the spaces adjacent to the concrete to the required elevation with suitable material. Place and thoroughly compact to 98 percent of the maximum density as determined by AASHTO T- 180. 024404 02440 — Concrete Driveways, etc... 3.04 REQUIRED TESTS A. Obtain one strength test per day for each 50 cu. yds. or fraction thereof. A minimum of one test shall be taken from each batch of concrete delivery to the sight and used. Obtain one set of three (3) standard cylinders for each strength test. Mold and cure cylinders under standard temperature and moisture conditions in accordance with ASTM C31. Test one cylinder at 7 days, one cylinder at 28 days and retain the third cylinder for later testing, if required. Testing shall be done in accordance with the requirements of ASTM C39. B. Perform and record the results of a slump test on a sample of concrete at the same location and time concrete is obtained for the cylinders for the compressive strength test in accordance with ASTM C94, Section 19. Also obtain the unit weight of the concrete and perform an air test if the concrete is air entrained. The Engineer may require slump tests to be made more frequently. 3.05 CONCRETE FAILING TO MEET STRENGTH REQUIREMENTS A. Concrete having a 2&day strength of less than the minimum required strength shall be removed and replaced with concrete meeting the strength requirements, at the Contractor's expense. + + END OF SECTION + + 02440-5 02440 — Concrete Driveways, etc... L SECTION 02510 STABILIZED SUBGRADE PART 1 - GENERAL 1.1 SCOPE A. The work specified in this Section consists of furnishing all material, transportation, tools, labor, and equipment to construct a firm and unyielding subgrade and all items called for or that can be reasonably inferred from the Drawings, including adding material, mixing, stabilizing, compacting, grading, testing, and other work as required for a complete job. This does not include subgrade for pump station driveway which is included in Section 02714, PART 2 - PRODUCTS 2.1 PRODUCTS A. MATERIAL - Use local or hauled -in clean sand or sand and clay. Be STABILIZERS - Use high -bearing -value soil, sand -clay, ground limestone, crushed limerock, oyster shell, coquina shell, or rock screenings. Do not use muck, trash or hardpan. C. If soil cement paving is proposed do not use local yellow sand. D. In addition to these Specifications, the materials shall be in accordance with Section 914, "Materials for Subgrade Stabilization," of the DOT Standard Specifications for Road and Bridge Construction, latest edition. In the event of a conflict, the more stringent specification shall govern. PART 3 - EXECUTION 3.1 EXECUTION A. When completed, the stabilized subgrade shall conform to the sections shown on the Contract Drawings. Be If the natural soils are acceptable for subgrade material, but do not meet the required stability, approved stabilizing material may be brought in and uniformly mixed with the existing material to the depths shown on the Contract Drawings to produce the required bearing values, in accordance with Section 160-5.3 "Mixing" of the DOT Specifications for Road and Bridge Construction, 02510-1 02510 — Stabilized Subgrade C. The required density and cross section of the subgrade shall be maintained until the base has been laid. If the final grade becomes rutted or displaced, regardless of the reason, re -grade and re -compact it at no additional expense to the OWNER. All ditches, drains, and swales shall be maintained along the completed subgrade section after their construction. D. All drainage culverts, conduits, water and sewer lines, and all other construction to be placed under the pavement shall be installed before the final shaping and compaction of the subgrade. 3.2 COMPACTION A. FLORIDA BEARING VALUE - Unless otherwise specified or shown on the Plans, the stabilized subgrade shall have a minimum Florida Bearing Value of 50 psi. All subgrade material shall also meet minimum 40 LBR, compacted to 98% maximum density per AAS HTO -180. Be The subgrade shall be shaped to within 1/4 inch of the cross section grade shown on the DRAWINGS prior to taking density tests. Work shall not proceed until all required density tests have passed. C. All subgrade shall be compacted to minimum 98 percent of the maximum dry density per AASHTO T-180. D. Compaction shall be accomplished with a self-propelled steel drum or pneumatic tired roller weighing at least 8 tons. Fill all hollows or depressions forming due to rolling with appropriate suitable material. Repeat grading and rolling until depressions no longer develop. 3.2 COMPACTION TESTS A. Take compaction tests at the locations specified herein or at locations selected by the ENGINEER or his authorized representative. Be As a minimum, Florida Bearing Value tests shall be taken at 300 linear foot intervals. C. Density tests (Modified Proctor Test) per AASHTO TA 80 shall be taken at minimum 300 linear foot intervals. Each subgrade material which is inherently different in composition from other subgrade material shall require an additional modified Proctor Test. + + END OF SECTION + + 02510-2 02510 — Stabilized Subgrade SECTION 02511 BASE COURSE PART 1 - GENERAL 1.1 SCOPE A. The work specified in this Section consists of the construction of a base course composed of limerock constructed on prepared subgrade in accordance with these Specifications and in conformity with the lines, grades, notes, and typical cross sections shown on the Contract Drawings. PART 2 - MATERIALS 2.1 MATERIALS A. All limerock shall comply with Section 911 "Limerock Material for Base and Stabilized Base" or Section 915 "Cemented Coquina Shell Material of the DOT's Standard Specifications for Road and Bridge Construction latest edition. All limerock used on the project shall be of the same grade and from the same source. Be The cemented coquina shell material shall have a minimum LBR of 100. Co Before placement, 97 percent of the material shall pass a 3A/2 inch sieve and it shall be graded uniformly down to dust. PART 3 - EXECUTION 3.1 DUMPING AND SPREADING A. Transport the limerock to the point where it is to be used over rock previously placed, and dump on the end of the last spread. In no case shall rock be dumped directly on the subgrade. Be Base material shall not be placed until the stabilized subgrade has passed all required compaction testing and been approved by the Engineer or his authorized representative. C. Spread the limerock uniformly. Remove and replace all segregated areas of fine or coarse rock with well -graded rock. D. When the specified compacted thickness of the base is greater than 6 inches, construct the base in two courses. The thickness of the first course shall be 02511-1 02511 — Base Course approximately one-half of the total thickness of the finished base, or enough additional to bear the weight of the construction equipment without disturbing the subgrade. 3.2 FINISHING A. For double -coarse bases, blade the first course if necessary to secure a uniform surface and compact to the density specified herein immediately prior to spreading the second course. No other finishing of this course is required. Be After all spreading is completed, scarify the entire surface and shape it to produce the exact grade and cross section after compaction. For double -course bases, scarifying shall slightly penetrate the surface of the first course. C. If at anytime, the subgrade material becomes mixed with the base course material, excavate and remove the mixture, reshape and compact the subgrade, and replace the materials removed with clean base material, shaped and compacted as specified herein. 3.3 MOISTURE CONTENT A. If the base material does not have the proper moisture content to obtain the specified density, wet or dry it as required. When water is added, mix it uniformly with the limerock. If wetting or drying is required, these operations shall involve the manipulation of the entire width and depth of the base course before compaction. 3.4 COMPACTION A. All limerock base shall be compacted to a minimum of 98 percent of the maximum density as determined by AASHTO T-180. Be Compaction shall be accomplished with a self-propelled steel drum or pneumatic tired roller weighing at least 8 tons. All areas which are low and do not conform to the design template after rolling shall be scarified, filled with well -graded base material and the grading and rolling continued until the base conforms to the design grade and section. C. During final compaction operations, if blading of any area is necessary to obtain the true grade and cross section, complete the compacting operations for such area prior to making the density tests on the finished bases. D. If cracks or checks appear in the base, remove them by rescarifying, reshaping, refilling with limerock where needed, and recompacting, at no cost to the OWNER. 02511-2 02511 —Base Course 3.5 DENSITY TESTS A. Compaction tests shall be taken at the locations specified herein or at locations selected by the ENGINEER or his authorized representative. Be All tests shall be taken at 300 linear foot intervals (minimum) or a minimum of 5 tests as requested by the Engineer. 3.6 TESTING THE FINISHED SURFACE A. The finished surface of the base course shall be checked with a template cut to the required cross section and with a 15 foot straight edge laid parallel to the centerline of the road. Correct all irregularities greater than plus or minus 1/4 inch by scarifying and removing or adding base, as may be required, after which the entire areas shall be compacted as specified herein. 3.7 THICKNESS A. After the base is complete, the Engineer or the soils laboratory shall take cores at intervals of 300 linear feet or less. Completely fill said core holes with a sand cement grout before the base is primed, or else completely fill said core holes with 3 or more equal layers of base material and adequately compact each layer using a short steel rod and hammer. Where the base is more than 1/2 inch deficient in thickness, correct such areas by scarifying and adding limerock. Scarify to a depth of at least 3 inches and add more base material for a distance of 100 feet in each direction from the edge of the deficient area, so that after proper compacting the thickness will conform to the DRAWINGS. 3.8 PROTECTION AND MAINTENANCE A. "Hard -plane" the base with a blade grader immediately prior to the applications of prime coat to remove thin -glazed or cemented surfaces, leaving a granular or porous condition that will allow free penetration of the prime material. Remove all materials planed from the base area. Be Protect the base in accordance with Section 02518, "Prime and Tack Coats for Base Courses". This surface shall have a minimum curing time of one week before the wearing course is applied. Co Maintain the true crown and grade with no rutting or other distortion until the surface course is applied. + + END OF SECTION + + 02511-3 02511 — Base Course SECTION 02514 GATE VALVES PART 1 -SCOPE 1.01 GENERAL The work to be performed under this item shall include furnishing and installing gate valves as specified by the Engineer and as shown on the Plans. 1.02 REFERENCES Standards applicable in this Specification shall be: A. American Water Works Association (AWWA) 1. AWWA Cl l l-80 - Rubber -Gasket Joints for Ductile Iron and Gray -Iron Pressure Pipe and Fittings. 2. AWWA C509-87 - Resilient -Seated Gate Valves for Water and Sewerage Systems. B. American Society of Testing and Material (ASTM) 1. ASTM A126-84 - Gray -Iron Castings for Valves, Flanges and Pipe fittings. 1.03 SUBMITTALS A. Shop Drawings - Prior to any fabrication or installation work, the Contractor shall furnish to the Engineer, for review and approval five (5) sets of shop drawings for the following items. All drawings shall be reviewed, approved and stamped by the Contractor pursuant to the provisions of the General Conditions. 1. Gate Valve 2. Valve Box PART 2 - MATERIAL 2.01 GATE VALVES (SIZES 4" TO 12") Gate valves shall be of the solid wedge type with resilient seats. Gate valves shall be mechanical jointed and meet the requirements of AWWA C509-87. Valves shall be iron bodied, bronze mounted, utilizing "O-ring" seals. Resilient seat shall be applied to the gate and shall seal against an epoxy coated metallic surface. The stem shall be of the non -rising type, operated by a standard AWWA, 2 -inch wrench nut. All valves shall open to the left, using a counterclockwise motion. The stem shall be sealed with a dual "O- ring" system designed such that the seal above the stem collar can be replaced with the valve under pressure in the fully open position. 02514 — Gate Valves 02514-1 Valves shall be rated for a minimum 150 psi working pressure and a minimum body test pressure of 300 psi. When closed, the valve shall be drip -tight under rated pressure differential applied alternately to each side of the gate. The interior of the valve shall be epoxy lined in accordance with AWWA C550. The exterior of the valve shall receive a minimum of two, 2 mill dry film thickness, asphaltic coating. All exterior exposed bolts, studs, and nuts shall be corrosion resistant, zinc -coated in conformance with ASTM A153. 2.02 VALVE BOXES All buried valves shall have cast two or three piece valve boxes with cast iron covers. Valve boxes shall be provided with suitable heavy bonnets and extend to an elevation at or slightly above the valve bonnet. The barrel shall be one or two-piece, screw type, having 5 -1/4 inch shaft. Covers shall have "WATER" cast into the top for all water main. All valves shall have actuating nuts extended to within six inches of the top of valve box cover. All valve boxes shall be set in a square concrete valve box bonnet in accordance with the Drawings. PART 3 - EXECUTION OF WORK 3.01 Gate valves shall be installed as typical sections of the pipeline. The requirements for pipeline foundation and backfill shall be followed in all regards when installing buried service gate valves. 3.02 Care shall be taken so that the valve box does not transmit loads directly to the valve body. Valve boxes shall be installed perpendicular and flush with the ground surface as shown on the Plans. 3.03 All gate valves shall be mechanically restrained to the attached pipe sections. Pipe sections both upstream and downstream of each valve shall be restrained the minimum required length as that shown for a plug in the Restraint Length Detail on the Drawings. END OF SECTION 02514 — Gate Valves 02514- 2 SECTION 02515 MISCELLANEOUS WATER APPURTENANCES PART 1 -GENERAL 1.01 All types of valves and appurtenances shall be products of well established reputable firms who are fully experienced and qualified in the manufacture of the particular equipment to be furnished. The equipment shall be designed, constructed and installed in accordance with the best practices and methods and shall comply with these specifications as applicable. 1.02 All valves and appurtenances shall have the name of the maker and the working pressure for which they are designed cast in raised letters upon some appropriate part of the body. 1.03 All valves and appurtenances shall be of a manufacturer and/or model number as listed in SECTION 15, "APPROVED MANUFACURES'S PRODUCTS LIST" from the most recent edition of INDIAN RIVER COUNTY UTILITY DEPARTMENT WATER & WASTEWATER STANDARDS, PART 2 - PIPE TAPPING SADDLES 2.01 WATER SERVICE TAP Tapping saddles shall be manufactured of high strength ductile iron bodies, coated with a minimum 12 mills of fusion bonded epoxy. The body shall incorporate a Buba- N rubber gasket conforming to ASTM -132000 and be provided with a F.I.P. threaded top. The saddle shall be double bolted, with the band, bolts and all hardware of type 304 stainless steel. The tapping saddles shall be "Ford" model FC202, or approved equal. 2.02 WATER MAIN TAP AND VALVE Tapping sleeves shall be long body, mechanical joint end with flanged outlet, ductile iron construction, split in two sections and designed for assembly around the main without halting service. The sleeve shall be suitable for use with the type and O.D. of pipe being tapped. Tapping valves ends shall be a standard flange (for bolting to the sleeve) by mechanical joint. Valves shall have oversized seat rings to permit entry of the tapping machine cutters and, except as otherwise specified, shall be similar in construction and operation to AWWA C509 gate valves (NRS). Tapping valves and sleeves shall be cold water pressure rated at 200 psi minimum for valve sizes up to 12 inches or less and 150 psi minimum for valve size over 12 inches. Tapping sleeves and valves shall be "Mueller" or approved equal. PART 3 - CORPORATION STOPS Corporation stops for use with polyethylene pipe shall be of the ball type, constructed of 85-5-5-5 brass alloy conforming to ASTM -1362. The corporation stop shall have an M.I.P.T. end by compression end with split gland retainer. Corporation stop shall meet AWWA-C800 standards. Corporation stops shall be "Ford", model FB 1101, or approved equal. 02515- Miscellaneous Water Appurtenances 02515-1 PART 4 -CURB STOP Curb stop for connecting the polyethylene water service line to P.V.C. pipe shall be of the ball type, constructed of 85-5-5-5 brass alloy conforming to ASTM -B62. The curb stop shall have a compression end by F.I.P.T. end. The curb stop shall meet AWWA-C800 standards. Curb stop shall be a "Ford", model KV43, or approved equal. PART 5 - FLEXIBLE COUPLINGS 4.01 Flexible couplings shall be either the split type or the sleeve type as shown on the Drawings or as further specified hereafter. Sleeve type couplings shall be used with all buried piping. The couplings shall be of steel and shall be Dresser Style 38, Smith Blair Style 413, Baker Allsteel, or equal. The coupling shall be provided with hot dipped galvanized steel bolts and nuts unless indicated otherwise. All couplings shall be furnished with the pipe stop removed. Couplings shall be provided with gaskets of a composition suitable for exposure to the liquid within a pipe. PART 6 - POLYETHYLENE WATER SERVICE PIPE Potable water service pipe shall be single piece, SDR9, PE -3408 polyethylene pipe, conforming to AWWA-C901. Polyethylene pipe ends shall be provided with stainless steel tube stiffeners. Joints for plastic tubing shall be of the compression type, utilizing at totally confined grip seal and coupling nut, along with a split clamp locking device. END OF SECTION 02515 — Miscellaneous Water Appurtenances 02515 - 2 SECTION 02519 TESTING AND DISINFECTING WATER SYSTEM PART 1 - DISINFECTING POTABLE WATER PIPELINES 1.01 The new water system shall remain disconnected from existing water lines except for the temporary jumper connection. All water used to fill and test the new water system shall be obtained through the temporary jumper connection. Flushing shall be accomplished through the new connection only under direction by the Utility Authority and only after installation of upstream and downstream pressure gauges. 1.02 Before pressure testing against existing water system valves, and before being placed into service, potable water pipelines shall be chlorinated in accordance with the latest edition of AWWA C-651, "Standard Procedure for Disinfecting Water Mains". The procedure shall be approved by the Engineer. The location of the chlorination and sampling points will be as shown on the Drawings. Taps for chlorination and sampling shall be uncovered and backfilled by the Contractor as required. 1.03 The pressure required for the field hydrostatic pressure test shall be 50 percent above the normal working pressure but not less than 150 psi. The Contractor shall provide temporary plugs and blocking necessary to maintain the required test pressure. Corporation cocks at least 3/4 -inches in diameter, pipe riser and angle globe valves shall be provided at each pipe dead-end in order to bleed air from the line. Duration of pressure test shall be at least 2 hours. The cost of these items shall be included as a part of testing. 1.04 The leakage test shall be conducted concurrently with the hydrostatic pressure test and shall be of not less than 2 hours duration. All leaks evident at the surface shall be repaired and leakage eliminated regardless of total leakage as shown by test. Lines which fail to meet tests shall be repaired and retested as necessary until test requirements are complied with. Defective materials, pipes, valves and accessories shall be removed and replaced. The pipe section to be tested shall be between valves or in such sections as may be directed by the Engineer by shutting valves or installing temporary plugs as required. In no case shall the section of line to be hydrostatically tested exceed 2000 feet in length. The line shall be filled with water and all air removed and the test pressure shall be maintained in the pipe for the entire test period by means of a force pump to be furnished by the Contractor. Accurate means shall be provided for measuring the water required to maintain this pressure. The amount of water required is a measure of the leakage. 1.05 The Contractor must submit his plan for testing to the Engineer for review at least five (5) working days before starting the test. The Contractor shall remove and adequately dispose of all blocking material and equipment after completion and acceptance of the field hydrostatic test, unless otherwise directed by the Engineer. Any damage to the pipe coating shall be repaired by the Contractor. Lines shall be totally free and clean prior to final acceptance. 1.06 The Engineer or the Engineer's representative must be present during testing. PART 2 - PRESSURE AND LEAKAGE TESTS OF UNDERGROUND PRESSURE PIPING 2.01 Hydrostatic pressure and leakage tests for ductile iron pipe shall conform with Section 4 of AWWA Standard C-600, with the exception that the Contractor shall furnish all gauges, meters, pressure pumps and other equipment needed to test the line. PVC pipe shall be tested in accordance with 02519 -1 02519 — Testing and Disinfecting Water System AWWA Standard C605, "Underground Installation of Polyvinyl Chloride (PVC) Pressure Pipe and Fittings for Water". Engineer shall be present during all testing, and final inspections. No hydrostatic testing against existing system valves shall be allowed until the section to be tested has been bacteriologically cleared. 2.02 The new water system shall remain disconnected (connecting valve to be locked in the closed position) from existing water lines except for the temporary jumper connection. All water used to fill and test the new water system shall be obtained through the temporary jumper connection. Flushing shall only be conducted in accordance with the plans. 2.03 The general procedure for chlorination shall be first to flush all dirty or discolored water from the lines, and then introduce chlorine in approved dosages in accordance with Table 11-1 through a tap at one end, while water is being withdrawn at the other end of the line. The chlorine solution shall remain in the pipeline for no less than 24 hours. 2.04 Following the chlorination period, all treated water shall be flushed from the lines at their extremities and replaced with water from the distribution system. Bacteriological sampling and analysis of the replacement water shall then be made in the presence of the Engineer in full accordance with the AWWA Standard C-651. The Contractor will be required to re -chlorinate, if necessary. The line shall not be placed in service until the requirements of the State and County Public Health Department are met. 2.05 The Contractor shall make all arrangements necessary with an independent commercial laboratory approved by the Department of Health and Rehabilitative Service (HRS) for the collection and examination of samples of water from disinfected water mains. These samples shall be examined for compliance with HRS requirements. Sampling shall be made daily and continuously until two successive examinations are found satisfactory. Should three examinations be found unsatisfactory, the line shall be flushed and disinfected again. Certified copies of all laboratory analyses shall be provided to the Owner. The cost of all sampling, flushing, and disinfecting shall be included in the contract price and no additional charge shall be made to the Owner for this work. County personnel shall operate all valves and be present to determine volume of water used for flushing. (continued on next page) 02519 - 2 02519 — Testing and Disinfecting Water System TABLE 11-1 Chlorine Required to Produce 25-mg/L Concentration in 100 ft. of Pipe by Diameter Pipe 100 -Percent 1 -Percent Diameter Chlorine Chlorine Solution in. lb. gal. 4 0.013 0.16 6 0.030 0.36 8 0.054 0.65 10 0.085 1.02 12 0.120 1.44 16 0.217 2.60 END OF SECTION 02519 - Testing and Disinfecting Water System 02519 = 3 SECTION 02520 ASPHALTIC CONCRETE PAVEMENT PART 1 - GENERAL 1.1 SCOPE A. The work consists of the construction of an asphaltic surface course composed of a mixture of aggregate mineral filler (if necessary) and asphalt cement to produce the desired stability hereinafter described, properly laid and compacted upon a prepared base, or an existing surface course in accordance with these Specifications and in conformity with the lines, grades, thickness and typical cross section shown on the Contract Drawings. PART 2 - PRODUCTS 2.1 PRODUCTS A. The asphaltic concrete pavement shall be type S-1 and conform with Section 334, of the Florida Department Of Transportation Specifications for Road and Bridge Construction (hereinafter referred to as the FDOT Specifications).The following are exceptions to the FDOT Specification Section 334: 1. In Section 334-1.1 for 330-8.5 where referenced via Section 300, substitute Section 02518, 2. Except 330-12.5.2 3, Except RAP will not be used as a mix component 4. Except 334-7 and 334-8 PART 3 - EXECUTION 3.1 LIMITATIONS OF LAYING OPERATIONS A. Apply the asphaltic concrete only when the temperature in the shade is 50 degrees Fahrenheit and rising. The CONTRACTOR may lay bituminous mixtures which have been rained upon in transit, at CONTRACTOR's risk. However, if local conditions indicate that rain is imminent, no work shall be started. Under no circumstances shall the mixture be laid while it is raining, or when there is water on the base. If the wind is blowing such that sand, dust, etc. are being deposited on the surface being paved to the extent that the bond between layers will be reduced, the asphalt shall not be spread on the surface. B. Supply thermometers so that the ENGINEER may determine the temperature of 02520-1 02520 — Asphaltic Concrete... the bituminous materials as they are applied. Do not lay the bituminous materials unless they are the proper temperature. 3.2 TACK A. If required, a tack coat shall be applied per Section 02741 of these Specifications. 3.3 PLACEMENT OF ASPHALTIC CONCRETE A. Asphaltic concrete mix shall be placed in accordance with FDOT specifications Sections 320 and 330, with the following exceptions: 1. Substitute "Resident Project Representative" for Engineer. 2. Delete all phrases such as "when directed by the Engineer" that implicitly or explicitly indicate that the Engineer or Resident Project Representative shall have authority to supervise or direct performance of the work or authority to undertake responsibility contrary to the provisions of paragraph 9.10 of the "Standard General Conditions of the Construction Contract Section 00700". Be Unless otherwise approved by the Engineer, the Contractor shall saw -cut edges of existing pavement where (a) existing pavement is to be removed, and (b) new pavement is to be placed against existing pavement. 3.4 FINISHED CROSS SECTION A. The finished surface shall not vary from the approved section on the Plans by more than 1/4 inch from a 10 foot straight edge applied both parallel and perpendicular to the centerline of the pavement. The parallel measurement shall not be required if the road centerline is sloped to the grades shown on the Plans. The parallel measurement will be required only on flat (zero slope) grades. Areas with improper cross sections shall be corrected to the proper cross section as specified herein. 3.5 PAVEMENT THICKNESS A. All new pavement shall be 2 Y2" thick asphalt Concrete type S-1 Be To achieve finished grades, the Contractor shall apply 1" thick asphalt Concrete type S-1 over existing pavement. C. The finished pavement thickness shall vary by no more than plus or minus 1/4 inch from the thickness called for on the Plans. Corrections of deficiencies in pavement thicknesses shall be in strict accordance with the above FDOT Specifications. 02520-2 02520 — Asphaltic Concrete... 3.6 TESTS A. The testing laboratory shall provide the following: 1. Verify performance of the CONTRACTOR's proposed mix with these Specifications. 2. Perform in -plant testing of aggregate, gradation, and bitumen content. Perform at least one test per 100 tons of asphaltic concrete produced or part thereof during each day of operation. 3. Using a nuclear gage, determine the density of the finished pavement as compared to the density of the design mix. Fill and compact all core holes to match the pavement properly. 4. Take core borings as specified above, to determine pavement thickness. Fill and compact all core holes to match the pavement properly. + + END OF SECTION + + 02520-3 02520 — Asphaltic Concrete... J PART 1 - GENERAL 1.01 SCOPE SECTION 02530 GRAVITY SANITARY SEWER PIPING The work to be performed under this item shall include the selling and delivering and the installing of polyvinyl chloride gravity sewer mainline pipe and service laterals as herein specified. Installation of service laterals shall follow the installation of service wye or tee in the main within seven (7) calendar days. 1.02 REFERENCES Standard applicable in these Specifications shall be: A. American Society for Testing and Materials (ASTM). 1. ASTM D3034-81 Standard Specification for Type PSM (Polyvinyl Chloride) PVC Sewer Pipe and Fittings. 2, ASTM D2321-80 Standard Recommended Practice for Underground Installation of Flexible Thermoplastic Sewer Pipe. 3. ASTM F477-76 Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe. 4, ASTM D3212-81 Standard Specification for Joints for Drain and Sewer Plastic Pipes Using Flexible Elastomeric Seals. B. American Association of State Highway and Transportation Officials, 1. AASHTO T-180-74 Moisture -Density Relations of Soils Using a 10 lb. (4.54 kg.) Rammer and an 18 -inch (457 mm) Drop. 2. AASHTO T-99-74 The Moisture -Density Relations of Soils Using a 5.5 lb. (2.5 kg.) Rammer and a 122 -inch (305 mm) Drop, as modified by T-99-801 (Dated 1981). 1.03 SUBMITTALS A. Shop Drawings - Prior to any fabrication or installation work, the Contractor shall furnish to the Engineer, for review and approval five (5) sets of shop drawings for the following items. All drawings shall be reviewed, approved and stamped by the Contractor prior to submission to the Engineer. 1. Pipe length and class, fittings and special pieces. 2. Joint method to be used. 3. Manufacturers' data on identification tape and electronic location trace wire to be supplied. 02530-1 02530 — Gravity Sanitary Sewer Piping PART 2 - MATERIALS 2.01 DIRECTIONAL BORED POLYETHYLENE PIPE A. Polyethylene pipe used for directional bored sanitary sewer shall meet the specifications of SECTION 02400, paragraph 2.A. Pipe shall be co -extruded with green colored sheath or green striping. 2.02 POLYVINYL CHLORIDE (PVC) PIPE AND FITTINGS A. PVC Pipe (SDR26) - PVC pipe shall meet ASTM D-3034 requirements. The joints shall consist of an integral bell with elastomeric gasket. The gasket shall be locked securely in the bell. The pipe shall be approximately 12.5' or 20' lengths. Pipe shall be green in color. The pipe must meet or exceed the testing procedure per ASTM D-2412, D -3212-73T and D-2444. The pipe shall be manufactured from clean virgin, Class 11332-B PVC compound conforming to the latest ASTM Standard C-1784. Connections to pipes of other materials or to pipes with dimensions not compatible with SDR 26 pipe shall be made using couplings of rigid P.V.C. construction with elastomeric gaskets, as manufactured by "Harco", or equal. 2.03 SERVICE LATERAL MARKER SYSTEM A. Each lateral installed by the nderground contractor shall have an electronic marker location ball taped to the unconnected end of the service lateral. Also, a stake shall be placed at the end of each service lateral and shall be 4" x 2" pine, 4 feet long. The stake shall be pressure treated lumber, painted green at the top. 2.04 BURIED IDENTIFICATION TAPE Detectable buried identification tape shall be installed for all trenched pipe. Tape shall be 2 inches minimum width, consisting of a minimum 5 mil overall thickness with a solid aluminum foil core. Construction shall be 2 mil clear film, reverse print laminated to aluminum foil to 2 mil clear film, making the film permanently printed. Tape shall be furnished in manufacturers' standard roll length, meeting the "American Public Works Association" (APWA) color code, and shall be imprinted continuously with the following words, unless otherwise approved: "GRAVITY SEWER" Detectable buried warning tape shall be equal to or better than "PRO -LINE" underground utility marking tape as manufactured by Pro -Line Safety Products Co., 1099 Atlantic Drive, Unit #1, West Chicago, IL. 2.05 DETECTABLE BURIED TRACE WIRE Trace wire shall be continuous #10 THHN, stranded conductor copper wire. PVC color sheathing shall meet the color code of the "American Public Works Association" (APWA). 02530 — Gravity Sanitary Sewer Piping 02530-2 2.06 FOUNDATION ROCK A sieve analysis of the limerock shall conform to the following limits: Passing 1" Passing 3/4" Passing 3/8" Passing #4 Passing #8 PART 3 - INSTALLATION 3.01 GENERAL REQUIREMENTS 100% - 90 - 100% - 20 - 55% - 0 - 10% - 0 - 5% A. All work shall be proved to be in first class condition and constructed properly in accordance with the Drawings and Specifications. All defects and leaks disclosed by required testing shall be remedied. All tests shall be performed by the Contractor and observed by the Engineer. B. All pipe and structures shall be installed on dry, firm bedding. The free water surface shall be shall be lowered to at least 12 inches below the bedding surface prior to placing pipe or structures and shall be maintained at that depth throughout bedding, haunching, and initial backfilling of the work. During subsequent backfilling, the water level shall be kept sufficiently below the working surface to allow compaction of backfill to the required density, and until required density tests have been performed. C. Temporary supports shall be installed for adequate protection and maintenance of all underground and surface structures, water lines, drains, and other obstructions encountered in the progress of the work. Any structure which may have been disturbed shall be restored upon completion of the work. D. Blasting shall not be permitted except by written approval of the Engineer. E. Trenching and subsequent backfilling within the general construction site shall be accomplished as expeditiously as possible in order to prevent trench decay and maintain a clear operational area. F. Prior to any excavation or trenching outside the designated limits of the work site, the Contractor shall secure the necessary permits and/or authorization from the applicable Owner, or confirm that such has been previously obtained. The stipulations of said permit or authorization shall be completely followed and, prior to construction operations, notice shall be provided to the appropriate Owner and Engineer. 3.02 HANDLING MATERIALS A. Pipe, fittings, and accessories shall be loaded and unloaded by hand or skidding so as to avoid shock or damage. Under no circumstances shall such materials be dropped. Pipe handled on skidways shall not be skidded or rolled against pipe already on the ground. B. In distributing the material at the site of the work, each piece shall be unloaded opposite or near the place where it is to be laid in the trench. 02530- 3 0 02530 — Gravity Sanitary Sewer Piping 3.03 ALIGNMENT, GRADE AND COVER FOR BURIED PIPING SYSTEMS A. Gravity sewers shall be laid and maintained to the required lines, depths, and grades. B. Wherever obstructions not indicated on the Drawings are encountered during the progress of the work and interfere to such an extent that an alteration in the Drawings is required, the Engineer will order a deviation from the line and grade or arrange with the Owners of the structures for the removal, relocation, or reconstruction of the obstructions. C. The maximum permissible deflection for pipe and fittings shall be as recommended by the manufacturer. D. Installation of gravity sewers shall be controlled by use of a laser to maintain proper grade. The Contractor shall also be responsible for verifying elevations of the pipe, as indicated on the Drawings, at sufficient points during progress of the work to identify discrepancies between actual and plan elevations due to laser misalignment, equipment error, etc., and to correct the work as required to conform to the Drawings. 3.04 PIPE TRENCH EXCAVATION A. Trench Dimensions 1. The minimum width of the trench shall be equal to the outside diameter of the pipe at the joints plus 8 inches for unsheeted trenches, or 12 inches for sheeted trench, and the maximum width of trench, measured at the top of the pipe, shall not exceed the nominal pipe diameter plus two feet, unless otherwise shown on the Drawing details or approved by the Engineer. Trench walls shall be vertical from the bottom of the trench to a line measured one foot above the top of the pipe. From one foot above the top of the pipe to the surface, the trench walls shall be as nearly vertical as soil conditions will permit, unless otherwise detailed on the Drawings. Spaces for joints, fittings, manholes and other structures shall be maintained unless otherwise approved by the Engineer, or alternate methods are detailed on the Drawings. Should the specified maximum width of trench be exceeded, the pipe shall be adequately reinforced as directed by the Engineer, at the Contractor's expense. 2. Trench grade for utilities or structures not requiring special bedding material shall be defined as the grade of the bottom surface of the utility or structure to be constructed or placed within the trench. Such shaping of the trench bottom, as may be required to provide suitable bedding, shall be considered to be a part of this work. Trench grade in non -cushioning material shall be defined as 6 inches below the outside of the bottom of the utility, which 6 inches shall be backfilled with suitable bedding material. Unauthorized excavation below trench grade shall be backfilled to trench grade and suitably compacted by the Contractor without additional cost to the Owner. Final trimming and grading of trench bottom shall be done manually. 3.05 BACKFILL AND BEDDING MATERIALS A. TYPE 1 - Type 1 material shall be either well -graded crushed stone or crushed gravel meeting the requirements of ASTM Designation C33 -71a, Gradation 67 (3/4 inch to No. 02530 — Gravity Sanitary Sewer Piping 02530- 4 J 4 Sieve) or air cooled blast furnace slag along or in combination with crushed stone and/or crushed gravel conforming to ASTM Designation C33 -71a requirements. This material shall be used primarily for pipeline and manhole foundations. B. Type 2 - Type 2 material shall be unclassified material obtained from the Contractor's excavations and approved by the Engineer. The material shall be substantially free from wood, roots, humus, peat, muck, and other organic materials, and shall not contain clods, stones, masonry rubble, and the like, greater than 6 inches through the largest dimension. In general, the material shall consist of sand, loam, sandy- loam, clayey -sand, gravel, or crushed stone. C. Type 3 - Type 3 material shall be select granular material, free from organic matter, of such size and gradation that the desired compaction can be readily attained and shall meet the requirements for A3 material according to the Revised Bureau of Public Roads Classifications. Material from the Contractor's excavations may be used, if it meets the above requirements. Otherwise it must be imported. 3.06 BEDDING AND FOUNDATIONS A. Ordinary Bedding The bottom of the trench shall be hand shaped to provide a firm bedding for the utility pipe. The utility shall be firmly bedded in undisturbed firm soil. The bedding shall be shaped so that the pipe will be in continuous contact therewith for its full length and shall provide a minimum bottom segment for the pipe equal to 0.6 of the outside diameter of the barrel. Excavation under the bell shall be sufficient so that the bell does not support the pipe and the joint can be made without interference. B. Unsuitable Bedding Material Class C Bedding shall be used for all pipeline construction unless otherwise shown on the Drawings or unless unsuitable material is encountered at the bedding surface. In the event that the materials encountered at normal bottom of trench excavation are, in the judgment of the Engineer, unsuitable to act as foundation for the pipe, such material shall be excavated for the full width of the trench to the depth necessary to obtain a suitable foundation. The Engineer will notify the Contractor, in writing, of the necessity for and extent of the material to be removed and the Contractor shall remove such unsuitable material as soon as possible and backfill in accordance with the requirements for Class B Bedding. All unsuitable material shall be disposed of by the Contractor. 3.07 PIPE TRENCH BACKFILL A. Initial Backfill 1. Initial backfill shall be placed as soon as possible after laying the pipe and shall maintain a pace with the pipe laying so that no more than five pipe joints separate laying and backfilling operations. Initial backfill shall include all haunching and backfill from the top of the bedding to a compacted depth of twelve inches over the pipe. All haunching and backfilling shall be done in the dry. 2. Initial backfill shall be done as specified below: 02530n5 02530 — Gravity Sanitary Sewer Piping 2.1 Haunching of the pipe shall be by hand placement and compaction of material in maximum 4 inch layers from the bottom of the trench to the springline of the pipe, taking care to fill all voids below and around the pipe. Backfilling shall be carefully continued in layers not exceeding 6 inches in thickness for the full trench width until the compacted fill is 12 inches above the top of the pipe. 2.2 During initial backfilling the fill shall be deposited evenly along both sides of the pipe from a height not to exceed 2 feet above the top of pipe, and fill shall not be dropped directly on the unprotected pipe surface. 2.3 Where thrust blocks, encasement, or other cast -in-place concrete items are below grade, no backfilling shall start until the specific items have been inspected and approved by the Engineer or his authorized representative. 2.4 The backfill to one foot above the top of the utility shall be thoroughly compacted with curved end tamping bars under and on each side of the pipe and flat tamped between the pipe and trench wall and shall be completed before the remainder of the trench is backfilled. Initial backfill shall be compacted to 100 percent of maximum density as determined by AASHTO T-180. No subsequent backfill will be permitted until the initial backfill has been accepted by the Engineer or his authorized representative. B. Subsequent Backfill 1. Subsequent backfill is that backfill between the initial backfill and the finished ground level or bottom of subbase. 2. Subsequent backfill material shall be placed full trench width in horizontal layers not exceeding 12 inches loose depth and compacted by power -operated tampers, rollers, or vibratory equipment to a density equal to 98 percent of the maximum density as determined by AASHTO T-180 for pipe placed under and adjacent to roadways or paved surfaces, and 95 percent under areas where no pavement is to be constructed and vehicular traffic is not to pass over the pipe. Each layer shall be compacted to the specified density prior to placing subsequent layers. The thickness of the loose layer may be increased when in-place density tests show that the specified density can be obtained. C. Backfill Material 1. Type 2 material shall be used for initial backfill and subsequent backfill with the following conditions: Initial backfill shall be predominately sandy material free from rock or stone greater than 1 1/2 inches diameter, and the maximum allowable dimension of a stone or rock fragment for subsequent backfill shall be 6 inches. If in the opinion of the Engineer the Type 2 material will not provide adequate and uniform support for load distribution to the pipe, the Contractor shall obtain and place either Type 1 or Type 3 backfill as determined by the Engineer. 2. All excavated material not suitable for backfill shall be placed on site at an acceptable location, by Owner, or hauled off the job at the price set forth in the 02530 — Gravity Sanitary Sewer Piping 02530&6 L accepted Bid Documents. All material that is brought in from other sources for backfill shall be at the price set forth in the Contract. 3. Excavated material to be used for backfill shall be neatly deposited at the sides of the trenches where space is available to protect against caving or sloughing into the trench. Where stockpiling of excavated material is required, the Contractor shall coordinate the site location with the Engineer and shall maintain his operations to provide for natural drainage and not present an unsightly appearance. No excavated material shall be placed on private property without the consent of the property owner. D. Compaction Methods 1. Mechanical compaction shall be accomplished using pneumatic or gasoline -powered tampers or flat -plate vibrators. Self propelled rollers may be used with the exception that the first two feet of backfilling over the pipe shall be compacted by hand- operated tamping devices. 2. Flooding or puddling with water to consolidate backfill is not acceptable, except where sand is encountered below unpaved areas only, and only with prior approval by the Engineer. The flooding or puddling operation shall be repeated with each two feet of backfill placed. E. Density Tests 1. The Contractor shall arrange to have sufficient soil tests made by an independent testing laboratory selected by the Engineer to demonstrate conformance of his work with the stability and compaction levels required by these specifications. Compaction tests shall be taken at intervals listed herein or as deemed necessary by the Engineer. All test results shall be signed and sealed by a Florida Registered Engineer, and a copy provided to the Owner and Engineer. 2. Any proposed alternative test methods to those specified herein must be approved by the Engineer prior to testing. At the request of the Engineer, the Contractor shall provide such documentation of a proposed alternative test method as the Engineer may require to evaluate the method for approval. 3. In no case shall the Contractor proceed with construction on compacted material until the tests prove satisfactory and approval is given by the Engineer. 4. In general, at least one test for maximum dry density/optimum moisture content shall be performed on representative samples of each inherently different material to be used for compacted backfill or embankment fill. For material of uniform composition and textural class, a minimum of two test locations per mainline run between manholes shall be performed. 5. As a minimum, in-place density tests shall be performed at the following rates on the compacted backfill, and shall be taken in one foot intervals beginning at one foot above the pipe and ending at the final grade. Test locations shall be as directed by the Engineer or his authorized representative. For material of uniform composition and textural class, a minimum of one test location per 02530-7 02530 - Gravity Sanitary Sewer Piping mainline run between manholes shall be performed. If any test results are unsatisfactory, the Contractor shall re -excavate and recompact the backfill, at his expense, until the required compaction is obtained. 6. The costs of all sampling, proctor and density testing shall be paid for by the Contractor. 3.08 PIPE SYSTEM LAYING AND JOINTING A. General 1. Unless otherwise specified herein or directed by the Engineer, all pipe and fittings shall be laid and joined in accordance with the appropriate manufacturer's directions with regard to allowable barrel and joint deflection, spigot seating depth, gasket placement, lubrication, bolt torque, field cutting/trimming, and pushing/pulling methods for joint assembly. 2. Prior to placing in the trench, each pipe section, joint, and fitting shall be checked for damage or defects such as cracks, blisters, coating/lining separation, gouges, and the like. Any damage or defective materials found shall not be installed unless approved by the Engineer, and shall be marked "REJECTED" and immediately removed from the work site. 3. Prior to installation, the interior of all pipe and fittings shall be inspected for debris, sediment accumulation, sand, and the like, and shall be cleaned as required to remove such foreign matter. Joint surfaces such as gaskets, gasket grooves, spigots, and bells shall be cleaned of sand and grit prior to joining. 4. Gasket lubricants shall be stored and applied in a manner that will prevent significant contamination or pick-up of sand and grit. 5. The pipe spigot shall be centered in and aligned with its mating bell prior to insertion and forced evenly in a straight line to seating depth, taking care not to over -bell the joint. Where required, deflections shall be made after the joint is seated. 6. Joining shall generally be done by hand or by push -bar with a cushion block whenever pipe size and weight permit. When a mechanical pushing/pulling device such as chain -puller, come -along, and the like is required, the device shall be used in a manner that will not deform gouge, chip, or otherwise damage the pipe or cause significant disturbance of the prepared bedding. In no case shall joints be made by "popping -on" or swinging the spigot into the bell to seat the joint. 7. Fittings and appurtenances shall be fully, independently supported on the bedding or on a permanent foundation so as not to bear on the pipe upon completion of the installation. 8. The installed piping system shall be kept free of dirt, trench water, and other foreign matter during the progress of the work, and all open ends of the line shall be sealed with watertight plugs whenever work is not in progress. 02530 — Gravity Sanitary Sewer Piping 02530- 8 4 L 9. Empty installed pipe shall be secured against flotation due to potential trench flooding by timely placement of sufficient backfill or approved anchoring devices sufficient to resist pipe buoyancy. 3.09 INSTALLATION OF FITTINGS A. Fittings, plugs, and caps shall be set and jointed to pipe in the manner heretofore specified for cleaning, laying and jointing pipe. B. Installation of manholes shall conform to the details as shown on the Drawings and, unless otherwise specified, shall conform with Section 425 of the 1986 Edition of the Florida D.O.T. Standard Specifications for Road and Bridge Construction. Backfill shall be placed in lifts not to exceed 12 inches loose depth and compacted to 95 percent of maximum density per AASHTO T-180 in unpaved areas and to required subgrade density in areas of paving or curbing. C. Density tests shall be taken on the compacted backfill at all manholes. There shall be a minimum of one test location for each manhole. The test location shall be taken at the location designated by the Engineer's representative. The density tests shall be taken at each location at one foot intervals beginning at the bottom of the excavation and ending at the final grade. The costs of all testing shall be paid for by the Contractor. 3.10 INSTALLATION OF DETECTABLE BURIED WARNING TAPE Tape shall be attached to the pipe for its entire length. Tape shall also be placed at a maximum depth of 12 inches below finished grade directly above the pipe centerline. Following placement of tape, the trench shall be backfilled with due caution to prevent displacement or damage to the tape. 3.11 INSTALLATION OF DETECTABLE BURIED TRACE WIRE Trace wire shall be installed on all pipe and fittings, with splices, branches, connections and terminations as shown on the plans. 3.12 AS -BUILT DRAWINGS During the installation of gravity sewer lines, the Contractor's Registered Florida Surveyor and Mapper shall keep accurate records of the As -Built construction showing the location of all changes in elevation, alignment, services, utility crossings, structures and similar data. Items shall be located from permanent objects such as centerline of street, manholes, valves, etc. Immediately upon completion of the sanitary sewer inverts and prior to placement of roadway base, the Contractor shall deliver to the Engineer an As -Built Drawing, signed and sealed by a Florida registered surveyor, showing the manhole separations, inverts and rim elevations. END OF SECTION 02530-9 6 02530 — Gravity Sanitary Sewer Piping SECTION 02531 GRAVITY SEWER MANHOLES PART 1 - GENERAL 1.01 SCOPE The work to be performed under this item shall include the furnishing of all materials, equipment and labor required for the installation of pre -casts gravity sewer manholes as herein described and as shown on the Plans. The Contractor shall perform all excavation, backfilling, and related work required for the construction of the gravity sewer manholes in accordance with the provisions set forth under the applicable items of this Specification. 1.02 REFERENCES Standard applicable in this Specification shall be: A. American Society for Testing and Materials (ASTM) 1. ASTM A48-76 - Specifications for Gray Iron Castings. 2. ASTM C478 -82a - Standard Specification for Pre -cast Reinforced Concrete Manhole Section 1.03 SUBMITTALS A. Shop Drawings - Prior to any fabrication or installation work, the Contractor shall furnish to the Engineer, for review and approval five (5) sets of shop drawings for the following items. All drawings shall be reviewed, approved and stamped by the Contractor prior to submittal to the Engineer. 1. Pre -cast manholes B. Manufacturer's Data - Prior to any fabrication or installation work, the Contractor shall furnish to the Engineer, for review and approval, manufacturer's data for the following items: 1. Manhole frames and covers 2. Manhole rainguard boots 3. Press seal pipe connectors 4. "Ram-Nek" mastic joint sealer PART 2 - MATERIALS 2.01 MANHOLES A. Pre -cast Manholes - Pre -cast manholes shall conform with the typical manhole details as shown on the Plan and shall consist of a pre -casts reinforced base, cast monolithically with a minimum two foot length of barrel section, additional barrel sections and manhole cones. All concrete used in the construction of pre -cast manholes shall be Type H with a 28 -day compressive strength of 4000 psi. 02531 — Gravity Sewer Manholes 02531-1 Pre -cast manhole sections shall be circular and formed with male and female ends so that when assembled they will make a continuous, uniform manhole. Joints shall be of such design as will permit effective jointing by using a continuous keyed construction joint. Keyed sections shall be joined and sealed using "Ram-Nek" or other mastic sealant approved by the Engineer and capable of preventing leaks between the sections. After placement of the manhole sections, anti -hydro grout shall be used to point all remaining joint surfaces and lifting holes. Alternate designs will be permitted only when they have received approval from the Engineer prior to their fabrication. Pre -cast concrete manholes shall conform with the requirements of ASTM Designation C478, except that the minimum acceptable wall thickness shall be 8 -inches. Manhole steps will not be provided. After the manhole is assembled and before backfilling, all joints shall be filled with anti - hydro grout and pointed to form a dense hard joint. Two coats (minimum of 8 mil dry thickness per coat), of Coal Tar Epoxy coating, or approved equal, shall be applied to the entire surface, inside and outside, of the manhole. These coatings shall be applied in accordance with the manufacturer's directions. Brick collars, above the roof slab or manhole cone, to bring the manhole to finished grade, shall be laid to the thickness and dimensions shown on the Plans. All brick shall be thoroughly wetted before laying and shall be laid in a full bed and joint of mortar. B. Manhole Frames and Covers Manhole frames and covers shall be close -grained gray cast iron castings conforming to ASTM A48, Class 30 iron. Castings shall be of uniform quality, free from blow holes, porosity, hard spots, shrinkage, defects, cracks or other injurious defects. They shall be smooth and well cleaned by shot blasting and, unless otherwise specified shall be coated with coal tar pitch varnish of a type which will make a smooth coating, tough and tenacious when cold, not tacky and not brittle. Frame and covers shall have a minimum total weight of 400 pounds. Manhole covers shall have a minimum thickness along the rim of 2 inches. Covers shall have concealed watertight pick holes. All frames and covers shall be U.S. Foundry and Manufacturing Corporation, No. 420 "B" or approved equal, marked "Sanitary Sewer". C. Resilient Pipe Connectors for Precast Concrete Manholes The connection of any pipe to an existing manhole shall be performed utilizing a resilient connector conforming to ASTM C923-84. All metallic components of the connector shall be stainless steel. Acceptable manufacturers shall be as listed in SECTION 15, "APPROVED MANUFACURES'S PRODUCTS LIST" from the most recent edition of IRCDUS WATER & WASTEWATER STANDARDS. 02531a2 WP 02531 - Gravity Sewer Manholes PART 3 - EXECUTION 3.01 Foundations The standard foundation for pre -cast manholes shall be as follows: A. Undisturbed, existing in-place, natural granular soils consisting which have been finished graded by hand to final elevation. No over excavation shall be permitted. B. For manholes not placed on undisturbed, existing, in-place natural granular soils, a 12 inch layer of 3/8" to 3/4" crushed rock shall be placed on the prepared trench bottom, and compacted. A two inch layer of high early strength cement grout may be placed on top of the rock base for leveling. The manhole base shall be set on the foundation, to the proper invert elevation, while the grout is still workable, so that the grout will fill all voids beneath the manhole base. 3.02 Manholes All workmanship shall conform to best standard practice. Manholes shall be built accurately to the dimensions shown on the Plans. The top of the manholes shall be brought accurately to grade with masonry. Manholes shall be completed (with inverts, frames and covers) as the work progresses. Particular care shall be taken that no water rises on the masonry until the mortar is thoroughly set. Any masonry damaged in this manner shall be removed upon the order of the Engineer. All pipes or castings to be embedded in masonry work shall be accurately set and if so required, headers shall be laid around the casting so embedded. Spurs and stubs for branch lines shall be built in the manholes where shown on the Plans or otherwise required by the Engineer. They shall be closed with vitrified plugs. 3.03 Watertight Workmanship The entire work of constructing manholes must be carried on in a manner to insure watertight work. Any leaks in manholes shall be caulked, repaired or the entire work shall be removed and rebuilt. 3.04 Disposal of Water from Excavations All water pumped or bailed from excavations shall be conveyed in a proper manner to a suitable point of discharge by the Contractor at his own expense. The Contractor shall provide for the disposal of water removed from excavations in a manner that will not cause injury to public health, private or public property, any portion of the work completed or in progress, the surface of the streets, or cause any impediments to the reasonable use of the site by other Contractors. The Contractor shall be responsible for complying with all the local regulations of the Department of Environmental Regulation regarding pollution of the canals. The Contractor shall take special precautions to eliminate any odor problems resulting from the discharge of sulfide water, such as submerged discharge outlets and overflow basins. 02531 — Gravity Sewer Manholes 02531- 3 3.05 Bedding and Backfill Except for additional foundation rock as indicated above, each manhole shall be bedded and backfilled in accordance with the specification for "Gravity Sewer Piping". Density tests shall be taken at each manhole structure installed on the project. 3.06 Inverts Invert channels shall be constructed smooth and semi -circular in shape conforming to the inside of adjacent sewer sections. Changes in direction of flow shall be made in a smooth curve of as large a radius as possible. Changes in size and grade of channels shall be made gradually and evenly. Invert channels shall be formed by one of the following methods: A. Form directly into concrete manhole base. B. Lay half tile in concrete. C. The Manhole floor outside of channels shall be made smooth and sloped toward channels. 3.07 Field Quality Control Testing - Tests for water tightness shall be made by the Contractor in the presence of the Engineer. The tests and measurement of infiltration/exfiltration shall be conducted in a manner as accepted �y and approved by the Engineer. All visable leakage shall be plugged and repaired by the Contractor. END OF SECTION 02531- 4 02531 — Gravity Sewer Manholes APPURTENANCES FOR GRAVITY SEWER SERVICES PART 1 - SCOPE This section describes the materials for appurtenances to be used in construction of gravity sewerage services as shown on the Plans and specified. PART 2 - SEWER CONNECTIONS AT MANHOLES AND WET WELLS The first joint shall be not more than 24" from the outside of the manhole. PVC pipe must enter the manhole through an elastomeric manhole coupling as manufactured by Kor-N-Seal, Inc. or approved equal. PART 3 - CLEAN OUTS Clean -outs shall be provided immediately prior to the service lateral end and where shown or specified. Clean-out sizes for pipe 8 inches or larger in diameter shall be not less than 6 inches in diameter. Clean out sizes for pipe less than 8 inches in diameter shall be of the same diameter as the pipe except at the ends of service laterals where they may be 4 inch in diameter as shown on the Drawings. Materials for Clean-out construction shall be as shown on the drawings. SDIRC Middle School "BB" END OF SECTION 02532-1 02532 - Appurtenances for Gravity Sewer J SECTION 02533 TESTING OF GRAVITY SEWER SYSTEM 1.01 GENERAL The Contractor shall perform testing of all sanitary gravity sewers as set forth in this section and shall conduct the tests in the presence of a authorized County representative and the project Engineer. The Contractor shall schedule the tests with the County at least five days in advance. 1.02 LAMPING Lamping shall be conducted as installation of the line progresses. The installed sewers shall be visually inspected by "lamping" between each manhole, lamphole, or other structures in order to ascertain that they are clear, to correct alignment and have no visual bellies. The concentricity of the lamp image received shall be such that the diameter of said image shall have no vertical or horizontal reduction from that of the pipe inside diameter. 1.03 PRE — T.V. DEFLECTION TESTING Deflection testing shall be performed on all flexible pipe (thin wall PVC, HDPE, etc.) after the final backfill has been in place a minimum of 30 days. A rigid ball or mandrel shall be used which shall have a diameter at least 95 percent of the base inside diameter or average inside diameter of the pipe, depending on the specified ASTM pipe specification. The test shall be performed without mechanical pulling devices. No pipe shall exceed a deflection of 5 percent. If deflection exceeds 5 percent, the pipe shall be replaced or corrected in accordance requirements in the approved specifications. 1.04 T.V. INSPECTION Upon completion of deflection testing, gravity sewer mainline between manholes will be inspected by the Contractor, using a television camera. TV inspection will be done at a point in time that the area of pipe construction has been compacted and road material compacted to support heavy trucks. Service laterals shall be thoroughly flushed. Mainlines shall then be jet cleaned prior to inspection. Any sand or dirt found in the sewers shall be removed by the Contractor. All leaking joints or fittings shall be replaced, encased with concrete or sealed from the inside with grout as determined by the Engineer and Owner. All cracked or defective pipe shall be replaced by the Contractor. Bellies in the pipe or at the joints which retain more liquid that allowable shall be replaced. TV re- inspection as required by the Engineer or the Owner will be at Contractor's expense. 1.05 INFILTRATION/EXFILTRATION TESTING All sewer mains, house laterals and manholes shall be subjected to infiltration and/or exfiltration tests. In general, infiltration testing shall be performed on sewers lying below the ground water table and exfiltration testing shall be performed on sewers lying above the groundwater table. (The Owner and project Engineer shall agree which type of test shall be utilized for each section of pipe being tested. A. Infiltration Test: Infiltration testing shall be conducted in a dry system prior to the system being filled with water. Testing shall proceed for a continuous period of four hours with infiltration amounts measured by a weir or other approved method by the City. In no case 02533-1 k L 02533 — Testing Gravity Sewer System shall the infiltration exceed 50 gal/day/inch of pipe diameter/mile of pipe (or 0.4 gal/hr/in/ 1000 ft). B. Exfiltration Test: Exfiltration testing shall be conducted by filling the system with water and measuring the amount of exfiltration. Water shall be added to the system until the manhole with the lowest top elevation (test manhole) of that portion of the system being tested is filled to within 24 inches of its top. Testing of the system shall be segmented such that the difference between the top elevation of any two manholes being tested does not exceed 2 feet. Testing shall proceed for a continuous period of four hours with exfiltration amounts measured by adding known amounts of water to the beginning water level in the test manhole. In no case shall exfiltration exceed 100 gal/day/inch of pipe diameter/mile of pipe (or 0.8 gal/hr/in/1000 ft). Leakage from any manholes shall be included in the pipe exfiltration determination. C. Air Leakage Test: Air leakage tests may be required in lieu of infiltration/exfiltration at the option of the Owner. Air leakage tests on PVC gravity sewer pipe shall conform to ASTM F-1417. The testing shall be by compressed air from manhole to manhole. Plugs, caps and branch connections must be secured against blow -off during the test. The pipe and manholes shall be free of water during the test. The pipe shall be tested at 3.5 psi in excess of the groundwater pressure above the pipe. For each foot of water above the pipe at the deepest point, the air pressure shall be increased by 0.43 psi. The minimum time for the air pressure to drop by 0.5 psi shall be: Pipe Size Time in Minutes 6 inch 4.0 8 inch 5.0 10 inch 6.5 12 inch 7.5 15 inch 9.5 D. Test Failures: Should a test failure occur, necessary repairs shall be accomplished by the Contractor and the test repeated until within the established limits. The Contractor shall furnish the necessary labor, water, and all other items required to conduct the required testing and shall perform the necessary system repairs required to comply with the specified test. If the water supply is from the County's potable water system, a meter is required. Contractor is responsible for all costs associated with retesting. END OF SECTION 02533 - Testing Gravity Sewer System 02533= 2 J SECTION 02534 SANITARY SEWER FORCE MAINS imei31 1p1:7\fw A. Scope The work to be performed under this Item shall include the furnishing of all materials, equipment and labor required for the installation of force mains as herein described and as shown on the Plans. The Contractor shall perform all excavation, backfilling, compacting, testing and related work required for the construction of these mains in accordance with the provisions set forth under the applicable items of this Specification. B. References Standards applicable in this Specification shall be: 1) American Water Works Association (AWWA) and American National Standards Institute (ANSI). a. AWWA C104 (ANSI A21.4) Cement -Mortar Lining for Ductile -Iron and Gray -Iron Pipe and Fittings for water. b. AWWA (ANSI) C110 Gray -Iron and Ductile -Iron Fittings, 34nch through 48 - inch for water and other liquids. C. AWWA C111 (ANSI A21.11) Rubber Gasket Joints for Ductile -Iron and Gray - Iron Pressure Pipe and Fittings. d. AWWA C150 (ANSI A21.50) Thickness Design of ductile -Iron Pipe. e. AWWA C151 (ANSI A21.51) Ductile -Iron Pipe, Centrifugally cast in Metal Molds or Sand Lined Molds for water or other liquids. f. AWWA C153 (ANSI A21.53) Ductile -Iron Compact Fittings, 3 -inch through 112 -inch for water and other liquids. g. AWWA (ANSI) C600 Installation of Gray and Ductile Cast Iron Water Mains and Appurtenances. h. AWWA (ANSI) C900 Standard for Polyvinyl chloride (PVC) Pressure Pipe, 4 -inch through 12 -inch. i. AWWA (ANSI) C905 Standard for Polyvinyl Chloride (PVC) water transmission pipe, nominal diameters 14 -inch through 36 -inch. 2) American Society for Testing and Materials (ASTM) a. ASTM D-1248 Polyethylene Plastics Moldings and Extrusion Materials. 3) American Association of State Highway and Transportation Officials 02534— Sanitary Sewer Force Mains 02534 -1 a. AASHTO T-99 (2.5 kg.) Rammer and a 12- inch (305 mm) Drop, as modified by T-99-801 (Dated 1981). b. AASHTO T-180 Density Relations of Soils using a 10 lb. Rammer and an 18 - inch drop. C. Submittals 1) Shop Drawings - Prior to any fabrication or installation work, the Contractor shall furnish to the Engineer, for review and approval five (5) sets of shop drawings for the following items. a. Material specifications for all pipe types, fittings, joints, joint restraint, and specials. All drawings shall be reviewed, approved and stamped by the Contractor pursuant to the provisions of the General Conditions, Article 6.24 through 6.28. 2. MATERIALS A. Pipe 1) Ductile Iron Pipe - All ductile iron pipe shall conform to AWWA C151, ANSI A21.51 and have a rated working pressure of 350 psi (minimum). All pipe shall be factory lined and coated. The pipe interior shall receive a 40 mil lining of "Protecto 401". The exterior of the pipe shall have a minimum 10 mil. thick bituminous coating in accordance with AWWA C 151. The pipe shall be marked the entire length with three color coded stripes. These stripes shall be applied in the manner as the required ASTM coding using paint and with the word "Force Main" in %-inch high letters appearing one or more rimes every 21 - inches. As an alternative to lettering, buried pipe may be continuously spiral wrapped with plastic identification tape marked "Force Main". Lettering or identification tape shall be brown in color for force main. Ductile Iron Pipe shall conform to the following classes: a. Ductile Iron Pipe under roadways shall be minimum pressure class 350. b. Flanged Ductile Iron Pipe shall be minimum thickness class 53. C. Ductile Iron Pipe in roadway shoulders or in unimproved areas shall be minimum pressure class 350. Unless otherwise indicated on the Drawings, ductile iron pipe shall be furnished in standard 18 or 20 foot laying lengths. 2) Polyethylene pipe used for directional bored sanitary sewer shall meet the specifications of SECTION 02400, paragraph 2.A. Pipe shall be co -extruded with green colored sheath or green striping. 02534— Sanitary Sewer Force Mains 02534 - 2 B. Fittings All underground fittings shall be ductile iron with mechanical or manufacturer's mechanically restrained joints. Fittings shall conform to the following: 1) Fittings for pipe shall be compact ductile iron conforming to AWWA C 153. Fittings shall have a minimum pressure rating of 350 psi. All fittings and the appropriate number of downstream and upstream joints must be restrained. 2) All fittings shall be lined and coated as specified for ductile iron pipe. 3) Retainer glands or thrust blocks for restraint shall not be permitted. C. Joints 1) Push on Joints - Joints for D.I. pipe shall be bell and spigot, rubber gasket compression, push -on type as specified in AWWA C111 (ANSI A21.11). Special fittings and joints shall be considered for specific installation. 2) Mechanical Joints - Mechanical joints may be used for downstream restrained joint pipe. In this circumstance, the joint shall be restrained in accordance with the following paragraph C.3) d. 3) Restrained Joints - Fittings used for changes in alignment, size reduction, valves and plugs shall all be restrained along with the appropriate number of downstream and upstream joints. Restraint shall be by the use of mechanical methods. As indicated on the drawings, pipe lengths located upstream and downstream of restrained fittings shall also be restrained. Method of joint restraint shall be as follows: a. Ductile iron pipe with manufacturer's mechanical restrained joints using locking rings or wedges may be utilized. These restraints shall be American Pipe "LOK-FAST" joints, McWane "SUPER LOCK" or approved equal. b. Ductile iron pipe and fittings with mechanical joint ends shall be restrained with Ebba Iron "MEGA -LUG" grip type restrainers, series 1100. C. Ductile iron pipe with push -on joint ends shall be restrained with "UNI - FLANGE", large diameter, series 1390 restrainers, or approved equal. d. Retainer glands or locking gaskets shall not be approved as mechanical restraints. 4) Gaskets - All gaskets shall be manufactured of an elastomeric material. The gasket shall provide a positive, tight seal under all combinations of joint and gasket tolerances. Installation and lubrication of gaskets shall be as directed by the manufacturer. D. Foundation Rock 02534 - 3 02534- Sanitary Sewer Force Mains E. A sieve analysis of Foundation Rock shall conform to the following limits: Passing 3/4" - 100% Passing 3/8" - 20 - 55% Passing #4 - 0 - 10% Passing #8 - 0 - 5% Buried Trace Wire All mainlines, fittings and appurtenances installed underground shall have #10 gauge, type THHN stranded copper trace wire attached for locating purposes. Trace wire shall have a brown colored sheath for wastewater force mains. 3. EXECUTION OF WORK The installation and testing of the mainlines shall be done in accordance with AWWA (ANSI) C600, plus the additional requirements described herein or as shown on the Plans. A. Preparation 1) Clearing - The Contractor shall perform all clearing necessary, where applicable, for the proper installation of all mainlines and appurtenances in the locations shown on the drawings. Plantings, ornamental shrubbery, protected trees, utility poles or structures subject to damage resulting from the excavation shall be transplanted, relocated, braced, shored or otherwise protected and preserved unless otherwise directed by the Engineer. Protected trees shall be considered as all trees outside five (5) feet either side of the mainline to be installed. Only under special circumstances with Engineer's written approval may trees outside these limits be considered for removal. All debris generated from the clearing process shall be disposed of by the Contractor at a disposal site approved by the Engineer. B. Trenching 1) Pavement Cutting - Asphaltic pavements shall be cut by pneumatic hammers or mechanical pavement cutters; saws, or other method approved by the Engineer. Concrete pavement or concrete base pavement shall be sawed. Both types of pavement shall be cut and removed prior to any excavation. 2) Excavation - The excavation in which the pipes and appurtenances are to be constructed shall be excavated in open cut, except where otherwise stated on the Plans, in such a manner to such depths and widths as will give suitable room for bracing, supporting, pumping, draining and for removing from the excavation any material which the Engineer may decide is inadequate for foundation. The maximum trench width at the top of the pipe shall be in accordance with the trenchingdetails. The Contractor may, where it will not interfere with the work or adjacent structures or property, slope the sides of excavation. The sides of the trench may only be sloped from a point in compliance with the trenching details. No compensation will be allowed for such excavation and the Contractor shall include its cost in the prices bid. The materials of excavation shall include all materials encountered, such as clay, sand, rock, marl, muck, gravel, boulders, heterogeneous fill materials, old timbers, or any combination of these. Any unforeseen obstacles such as buried trees or timbers, 02534- Sanitary Sewer Force Mains 02534 = 4 abandoned utilities, metal objects, concrete masses or any debris encountered shall be removed. All "materials of excavation" and "unforeseen obstacles" will be considered as incidental to construction and no additional compensation will be allowed. All roots, stumps, logs, limbs, boulders or any material which is not suitable for backfill material shall be removed from the site promptly as excavated and disposed of by the Contractor at his expense. 3) Length of Trench to be Opened - The length of trench to be opened or the area of surface to be disturbed and unrestored at any time will be limited by the Engineer with regard to expeditious construction and the convenience of the Owner. Excavation shall not advance more than 100 feet ahead of the pipe laying without the consent of the Engineer. 4) Sheeting and Bracing - The Contractor shall be responsible for properly supporting the sides of all trenches and excavations with timbers or other supports wherever necessary or required to properly safeguard the trenches, adjacent properties and structures and at restricted right-of-way. The cost of all necessary timber, sheeting and bracing whatsoever (left in place or removed), shall be included in the unit prices bid for mainlines. Portions of the timber sheeting driven below the elevation of the top of the pipe shall not be disturbed or removed. Timber sheeting and bracing shall be left in place if so ordered by the Engineer and/or where shown on the Plans to avoid undermining or otherwise endangering the work or adjacent structures. All sheering left in place shall be cut off or driven at least 18 -inches below finished grade, unless otherwise ordered. Great care shall be exercised in the selection of sheeting and bracing of adequate design, type, size and strength. The adequacy of the timber used for all supporting and bracing purposes shall be the responsibility of the Contractor, who shall use only men of seasoned experience for this type of work. The sizes and lengths of the timber used shall conform closely to the needs of the work and oversizing as well as undersizing should be avoided. In placing and driving the sheeting, proper workmanship and equipment shall be used to achieve a true alignment and close contact of the sheeting boards. Timber sheeting shall be straight and sound, free from shakes, cracks, large or loose knobs and other defects impairing its strength and durability. It shall be squared to the required dimension throughout its entire length. If required for the proper execution of the work where running sand, quicksand or other semifluid material difficult to handle is encountered, the timber sheering shall be tongue and groove. The Contractor may, in lieu of sheeting, bracing and shoring to maintain the allowable trench widths, use a "trench box" ("trench shield" or "mule") provided pipe sections are secured downstream by a cable(s) stretched through and secured to the end section of pipe by means of a timber and a cable clamp, all materials being of adequate size and strength. The cable shall be held taut during the process of advancing the "box". 02534 - 5 02534— Sanitary Sewer Force Mains This procedure may be used so long as, in the opinion of the Engineer, the work is proceeding satisfactorily. The Engineer may revoke permission to use the "trench box" at any time he feels unsatisfactory or inadequate work is being performed and the Contractor shall, without appeal, immediately begin using sheeting, bracing and shoring to maintain the allowable trench widths. At all times, when soil conditions permit, the bottom edge of the "trench box" shall be no lower than the springline of the pipe, so as to disturb the trench compaction when advancing the "trench box". 5) Placing of Excavated Material - All excavated materials shall be placed where indicated by the Engineer in such a manner as not to endanger the work and so that free access will be maintained at all times to all parts of the trench and to all fire hydrants and their gate valves in the vicinity. Such material shall be neatly piled so as to interfere as little as possible with traffic. 6) Drainage - The Contractor shall furnish sufficient pumping or other dewatering equipment and shall provide at his own expense satisfactory drainage whenever needed in trenches and other excavations during the progress of the work and its completion for inspection. Water shall not be allowed to flow over or raise upon any concrete, masonry or pipe until work has been inspected and the mortar or concrete has properly set. Unless otherwise permitted by the Engineer, the water table shall be lowered by the use of a well point system. Open trench pumping may be permitted only upon approval by the Engineer of the method of pumping and drainage to be used. If open trench pumping is approved, the water must be conveyed entirely through approved coarse material placed below the bottom of the foundation. The depth of this coarse material shall be determined by the Contractor and approved by the Engineer. Materials and workmanship used for the well point system shall be in keeping with the approved standard practice. The well point system shall function so as to enable pipe, concrete cradle and appurtenances to be installed without interference from running or standing water at the bottom of the trench. The Engineer shall make the final decision as to the acceptability of the well point system or any part thereof. Where necessary, pea gravel or graded sand shall be used in conjunction with the well points as they are installed in insure continuous pumping in the dewatering of fine material. The cost of dewatering shall be included in the various unit prices bid under the mainlines. 7) Disposal of Water from Excavations - All water pumped or bailed from trenches or other excavations shall be conveyed in a proper manner to a suitable point of discharge by the Contractor at his own expense. The Contractor shall provide for the disposal of water removed from excavations in a manner that will not cause injury to public health, private or public property, any portion of the work completed or in progress, the surface of the streets, or cause any impediments to the reasonable use of the site by other Contractors. The Contractor shall be responsible for complying with all the local regulations and those of the 02534- Sanitary Sewer Force Mains 02534 - 6 Department of Environmental Protection regarding pollution of waterways. Should the size of Contractor's dewatering equipment, or the quantity of disposed water, or the method of disposal require a St. Johns' River Water Mgmt. District permit, the Contractor shall obtain such permit at no additional expense to the Owner and with no additional time added to the Contract. The Contractor shall take special precautions to eliminate any odor problems resulting from the discharge of sulfide water, such as the use of submerged discharge outlets and overflow basins. 8) Preparation of Trench - Trenching as shown on the Plan details shall be standard for this project. The trenches shall be constructed by excavating to the depth indicated on the Plans. The trenches shall then be manually shaped to fit the bell and lower quadrant of the pipe barrel. Mechanical excavation shall be limited to provide an undisturbed trench bottom for the lower quadrant and bell of the pipe. Final excavation shall require hand shaping for placement of the pipe. If mechanical over cutting occurs, the pipe bedding shall consist of four (4) inches of washed and graded sand or crushed rock on undisturbed soil. C. Laving_of Pipe All pipe, fittings and valves shall be installed according to AWWA Specification C600. Prior to installation, all pipe and appurtenances shall be examined for damage and defects. Under no circumstances shall defective pipe be installed. All lumps, blisters and excess coating materials shall be removed from the socket and plain ends of each pipe. While being placed in the trench, care shall be taken to prevent foreign material from entering the pipe. As each length of pipe is placed in the trench, the joint shall be assembled and the pipe brought to correct line and grade. At times when pipe laying is not in progress, the open end of the pipe shall be closed by a watertight plug. When practical, the plug shall remain in place until the trench is pumped completely dry. When it is necessary to deflect the pipe from a straight line in either the vertical or horizontal plane, or where long radius curves are permitted, the amount of deflection shall not exceed that of Table 5 and 6 in AWWA Specification C600. 1) Thrust Restraint - All dead ends, valves, tees, and fittings for changes in alignment shall be appropriately restrained against pipeline thrust. All changes in alignment shall require the fitting and appropriate length of upstream and downstream pipe to be mechanically restrained with approved devices. 2) Backfill a. General - Where the trench has been dewatered, backfilling must progress sufficiently before pumps are shut off to prevent flotation of pipe. Any pipe that has been displaced perceptibly from its correct position shall be removed and relaid properly at the Contractor's expense. Backfilling shall follow pipe laying within 100 feet, unless otherwise directed by the Engineer, but shall not be performed in any case until the Engineer has approved the line for backfilling. Water shall not be added except as required to obtain Optimum Moisture Content and "flooding' or "puddling" for compaction will not be allowed. Backfill material shall be free of roots, logs, limbs, clays, large rocks or any material or debris determined to be unsuitable by the Engineer. The Engineer may reject any material which he considers unsuitable for backfill. The compaction procedures 02534 - 7 02534— Sanitary Sewer Force Mains 3) specified herein shall be considered "minimum procedures" to prevent after -settlement and the Contractor shall reopen, refill and recompact any trenches indicating improper backfill procedures or after -settlement. All road crossings shall be backfilled immediately, made passable and maintained passable until the permanent repair is made. b. All Other Areas Under Pavements - The initial lift shall consist of clean, fine, select materials, not exceeding 3/4" in diameter under the haunches of the pipe. The material shall be placed in layers not to exceed 4". The initial lift shall be manually compacted to 95% of the maximum density as determined by AASHTO T-180. Subsequent lifts to 12" above the pipe shall be constructed as specified for the initial lift, except that had operated mechanical tampers may be used. Additional lifts from 12" above the pipe to the top of subgrade shall be carefully backfilled with material free from organic material and stones or clumps exceeding 3 -inches (2 -inches in the final 6 -final layer) in diameter, and compacted in 6 -inch layers to an average maximum density of 95% as determined by AASHTO T-180. C, Areas Outside of Pavements - Backfill of all areas outside of pavements shall be constructed as specified above for "all other areas under pavements" except that the additional lifts shall be constructed as specified to the finished grade. d. Density Testing - The Contractor shall arrange to have sufficient soil tests made by an independent testing laboratory approved by the Engineer to demonstrate conformance of his work with the stability and compaction levels required by these specifications. Compaction tests shall be taken at intervals listed herein or as deemed necessary by the Engineer. In no case shall the Contractor proceed with construction over compacted material until the tests prove satisfactory and approval is given by the Engineer. In general, at least one test for maximum dry density/optimum moisture content shall be performed on a representative sample of each inherently different material to be used for compacted backfill or embankment fill. As a minimum, in-place density tests shall be performed at the rate of one test location per 200 lineal feet (or fraction thereof) of trench on the compacted backfill and under each drive lane at all open cut, roadway crossings. Tests shall be taken in one foot lifts beginning at one foot above the pipe and ending at the final grade. Test locations shall be as directed by the Engineer or his authorized representative. If any test results are unsatisfactory, the Contractor shall re -excavate and recompact the backfill, at his expense, to the extent directed by the Engineer until the required compaction is obtained. The cost of all proctor and density tests shall be the responsibility of the Contractor and shall be included in the cost of installed and completed water main. Installation of Trace Wire 02534 - 8 02534- Sanitary Sewer Force Mains Trace wire shall run continuously along the pipeline from valve to valve or fitting. All splices shall be hot -soldered to provide continuity along the entire installation. Installation and splicing shall be in accordance with the details shown on the following insert. 4) Separation Requirements Force mains shall be laid at least ten (10) feet horizontally from any existing or proposed water main. Force mains crossing water mains shall be laid to provide a minimum vertical clearance of 18 inches between the outside of the water main and the outside of the force main. Where the force main passes over the water main, there shall be no joints within 10 feet of the water main. D. Field Quality Control 1) Hydrostatic Tests - The Contractor shall provide all necessary testing materials and shall perform all work required in connection with the test. All pipe shall be tested to a hydrostatic pressure of 100 p.s.i. for force mains and 150 p.s.i. for reuse mains. The required pressure as measured at the point of highest elevation shall be applied for not less than two hours, and all pipe, fittings, valves and joints shall be made water tight if leakage is evident. At a maximum, mains shall be tested from shut-off valve to shut-off valve. New mains shall be temporarily plugged or valved and pressure tested prior to tie-in or modification of existing pressure mains. No ductile iron pipe installations will be accepted unless and until the leakage is less than that as specified under Section 4.2 of the AWWA (ANSI) C600, P.V.C. pipe installations shall meet the leakage requirements of AWWA M23 as applicable. E. Adjusting and Cleaning 1) Restoring Surfaces - The top surfaces of the backfill shall be restored to the original or planned conditions. Trenches shall be carefully examined upon the completion of backfilling and surface irregularities that are dangerous or obstructive to traffic are to be removed. Paved sections shall conform in grade with adjacent areas and shall be of at least equal quality. Design mixes for flexible pavement shall be subject to approval by the Engineer. All damaged or undermined areas of existing pavement, not previously removed, shall be removed and restored to original conditions or in the specified manner. Equipment shall not travel over loose rock fragments, or other hard material, lying on sections or pavement which are not to be removed. Removal, replacement and restoration of areas of pavement shall be as indicated on drawings. F. Connection to Existing Mains The Contractor shall make no connection (open new valve) to another Contractor's work or the Owner's existing mains unless the work has been substantially completed, accepted, and paid for by the Owner, or expressed written permission to connect to the work has been given by the other Contractor and said written permission has been forwarded to the Engineer. END OF SECTION 02534 - 9 02534- Sanitary Sewer Force Mains 1. 2. 3. SECTION 02535 TESTING FORCE MAINS SCOPE A. This Section describes the procedural, material, and acceptance requirements for cleaning and testing of the mainlines with regard to quality, alignment, tightness, and overall integrity of the installed system. GENERAL A. The Contractor shall furnish all labor, materials, transportation, pumps, gauges, and equipment necessary to flush and test the installed pipe system as required by these Specifications. B. The Contractor shall provide and install all temporary connections, corporation stops, blowoffs, and the like required for flushing and testing, and upon completion of satisfactory tests, shall remove same and install appropriate plugging/capping devices or permanent connections as required. Co The Contractor shall notify the Owner and Engineer at least 48 hours in advance of all acceptance testing to be performed. No testing for acceptance of the work shall begin until the Owner and Engineer or his authorized representative are present. D. No interconnection shall be made between the new work and an existing active pipe system, except that necessary and approved by the Owner for testing, until the work is approved for use by the Engineer and until all approvals and clearances required by applicable construction permits for use of the work are issued by the permitting agency. E. At least 3 business days prior to conducting each item of work under this Section, the Contractor shall submit to the Engineer for approval a description of the specific equipment, materials, and procedures to be used, plus identification of proposed water source(s), to be used for this particular work item. FLUSHING A. Upon completion of each run of pipe between main valves or between a main valve and a terminal point, the pipe run shall be flushed with clean water at a minimum full diameter velocity of 2.5 ft./sec. in order to remove sand, debris, and other foreign materials prior to pressure testing. B. The pipe run to be flushed shall be slowly filled with clean water with all valves open to allow escape of air pockets. High points in the pipe shall be vented with air release valves. When the system is full and prior to flushing, all valves shall be fully closed. 02535 = 7 02535 - Testing Force Mains C. Flushing shall continue until a minimum water volume of two times the aggregate pipe volume has passed through the pipe section being cleaned. The aggregate pipe volume shall include all pipe carrying flushing water from the point of introduction to the work to the point(s) of discharge from the run being cleaned. D. For nominal pipe sizes of 6 inches and smaller, the pipe shall be flushed through a discharge extension of at least the full pipe diameter. For nominal pipe sizes greater than 6 inches, a 6 inch diameter discharge extension pipe, connected to the work with reducer(s), may be used in lieu of a full diameter blowoff. E. Flushing water shall be carried beyond the trench and shall be discharged in a manner that will not cause erosion nor structural damage on or off-site, and will not cause contravention of State water quality standards in receiving surface waters. The Contractor shall provide adequate extension pipe, sedimentation basin(s), and/or diffusion devices as necessary to prevent such damage. 4. HYDROSTATIC LEAKAGE AND PRESSURE TESTING A. Hydrostatic pressure and leakage tests for ductile iron pipe shall conform with Section 4 of AWWA C-600 Specification with the exception that the Contractor shall furnish all gauges, meters, pressure pumps and other equipment needed to test the line. P.V.C. pipe shall be tested in accordance with the applicable sections of AWWA M23. Upon completion of flushing, the installed pipe system shall be tested for tightness under a continuous hydrostatic gauge pressure of 25 psi and then 100 or 150 psi as applicable, ± 5 psi, determined at the lowest point in the system, for a period of 2 hours. The allowable leakage rate shall not exceed that defined in and specified by AWWA C600-82 or AWWA M23. B. If the work is subject to acceptance by a municipal or private utility with its own adopted test requirements more stringent than those stated herein with regard to pressure, duration, and/or allowable leakage rate, such requirements shall supersede these specifications. C. Testing shall be performed separately on each valved -off section of the installed system. Testing shall be against closed in-line valves with each valve in the system subject to the full test pressure differential for full test time at least once during the course of testing. D. Allowable leakage shall be calculated based on the pipe diameter(s) and total laid length of the run being tested, with no additional allowance for fittings, or joints. No visible leakage shall be allowed. If visible leakage is noted during the course of testing, or if allowable leakage is exceeded, such leakage shall be repaired to the satisfaction of the Engineer and the test repeated or extended for an additional period up to the full test time with suitable adjustment for previous make-up water used, at the Engineer's discretion. 02535 = 2 02535 - Testing Force Mains E. The pumping/pressurizing and make-up water measuring equipment shall be provided by the Contractor and approved by the Engineer prior to testing. The pressurizing equipment shall be designed and operated in a manner that will minimize pressure surging and pulsing within the pipe. F. The Contractor shall provide and install a temporary valved tap with a 1/4" FPT connection to receive the pressure gauge in each pipe run to be tested. Upon satisfactory completion of testing, the Contractor shall remove and plug the pipe. G. In preparation for testing, the pipe shall be slowly filled with clean water from an approved source, taking care to purge all air pockets. Water remaining in the pipe system after flushing may be used and supplemented as necessary with prior approval by the Engineer, and clean test water may be reused for sequential testing of pipe segments. H. In conducting the test, water shall be pumped into the full pipe until test pressure is attained, and make-up water shall be added as soon as the pressure drops to 5 psi below test pressure. All make-up water shall be accurately measured, and the total test leakage shall be defined as the volume of make-up water added. I. Should the tested section fail to meet these requirements, the Contractor shall, at his own expense, locate and repair the defects and retest the section until it is acceptable. J. Immediately upon completion of a passing pressure test, all valves shall be operated to insure their full opening and closing. 02535 — Testing Force Mains 02535 - 3 r SECTION 02536 PAVEMENT MARKINGS PART 1 - GENERAL 1.1 SCOPE A. This Section discusses painting thermoplastic traffic stripes and pavement markings. 1.2 TEMPORARY TRAFFIC STRIPING AND MARKING A. If required for traffic safety or if required by the ENGINEER or other agencies having jurisdiction, install temporary traffic striping and marking as soon as practical after the asphalt has been laid. If the temporary traffic stripes or marks become faded out before the permanent stripes and marks are applied, repaint them at no additional expense to the OWNER. B. Maintain safety along the road improvements using warning signs, traffic cones, emergency lights, and other necessary equipment until the temporary traffic striping and marking is applied. 1.3 TRAFFIC STRIPES AND MARKINGS WITHIN D.O.T. RIGHT-OF-WAY A. Use thermoplastic traffic stripes and markings for all work within FDOT right -of --ways and apply per Section 711 of the D.O.T. "Specifications for Road and Bridge Construction" and any other applicable D.O.T. specification or regulation articles 711-9 and 711-10 do not apply B. At least 30 days must pass after the asphalt has been laid before any thermoplastic stripes or markings may be applied. 1.4 THERMOPLASTIC STRIPES AND MARKINGS WITHIN COUNTY RIGHT-OF-WAY AND ON SITE PAVING A. All thermoplastic stripes and markings to be applied within County right-of-ways or where shown on the DRAWINGS for the project site paving, shall be applied per paragraph 1.3 above and the Manual on Uniform Traffic control Devices. 1.5 INTERIOR ROADWAY AND PARKING LOT STRIPING A. The work under this heading consists of constructing centerline roadway stripes, stripes on the edge of the roadway, and parking spaces, stop bars, pavement markings etc, where shown on the DRAWINGS as either paint or thermoplastic. 02536-1 02536 — Pavement Markings B. COLORS - All road centerline stripes shall be yellow. All road edge stripes, stop bars, parking spaces stripes, markings, etc, shall be white. Handicap areas shall be painted per the details on the Drawings and all stripes and markings per the Manual on Uniform Traffic Control Devices (MUTCD). C. PAINT 1) The paint shall be traffic paint formulated and manufactured from first grade materials. It shall be free from imperfections and defects that may adversely affect the finished product. 2) The paint shall conform to the FDOT Standard Specification for Road and Bridge Construction Section 710. Submit shop drawings containing the manufacturer's technical literature on the paint in accordance with Section 01340. 3) GLASS BEADS - The road centerline stripe, edge of road stripes, stop bars, and all other painting within the road shall have durable reflective glass spheres. The glass spheres shall be applied at a rate of 6 pounds per gallon of paint while the paint is still tacky enough for them to adhere. Glass spheres are not required for parking lot space stripes. . D. APPLICATION OF THE PAINT 1) Wait a minimum of 3 weeks after laying the asphalt before applying paint to it. Equipment and application shall comply with FDOT Standard Specification for Road and Bridge Construction Section 710-3, 7104, and 710-5. 2) Paint stripes shall be as per the MUTCD. Before applying any striping, mark the locations with chalk, tacks, or other suitable means. 3) The paint application equipment shall be in good working condition and shall apply the paint uniformly at the required thickness with well-defined edges. The pavement surface must be dry when the paint is applied. 4) All paint spills, application defects, alignment errors, discolored paint, etc., shall be removed in a manner that will remove the paint without harming the pavement. + + END OF SECTION + + 02536-2 02536 — Pavement Markings SECTION 02537 TRAFFIC SIGNS PART 1 - GENERAL 1.1 SCOPE A. Furnish and install street signs and traffic control signs as specified. 1.2 GENERAL A. All signs shall meet the requirements of the "Federal Highway Administration Manual of Uniform Traffic Control Devices latest edition. Sign locations shall be subject to the approval of the Indian River County Public Works Department, Traffic Engineering Division. Be The Contractor shall replace all signs damaged during its work, at its expense. The ENGINEER shall determine if damages are such that a new sign will be required. + + END OF SECTION + + 02537-1 02537 — Traffic Signs PART 1- GENERAL 1.01 1.02 1.03 SECTION 02539 SUBMERSIBLE PUMPING STATION RELATED WORK SPECIFIED ELSEWHERE A. Site Work Division 02000 Sections B. Concrete Work Division 03000 Sections C. Coating Systems Division 09000 Sections D. Electrical - General Division 16000 Sections SCOPE OF SERVICES A. The pumping station shall consist of a wet well structure, two (2) submersible sewage pumps, an electrical control panel, liquid level controls, valve vault, valves, pump -out connection, electric meter, electric and water service and all appurtenant piping and equipment as shown on the Drawings and/or as specified. B. The Contractor shall furnish all labor, materials, equipment and incidentals required and install, place in operation, and field test a submersible wastewater pumping station. The station shall be complete with pumps, motors, piping, valves, buried electric service, electrical work (including motor controls and RTU), structures, connections and appurtenances, tested and ready for service. C. These specifications are intended to give a general description of what is required, but do not cover all details which will vary in accordance with the requirements of the equipment as offered. It is, however, intended to cover the furnishing, the shop testing, the delivery and complete installation and field testing, of all materials, equipment and appurtenances for the complete pumping units as herein specified and as shown on the Drawings, whether specifically mentioned in these specifications or not. D. For all units there shall be furnished and installed all necessary an desirable accessory equipment and auxiliaries whether specifically mentioned in these specifications or not, and as required for an installation incorporating the highest standard for the type of service including field testing of the entire installation and instructing the regular operating personnel in the care, operation and maintenance of all equipment. PUMP SYSTEM REQUIREMENTS A. Qualifications: 1. To assure unity of responsibility, the motors and control system shall be furnished and coordinated by the pump manufacturer. The Contractor and manufacturer shall assume responsibility for the satisfactory installation and operation of the entire pumping system, including pumps, motors, and controls as specified. 2. The pumps covered by these specifications are intended to be standard pumping equipment of proven ability as manufactured by a reputable manufacturer having long experience in the production ofsuch pumps. The pumps furnished shall be designed, constructed and installed in accordance with the best practice and methods, 02539 - Submersible Pump Station (Rev.) 02539-1 and shall operate satisfactorily when installed. Pumps shall be manufactured in accordance with the Hydraulic Institute Standards. 3. The control system shall be manufactured by a company with an established record of successful performance for similar products. 4. All equipment furnished under this specification shall be new and shall be the standard product of manufacturers having a successful record of manufacturing and servicing the equipment and systems specified herein for a minimum of five (5) years. 5. The pumps shall be furnished complete with controls, and accessories required and shall be as manufactured by Flygt or ABS. 1.04 SUBMITTALS A. Shop Drawings - The Contractor shall furnish the Engineer a minimum five (5) copies of shop drawings of the items listed below, prior to their delivery. This shall be done in accordance with the provisions of the General Conditions. 1, Pumps 2, Pump Accessories 3. Access Covers 4, Control Panel and RTU 5, Electrical Devices 6. Precast Structures 7. Poured In Place Concrete Design Mix B. Manufacturer's Data - The Contractor shall furnish the Engineer a minimum five (5) copies of manufacturer's data of the items listed below, prior to their delivery. 1. Pipe 2, Fittings 3. Joints and Restrainers 4, Plug Valve 5, Check Valve 6, Quick Disconnect C. Operation and Maintenance Data - The Contractor shall furnish the Engineer three (3) sets of each of the following for each mechanical unit installed. 1. Instructions 2, Maintenance Manual 3, Parts Lists 4, Wiring Diagrams 5. Pump Performance Curves D. Operating Instructions and Service 1. Three sets of operating and maintenance manuals shall be furnished. The manuals shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment list, descriptions, etc. that are required to instruct operating and 02539 — Submersible Pump Station (Rev.) 02539-2 maintenance personnel unfamiliar with such equipment. The number and special requirements shall be as specified by the County, 2. A factory representative of all major component manufacturers, who has complete knowledge of proper operation and maintenance, shall be provided for one (1) day to instruct representatives of the Owner and the Engineer on proper operation and maintenance. If there are difficulties in operation of the equipment due to the manufacturer's design or Contractor's installation, additional service shall be provided by the Contractor at no cost to the Owner. 1.05 TOOLS AND SPARE PARTS A. One (1) set of all special tools required for normal operation and maintenance shall be provided. All such tools shall be furnished in a suitable steel tool chest complete with lock and duplicate keys. The manufacturer shall furnish a complete set of recommended spare parts necessary for the first five (5) years operation of the pumping system, which shall include at least the following: 1. 1 - set of upper bearings for each pump supplied 2. 1 - set of lower bearings for each pump supplied 3, 1 - set of upper and lower shaft seals for each pump supplied 4. 2 — replacement fuses for each installed fuse 5. 1 — relay and phase monitor for each type supplied with the pump control panel 6. 1 — spare impeller B. Spare parts shall be properly bound and labeled for easy identification without opening the packaging and suitably protected for long term storage. 1.06 WARRANTY A. All equipment supplied under this section shall be warranted for a period of one (1) year by the Contractor and the equipment manufacturers. Warranty period shall commence on final date when project is accepted by the. Owner. B. The equipment shall be warranted to be free from defects in workmanship, design and materials. If any part of the equipment should fail during the warranty period, it shall be replaced and the machine(s) and/or the unit(s) restored to service at no expense to the Owner. C. The manufacturer's warranty period shall run concurrently with the Contractor's warranty period. No exception to this provision shall be allowed. PART 2 - EQUIPMENT AND MATERIALS 2.01 PUMP FOUNDATION PLATES A. Each pump shall be furnished with a foundation base plate which shall be rigidly and accurately anchored into position. The pump manufacturer shall furnish all necessary foundation bolts, plates, nuts, and washers for installation by the Contractor. Each foundation plate shall be '/2" thick, Type 316 stainless steel. Foundation bolts, nuts, washers, and spare parts shall be Type 316 stainless steel. 2.02 SEWAGE PUMPS 02539 — Submersible Pump Station (Rev.) 02539-3 r� ■ A. The pumps shall be totally submersible, non -clog, centrifugal pumps with close -coupled motors designed to pump sewage. The pumps shall be capable of passing a minimum 3- inch diameter spherical solid. The motor shall be an integral part of the pumping unit. The design shall be such that the pumping units shall be automatically connected to the discharge piping when lowered into place on the discharge connection. The pumps shall be easily removable for inspection or service, requiring no bolts, nuts or other fastenings to be removed for this purpose, or need for personnel to enter the wet well. B. At the rated m eacn um 111X uim onaiivav� �+.� • •" ••-_ _ ____- FLOW - mm Total —H —ea—d (ft.) 0 36 80 32 190 26 The pumps shall be as manufactured by "ABS", model AFP 1040, with 177 mm impeller, or approved equal. Co Pump Construction - The pump shall be of the centrifugal type with a solids handling, single vane, dynamically balanced, shearing type impeller. The common pump and motor shaft shall be series 400 stainless steel. The shaft and rotor assembly shall be supported by two ball act ball bearings; the lower ball bearing shall be a heavy duty, double row, angular bearings. Each pump shall be provided with a tandem double mechanical seal running in an oil reservoir, composed of two separate lapped face seals, each consisting of one stationary and one rotating tungsten -carbide or silicon carbide ring with each pair held in contact by a separate spring, so that the outside pressure assists spring compression in preventing the seal faces from opening. The compression spring shall be protected against exposure to the pumped liquid. The pumped liquid shall be sealed from the oil reservoir by one face seal and sealed from the oil reservoir from the motor chamber by the other. The seals shall require neither maintenance nor adjustment, and shall be easily replaced. Conventional double mechanical seals with a single spring between the rotating faces, requiring constant differential pressure to effect sealing and subject to opening and penetration by pumping forces, shall not be considered equal to tandem seal specified and required.The impeller shall be constructed of nodular iron SP. All other parts shall be of close grain gray iron construction, with all parts coming into contact with sewage protected by a coat of rubber - asphalt paint. All external bolts and nuts shall be of stainless steel. D. Pump Identification - Stainless steel nameplates giving the name of the manufacturer, head, speed, and all other pertinent data shall be attached to each pump and motor. 2.03 PUMP MOTORS AND CABLES A. Pump motors shall be of the submersible type, housed in an air-filled, watertight casing. Motors shall be a NEMA Design B. Insulation shall be moisture -resistant NEMA Class F with a maximum temperature rise of 90 degrees Celsius above ambient temperature (40 degrees Celsius). The motor shall be rated for a maximum of 3.0 Hp at 1780 RPM, connected for operation at 230 volt, 60 hertz, 3-phase service. The motor shall be non -overloading along the entire operation of the published pump curve. The full load current shall not exceed 10.0 amps at 230 volts, 3 phase, electric service. Pump motors shall have cooling characteristics suitable to permit continuous operation, in a totally, partially or nonsubmerged condition. Each motor shall incorporate an ambient temperature compensated overheat sensing device and a moisture sending device wired in series. The protective devices shall be wired into the 02539 — Submersible Pump Station (Rev.) 02539-4 pump controls in such a way that if either device operates, the pump will shut down. The devices shall be self -resetting. The cable shall be fixed to the pump using a watertight trumpet assembly. The pump shall be capable of running continuously in a totally dry condition under full load, without damage, for extended periods. Before final acceptance, a field running test demonstrating this ability, with four (4) hours of continuous operation (water supplied by the contractor) under the above conditions, shall be performed for all pumps being supplied, if required by the IRCDUS. Pump motor cables shall be suitable for submersible pump applications and shall be properly sealed. B. Power cables shall be sized according to NEC standards and shall be of sufficient length to reach the control panel without splicing. The cable shall be oil resistant and capable of continuous submerged operation in raw sewage. The pump cable entry shall provide strain relief for the cable. The cable and entry into the pump shall be "Factory Mutual" approved for use in NEC Class 1, Division 1, Groups C and D hazardous locations. C. Lifting cables shall be provided for each pump. Each pump shall be fitted with a braided, 316 stainless steel lifting cable of adequate strength, and shall be five (5) feet longer than wet well depth to control panel to permit raising the pump for inspection and removal. 2.04 PUMP GUIDE RAILS & BRACKETS A. A guide rail base for sliding pump mount shall be an integral part of the pumping unit, and the pump casing shall have a machined connecting flange to connect with the cast iron guide rail base. The base shall be bolted to a stainless steel base plate affixed to the wet well bottom with stainless steel anchor bolts and so designed as to receive the pump connection without the need of any bolts or nuts. Sealing of the pumping units to the guide rail base shall be accomplished by a simple linear downward motion of the pump with the entire weight of the pumping unit guided by stainless steel guide tubes or T -bars which will press it tightly against the discharge connection or a single stainless steel guide with a locking guide rail base as approved by the Engineer. No portion of the pump shall bear directly on the floor of the sump and no rotary motion of the pump shall be required for sealing. The guide rail base shall have a 4 -inch discharge elbow which shall be totally supported by the pump mount. 2.05 PUMP CONTROL SYSTEM A. General 1. A pump controller shall be provided for the wastewater pumping station. The controller shall respond to the liquid level switches to automatically start and stop pumps in response to liquid level in the wet well. 2. The pump controller shall be the standard system of the manufacturer as modified for this application. The wet well levels to be used in operation are as shown on the Drawings. 3. All components within the pump control system shall be designed and sized to handle their maximum potential full load amperage and ground fault capacities. 4. All electrical installations shall be conducted in accordance with the National Electric Code and all applicable local codes. 51 Prior to ordering electrical components the Contractor shall contact Florida, Power and Light to confirm the electric service and ground fault currents. This information 02539 - Submersible Pump Station (Rev.) 02539=5 shall be transmitted to the panel manufacturer. Any discrepancy between the information shown on the plans and that provided by the electric company shall be brought to the attention of the Engineer. B, Components The control panel shall include power distribution components for a duplex motor control center including but not limited to the following components: 1. Main Circuit Breaker 2, Generator Circuit Breaker w/Mechanical Interlock 3, Surge Arrestor 4, Motor Circuit Breaker 5, Motor Starters 6, 120 V. Duplex Receptacle with 15 Amp. Breaker 7. Control Power Circuit Breaker g. Generator Receptacle The control panel shall include control components including but not limited to the following: 1, Control Relays 2, Automatic Alternator 3, Hand -Off -Auto Switches 4, Run Lights 5, Elapsed Time Meters 6, Exterior Alarm Horn T Exterior Flashing Alarm Lamp g. Phase monitor and shutoffs for each pump 9, Seal failure detector with indicator lamp and reset for each pump 10. RTU data acquisition and control system C. . Component Requirements 1. All motor branch circuit breakers, motor starters and control relays shall be of highest industrial quality, securely fastened to the removable back panels with screws and lock washers. Back panels shall be tapped to accept all mounting screws. Self - tapping screws shall not be used to mount any component. 2, A thermal -magnetic circuit breaker, appropriately sized for the service and ground fault interrupting capacity, as manufactured by Square D Company, or approved equal, shall be furnished for the main breaker. All circuit breakers shall be sealed by the manufacturer after calibration to prevent tampering. A motor circuit breaker shall be provided for each motor starter. Each motor circuit breaker shall be adequately sized to meet the pump motor and station operating conditions. 3. A mechanical disconnect mechanism shall be installed on each circuit breaker to provide a means of disconnecting power to the pump motors. Operator handles for the disconnect mechanisms shall be located on the exterior of the control compartment door. 4, An open frame, across -the -line, NEMA rated, magnetic motor starter, Bulletin 709 as manufactured by Allen-Bradley Company, or approved equal, shall be furnished 02539 — Submersible Pump Station (Rev.) 025394 D. E. for each pump motor. All motor starters shall be equipped to provide under -voltage release and overload protection on all three phases. Motor starter contacts shall be easily replaceable without removing the motor starter from its mounted position. Overload reset push -buttons shall be located on the exterior of the control compartment door. 5. Time delay relays shall be of the electronic type. 6. An emergency power receptacle shall be installed in the side of the control panel and connected to the line side of the generator breaker. The receptacle shall be 100A, 4P, 3W, Crouse -Hinds No. AR1042-S22 with AR610 panel adapter. 7. A ground fault interrupting duplex utility receptacle providing 120 volts, 60 hertz, single phase current shall be mounted on the dead front of the enclosure. 8. Pump mode selector switches shall be Hand -Off -Auto type to permit over -ride of automatic level control and manual actuation of shutdown of either pump motor. Operation of pumps in Hand mode shall bypass all safety shutdown circuits except pump motor overload shutdown and duplex lockout. Switches shall be oil -tight, as manufactured by Allen-Bradley, or approved equal, providing three (3) switch positions, each of which shall be clearly labeled according to function. Separate indicator lamps, which shall operate at 115 volts input, shall be provided, mounted above the H.O.A. selector switches. Lamps shall be easily replaceable from the front of control compartment door without removing switch modules from their mounted positions. 9. Indicator lamps shall be mounted in oil -tight modules, as manufactured by Allen- Bradley, or approved equal. Lamp modules shall be equipped to operate at 115V. Lamps shall be easily replaceable from the front of the control compartment door without removing lamp module from its mounted position. 10. A six (6) digit, non reset elapsed time meter shall be connected to each motor starter to indicate the total running time of each pump in "hours" and "tenth of hours". The elapsed time meters shall be Bulletin 705, HK Series as manufactured by Eagle Signal, or approved equal. Enclosure The electrical control equipment shall be mounted within a NEMA Type 4X, stainless steel, dead front enclosure. The enclosure shall be equipped with an outer door, a dead front panel on which control components shall be mounted, and a removable back panel on which the power components shall be mounted. Back panel shall be secured to enclosure -with collar studs.. All conduits entering the enclosure from the wet well shall be sealed at the panel. The seal shall prevent sewage gases from entering the enclosure. Three Crouse -Hinds Type "CGB" cable connectors shall be provided to terminate the motor cables and float switch cables in the control panel bottom. The connectors shall be suitable for a 2" conduit with a neoprene bushing suitable for the motor cables supplied. All operating, controls and instruments shall be securely mounted on the control compartment door. All controls and instruments shall be clearly labeled to indicate function. Remote Telemetry Unit (RTU) 02539-7 02539 — Submersible Pump Station (Rev.) A radio communication, Remote Telemetry Unit (RTU), complete with antenna and all data acquisition and control components, shall be supplied with the pump control system. The RTU shall be capable of acquiring analog and discrete data for transmission to the Central Telemetry Unit (CTU); The RTU shall also be capable of receiving instructions from the CTU for the operation of the pumps. 2.10 ACCESS COVERS A, The wet well shall be furnished with a single leaf, and valve vault with a double leaf, hinged, aluminum access cover, with recessed key wrench lock and stainless steel accessories. The wet well cover frame shall be placed and securely mounted above the pumps with stainless steel guide bar brackets accurately aligned. The frame shall be equipped with safety handles to maintain the door in an open position. The covers shall be fabricated from checkered plate aluminum sheet and shall be designed to withstand 300 psf loading. The valve pit access cover shall be identical in construction to the wet well access cover, except that it shall be a double leaf cover of larger opening size. Access covers shall be Bilco JD, or approved equal. Minimum size of the wet well opening shall be 4 -foot by 346ot, adequate to accommodate the two (2) pumps as shown on the Drawings. The stainless steel upper guide rail holder and a stainless steel level sensor cable holder shall be mounted to the frame of the wet well access cover. 2.10 MISCELLANEOUS CONCRETE A. All miscellaneous concrete pours shall have a design mix with a 28 -day compressive strength of 3,500 pounds per square inch, and shall comply in all respects with the requirements of Division 03 of these specifications. B, Concrete used for tremie pours shall have the same design mix as miscellaneous concrete, except that the following admixtures shall be included in the mix: 1. High -Range Water Reducing Admixture shall be incorporated into the design.mix to provide enhanced: water reduction; high slump retention; high flowability; and self compacting properties. The admixture shall be based on polycarboxylate chemistry and shall be as manufactured by "Master Builders Technologies", Glenium 3030 NS, or approved equal. 2. Anti -Washout Admixture shall eThe admixture shallbe based o e mthe n liqu1d celluloix to se washout and segregation resistant chemistry and shall be as manufactured by `BASF", Rheomac UW450, or approved equal. C, Admixtures shall be incotrete supplierted w with any othence with radmixtures recommendations. Co shall confirm ompatability to be used in the design mix. 2.11 REINFORCING STEEL A. All reinforcing steel shall be grade 60, and shall comply in all respects with the requirements of Division 03 of these specifications. 2.12 PRECAST CONCRETE WET WELL SECTIONS 02539 — Submersible pump Station (Rev.) 02539-8 2.13 2.14 2.15 A. Precast manhole sections used for the wet well shall conform to the wet well details shown on the Plans and shall -consist of a precast base cast poured monolithically with a minimum three foot length of barrel section. Additional barrel sections shall also be a minimum three feet in length. All concrete used in the construction of precast sections shall utilize Type II cement and have a 28 day compressive strength of 4,000 pounds per square inch. The precast sections shall conform with all applicable requirements of Division 03 of these specifications. PRECAST CONCRETE VAULTS B. Precast concrete vaults shall conform to the vault details shown on the Drawings and shall consist of a precast monolithic base section and top slab. All concrete used in the construction of precast sections shall utilize Type II cement and have a 28 day compressive strength of 4,000 pounds per square inch. The precast sections shall conform with all applicable requirements of Division 03 of these specifications.. MISCELLANEOUS HARDWARE A. All hardware, bolts, anchors, accessories in the wet well and valve vault shall be stainless steel. B. Safety Netting — The wet well opening shall be provided with a rail mounted safety net system designed to be installed to the access hatch. The safety net shall easily slide on the guide rails to facilitate entry and then repositioned to prevent fall through. The net system shall be manufactured to fit the 300# access hatch specified in paragraph 2.10 above. The net system shall be manufactured of durable synthetic netting with all mounting and rail components constructed of stainless steel. The net system shall be as manufactured by "U.S. Netting", Hatch net 121 System, or approved equal. PIPE AND FITTINGS 1. Ductile iron pipe shall conform to AWWA C151 (ANSI A21.51) and shall be minimum pressure class 350 unless specified otherwise or shown otherwise on the Drawings. Pipe shall be furnished in standard 18 or 20 foot lengths unless shown otherwise on the Drawings. External surfaces of DI pipe shall be coated with a minimum 10 mil thickness of "Kop-Coat" Bitumastic 300M or Protech EP214 Epoxy Mastic or approved equivalent. Internal surfaces shall be coated to a minimum thickness of 40 mil with McWane's Protecto 401 ceramic lining or approved equal. 2. Polyethylene pipe shall be new, unused, sections of polyethylene pipe having a nominal density of 0.955. The polyethylene resin used to manufacture the pipe shall. have a "Plastic Pipe Institute" material designation of PE 3408, with an ASTM D3350 cell classification of 34544C. The pipe shall be black in color, containing approximately 2 percent U.V. stabilizer. Pipe shall be extruded to the wall thickness described in AWWA C906 for DRI 1. Pipe outside dimensions shall meet that of ductile iron pipe size (D.I.P.S.). Pipe shall be provided in nominal 40 foot long sections or pre-cut for the project. During the extrusion process, the HDPE pipe shall be continuously marked with durable printing including the following information: 02539-9 02539 — Submersible Pump Station (Rev.) a. Nominal Size (O.D. Base) _ b, . Dimension Ratio (for wall thickness) C, Manufacturer Name and Product Series d. Cell Class e. ASTM Basis f. Pipe Test Category g, Plant Identification h, Production Date i, Operator Number (Shift Letter optional) j, Resin Supplier Code B, Fittings. 1. All underground fittings shall be ductile iron with mechanical or manufacturer's mechanically restrained joints. Fittings shall be compact ductile iron conforming to AWWA C 153. The fittings shall lie lined and coated in accordance with the ductile iron pipe specification. Fittings shall have a minimum pressure rating is 350 psi. All fittings and the appropriate number of downstream and upstream joints must be restrained. 2, Unless otherwise indicated on the Drawings, all above ground fittings or fittings in boxes shall be ductile iron flanged fittings, conforming to AWWA-C110 Standards. The fittings shall be lined and coated in accordance with the ductile iron pipe specification. 3. Where indicated on the Drawings, HDPE fittings shall be in accordance with ASTM D 3261 and shall be manufactured by injection molding, a combination of extrusion and machining, or fabricated from HDPE pipe conforming to this specification. The fittings shall be designed for a working pressure of 160 psi. The fittings shall be manufactured from the same resin type and cell classification as the pipe itself. The fittings shall be homogeneous throughout and free from cracks, holes, foreign inclusions, voids, or other injurious defects. All fittings shall be constructed to have a minimum D.R. 11 sidewall thickness. C. Joints: 1, Standard joints for ductile iron pipe shall be bell and spigot, rubber gasket, compression, push -on type as specified in AWWA C111 (ANSI A21.11). 2, Flanged joints shall utilize NST threaded flanges and pipe barrels conforming to AWWA specification C115. Flanged joints through 12 -inches shall be rated for a working pressure of 350 psi. Bolt pattern and hole sizes shall comply with ANSI B16.1, Class 125. Each flange joint shall have a 1/8 -inch thick, full-faced, rubber gasket. Size, length and number of bolts shall conform to AWWA C115. -Bolts and nuts shall be stainless steel, series 304 or 316. 3, Mechanical joints shall be used on all underground fittings for changes in horizontal or vertical alignment on all runs of pipe. All mechanical joints shall be restrained in accordance with AWWA C111. 4, Restrained Joints - Fittings used for changes in alignment of pipe shall be mechanically restrained. As indicated on the drawings, pipe lengths located i upstream and downstream of restrained fittings shall also be restrained. Method of joint restraint shall be as follows: 02539 —Submersible Pump Station (Rev.) 02539-10 2.16 2.17 2.18 a. Push -on ductile iron pipe joints shall be restrained with "EBBA IRON" series 4500 restrainers, pipe manufacturer's restrained joints, such as U.S. Pipe "TR -FLEX GRIPPER RING", American Pipe "LOK-RING" or "LOK- FAST" joints, or approved equal. b. Mechanical joint ductile iron pipe and fittings shall be restrained with "EBBA IRON", Megalug Series 1100 restrainers, or approved equal. C, Set screw type Adapter or Retainer glands shall not approved. 5. Sections of polyethylene pipe and fittings shall be joined in the field by the butt fusion process into one continuous length at the job site. The joining method shall be the heat fusion method and shall be performed in strict accordance with the pipe manufacturer's recommendations. The heat fusion equipment used in the joining procedures shall be capable of meeting all conditions recommended by the pipe manufacturer. D. Gaskets - All gaskets shall be manufactured of an elastomeric material. The gasket shall provide a positive, tight seal under all combinations of joint and gasket tolerances. Installation and lubrication of gaskets shall be as directed by the manufacturer. VALVES A. Plug Valves Plug valves shall be of the non -lubricated, eccentric type with neoprene faces and have flanged joint ends as shown on the Plans and shall be for hand operated service. Ports on valves to 20 -inches shall beat least 80% of full area. Valve bodies shall be semi -steel. Seats shall have a welded -in overlay of not less than 90% pure nickel on all surfaces contacting the plug face. Valves shall have stainless steel permanently lubricated upper and lower plug stem bushings. Valves shall be designed so they can be repacked without removing the bonnet from the valve body or the actuator, and the packing shall be adjustable. Actuators shall clearly indicate the valve position and an adjustable stop shall be provided to set closing torque. Plug valves shall be DeZurik Series 100 or approved equal, suitable for a working pressure of 150 psi. Plug valves shall be provided with concrete supports to prevent the transmittal of shear forces to the P.V.C. pipe. B. Check Valves Check valves shall be of the horizontal, single -disk, non -slam, swing type, having a 150 psi pressure rating. The valves shall be equipped with an externally mounted lever with adjustable weight for control of closing speed. Access Covers and Guide of valve shall be designed for non -buried service. Valves shall have semi -steel bodies with 125 lb. flanged ends. The discs shall be semi -steel with elastomeric seat rings designed for use with raw sewage. WATER SUPPLY A. A metered water supply shall be supplied to the pump station by the Contractor as indicated on the Drawings. Contractor shall provide and install the service, backflow preventer, and hose bib as shown on the Drawings. ELECTRICAL SUPPLY 02539-11 02539 — Submersible Pump Station (Rev.) A. The Contractor shall coordinate with the provider of electric power and install an unspliced, underground power supply from the pump station to the power pole or transformer designated by Florida, Power and Light. The Contractor shall install properly sized conductors in conduit to provide a 230 volt, 3 phase, four (4) wire electric service with no more than a 5% voltage drop when two pump are operating. Pull or Terminal boxes (if needed) shall be polymer concrete and fiberglass, with the words "ELECTRIC" embossed on the top. Boxes shall be "CDR Systems Corp.", model PA12-1730-26, or approved equal. All conductors shall be installed in conduit (schedule 40 underground) with long radius sweeps at all bends. All electrical components and accessories shall be provided and installed in accordance with the NEC and local ordinances. All costs for coordinating and installation of the electric service shall be the responsibility of the Contractor. 2.19 COATINGS A. All coatings shall be industrial grade, designed to achieve maximum protection of all structures and mechanical equipment. All coating components and accessories shall be provided and installed in accordance with the Drawings and the requirements of Division 09 of these specifications PART 3 - EXECUTION OF WORK 3.01 SITE PREPARATION A. Clearing The Contractor shall perform all clearing necessary, where applicable, for the proper installation of the Pumping Station and its appurtenances as shown on the Plans. B. Excavation Excavation shall be to the depth shown on the Plans. The materials of excavation shall include all materials encountered and no additional compensation shall be allowed for difficulty in their removal. The Contractor shall be responsible for the disposal of the excess material as directed by the Engineer. 1. Sheeting and Bracing - The Contractor shall be responsible for properly supporting the sides of all trenches and excavations with timbers or other supports wherever necessary or required to properly safeguard the trenches, adjacent properties and structures. The cost of all necessary timber, sheeting and bracing whatsoever (left in place or removed), shall be included in the prices bid. Timber sheeting and bracing shall be left in place if so ordered by the Engineer and/or where shown on the Plans to avoid undermining or otherwise endangering the work or adjacent structures. All sheeting left in place shall be cut off or driven at least 18 -inches below finished grade, unless otherwise ordered by the Engineer. 2. Dewatering - The Contractor shall furnish sufficient pumping or other dewatering equipment and shall provide satisfactory drainage during the construction to properly complete the work. Except for the wet well which is to be installed by the caisson method, all work shall be installed in the dry. Unless otherwise permitted by the Engineer, the water table shall be lowered by the use of a well point system. The 02539 — Submersible Pump Station (Rev.) 02539-12 3.02 3.03 Engineer shall make the final decision as to the acceptability of the well point system or any part thereof. _ The Contractor shall provide for the proper disposal of water removed from the excavation in a manner that will not cause injury to public health, private or public property, any portion of the work completed or in progress, the surface of the streets, or cause any impediments to the reasonable use of the site by other Contractors. The Contractor shall be responsible for complying with all the local regulations, St. Johns River Water Management District and the Department of Environmental Regulation regarding pollution of the surface waters. The Contractor shall take special precautions to eliminate any odor problems resulting from the discharge of sulfide water, such as submerged discharge outlets and overflow basins. C. Utility Relocation The existing utilities and irrigation system noted on the Plans to be relocated shall removed and relocated at the Contractor's expense. The contractor shall coordinate with the affected utility Owner to have the utilities adjusted as needed. The existing irrigation system shall be be removed (including existing wells) and a new system of equal capacity and components shall be installed in INSTALLATION A. The station including wet well, valves and meter pits, valves, pumps, motor controls, electric system, and all accessories shall be installed at the locations as shown on the Drawings in accordance with the applicable Sections of these specifications. B. Backfilling - No backfill shall be placed until setting of the wet well and valve pits have been inspected and approved by the Engineer. Backfill shall be brought to within 3 inches of the surrounding finished grade surface. Backfill material shall be free of roots, logs, limbs, large rocks or any material or debris determined to be unsuitable by the Engineer. The backfill shall be placed in 12 -inch layers and compacted to a minimum density of 95% as determined by AASHTO T-180. C. Restoration - All ground surfaces damaged or disturbed by pump station installation either within or adjacent to the limits of lump sum pay item shall be restored to the condition which existed prior to pump station construction. D. Coating Preparation and Application - The surfaces requiring coating shall be prepared and surface coated by the Contractor in accordance with Division 09. All other components shall remain as prepared and coated by their Manufacturer. The Contractor shall be responsible for touch-up or restoration of any finish coatings provided by the Manufacturer which may be damaged or scratched during shipping or installation. TESTING A. Field Quality Control All systems and equipment shall be tested, under the observation of the Engineer and a representative of the Owner, to assure operation in accordance with the plans and specifications. All water, electricity, or other materials or services required for these tests shall be furnished by the Contractor at no cost to the Owner. Contractor shall furnish all labor, piping, equipment and materials necessary for conducting the tests. 02539-13 02539 — Submersible Pump Station (Rev.) L B. Manufacturer's Certificatiorr Contractor shall coordinate with the Manufacturer's of major control components and pump equipment to provide all pre start-up work and inspections as necessary to prepare the pump station for final start-up. At start-up, the Manufacturer's representatives shall be present for a minimum of one 8 -hour day to provide the following services: 1. Check final installation of equipment 2, Provide start-up of equipment 3. Run specified tests 4. Train personnel in operation and maintenance of equipment 5. Certify as to acceptability of final installed and tested product C. The pump test shall demonstrate their ability to: 1, Operate without vibration or overheating at the specified conditions. 2. Perform as specified. 3. Load test, check amperage, phase to voltage test and insulation test. 4. Flow test based on timed draw down of the wet well and force main pressure reading. D. All defects revealed by or noted during the tests shall be corrected or equipment replaced promptly at no additional expense to the Owner. E. Should the Contractor be unable to demonstrate to the satisfaction of the Engineer that the units will satisfactorily perform the service required, the units may be rejected. Contractor shall remove and replace the equipment at his own expense. F. Prior to final acceptance by the Owner, all required: as -built record drawings; pump curves; operation and maintenance manuals; special tools necessary to disassemble, service, repair and adjust the equipment and all spare parts shall be delivered to the Owner. END OF SECTION 02539-14 02539 — Submersible Pump Station (Rev.) SECTION 02714 STABILIZED SUBGRADE PART 1 - GENERAL 1.01 SCOPE Under this item, the Contractor shall furnish all equipment, labor, materials, and transportation necessary to construct a stabilized subgrade course upon the compacted in-place material for the pump station driveway. 1.02 REFERENCES Standards applicable in this Specification shall be: A. Florida Department of Transportation - Standard Specifications. for Road and Bridge Construction (latest edition) B. American Association of State Highway and Transportation Officials (AASHTO) 1. AASHTO T-180 -Test for Moisture -Density Relations of Soils using a 10 lb. Rammer and an 18 -inch Drop. C. ASTM International (ASTM) 1. ASTM D 1557 - Test Method for Laboratory Compaction Characteristics of Soil Using Modified Effort 2. ASTM D 2167 - Density and unit weight of soil in place by the rubber balloon method 3. ASTM D 2922 (2001) - Standard Test Methods for Density of Soil and Soil - Aggregate in Place by Nuclear Methods (Shallow Depth) 1.03 DESCRIPTION The subgrade will be constructed such that after being compacted it will conform to the lines and grades as shown on the Drawings. The subgrade shall be Type -B (LBR), stabilized and constructed in accordance with the 2002 edition of the Florida D.O.T. Specifications, Section 160. PART 2 - MATERIALS 2.01 The subgrade shall have a minimum Florida Bearing Value of 50 as determined by the Florida Soil Bearing Test. In an area where the bearing value is less than 50, stabilizing material approved by the Engineer shall be furnished by the Contractor, spread and mixed in accordance with Section 160-5.3 "Mixing" of the 2006 Edition of the Florida D.O.T. Specifications, PART 3 - EXECUTION OF WORK 3.01 The subgrade shall be shaped, graded, and rolled to conform to the lines and grades as shown on the Drawings. Fine grading of the subgrade to its final profile shall be accomplished after the existing ground has been excavated as close as possible to the design elevations. 02714 — Stabilized Subgrade 02714,1 SECTION 02714 STABILIZED SUBGRADE PART 1 - GENERAL 1.01 SCOPE Under this item, the Contractor shall furnish all equipment, labor, materials, and transportation necessary to construct a stabilized subgrade course upon the compacted in-place material for the pump station driveway. 1.02 REFERENCES Standards applicable in this Specification shall be: A. Florida Department of Transportation - Standard Specifications for Road and Bridge Construction (latest edition) B. American Association of State Highway and Transportation Officials (AASHTO) 1. AASHTO T-180 -Test for Moisture -Density Relations of Soils using a 10 lb. Rammer and an 18 -inch Drop. C. ASTM International (ASTM) 1. ASTM D 1557 - Test Method for Laboratory Compaction Characteristics of Soil Using Modified Effort 2, ASTM D 2167 - Density and unit weight of soil in place by the rubber balloon method 3. ASTM D 2922 (2001) - Standard Test Methods for Density of Soil and Soil - Aggregate in Place by Nuclear Methods (Shallow Depth) 1.03 DESCRIPTION The subgrade will be constructed such that after being compacted it will conform to the lines and grades as shown on the Drawings. The subgrade shall be Type -B (LBR), stabilized and constructed in accordance with the 2002 edition of the Florida D.O.T. Specifications, Section 160. PART 2 - MATERIALS 2.01 The subgrade shall have a minimum Florida Bearing Value of 50 as determined by the Florida Soil Bearing Test. In an area where the bearing value is less than 50, stabilizing material approved by the Engineer shall be furnished by the Contractor, spread and mixed in accordance with Section 160-5.3 "Mixing" of the 2006 Edition of the Florida D.O.T. Specifications. PART 3 - EXECUTION OF WORK 3.01 The subgrade shall be shaped, graded, and rolled to conform to the lines and grades as shown on the Drawings. Fine grading of the subgrade to its final profile shall be accomplished after the existing ground has been excavated as close as possible to the design elevations. 02714 - Stabilized Subgrade 02714-1 3.02 Record Drawing elevations shall be confirmed to meet design drawing grades prior to placement of base material. 3.03 The top of the subgrade in both cuts and fills shall be compacted to a minimum of 98 percent of the maximum dry density to the depth specified on the Plans. The required density shall be maintained until the surface course has been constructed. The subgrade shall be compacted with an approved self-propelled steel drum or pneumatic tired roller weighing not less than 8 tons. All hollows and depressions which develop under rolling shall be filled in with suitable material. The process of grading and rolling shall be repeated until no depressions develop. After compaction, the top surface of the fine grade shall be true to line and grade at all locations. If the fine grade becomes rutted or displaced due to any cause whatsoever, the Contractor shall regrade it and recompact it. Ditches, drains, and swales shall be maintained along the completed subgrade section after their construction. 3.04 In no case shall the Contractor proceed to construct further courses on the subgrade until the subgrade has been tested for Florida Bearing Values, compaction, checked for line and grade, and approval given by the Engineer. 3.05 Material and Compaction Testing A. Florida Bearing Value tests on the subgrade shall be taken at a minimum of four (4) test locations per 10,000 sf of area to be paved, where designated by the Engineer. Smaller projects shall have a minimum of two (2) test locations. B. The maximum density and optimum moisture shall be determined in accordance with the Modified Proctor Test procedures of AASHTO T180 (Method D as modified by the F.D.O.T.). The percentage compaction and in place density shall be determined according to procedures of ASTM D2167 "Test for Density of Soil In Place by the Rubber Balloon Method" or the nuclear method ASTM D2922, C. Each material which is inherently different in composition from other subgrade material and which is used over a widespread area of the project, will necessitate an additional Modified Proctor Test, END OF SECTION 02714- 2 02714 — Stabilized Subgrade SECTION 02722 CEMENTED COQUINA SHELL BASE COURSE PART 1 - GENERAL 1.01 SCOPE Under this item, the Contractor shall furnish all equipment, labor, materials, and transportation necessary to construct a Coquina shell base course upon the "off-site" completed stabilized subgrade restoration. 1.02 REFERENCES Standards applicable in this Specification shall be: A. Florida Department of Transportation Bridge Construction (2002) 1. Section 250 — Shell - Standard Specifications for Road and 2. Section 915 - Cemented Coquina Shell Material 3, Section 300 — Prime and Tack Coats for Base Courses 4, Section 916 — Bituminous Materials B. American Association of State Highway and Transportation Officials (AASHTO) 1. AASHTO T-180 - Test for Moisture -Density Relations of Soils using a 10 lb. Rammer and an 18 -inch Drop. C. ASTM International (ASTM) 1. ASTM D 1557 - Test Method for Laboratory Compaction Characteristics of Soil Using Modified Effort 2, ASTM D 2167 - Density and unit weight of soil in place by the rubber balloon method 3. ASTM D 2922 (2001) - Standard Test Methods for Density of Soil and Soil - Aggregate in Place by Nuclear Methods (Shallow Depth) PART 2 - MATERIALS 2.01 Coquina shell shall conform to the requirements of Florida D.O.T. Standard Specifications, 2002 Edition, Section 915, and shall be from a source acceptable to Florida D.O.T. The material shall have a minimum LBR value of 100. Prior to placement, the material shall be crushed or broken to such a size that no less than 97 percent by weight will pass a 3 1/2 inch sieve and no more than 20 percent dry weight shall wash through a No. 200 sieve. No visible clay or organic matter will be permitted. 02722 - Cemented Coquina Shell Base 02722.1 PART 3 - EXECUTION OF WORK 3.01 PLACEMENT OF MATERIAL The base course shall be constructed in accordance with the lines, grades, and typical section as shown on the Drawings. Unless otherwise noted construction shall conform to the provisions of Florida D.O.T. Standard Specifications for Road and Bridge Construction, Section 250, 2002 Edition. After the subgrade is completed and approved, the Contractor shall furnish and spread the coquina shell in a uniform distribution. Spread thickness shall be a minimum of 9 inches. Segregated areas of fine or course rock will not be permitted. Such areas shall be removed and replaced with properly graded rock. After the spreading is completed, the entire surface shall be compacted, scarified and shaped so as to produce the required grade and cross section after compaction. 3.02 COMPACTION The required compaction of the coquina shell base course shall be a minimum of 98 percent of the maximum dry density. No less than 8-10 ton steel drum or pneumatic tired roller shall be used to compact the base course. All depressions shall be filled and the process of rolling and filling shall continue until a thoroughly compacted uniform surface is produced. During final compaction operations, if blading of any area is necessary to obtain the true grade and cross section, the compaction operations for such areas shall be completed prior to making the field density -compaction test on the finished base. Should the subgrade material become mixed with the base course material at any time, the Contractor shall remove the mixture, reshape and recompact the subgrade, replace the materials removed with additional coquina shell and reshape and recompact the coquina shell base at no cost to the Owner. If cracks or checks appear in the base which would impair the structural integrity of the base in the opinion of the Engineer, the Contractor shall remove the cracks or checks by rescarifying, reshaping, refilling with coquina shell where necessary, and recompacting at no cost to the Owner. The finished coquina shell base shall be checked for thickness at intervals of not more than 300 feet on center. Finished thickness shall be as shown on the Drawings. Any areas which are less than 1/2 inch of the specified thickness shall be corrected by scarifying and adding rock. The scarifying shall extend for 50 feet either side of the deficient area. Areas which are less than 1/2 inch deficient in thickness shall be corrected if the Engineer determines that the area is extensive or may adversely affect the quality of the finished work. 3.03 PRIME COAT The prime coat shall be a rapid curing liquid cut back asphalt equal or equivalent to RC -70 or RC - 250 at the Contractor's option, and conforming to Sections 300 and 916-2 of the 2002 Edition of the Florida D.O.T. Standard Specifications for Road and Bridge Construction. 02722 - 2 02722 — Cemented Coquina Shell Base The surface of the base material shall be cleaned after final compaction and the moisture content of the base shall not exceed 90 percent of the optimum moisture before the prime coat is applied. The prime coat shall be applied uniformly with a pressure distributor. The entire length of the spray bar shall be set at the height above the surface recommended by the Manufacturer for even distribution. The prime coat shall be applied to the finished base course at the rate of 0.15 gallons per square yard at a temperature between 100°F to 150°F. The prime coat shall be applied such that a period of no longer than two (2) hours lapse prior to application of the asphaltic concrete wearing course, unless the prime coat is covered with sand or screenings as outlined in Section 300-6.5 of the 2002 Edition of the Florida D.O.T. Specifications. 3.04 TESTING The maximum density and optimum moisture shall be determined in accordance with the Modified Proctor Test procedures of ASTM -D1557 or AASHTO-T180 (Method D). At a minimum, one (1) Modified Proctor Test shall be performed for each 10,000 square feet of base material on representative samples from location(s) designated by the Engineer. The percentage compaction and in-place density shall be determined according to procedures of ASTM -132167 "Test for Density of Soil In -Place by the Rubber Balloon Method" or the nuclear method ASTM- D2922. In-place density testing shall be performed at a minimum rate of four (4) Modified Proctor tests per 10,000 square feet of area to be paved unless quality control measures allow the Engineer to dictate fewer tests. Smaller projects shall require a minimum of two (2) test locations. END OF SECTION 02722 — Cemented Coquina Shell Base 02722 - 3 J SECTION 02741 ASPHALT CONCRETE SURFACE COURSE PART 1 - GENERAL 1.01 SCOPE The work to be performed under this item shall include the selling, delivering and installing of asphalt concrete surface courses on "off-site" restored bases, as further specified herein. Final asphalt concrete surface course shall be completed within 30 days after placement of any temporary asphalt surface course. 1.02 REFERENCES Standards applicable in this Specification shall be: A. Florida Department of Transportation - Standard Specifications for Road and Bridge Construction (2006) I. Section 300 -Prime and Tack Coats for Base Courses. 2. Section 320 -Hot Bituminous Mixtures -Plant, Methods and Equipment. 3. Section 330 - Hot Bituminous Mixtures - General Construction Requirements. 4. Section 334 — Superpave Asphalt Concrete. 1.03 SUBMITTALS A. Manufacturer's Data - Prior to fabrication or installation of the final asphalt concrete surface course, the Contractor shall furnish to the Engineer, for review and approval the following: 1. Certification from the asphalt supplier that their plant meets or exceeds the requirements of Section 320 above. 2. Asphalt mix design with supporting test data indicating compliance with all mix design criteria. PART 2 - MATERIALS 2.01 PRIME AND TACK COAT A. Prime Coat shall be applied on all prepared bases. Prime coat material shall be Cut-back Asphalt Grade RC -70 or RC -250, conforming to the Florida D.O.T. Standard Specifications for Road and Bridge Construction, 2006 Edition, Section 916-3, B. Prime Coat Cover Material shall consist of sand or screenings, conforming to the Florida D.O.T. Standard Specifications for Road and Bridge Construction, 2006 Edition, Section 902. 02741 -1 02741 — Asphaltic Concrete Surface Course C. Tack Coat shall be applied on all prepared bases and existing pavement immediately prior to surfacing. Tack coat material shall be Asphalt Grade RA -500 or Emulsified Asphalt Grades Rs -1 or RS -2, conforming to the Florida D.O.T. Standard Specifications for Road and Bridge Construction, 2006 Edition, Section 916-2. 2.02 SUPERPAVE ASPHALT CONCRETE A. Asphalt used for structural, leveling or patching courses shall be Type SP -12.5, conforming to the Florida D.O.T. Standard Specifications for Road and Bridge Construction, 2006 Edition, Section 334. Asphalt gradation shall be fine or course depending on planned thickness. B. Asphalt used for final surface course shall be Type SP -9.5, conforming to the Florida D.O.T. Standard Specifications for Road and Bridge Construction, 2006 Edition, Section 334. Asphalt gradation shall be fine or course depending on planned thickness. PART 3 - EXECUTION OF WORK 3.01 CLEANING SURFACES Prior to the laying of any surface courses, the surface of the pavement or base to be covered shall be cleaned of all loose and deleterious material by the use of power brooming or hand brooming where necessary. All such material shall be collected and disposed of by the Contractor. 3.02 APPLICATION OF PRIME AND TACK COATS A. Prime Coat material shall be heated to a suitable temperature and applied to the base in a thin, uniform layer at a rate of between 0.1 and 0.15 gallons per square yard, as determined by the Engineer. The prime coat shall be applied using a pressure distributor. Uniformly cover the primed surface with a light application of cover material. Roll the covered prime coat with a traffic roller to provide a dense mat. B. Where primed base courses have become dirty or lost their bonding effect and on all underlying asphalt courses, a tack coat shall be required. Tack coat material shall be heated to a suitable temperature and applied in a thin, uniform layer at a rate of between 0.02 and 0.08 gallons per square yard. The tack coat shall be applied sufficiently in advance of the surface course installation to permit drying but not so far in advance as to lose its adhesiveness as a result of being covered with dust. The tack coat shall be kept free from traffic until the surface course has been laid. 3.03 PREPARATION OF ASPHALT CONCRETE The batching of aggregates, fillers and asphalt binder as well as the mixing and heating of the mixture shall conform to the Florida D.O.T. Standard Specifications for Road and Bridge Construction, 2006 Edition, Section 330. The "Master Temperature Range" for all mix designs shall be the accepted mix design temperature t 30 degrees Fahrenheit ff). Any load or portion of a load measured by the Engineer's Representative which is outside the "Master Temperature Range" shall be rejected prior to installation. 3.04 TRANSPORTATION OF ASPHALT CONCRETE 02741 - Asphaltic Concrete Surface Course 027414 The surface course shall be transported in tight sealing vehicles previously cleaned of all foreign material. The inside surface of the truck bodies shall be thinly coated with soapy water or an acceptable asphalt release agent prior to receiving asphalt concrete.. Diesel, kerosene, gasoline or any other hazardous or environmentally detrimental material shall not be used to lubricate the truck bed. Cover each load during cool and cloudy weather when there is a possibility of rain. 3.05 PATCHING AND LEVELING COURSES Where asphalt concrete is to be installed on an existing paved surface or old base which is irregular, or where indicated on the Plans, the existing surface shall be brought to proper grade and cross section by the application of patching or leveling courses. 3.06 PLACING ASPHALT CONCRETE The placement of asphalt concrete for patching, leveling and subsequent courses shall conform to the Florida D.O.T. Standard Specifications for Road and Bridge Construction, 2006 Edition, Section 330-9, 3.07 COMPACTING ASPHALT CONCRETE The Contractor shall provide a separate set of rollers, with their operators, for each paving or leveling train crew working at the job. All coverage requirements for rolling shall be conducted before the surface temperature of the asphalt concrete drops to the extent that effective compaction can not be achieved or the rollers begin to damage the pavement course. Compaction and joints for as freshly laid asphalt concrete courses shall be installed in compliance with the Florida D.O.T. Standard Specifications for Road and Bridge Construction, 2006 Edition, Section 330-10 and 330-11. 3.08 FIELD QUALITY CONTROL A. The longitudinal installation of all asphalt concrete courses shall be required to be checked by a rolling straightedge. The straightedge shall have a minimum effective length of 15 feet. The finished surface of base or structural surface courses shall not vary more than 3/8 inch from the straightedge applied parallel to the centerline of the pavement. The finished surface of final surface courses shall not vary more than 3/16 inch from the straightedge applied parallel to the centerline of the pavement. Any pavement section exceeding the above tolerances may be rejected by the Engineer. B. The transverse cross slope shall be checked at up to 10 locations for each days work. When the difference between the measured cross slope and the design cross slope varies by more than t 0.2% for travel lanes or f 0.5% for shoulders, the paving operation shall be stopped and corrected. Should the average measurement for the 10 locations be above the specified tolerance, the measured pavement section may be rejected by the Engineer. 3.07 CORRECTING UNACCEPTABLE ASPHALT CONCRETE The Contractor shall be required to correct rejected pavement sections by; removing and replacing; overlaying; or other method in compliance with the Florida D.O.T. Standard Specifications for Road and Bridge Construction, 2006 Edition, Section 330-12.4. END OF SECTION 02741 a3 02741 - Asphaltic Concrete Surface Course J