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C9-Bid Documents - Issued for Bid
City and Borough of Sitka Blue Lake Expansion Project Contract No. 9 General Construction Bidding Documents May 2012 TABLE OF CONTENTS INVITATION TO BID INSTRUCTION TO BIDDERS BID FORM BID BOND FORM AGREEMENT PERFORMANCE AND PAYMENT BONDS GENERAL CONDITIONS SUPPLEMENTARY CONDITIONS SPECIFICATIONS - DIVISION 01 – GENERAL REQUIREMENTS - DIVISION 02 – SITE WORK - DIVISION 03 – CONCRETE - DIVISION 05 – METALS - DIVISION 06 – WOOD AND PLASTICS - DIVISION 07 – THERMAL AND MOISTURE PROTECTION - DIVISION 08 – DOORS AND WINDOWS - DIVISION 09 – FINISHES - DIVISION 10 – SPECIALTIES - DIVISION 13 – SPECIAL CONSTRUCTION - DIVISION 14 – CONVEYING SYSTEMS - DIVISION 15 – MECHANICAL - DIVISION 16 – ELECTRICAL - DIVISION 20 – TURBINE AND GENERATOR EQUIPMENT ATTACHMENT A – MILESTONE SCHEDULE ATTACHMENT B – GEOTECHNICAL BASELINE REPORT FOR TUNNEL AND ADIT CONSTRUCTION INVITATION TO BID BLUE LAKE EXPANSION PROJECT CONTRACT NO. 9 GENERAL CONSTRUCTION The City and Borough of Sitka will receive sealed bids no later than 2:00 p.m. local time, July 17, 2012 at the office of the Municipal Clerk, 100 Lincoln Street, Sitka, Alaska 99835 where the bids will be publicly opened. Bids stamped later than 2:00 p.m. will be rejected. A mandatory pre-bid conference will be conducted in Sitka starting at 8:00 am on May 22, 2012 and continuing into May 23. The Blue Lake Expansion Project includes raising the height of the Blue Lake Dam by 83 ft, construction of a new powerhouse with increased capacity, and related work. The scope of work for Contract No. 9 consists of general construction work for the expansion project, including construction of the dam extension, new intake structure, new intake tunnel section, modifications to the existing tunnel, new underground surge chamber, new penstock section, new powerhouse and associated modifications to the switchyard and other existing facilities. This contract is subject to the provisions of State of Alaska, Title 36, Minimum Wage Rates and Federal Davis-Bacon Wage Rates to the extent applicable to work performed within the State of Alaska. The contract will require certificates of insurance and performance and payment bonds. A Bid Bond in the amount of 5 percent of the total of all estimated prices in the Bid Form, as defined in the Instructions to Bidders, must accompany each bid. The Bid Bond may be in the form of a certified or cashier’s check made payable to the City and Borough of Sitka or a Bid Bond issued by a surety licensed to do business in Alaska. Questions can be directed to Andrew Pharis (Construction Manager) at (208) 342 4214 or Andrew.Pharis@mcmillen-llc.com. All Bidders must enroll on the official plan holders list by going to the City’s web site. To do this: Go to http://www.sitkaonline.com/sitka/CSBIDLST.pgm • Click on the bid document link and then the Blue Lake Expansion, Contract No. 9, General Construction DOWNLOADS. • Fill in the contact information and you will be added to the plan holders list. A Bidder not listed on the official City and Borough of Sitka plan holders list shall be deemed non- responsive. Bidding Documents may be obtained by downloading the documents from the City’s website. There are a large number of reference documents that accompany the Bidding Documents. For a fee of $100 a copy of these documents, on a usb thumb drive, will be sent by courier to Bidders on the plan holders list that request the reference documents. Contact the City and Borough of Sitka Electric Department at (907)747-1882 or jessica@cityofsitka.com to request the reference documents. It is the responsibility of the planholder to regularly check the website for addenda that may be issued for the projects for which they are bidding. The City and Borough of Sitka reserves the right to reject any and all bids and to waive informalities. CITY AND BOROUGH OF SITKA By: Dean Orbison, P.E. Generation Engineer INSTRUCTIONS TO BIDDERS Instructions To Bidders Instruction to Bidders Page 1 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction INSTRUCTIONS TO BIDDERS TABLE OF CONTENTS Page Article 1 – Defined Terms ................................................................................................................................. 2 Article 2 – Copies of Bidding Documents ........................................................................................................ 2 Article 3 – Qualifications of Bidders ................................................................................................................ 3 Article 4 – Examination of Bidding Documents, Other Related Data, and Site ............................................. 5 Article 5 – Pre-Bid Conference ......................................................................................................................... 8 Article 6 – Site and Other Areas ....................................................................................................................... 8 Article 7 – Interpretations and Addenda ........................................................................................................... 9 Article 8 – Bid Security ..................................................................................................................................... 9 Article 9 – Contract Times ................................................................................................................................ 9 Article 10 – Liquidated Damages and incentive payments ............................................................................ 10 Article 11 – Substitute and “Or-Equal” Items ................................................................................................ 10 Article 12 – Subcontractors, Suppliers and Others......................................................................................... 10 Article 13 – Preparation of Bid ....................................................................................................................... 10 Article 14 – Basis of Bid; Comparison of Bids .............................................................................................. 11 Article 15 – Submittal of Bid .......................................................................................................................... 12 Article 16 – Modification and Withdrawal of Bid ......................................................................................... 14 Article 17 – Opening of Bids .......................................................................................................................... 14 Article 18 – Bids to Remain Subject to Acceptance ...................................................................................... 14 Article 19 – Evaluation of Bids and Award of Contract ................................................................................ 14 Article 20 – Contract Security and Insurance ................................................................................................. 16 Article 21 – Signing of Agreement ................................................................................................................. 16 Article 22 – Sales and Use Taxes .................................................................................................................... 16 Article 23 – Retainage ..................................................................................................................................... 16 Article 24 – Prevailing Wage Rates ................................................................................................................ 16 Article 25 – Local construction testing and surveyor Services ...................................................................... 17 Instructions To Bidders Instruction to Bidders Page 2 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction ARTICLE 1 – DEFINED TERMS 1.01 Terms used in these Instructions to Bidders have the meanings indicated in the General Conditions and Supplementary Conditions. Additional terms used in these Instructions to Bidders have the meanings indicated below: A. Issuing Office – The office from which the Bidding Documents are to be issued and where the bidding procedures are to be administered. The Issuing Office is: City and Borough of Sitka, 100 Lincoln St., Sitka AK 99835 ARTICLE 2 – COPIES OF BIDDING DOCUMENTS 2.01 An electronic copy of the Bidding Documents may be obtained at no cost by downloading the documents from Owner’s bidding web site at: http://www.sitkaonline.com/sitka/CSBIDLST.pgm. To download the document, click on the bid document link and then the Blue Lake Expansion, Contract No. 9, General Construction, Project DOWNLOADS. Fill in your contact information as indicated on the web site and you will be added to the plan holders list. A Bidder not listed as a plan holder on the official City and Borough of Sitka plan holders list shall be deemed non- responsive. 2.02 Complete sets of Bidding Documents shall be used in preparing Bids; neither Owner nor Engineer assumes any responsibility for errors or misinterpretations resulting from the use of incomplete sets of Bidding Documents. It is the Bidder’s responsibility to obtain addenda or other communication from the Buyer’s website. Note that paper copies of addenda will not be mailed to plan holders. Owner and Engineer, in making copies of Bidding Documents available on the above terms, do so only for the purpose of obtaining Bids for the Work and do not authorize or confer a license for any other use. 2.03 Copies of Reference Documents, on a USB thumb drive will be sent by courier to all Bidders who have: requested the Reference Documents; paid a $100 fee for the Reference Documents; and; filled out complete and correct contact information on Owner’s bidding web site. Owner will send Reference Documents to Bidder’s mailing address within five days of the date a Bidder has paid the Reference Document fee and has added its name to the planholder’s list on Owner’s bidding web site. Contact City and Borough of Sitka Electric Department at 907-747-1882 or Jessica@cityofsitka.com for reference documents. 2.04 The usb drive with Reference Documents also contains the Contract Drawings in AutoCAD format for use by Bidders in estimating material quantities for preparing Bids. Bidders shall use these drawings only to assist in preparation of the Blue Lake Expansion Contract 9 Bid. The drawings shall not be distributed to other persons or companies, except for this purpose. 2.05 AutoCAD Civil 3D models have also been included with the AutoCAD Contract Drawings. Bidders are cautioned that these models do not reflect the latest design as shown on the Contract Drawings. Instructions To Bidders Instruction to Bidders Page 3 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction ARTICLE 3 – QUALIFICATIONS OF BIDDERS 3.01 To demonstrate Bidder’s qualifications to perform the Work, Bidder shall submit with its Bid a written qualification statement providing evidence such as financial data, previous experience, key staff experience, present commitments, work plan, and such other data as listed below. A. Evidence of Bidder’s authority to do business in the state of Alaska. B. Bidder’s Alaska state contractor license number. Alternately, Bidder may submit evidence of its ability to obtain required authority or licenses within the time for acceptance of Bids. C. Evidence of adequate financial strength to undertake this contract. Specifically, demonstrate the capacity to provide performance bonds for construction contracts with a bonding capacity of at least 150% of Bidder’s proposed cost for this Project. Evidence of this bonding capacity shall be provided by a letter from Bidder’s surety, indicating that the Bidder has additional bonding capacity of at least 50% over the Bid Price for this project, after providing a 100% performance bond as part of the Bid. D. A listing of the equipment and temporary facilities available for the Project. The following minimum equipment shall be described: 1) cranes for work at the Dam, Intake, and powerhouse; 2) tunnel drilling and excavating equipment; 3) raised shaft excavating equipment; 4) excavating equipment for surface structures; 5) concrete batch plant, transport, and placing equipment; 6) material handling, welding, and grouting equipment for tunnel liners. Identify who owns equipment, proposed subs, equipment lease, etc. E. A list of project references for the proposed project team that demonstrate the following elements. Note that it is desirable that these projects are ones where the proposed key project staff has worked on together. This is not a requirement, but experience of the proposed team, as a team on other projects, is preferred. Provide names, titles and phone numbers for owner references for each project: 1. Experience with demolition and raising of concrete dams. (at least two reference projects in the past eight years). 2. Experience with tunneling and raised shaft construction, similar to this Project (at least two reference projects in the past eight years). 3. Experience with hydroelectric project work, either new projects or major rehabilitation (at least two reference projects in the past eight years). F. A Project organization chart and resumes for the proposed project team. The team as a minimum should include the following key team members: 1. Home office project manager 2. On site project manager Instructions To Bidders Instruction to Bidders Page 4 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction 3. Project superintendent 4. Office Engineer or assistant project manager 5. Tunneling lead engineer or superintendent 6. Equipment installation superintendent or lead installer (for the turbine-generating equipment). Each of the team members listed above shall have at least eight years of engineering or construction/installation experience including at least four or more years in a position comparable to that proposed for this Project. Include names, titles and phone numbers for two (2) client references for each key team member. In addition to needed technical skills and experience, the Owner desires professionals who are particularly effective communicators and collaborators, with a demonstrated capability and ability to work well in a construction environment where rapid decision-making skill, creative problem-solving skills, excellent planning and scheduling and close coordination with the Owner’s RPR and design will be required. Please provide any specific credentials, training or expertise each key project member possesses to implement a collaborative, problem-solving project implementation approach on this type of project. The proposed team shall not be modified without written authorization of the Owner. The Owner intends to confirm in its Agreement that the key project staff proposed by Contractor will be obligated to perform on the project team, and that Contractor will provide management and financial commitments to assure that the key project team members complete their project responsibilities without replacement by others, except with the consent of the Owner. G. Subcontractor Qualifications: Provide two project references for comparable work for all subcontractors performing over 5% of the Work (if these portions of the Work are subcontracted): 1) Tunneling and underground excavations; 2) Steel building erection; 3) Turbine and generator equipment installation; 4) Dam construction; 5) Powerhouse construction. For each such subcontractor provide the name of the project, a narrative description identifying the scope of subcontractor’s work, dollar value, owner, owner contact name, email and telephone number. If these portions of the Work are not subcontracted, the above references should be provided as part of Bidder’s qualifications in addition to the references required in Paragraph H below. Instructions To Bidders Instruction to Bidders Page 5 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction H. Project References: A list of at least three comparable general construction contracts completed in North America the past 8 years , including a short description, project cost, duration, owner, owner contact name, e-mail address and telephone number. Comparable contracts should include the following: 1) Contract value of at least $30 million; 2) Concrete dam or major concrete structures for water resource or water navigation; 3) installation and startup of hydroelectric turbine-generating or pumping equipment. If necessary to cover the above criteria, up to 6 reference projects may be submitted. I. Safety Record: Documentation of Bidder’s safety record on recent projects. Also include the Bidder’s Worker’s Compensation Experience Modification Factor for the last three full years. J. Strategies to Achieve Completed Project within Project Schedule Milestones: Describe your strategy to provide your construction phase services to provide assurances that the final project can be completed within the Project’s schedule requirements, including all milestone dates. Please spell out in detail how you propose to: 1) work with Owner to provide timely clarifications of design or technical requirements, project cost estimates and project schedule updates, and (3) effectively manage and coordinate the performance of your project team during construction, including coordination with Owner consultants and suppliers of Owner- furnished materials and equipment. K. Project Risk Factors and Risk Mitigation: Identify from your experience and expertise a minimum of 10 of the most significant risk factors which should be considered during the construction planning and construction phase of the Project, and provide your recommendations on how you would mitigate each risk factor if selected as the construction contractor. If applicable, provide examples of situations where your firm or your proposed key project team members have successfully implemented a substantial risk mitigation activity to address successfully a serious project risk situation which prevented a substantial project delay or cost increase. L. Partnering: Identify your experience and suggested approach to implementing a partnering relationship for the project. Include three references of similar projects in which your proposed partnering approach has been implemented. M. Value Engineering: Provide a list and description of suggested value engineering proposals which provide the Owner value as defined in the Supplementary Conditions. N. Why Select Your Team? Discuss any unique expertise or advantages you believe your team has that would make you the preferred choice. ARTICLE 4 – EXAMINATION OF BIDDING DOCUMENTS, OTHER RELATED DATA, AND SITE 4.01 Subsurface and Physical Conditions Instructions To Bidders Instruction to Bidders Page 6 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction A. The Supplementary Conditions identify: 1. Those reports known to Owner of explorations and tests of subsurface conditions at or contiguous to the Site. 2. Those drawings known to Owner of physical conditions relating to existing surface or subsurface structures at the Site (except Underground Facilities). B. Copies of reports and drawings referenced in Paragraph 4.01.A are not part of the Contract Documents, but the “technical data” contained therein upon which Bidder is entitled to rely as provided in Paragraph 4.02 of the General Conditions has been identified and established in Paragraph 4.02 of the Supplementary Conditions. Bidder is responsible for any interpretation or conclusion Bidder draws from any “technical data” or any other data, interpretations, opinions, or information contained in such reports or shown or indicated in such drawings. 4.02 Technical Data A. Technical Data including the geotechnical data report, figures and appendices are provided as part of the Reference Documents mentioned in Article 2, Paragraph 2.03. 4.03 Underground Facilities Underground penstocks, conduits and piping in the powerhouse and switchyard are shown on drawings that are part of the Reference Documents. Owner is not aware of any other Underground Facilities at the Site. 4.04 Hazardous Environmental Conditions Owner’s reports of lead paint tests made at the Blue Lake facility are included in the Reference Documents. Owner is not aware of any other Hazardous Environmental Conditions at the Site and there are no other reports or drawings related to Hazardous Environmental Conditions at the Site. Owner has a Supplemental Emergency Action Plan which describes the appropriate notification and response to a dam failure. The plan will be explained to the Contractor and Subcontractors and Contractor will be given a copy of the plan. Instructions To Bidders Instruction to Bidders Page 7 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction 4.05 Provisions concerning responsibilities for the adequacy of data furnished to prospective Bidders with respect to subsurface conditions, other physical conditions, and Underground Facilities, and possible changes in the Bidding Documents due to differing or unanticipated subsurface or physical conditions appear in Paragraphs 4.02, 4.03, and 4.04 of the General Conditions. Provisions concerning responsibilities for the adequacy of data furnished to prospective Bidders with respect to a Hazardous Environmental Condition at the Site, if any, and possible changes in the Contract Documents due to any Hazardous Environmental Condition uncovered or revealed at the Site which was not shown or indicated in the Drawings or Specifications or identified in the Contract Documents to be within the scope of the Work, appear in Paragraph 4.06 of the General Conditions. 4.06 On request, Owner will provide Bidder access to the Site to conduct such examinations, investigations, explorations, tests, and studies as Bidder deems necessary for submission of a Bid. Bidder shall fill all holes and clean up and restore the Site to its former condition upon completion of such explorations, investigations, tests, and studies. Bidder shall comply with all applicable Laws and Regulations relative to excavation and utility locates. 4.07 It is the responsibility of each Bidder before submitting a Bid to: A. examine and carefully study the Bidding Documents, and the other related data identified in the Bidding Documents; B. visit the Site and become familiar with and satisfy Bidder as to the general, local, and Site conditions that may affect cost, progress, and performance of the Work; C. become familiar with and satisfy Bidder as to all federal, state, and local Laws and Regulations that may affect cost, progress, and performance of the Work; D. carefully study all: (1) reports of explorations and tests of subsurface conditions at or contiguous to the Site and all drawings of physical conditions relating to existing surface or subsurface structures at the Site (except Underground Facilities) that have been identified in Paragraph 4.02 of the Supplementary Conditions as containing reliable "technical data,", E. consider the information known to Bidder; information commonly known to contractors doing business in the locality of the Site; information and observations obtained from visits to the Site; the Bidding Documents; and the Site-related reports and drawings identified in the Bidding Documents, with respect to the effect of such information, observations, and documents on (1) the cost, progress, and performance of the Work; (2) the means, methods, techniques, sequences, and procedures of construction to be employed by Bidder, including applying any specific means, methods, techniques, sequences, and procedures of construction expressly required by the Bidding Documents; and (3) Bidder’s safety precautions and programs; Instructions To Bidders Instruction to Bidders Page 8 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction F. agree at the time of submitting its Bid that no further examinations, investigations, explorations, tests, studies, or data are necessary for the determination of its Bid for performance of the Work at the price(s) bid and within the times required, and in accordance with the other terms and conditions of the Bidding Documents; G. become aware of the general nature of the work to be performed by Owner and others at the Site that relates to the Work as indicated in the Bidding Documents; H. Promptly give Construction Manager written notice of all conflicts, errors, ambiguities, or discrepancies that Bidder discovers in the Bidding Documents and confirm that the written resolution thereof by Construction Manageris acceptable to Bidder; and I. Determine that the Bidding Documents are generally sufficient to indicate and convey understanding of all terms and conditions for the performance of the Work. 4.08 The submission of a Bid will constitute an incontrovertible representation by Bidder that Bidder has complied with every requirement of this Article 4, that without exception the Bid is premised upon performing and furnishing the Work required by the Bidding Documents and applying any specific means, methods, techniques, sequences, and procedures of construction that may be shown or indicated or expressly required by the Bidding Documents, that Bidder has given Construction Managerwritten notice of all conflicts, errors, ambiguities, and discrepancies that Bidder has discovered in the Bidding Documents and the written resolutions thereof by Construction Manager are acceptable to Bidder, and that the Bidding Documents are generally sufficient to indicate and convey understanding of all terms and conditions for performing and furnishing the Work. ARTICLE 5 – PRE-BID CONFERENCE 5.01 A mandatory pre-Bid conference will be held at the Centennial Building, 330 Harbor Drive, Sitka, Alaska, starting at 8:00 a.m. local time on May 22, 2012, and continuing into May 23. May 22 will include an all day, mandatory, tour of the project site. May 23 will include discussion about the project and a general question and answer session and an optional trip to view the geotechnical drill cores from the 2009 geotechnical investigation program. Representatives of Owner and Construction Manager will be present to discuss the Project. Bidders are required to attend and participate in the conference. Owner will post on the Owner’s web site such Addenda as Construction Manager considers necessary in response to questions arising at the conference. Oral statements may not be relied upon and will not be binding or legally effective. 5.02 A Bid will be considered invalid, if Bidder has not attended the pre-Bid conference. ARTICLE 6 – SITE AND OTHER AREAS Instructions To Bidders Instruction to Bidders Page 9 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction 6.01 The Site is identified in the Bidding Documents. Easements for permanent structures or permanent changes in existing facilities are to be obtained and paid for by Owner unless otherwise provided in the Bidding Documents. The Bidding Documents identify areas that will be made available to Contractor by Owner for construction equipment, storage of materials and parking at: the dam site; at the Sawmill Cove Industrial Park by lease; and at the Fish Valve Unit powerhouse. All additional lands and access thereto required for temporary construction facilities, construction equipment, or storage of materials and equipment to be incorporated in the Work are to be obtained and paid for by Contractor. ARTICLE 7 – INTERPRETATIONS AND ADDENDA 7.01 All questions about the meaning or intent of the Bidding Documents are to be submitted to Construction Manager in writing. Interpretations or clarifications considered necessary by Construction Manager in response to such questions will be issued by Addenda. All addenda will be posted to Owner’s web site on the dates the addenda are issued. Bidders who have downloaded the Bidding Documents from Owner’s web site will not be mailed paper copies of the addenda. Bidders who have downloaded the Bidding Documents have the responsibility to check Owner’s web site for any new addenda. Questions received less than ten days prior to the date for opening of Bids may not be answered. Only questions answered by Addenda will be binding. Oral and other interpretations or clarifications will be without legal effect. 7.02 Addenda may be issued to clarify, correct, or change the Bidding Documents as deemed advisable by Owner or Construction Manager. ARTICLE 8 – BID SECURITY 8.01 A Bid must be accompanied by Bid security made payable to Owner in an amount of five (5) percent of Bidder’s Bid price (the Total price in Table 1 of the Bid Form) and in the form of a certified check, bank money order, or a Bid bond (on the form attached) issued by a surety meeting the requirements of Paragraphs 5.01 and 5.02 of the General Conditions. 8.02 The Bid security of the Successful Bidder will be retained until such Bidder has executed the Contract Documents, furnished the required contract security and met the other conditions of the Notice of Award, whereupon the Bid security will be returned. If the Successful Bidder fails to execute and deliver the Contract Documents and furnish the required contract security within 15 days after the Notice of Award, Owner may consider Bidder to be in default, annul the Notice of Award, and the Bid security of that Bidder will be forfeited. Such forfeiture shall be Owner’s exclusive remedy if Bidder defaults. The Bid security of other Bidders whom Owner believes to have a reasonable chance of receiving the award may be retained by Owner until the earlier of seven days after the Effective Date of the Agreement or 61 days after the Bid opening, whereupon Bid security furnished by such Bidders will be returned. 8.03 Bid security of other Bidders whom Owner believes do not have a reasonable chance of receiving the award will be returned within seven days after the Bid opening. ARTICLE 9 – CONTRACT TIMES Instructions To Bidders Instruction to Bidders Page 10 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction 9.01 The number of days within which the Work is to be substantially completed and ready for final payment is set forth in the Agreement. ARTICLE 10 – LIQUIDATED DAMAGES AND INCENTIVE PAYMENTS 10.01 Provisions for liquidated damages and incentive payments, if any, are set forth in the Agreement. ARTICLE 11 – SUBSTITUTE AND “OR-EQUAL” ITEMS 11.01 The Contract, if awarded, will be on the basis of materials and equipment specified or described in the Bidding Documents without consideration of possible substitute or “or-equal” items. Whenever it is specified or described in the Bidding Documents that a substitute or “or-equal” item of material or equipment may be furnished or used by Contractor if acceptable to Engineer, application for such acceptance will not be considered by Engineer until after the Effective Date of the Agreement. ARTICLE 12 – SUBCONTRACTORS, SUPPLIERS AND OTHERS 12.01 A list of Subcontractors and Suppliers shall be provided as required in Article 15.01. The list shall be accompanied by an experience statement with pertinent information regarding similar projects and other evidence of qualification for each such Subcontractor, Supplier, individual, or entity if requested by Owner. If Owner, RPR, and/or Engineer, after due investigation, has reasonable objection to any proposed Subcontractor, Supplier, individual, or entity, Owner may, before the Notice of Award is given, request apparent Successful Bidder to submit a substitute, in which case apparent Successful Bidder shall submit an acceptable substitute, Bidder’s Bid price will be increased (or decreased) by the difference in cost occasioned by such substitution, and Owner may consider such price adjustment in evaluating Bids and making the Contract award. 12.02 If apparent Successful Bidder declines to make any such substitution, Owner may award the Contract to the next preferred Bidder that proposes to use acceptable Subcontractors, Suppliers, individuals, or entities. Declining to make requested substitutions will not constitute grounds for forfeiture of the Bid security of any Bidder. Any Subcontractor, Supplier, individual, or entity so listed and against which Owner or RPR makes no written objection prior to the giving of the Notice of Award will be deemed acceptable to Owner and RPR subject to revocation of such acceptance after the Effective Date of the Agreement as provided in Paragraph 6.06 of the General Conditions. 12.03 Contractor shall not be required to employ any Subcontractor, Supplier, individual, or entity against whom Contractor has reasonable objection. 12.04 Total work of all subcontracts shall not exceed 50% of the Contract Price. ARTICLE 13 – PREPARATION OF BID Instructions To Bidders Instruction to Bidders Page 11 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction 13.01 The Bid Form is included with the Bidding Documents. Additional copies required by Bidders should be printed from the electronic copy of the document provided by Owner. 13.02 All blanks on the Bid Form shall be completed in ink and the Bid Form signed in ink. Erasures or alterations shall be initialed in ink by the person signing the Bid Form. A Bid price shall be indicated for each Bid item and unit price item listed therein. In the case of optional alternatives the words “No Bid,” “No Change,” or “Not Applicable” may be entered. 13.03 A Bid by a corporation shall be executed in the corporate name by the president or a vice- president or other corporate officer accompanied by evidence of authority to sign. The corporate seal shall be affixed and attested by the secretary or an assistant secretary. The corporate address and state of incorporation shall be shown. 13.04 A Bid by a partnership shall be executed in the partnership name and signed by a partner (whose title must appear under the signature), accompanied by evidence of authority to sign. The official address of the partnership shall be shown. 13.05 A Bid by a limited liability company shall be executed in the name of the firm by a member and accompanied by evidence of authority to sign. The state of formation of the firm and the official address of the firm shall be shown. 13.06 A Bid by an individual shall show the Bidder’s name and official address. 13.07 A Bid by a joint venture shall be executed by each joint venturer in the manner indicated on the Bid Form. The official address of the joint venture shall be shown. 13.08 All names shall be printed in ink below the signatures. 13.09 The Bid shall contain an acknowledgment of receipt of all Addenda, the numbers of which shall be filled in on the Bid Form. 13.10 Postal and e-mail addresses and telephone number for communications regarding the Bid shall be shown. 13.11 The Bid shall contain evidence of Bidder’s authority and qualification to do business in the state where the Project is located, or Bidder shall covenant in writing to obtain such authority and qualification prior to award of the Contract and attach such covenant to the Bid. Bidder’s state contractor license number, if any, shall also be shown on the Bid Form. ARTICLE 14 – BASIS OF BID; COMPARISON OF BIDS 14.01 Lump Sum A. Bidders shall submit a Bid on a lump sum basis as set forth in the Bid Form for each lump sum item in the Bid Schedule. Instructions To Bidders Instruction to Bidders Page 12 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction 14.02 Unit Price A. Bidders shall submit a Bid on a unit price basis for each item of Work listed in the Bid schedule. B. The total of all estimated prices will be the sum of the products of the estimated quantity of each item and the corresponding unit price. The final quantities and Contract Price will be determined in accordance with Paragraph 11.03 of the General Conditions. C. Discrepancies between the multiplication of units of Work and unit prices will be resolved in favor of the unit prices. Discrepancies between the indicated sum of any column of figures and the correct sum thereof will be resolved in favor of the correct sum. 14.03 Bidder’s Qualifications A. Bidders shall submit a Bid that includes documents presenting Bidder’s qualifications as required by Article 3 of these Instructions to Bidders. Bidder qualifications as presented under Article 3 of these Instructions to Bidders will, in addition to the lump sum and unit price items described in Articles 14.01 and 14.02 above, be a basis of comparison of Bids and may result in selection of a preferred Bidder based on qualifications in addition to the bid amount. ARTICLE 15 – SUBMITTAL OF BID 15.01 With each copy of the Bidding Documents, a Bidder is furnished one Microsoft Word version of the Bid Form. Paper copies of the Bid Form and Bid Bond Form are to be completed and submitted with the Bid security and the following documents: • Bidder’s qualification documents, as described in Article 3 of these Instructions to Bidders. • A list of proposed subcontractors, in addition to those required as part of the qualification documents, who will be performing work on the Project and whose scope of work may exceed 3% of the total Contract Price. The list must indicate the work performed by each subcontractor and the percentage of the General Construction Contract. • A list of current projects and projects expected during the time frame anticipated for the Work, along with a statement that the Bidder has sufficient personnel and equipment resources to readily perform the Work. • A statement of the Bidder’s financial capabilities to support the project, including annual business volume over the past 3 years and bank references. Instructions To Bidders Instruction to Bidders Page 13 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction • Company description, including history, number of employees, capabilities, recent projects, office locations, and related company structure-organizational information. This may include company brochures and similar data. Do not exceed 60 pages for this information. • Bidder’s preliminary work plan for performing the Work. The preliminary work plan shall include the following: o Narrative description (about 30 pages in length) of the work sequence from start of mobilization through demobilizing from the site. Narrative shall include a discussion of durations for each task and Contractor’s plan for maintaining schedule. Include expected crew sizes, work hours per shift, shifts per day and per week. Describe work to be performed by subcontractors. o Description of equipment to be used on the project. As a minimum this should include: Cranes to be used at the dam, intake, tunnel liner staging area and powerhouse; Equipment utilized for site excavation; Tunnel drilling and mucking equipment; o Approach for disposal of soil, timber and rock; erosion control and pollution control. o Proposed overall project schedule, in Gantt chart format, including: At least 150 activities with key milestones identified. Clear definition of critical path work tasks and float. o Proposed preliminary work plan and detailed schedule for the Generation Outage. Activities in this schedule may be limited to those directly or indirectly related to the plant outage and the tunnel and penstock interconnections and work related to achieving operational status for the first Blue Lake Powerhouse turbine-generator unit. This schedule shall indicate available float for critical path activities as well as required interface with Owner-provided activities. o Clear definition of days required to achieve Substantial Completion Bidder’s approach to partnering. Identify your experience and suggested approach to implementing a partnering relationship for the project. Include three references of similar projects in which your proposed partnering approach has been implemented. Instructions To Bidders Instruction to Bidders Page 14 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction Value Engineering proposals. Provide a list and description of suggested value engineering proposals which provide the Owner value as defined in the contract supplementary conditions. 15.02 Bidder is advised to carefully review those portions of the Bid Form requiring Bidder’s representations and certifications. 15.03 A Bid shall be submitted no later than the date and time prescribed and at the place indicated in the advertisement or invitation to bid and shall be enclosed in a plainly marked package with the Project title, the name and address of Bidder, and shall be accompanied by the Bid security and other required documents. If a Bid is sent by mail or other delivery system, the sealed envelope containing the Bid shall be enclosed in a separate package plainly marked on the outside with the notation “BID ENCLOSED.” A mailed Bid shall be addressed to the Municipal Clerk, City and Borough of Sitka, 100 Lincoln Street, Sitka, Alaska 99835. 15.04 Bid shall be submitted as a “hard” or paper copy with an electronic copy in pdf format on a CD. The electronic copy shall be in multiple files if necessary, so that no one file is larger than nine MB. ARTICLE 16 – MODIFICATION AND WITHDRAWAL OF BID 16.01 A Bid may be modified or withdrawn by an appropriate document duly executed in the same manner that a Bid must be executed and delivered to the place where Bids are to be submitted prior to the date and time for the opening of Bids. 16.02 If within 24 hours after Bids are opened any Bidder files a duly signed written notice with Owner and promptly thereafter demonstrates to the reasonable satisfaction of Owner that there was a material and substantial mistake in the preparation of its Bid, that Bidder may withdraw its Bid, and the Bid security will be returned. Thereafter, if the Work is rebid, that Bidder will be disqualified from further bidding on the Work. ARTICLE 17 – OPENING OF BIDS 17.01 Bids will be opened at the time and place indicated in the Advertisement or Invitation to Bid and, unless obviously non-responsive, the total amount bid will be read aloud publicly. An abstract of the amounts of the base Bids and major alternates, if any, will be made available to Bidders after the opening of Bids. ARTICLE 18 – BIDS TO REMAIN SUBJECT TO ACCEPTANCE 18.01 All Bids will remain subject to acceptance for the period of time stated in the Bid Form, but Owner may, in its sole discretion, release any Bid and return the Bid security prior to the end of this period. ARTICLE 19 – EVALUATION OF BIDS AND AWARD OF CONTRACT Instructions To Bidders Instruction to Bidders Page 15 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction 19.01 Owner reserves the right to reject any or all Bids, including without limitation, nonconforming, nonresponsive, unbalanced, or conditional Bids. Owner further reserves the right to reject the Bid of any Bidder whom it finds, after reasonable inquiry and evaluation, to not be responsible. Owner may also reject the Bid of any Bidder if Owner believes that it would not be in the best interest of the Project to make an award to that Bidder. Owner also reserves the right to waive all informalities not involving price, time, or changes in the Work and to negotiate contract terms with the Successful Bidder. 19.02 More than one Bid for the same Work from an individual or entity under the same or different names will not be considered. Reasonable grounds for believing that any Bidder has an interest in more than one Bid for the Work may be cause for disqualification of that Bidder and the rejection of all Bids in which that Bidder has an interest. 19.03 In evaluating Bids, Owner will consider whether or not the Bids comply with the prescribed requirements, and such alternates, unit prices and other data, as may be requested in the Bid Form or prior to the Notice of Award. A. Owner will evaluate bids based on a combination of the following factors in the Priority listed below: 1. Total Bid Price, 2. Bidder’s evaluated qualifications and capability to perform the work, including: a. equipment and staff available to perform the Work; b. performance and safety record on recent similar projects, c. resumes of project manager, site superintendent and key staff; d. company’s financial strength; e. qualifications of proposed subcontractors, suppliers and other entities proposed for portions of the work; f. and overall qualifications of Bidder, 3. Proposed preliminary work plan and schedule. 4. Proposed generation outage work plan and schedule. 19.04 Owner may conduct such investigations as Owner deems necessary to establish the responsibility, qualifications, and financial ability of Bidders, proposed Subcontractors, Suppliers, individuals, or entities proposed for those portions of the Work in accordance with the Contract Documents. Instructions To Bidders Instruction to Bidders Page 16 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction 19.05 If the Contract is to be awarded, Owner will award the Contract to Bidder whose Bid is in the best interests of the Project. ARTICLE 20 – CONTRACT SECURITY AND INSURANCE 20.01 Article 5 of the General Conditions, as may be modified by the Supplementary Conditions, sets forth Owner’s requirements as to performance and payment bonds and insurance. When the Successful Bidder delivers the executed Agreement to Owner, it shall be accompanied by such bonds. ARTICLE 21 – SIGNING OF AGREEMENT 21.01 When Owner issues a Notice of Award to the Successful Bidder, it shall be accompanied by the required number of unsigned counterparts of the Agreement along with the other Contract Documents which are identified in the Agreement as attached thereto. Within 15 days thereafter, Successful Bidder shall sign and deliver the required number of counterparts of the Agreement and attached documents to Owner. Within ten days thereafter, Owner shall deliver one fully signed counterpart to Successful Bidder with a complete set of the Drawings with appropriate identification. ARTICLE 22 – SALES AND USE TAXES 22.01 Owner is exempt from Alaska state sales and use taxes on materials and equipment to be incorporated in the Work. Said taxes shall not be included in the Bid. Refer to Paragraph 6.10 of the Supplementary Conditions for additional information. ARTICLE 23 – RETAINAGE 23.01 The Contractor will not be allowed to deposit securities in lieu of retainage. Retainage amounts are set forth in the Agreement. ARTICLE 24 – PREVAILING WAGE RATES 1. This Contract is subject to the provisions of State of Alaska, Title 36, Minimum Wage Rates and Federal Davis-Bacon Wage Rates. State Wage Rates can be obtained at http://labor.state.ak.us/lss/pamp600.htm Use the State wage rates that are in effect 10 days before Bid Opening. A copy of the State Wage rates will be provided upon request. 2. Contractor may not begin work until he has submitted proof that a “Notice of Work” has been filed with the Alaska Department of Labor. A temporary receipt of the “Notice of Work” date- stamped by Wage & Hour will serve as proof. Instructions To Bidders Instruction to Bidders Page 17 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction 3. Contractor shall include with its final pay request a “Notice of Completion of Public Works”, from the Alaska Department of Labor showing that all employees’ wages and employment security taxes have been paid to its employees and the employees of its subcontractors (T36 Clearance Approved). Final payment will not be released until this has been submitted. ARTICLE 25 – LOCAL CONSTRUCTION TESTING AND SURVEYOR SERVICES 1. The following local technical service firms known to the Owner that may be hired by Contractor to perform construction testing and surveying services are shown below. The list is not all inclusive and the Owner does not require the Contractor to use these firms. 2. Surveying: O’Neill Surveying and Engineering PO Box 1849 Sitka, AK 99835 907-747-6700 oneillengr@ak.net O’Neill Surveying and Engineering has performed all of the land surveying required in design of the Blue Lake Expansion Project 3. Welding Inspection: Allen Puckett P.O. Box 2793 Sitka, Alaska 99835 907-747-6547 Hm. 907-747-7711 Wk. Allen.Puckett@uas.alaska.edu A.W.S - C.W.I # 02080341 expiration date August 1, 2014 4. Concrete Testing Dan Jones Baranof Materials Testing LLC 719 Sirstad Street Sitka, Alaska 99835 907-738-6998 danielgjonespe@gci.net Concrete Testing services available will include: Field- Preparation of test cylinders Slump Air Entrainment Instructions To Bidders Instruction to Bidders Page 18 of 18 Blue Lake Expansion Project – Contract No. 9 General Construction Temperature Lab- Compressive Strength testing (including cylinder cure to specifications) Material gradation and moisture determination lab work will also be available. The lab will meet ASTM E329 requirements. ARTICLE 26 - ENGINEER’S ESTIMATE The Engineer’s Estimate for Work under this contract is $45,000,000 - $50,000,000 BID FORM Blue Lake Expansion Project – Contract No. 9 Bid Form General Construction Page 1 BID FORM BLUE LAKE EXPANSION PROJECT CONTRACT NO. 9 GENERAL CONSTRUCTION CITY AND BOROUGH OF SITKA, ALASKA TO: City and Borough of Sitka Attn: Municipal Clerk 100 Lincoln Street Sitka, AK 99835 BIDDER: Company Name Company Contact Address Telephone E-mail address Blue Lake Expansion Project – Contract No. 9 Bid Form General Construction Page 2 TABLE OF CONTENTS Page Article 1 – Bid Recipient ................................................................................................................................... 3 Article 2 – Bidder’s Acknowledgements .......................................................................................................... 3 Article 3 – Bidder’s Representations ................................................................................................................ 3 Article 4 – Bidder’s Certification ...................................................................................................................... 4 Article 5 – Basis of Bid ..................................................................................................................................... 5 Article 6 – Attachments to This Bid ................................................................................................................. 5 Article 7 – Defined Terms ................................................................................................................................. 6 Article 8 – Bid Submittal................................................................................................................................... 7 Table 1 – Schedule of Bid Prices Table 2 – Summary of Bid Prices Blue Lake Expansion Project – Contract No. 9 Bid Form General Construction Page 3 ARTICLE 1 – BID RECIPIENT 1.01 This Bid is submitted to: City and Borough of Sitka, Alaska 1.02 The undersigned Bidder proposes and agrees, if this Bid is accepted, to enter into an Agreement with Owner in the form included in the Bidding Documents to perform all Work as specified or indicated in the Bidding Documents for the prices and within the times indicated in this Bid and in accordance with the other terms and conditions of the Bidding Documents. ARTICLE 2 – BIDDER’S ACKNOWLEDGEMENTS 2.01 Bidder accepts all of the terms and conditions of the Instructions to Bidders, including without limitation those dealing with the disposition of Bid security. This Bid will remain subject to acceptance for 60 days after the Bid opening, or for such longer period of time that Bidder may agree to in writing upon request of Owner. ARTICLE 3 – BIDDER’S REPRESENTATIONS 3.01 In submitting this Bid, Bidder represents that: A. Bidder has examined and carefully studied the Bidding Documents, other related data identified in the Bidding Documents, and the following Addenda, receipt of which is hereby acknowledged: Addendum No. Addendum Date B. Bidder has visited the Site and become familiar with and is satisfied as to the general, local, and Site conditions that may affect cost, progress, and performance of the Work. C. Bidder is familiar with and is satisfied as to all Laws and Regulations that may affect cost, progress, and performance of the Work. D. Bidder has carefully studied all: reports of explorations and tests of subsurface conditions at or contiguous to the Site and all drawings of physical conditions relating Blue Lake Expansion Project – Contract No. 9 Bid Form General Construction Page 4 to existing surface or subsurface structures at the Site (except Underground Facilities) that have been identified in SC-4.02 as containing reliable "technical data." E. Bidder has considered the information known to Bidder; information commonly known to contractors doing business in the locality of the Site; information and observations obtained from visits to the Site; the Bidding Documents; and the Site-related reports and drawings identified in the Bidding Documents, with respect to the effect of such information, observations, and documents on (1) the cost, progress, and performance of the Work; (2) the means, methods, techniques, sequences, and procedures of construction to be employed by Bidder, including applying the specific means, methods, techniques, sequences, and procedures of construction expressly required by the Bidding Documents; and (3) Bidder’s safety precautions and programs. F. Based on the information and observations referred to in Paragraph 3.01.E above, Bidder does not consider that further examinations, investigations, explorations, tests, studies, or data are necessary for the determination of this Bid for performance of the Work at the price(s) bid and within the times required, and in accordance with the other terms and conditions of the Bidding Documents. G. Bidder is aware of the general nature of work to be performed by Owner and others at the Site that relates to the Work as indicated in the Bidding Documents. H. Bidder has given Engineer written notice of all conflicts, errors, ambiguities, or discrepancies that Bidder has discovered in the Bidding Documents, and the written resolution thereof by Engineer is acceptable to Bidder. 1. The Bidding Documents are generally sufficient to indicate and convey understanding of all terms and conditions for the performance of the Work for which this Bid is submitted. ARTICLE 4 – BIDDER’S CERTIFICATION 4.01 Bidder certifies that: A. This Bid is genuine and not made in the interest of or on behalf of any undisclosed individual or entit y and is not submitted in conformity with any collusive agreement or rules of any group, association, organization, or corporation; B. Bidder has not directly or indirectly induced or solicited any other Bidder to submit a false or sham Bid; C. Bidder has not solicited or induced any individual or entity to refrain from bidding; and D. Bidder has not engaged in corrupt, fraudulent, collusive, or coercive practices in competing for the Contract. For the purposes of this Paragraph 4.01.D: Blue Lake Expansion Project – Contract No. 9 Bid Form General Construction Page 5 1. “corrupt practice” means the offering, giving, receiving, or soliciting of any thing of value likely to influence the action of a public official in the bidding process; 2. “fraudulent practice” means an intentional misrepresentation of facts made (a) to influence the bidding process to the detriment of Owner, (b) to establish bid prices at artificial non-competitive levels, or (c) to deprive Owner of the benefits of free and open competition; 3. “collusive practice” means a scheme or arrangement between two or more Bidders, with or without the knowledge of Owner, a purpose of which is to establish bid prices at artificial, non-competitive levels; and 4. “coercive practice” means harming or threatening to harm, directly or indirectly, persons or their property to influence their participation in the bidding process or affect the execution of the Contract. ARTICLE 5 – BASIS OF BID 5.01 Bidder will complete the Work in accordance with the Contract Documents for the prices in Table 1 Schedule of Bid Prices and Table 2 Summary of Bid Prices. Bidder acknowledges that estimated quantities are not guaranteed, and are solely for the purpose of comparison of Bids, and final payment for all unit price Bid items will be based on actual quantities, determined as provided in the Contract Documents. 5.02 Bidder agrees that the Work will be substantially complete and will be completed and ready for final payment in accordance with Paragraph 14.07 of the General Conditions on or before the dates or within the number of calendar days indicated in the Agreement. 5.03 Bidder accepts the provisions of the Agreement as to liquidated damages. ARTICLE 6 – ATTACHMENTS TO THIS BID 6.01 The following documents are submitted with and made a condition of this Bid: A. Required Bid security in the form of a 5% Bid Bond; B. Evidence of authority to do business in the state of Alaska; or a written covenant to obtain such license within the time for acceptance of Bids; C. Contractor’s License No.: ____________ [or] Evidence of Bidder’s ability to obtain a State Contractor’s License and a covenant by Bidder to obtain said license within the time for acceptance of Bids; D. Required Bidder Qualification Documents and Supporting Data as defined in Article 3 of the Instructions to Bidders. Blue Lake Expansion Project – Contract No. 9 Bid Form General Construction Page 6 E. Documents required in Article 15 of the Instructions to Bidders. ARTICLE 7 – DEFINED TERMS 7.01 The terms used in this Bid with initial capital letters have the meanings stated in the Instructions to Bidders, the General Conditions, and the Supplementary Conditions. Blue Lake Expansion Project – Contract No. 9 Bid Form General Construction Page 7 ARTICLE 8 – BID SUBMITTAL 9.01 This Bid is submitted by: If Bidder is: An Individual Name (typed or printed): By: (Individual’s signature) Doing business as: A Partnership Partnership Name: By: (Signature of general partner -- attach evidence of authority to sign) Name (typed or printed): A Corporation Corporation Name: (SEAL) State of Incorporation: Type (General Business, Professional, Service, Limited Liability):_______ By: (Signature -- attach evidence of authority to sign) Name (typed or printed): Title: (CORPORATE SEAL) Attest Date of Qualification to do business in Alaska is ____/____/____. A Joint Venture Name of Joint Venture: Table 1 Contract No. 9 - General Construction Schedule of Bid Prices Notes: (1) All prices are U.S. currency. (2) Unit prices have been computed in accordance with paragraph 11.03B of the General Conditions Page 1 of 2 Bid Item Description Quantity Unit Unit Price Bid Amount General and Multiple-Feature Payment Items 1.01 Work Plan --LS -- 1.02 Mobilization --LS -- 1.03 Performance and Payment Bonds --LS -- 1.04 Erosion, Sediment and Pollution Control Measures --LS -- 1.05 Contract Closeout --LS -- 1.06 Reservoir Access Road, Gate House Access Road, and Improvements to Blue Lake Road and Dam Staging Area --LS -- 1.07.a Place Crushed Rock Material at Campground CY 1.07.b Stockpile Crushed Rock Material at Campground CY 1.08 1" Diameter Rock Bolts in Tunnels LF 1.09 1" Diameter Rock Bolts in Shafts LF 1.10 1" Dia. Rock Bolts in Locations other than Tunnels and Shafts LF 1.11 Drilled Drain Holes LF 1.12 Drilled Tunnel Pre-Excavation Grout Holes LF 1.13 Injecting Grout in Tunnels Hour 1.14 Drilled Grout Holes in Shafts LF 1.15 Injecting Grout in Shafts Hour 1.16 Tunnel and Shaft Grout Materials Bag 1.17 Steel Sets in Tunnels and at Portals EA 1.18 Shotcrete (3" thick) and Wire Mesh in Tunnels and Shafts SF 1.19 Shotcrete (4" thick) and Wire Mesh in Tunnels SF 1.20 Hydraulic Liners in Tunnels LF 1.21 Powerhouse, Penstock, and Access Road Excavation --LS -- 1.22 Powerhouse Area Backfill --LS -- 1.23 Utilities Protection and Relocation --LS -- 1.24 Chain Link Fence LF Total for General Dam Extension (Feature No. 20) 20.01 Dam Extension --LS -- 20.02 Left Abutment Thrust Block and Cut-off Wall --LS -- 20.03 Abutment Piezometer LF 20.04 Plunge Pool Pressure Relief Wells and Monitoring System LF 20.05 Left Abutment Rock Anchors - 1-3/8" Dia, 31' to 50' Length LF 20.06 Foundation Grouting - Drill Holes LF 20.07 Foundation Grouting - Cement for Foundation Grouting BAG 20.08 Foundation Grouting - Plasticizer GAL 20.09 Foundation Grouting - Water Tests EA 20.10 Foundation Grouting - Grout Pipe LB 20.11 Dam Contraction Joint Grouting --LS -- Total for Feature No. 20 Spillway Plunge Pool Scour Wall (Feature No. 22) 22.01 Spillway Plunge Pool Scour Wall Concrete Head Beam LS 22.02 Spillway Plunge Pool Scour Wall Riprap Protection CY 22.03 Spillway Plunge Pool Scour Wall Micropiles 1 thru 29 LF 22.04 Spillway Plunge Pool Scour Wall Micropiles 39 thru 43 (Optional)LF Total for Feature No. 22 Drainage Tunnel (Feature No. 23) 23.01 Drainage Tunnel --LS -- 23.02 Exploratory Cored Holes LF 23.03 Exploratory Holes LF 23.04 Water Pressure Packer Tests EA Total for Feature No. 23 Intake Tunnel (Feature No. 24) 24.01 Intake Tunnel Excavation --LS -- Total for Feature No. 24 Intake Structure (Feature No. 25) 25.01 Intake Excavation --LS -- 25.02 Intake Structure --LS -- Total for Feature No. 25 Gate Shaft (Feature No. 26) 26.01 Gate Chamber, Gate Shaft and Gate House Structures --LS -- Total for Feature No. 26 Tunnel Modifications (Feature No. 30) 30.01 Temporary and Permanent Sealing of Existing Intake --LS -- 30.02 Tunnel Steel Liners --LS -- 30.03 Adit Tunnel and Surge Chamber --LS -- 30.04 Adit Tunnel Concrete Plug and Connection to Existing Tunnel --LS -- Total for Feature No. 30 Penstock and Penstock Drain (Feature No. 31) 31.01 Timber Crib Wall - Demolition, Excavation and Grading --LS -- 31.02 Install Owner Furnished Penstock and Manifold --LS -- Table 1 Contract No. 9 - General Construction Schedule of Bid Prices Notes: (1) All prices are U.S. currency. (2) Unit prices have been computed in accordance with paragraph 11.03B of the General Conditions Page 2 of 2 Bid Item Description Quantity Unit Unit Price Bid Amount Total for Feature No. 31 24 Inch Penstock Drain (Feature No. 32) 32.01 Penstock Drain System --LS -- Total for Feature No. 32 Water Treatment Building (Feature No. 33) 33.01 Water Treatment Building Modifications --LS -- Total for Feature No. 33 Powerhouse (Feature No. 45) 45.01 Powerhouse Concrete --LS -- 45.02 Erect Owner Furnished Powerhouse Structure --LS -- 45.03 Powerhouse Interior Build-out --LS -- 45.04 Powerhouse Electrical Equipment and Services --LS -- 45.05 Powerhouse Mechanical Equipment and Services --LS -- 45.06 Install Owner Furnished Turbine and Generator Equipment, Bridge Crane and 12.47kV Switchgear --LS -- Total for Feature No. 45 Fish Valve Unit (Feature No. 46) 46.01 Demolition and Salvage of Existing Turbine and Generator Equipment --LS -- 46.02 Install Owner Furnished Turbine and Generator Equipment --LS -- Total for Feature No. 46 Switchyard Modifications (Feature No. 55) 55.01 Switchyard Foundation Structures and Buried Conduit --LS -- Total for Feature No. 55 BASE BID AMOUNT Optional Bid Items 22.04 Spillway Plunge Pool Scour Wall Micropiles 30 thru 38 LF 22.06 Spillway Plunge Pool Scour Wall Grouting of Grout Piles 30 thru 38 CY Total for Optional Items BID BOND FORM EJCDC C-435 Bid Bond (Damages Form) Prepared by the Engineers Joint Contract Documents Committee. Page 1 of 2 BID BOND FORM Any singular reference to Bidder, Surety, Owner, or other party shall be considered plural where applicable. BIDDER (Name and Address): SURETY (Name and Address of Principal Place of Business): OWNER (Name and Address): City and Borough of Sitka 100 Lincoln St. Sitka, AK 99835 BID Bid Due Date: Description (Project Name and Include Location): BOND Bond Number: Date (Not earlier than Bid due date): Penal sum $ (Words) (Figures) Surety and Bidder, intending to be legally bound hereby, subject to the terms set forth below, do each cause this Bid Bond to be duly executed by an authorized officer, agent, or representative. BIDDER SURETY (Seal) (Seal) Bidder’s Name and Corporate Seal Surety’s Name and Corporate Seal By: By: Signature Signature (Attach Power of Attorney) Print Name Print Name Title Title Attest: Attest: Signature Signature Title Title Note: Above addresses are to be used for giving any required notice. Provide execution by any additional parties, such as joint venturers, if necessary. EJCDC C-435 Bid Bond (Damages Form) Prepared by the Engineers Joint Contract Documents Committee. Page 2 of 2 1. Bidder and Surety, jointly and severally, bind themselves, their heirs, executors, administrators, successors, and assigns to pay to Owner upon default of Bidder any difference between the total amount of Bidder’s Bid and the total amount of the Bid of the next lowest, responsible Bidder who submitted a responsive Bid as determined by Owner for the work required by the Contract Documents, provided that: 1.1 If there is no such next Bidder, and Owner does not abandon the Project, then Bidder and Surety shall pay to Owner the penal sum set forth on the face of this Bond, and 1.2 In no event shall Bidder’s and Surety’s obligation hereunder exceed the penal sum set forth on the face of this Bond. 1.3 Recovery under the terms of this Bond shall be Owner’s sole and exclusive remedy upon default of Bidder. 2. Default of Bidder shall occur upon the failure of Bidder to deliver within the time required by the Bidding Documents (or any extension thereof agreed to in writing by Owner) the executed Agreement required by the Bidding Documents and any performance and payment bonds required by the Bidding Documents. 3. This obligation shall be null and void if: 3.1 Owner accepts Bidder’s Bid and Bidder delivers within the time required by the Bidding Documents (or any extension thereof agreed to in writing by Owner) the executed Agreement required by the Bidding Documents and any performance and payment bonds required by the Bidding Documents, or 3.2 All Bids are rejected by Owner, or 3.3 Owner fails to issue a Notice of Award to Bidder within the time specified in the Bidding Documents (or any extension thereof agreed to in writing by Bidder and, if applicable, consented to by Surety when required by Paragraph 5 hereof). 4. Payment under this Bond will be due and payable upon default of Bidder and within 30 calendar days after receipt by Bidder and Surety of written notice of default from Owner, which notice will be given with reasonable promptness, identifying this Bond and the Project and including a statement of the amount due. 5. Surety waives notice of any and all defenses based on or arising out of any time extension to issue Notice of Award agreed to in writing by Owner and Bidder, provided that the total time for issuing Notice of Award including extensions shall not in the aggregate exceed 120 days from Bid due date without Surety’s written consent. 6. No suit or action shall be commenced under this Bond prior to 30 calendar days after the notice of default required in Paragraph 4 above is received by Bidder and Surety and in no case later than one year after Bid due date. 7. Any suit or action under this Bond shall be commenced only in a court of competent jurisdiction located in the state in which the Project is located. 8. Notices required hereunder shall be in writing and sent to Bidder and Surety at their respective addresses shown on the face of this Bond. Such notices may be sent by personal delivery, commercial courier, or by United States Registered or Certified Mail, return receipt requested, postage pre-paid, and shall be deemed to be effective upon receipt by the party concerned. 9. Surety shall cause to be attached to this Bond a current and effective Power of Attorney evidencing the authority of the officer, agent, or representative who executed this Bond on behalf of Surety to execute, seal, and deliver such Bond and bind the Surety thereby. 10. This Bond is intended to conform to all applicable statutory requirements. Any applicable requirement of any applicable statute that has been omitted from this Bond shall be deemed to be included herein as if set forth at length. If any provision of this Bond conflicts with any applicable statute, then the provision of said statute shall govern and the remainder of this Bond that is not in conflict therewith shall continue in full force and effect. 11. The term “Bid” as used herein includes a Bid, offer, or proposal as applicable. AGREEMENT Blue Lake Expansion Project – Contract No. 9 Agreement General Construction Page 1 of 10 BLUE LAKE EXPANSION PROJECT CONTRACT NO. 9 GENERAL CONSTRUCTION AGREEMENT TABLE OF ARTICLES 1.0 ARTICLE 1 – WORK ................................................................................................................ 2 2.0 ARTICLE 2 – THE PROJECT ................................................................................................. 2 3.0 ARTICLE 3 – ENGINEER ........................................................................................................ 2 4.0 ARTICLE 4 – CONTRACT TIMES ......................................................................................... 2 4.01 TIME OF THE ESSENCE .................................................................................................................... 2 4.02 DATES FOR PROJECT MILESTONES .................................................................................................. 3 4.03 DAYS TO ACHIEVE SUBSTANTIAL COMPLETION AND FINAL PAYMENT ................................................ 4 4.04 INCENTIVE PAYMENTS AND LIQUIDATED DAMAGES .......................................................................... 4 5.0 ARTICLE 5 – CONTRACT PRICE .......................................................................................... 5 6.0 ARTICLE 6 – PAYMENT PROCEDURES .............................................................................. 5 6.01 SUBMITTAL AND PROCESSING OF PAYMENTS .................................................................................... 5 6.02 PROGRESS PAYMENTS; RETAINAGE .................................................................................................. 5 6.03 FINAL PAYMENT .............................................................................................................................. 6 7.0 ARTICLE 7 – INTEREST ......................................................................................................... 6 8.0 ARTICLE 8 – CONTRACTOR’S REPRESENTATIONS ....................................................... 6 9.0 ARTICLE 9 – CONTRACT DOCUMENTS ............................................................................. 7 10.0 ARTICLE 10 – MISCELLANEOUS ......................................................................................... 8 10.01 TERMS ........................................................................................................................................ 8 10.02 ASSIGNMENT OF CONTRACT ........................................................................................................ 8 10.03 SUCCESSORS AND ASSIGNS .......................................................................................................... 8 10.04 SEVERABILITY ............................................................................................................................. 8 10.05 CONTRACTOR’S CERTIFICATIONS ................................................................................................ 8 Blue Lake Expansion Project – Contract No. 9 Agreement General Construction Page 2 of 10 1.0 ARTICLE 1 – WORK Contractor shall complete all Work as specified or indicated in the Contract Documents. The Work is generally as described in Specification Section 01010. 2.0 ARTICLE 2 – THE PROJECT The Blue Lake Expansion Project for which the Work under the Contract Documents is part of, is generally described as follows: • Increasing the height of the Blue Lake Dam by 83 ft, including a thrust block on the left abutment, to increase the maximum gross head of the project from 329 ft to 413 ft. • Construction of a drainage tunnel and drainage system in the left abutment. • Construction of a scour wall within the plunge pool and pressure relief wells downstream of Blue Lake Dam. • Construction of a new intake structure, gate shaft, gate house, and intake tunnel. • Modifications of the existing project tunnel, including steel liner extensions, construction of a surge chamber and permanent closure of the existing tunnel intake. • Construction of a new three-unit Blue Lake powerhouse and installation of a new generating unit in the existing Fish Valve Unit powerhouse. • Installation of new main 69 kV /12.47 kV transformers in the existing Blue Lake switchyard. • Site work including demolition of existing facilities, roadways, surfacing, and parking areas. 3.0 ARTICLE 3 – ENGINEER The Project has been designed by Hatch Associates Consultants, 6 Nickerson Street, Ann Building, Suite 101, Seattle, WA 98109 (Engineer), which is to assume all duties and responsibilities of the Engineer, as determined by the Owner and the Resident Project Representative (RPR). The Construction Management Firm is McMillen, LLC, (Construction Manager) 1401 Shoreline Drive, Suite 100, Boise ID, 83702. The Construction Manager will provide the RPR. 4.0 ARTICLE 4 – CONTRACT TIMES 4.01 Time of the Essence A. All time limits for Milestones, if any, Substantial Completion, and completion and readiness for final payment as stated in the Contract Documents are of the essence of the Contract. Blue Lake Expansion Project – Contract No. 9 Agreement General Construction Page 3 of 10 4.02 Dates for Project Milestones A. Milestone dates are based on Notice to Proceed on or before November 1, 2012. For each calendar day that the Notice to Proceed is delayed beyond November 1, 2012, the Milestone dates shall be extended by one calendar day. Project Milestones are as follows: 1. Milestone 1 – Drainage Tunnel Complete – July 1, 2013. Milestone includes excavation of the drainage tunnel, installation of all drain holes and drain hole instrumentation and exploratory work for the plunge pool scour wall. 2. Milestone 2 – Initial Intake Excavation Complete – August 19, 2013. Milestone includes all intake, intake tunnel and gate shaft work tasks described in Contractor’s Work Plan that are scheduled for completion by the end of the 2013 Lake Level Window. As a minimum these tasks shall include: excavation of the intake portal area to El 313; excavation of the intake tunnel to Sta. 66+00; and excavation of the gate chamber and gate shaft. 3. Milestone 3 – Intake Structure Complete – July 4, 2014. Milestone includes completion of intake structure and placement of intake bulkhead gate, sufficient to allow filling of the lake to at least El 350. 4. Milestone 4 – Project Sufficiently Complete to Allow Start of Generation Outage – August 24, 2014. Milestone includes completion of the following: • Intake structure, Bulkhead gate and Intake tunnel, except for connection to the existing tunnel • Gate Shaft and gate house including installation and dry testing of fixed wheel gate and hoist • Dam structure complete to El 428 with consolidation, curtain, and dam joint grouting complete. • Surge Chamber, Adit and plug except for connection to the existing tunnel • Penstock, except for portion that cannot be installed until after the generation outage begins • Powerhouse structure sufficiently complete to allow operation of at least one generating unit. • At least one BLU generating unit 100% dry tested and ready for wet testing. • Powerhouse afterbay, including flooding to tailwater level • Installation of one 69kV/12.47 kV transformer. 5. Milestone 5 – Substantial completion of the first Blue Lake Powerhouse generating unit – 61 days after start of Generation Outage. Milestone includes completion of the first generating unit to the point where this unit begins continuous operation to generate electric power for the Owner’s electric system. 6. Milestone 6 – Substantial completion of the second Blue Lake Powerhouse generating unit – 91 days after start of Generation Outage. Milestone includes completion of the second generating unit to the point where this unit begins continuous operation to generate electric power for the Owner’s electric system. 7. Milestone 7 – Substantial completion of the FVU – 80 Days after start of Generation Outage. Milestone includes completion of the FVU generating unit to the point where this unit can be released to Owner for Owner-installed wiring. Blue Lake Expansion Project – Contract No. 9 Agreement General Construction Page 4 of 10 4.03 Days to Achieve Substantial Completion and Final Payment A. All Work shall be substantially completed and shall be ready for final payment in accordance with Paragraph 14.07 of the General Conditions by February 1, 2015. 4.04 Incentive Payments and Liquidated Damages A. Owner will pay Contractor incentive payments to complete early the work for certain Milestone dates, as follows: 1. Twenty five thousand dollars ($25,000) if the work required for Milestone 5 – Substantial Completion of the first Blue Lake Powerhouse Generating Unit, is completed by midnight on the Milestone 5 date. An additional $25,000 per day for each day earlier than the Milestone date that Contractor completes the work required, up to 14 additional days incentive. The total maximum incentive payment for Milestone 5 shall be $375,000 if Contractor completes the Milestone 5 Work within 14 or more days prior to the Milestone date. 2. Six hundred and twenty five thousand dollars ($625,000) if both: a) the work required for Milestone3 (Intake Structure Complete) is completed before August 1, 2013; and b) work in the intake tunnel and gate shaft areas can be completed without a lake drawdown below elevation 330 in the 2014 spring-summer construction season. 3. Any incentive payments earned under this Article 4.04.A will be deferred until final payment is due. Any liquidated damages assessed for failure to meet any schedule milestone will first be reduced by any incentive payments earned under this Article 4.04.A. B. Contractor and Owner recognize that time is of the essence as stated in Paragraph 4.01 above and that Owner will suffer financial loss if the Work is not completed within the times specified in Paragraphs 4.02 and 4.03 above, plus any extensions thereof allowed in accordance with Article 12 of the General Conditions. The parties also recognize the delays, expense, and difficulties involved in proving in a legal or arbitration proceeding the actual loss suffered by Owner due to the Work not being completed on time. Accordingly, instead of requiring any such proof, Owner and Contractor agree that as liquidated damages for delay (but not as a penalty), Contractor shall pay Owner as follows: • $3,000 for each day that expires after the time specified for completion of Milestone 1 - Completion of Drainage Tunnel Complete. • A lump sum amount of $1,000,000 if Milestone 4 – Project Sufficiently Complete to Allow Start of Generation Outage is more than 15 days after the Milestone date. If the work required for Milestone 4 is not completed within 15 days of the date specified, Owner reserves the right to suspend or delay the project activities for up to one year including new completion dates for Milestones 4 through 7 and new Substantial Completion dates for the Project. In the event the work required for the Milestone 4 date is not completed (or is not able of being completed) within the 15 day period after the Milestone date, due to causes for which Contractor is responsible and for which there is no right to a time extension under the Agreement, Contractor shall not be entitled to any additional compensation for costs or impacts arising from a suspension or delay in the work under this section. Blue Lake Expansion Project – Contract No. 9 Agreement General Construction Page 5 of 10 • $45,000 for each day that expires after the time specified for completion of Milestone 5 – Substantial Completion of the first Blue Lake Powerhouse generating unit, until the work required for this milestone is completed. • $5,000 for each day that expires after the time specified for completion of Milestone 6 – Substantial Completion of the second Blue Lake Powerhouse generating unit, until the Work required for this milestone is completed. • $2,000 for each day that expires after the time specified for completion of Milestone 7 – Substantial Completion of the FVU, until the Work required for this milestones completed. C. After Substantial Completion, if Contractor shall neglect, refuse, or fail to complete the remaining Work within the Contract Time or any proper extension thereof granted by Owner, Contractor shall pay Owner $1,000 for each day that expires after the time specified in Paragraph 4.02 above for completion and readiness for final payment until the Work is completed and ready for final payment. D. The sum of all Liquidated Damages, after reduction for any incentive payments payable under Article 4.04.A, shall not exceed 10% of the Contract Price at the time of Notice to Proceed. 5.0 ARTICLE 5 – CONTRACT PRICE Owner shall pay Contractor for completion of the Work in accordance with the Contract Documents an amount in current funds equal to the sum of the amounts determined pursuant to Paragraphs 5.0.A below: A. For all Work, at the prices stated in Contractor’s Bid, attached hereto as an exhibit. 6.0 ARTICLE 6 – PAYMENT PROCEDURES 6.01 Submittal and Processing of Payments A. Contractor shall submit Applications for Payment in accordance with Article 14 of the General Conditions. Applications for Payment will be processed by RPR as provided in the General Conditions. 6.02 Progress Payments; Retainage A. Owner shall make progress payments on account of the Contract Price on the basis of Contractor’s Applications for Payment on or about the 10th day of each month during performance of the Work as provided in Paragraph 6.02.A.1 below and Article 14.02 of the General Conditions. All such payments will be measured by the schedule of values established as provided in Paragraph 2.07.A of the General Conditions and specification section 01290 (and in the case of Unit Price Work based on the number of units completed) or, in the event there is no schedule of values, as provided in the General Requirements. 1. Prior to Substantial Completion, progress payments will be made in an amount equal to the percentage indicated below but, in each case, less the aggregate of payments previously made and less such amounts as RPR may determine or Owner may withhold, including but not limited to liquidated damages, in accordance with Paragraph 14.02 of the General Conditions. Blue Lake Expansion Project – Contract No. 9 Agreement General Construction Page 6 of 10 a. 95 percent of Work completed (with the balance being retainage); and b. 95 percent of cost of materials and equipment not yet incorporated in the Work and stored onsite (with the balance being retainage). C. Upon Substantial Completion of all Work, Owner shall pay an amount sufficient to increase total payments to Contractor to 100 percent of the Work completed, less such amounts as RPR shall determine in accordance with Paragraph 14.02.B.5 of the General Conditions and less 200 percent of RPR’s estimate of the value of Work to be completed or corrected as shown on the tentative list of items to be completed or corrected attached to the certificate of Substantial Completion. 6.03 Final Payment A. Upon final completion and acceptance of all Work in accordance with Paragraph 14.07 of the General Conditions, Owner shall pay the remainder of the Contract Price as recommended by RPR as provided in said Paragraph 14.07. 7.0 ARTICLE 7 – INTEREST All moneys not paid when due as provided in Article 14 of the General Conditions shall bear interest at the rate of three and three quarters (3.75) percent per annum. 8.0 ARTICLE 8 – CONTRACTOR’S REPRESENTATIONS In order to induce Owner to enter into this Agreement, Contractor makes the following representations: A. Contractor has examined and carefully studied the Contract Documents and the other related data identified in the Bidding Documents. B. Contractor has visited the Site and become familiar with and is satisfied as to the general, local, and Site conditions that may affect cost, progress, and performance of the Work. C. Contractor is familiar with and is satisfied as to all federal, state, and local Laws and Regulations that may affect cost, progress, and performance of the Work. D. Contractor has carefully studied all: (1) reports of explorations and tests of subsurface conditions at or contiguous to the Site and all drawings of physical conditions relating to existing surface or subsurface structures at the Site, if any, that have been identified in Paragraph SC-4.02 of the Supplementary Conditions as containing reliable "technical data," and (2) reports and drawings of Hazardous Environmental Conditions, if any, at the Site that have been identified in Paragraph SC-4.06 of the Supplementary Conditions as containing reliable "technical data." E. Contractor has considered the information known to Contractor; information commonly known to contractors doing business in the locality of the Site; information and observations obtained from visits to the Site; the Contract Documents; and the Site-related reports and drawings identified in the Contract Documents, with respect to the effect of such information, observations, and documents on (1) the cost, progress, and performance of the Work; (2) the means, methods, techniques, sequences, and procedures of construction to be employed by Contractor, including any specific means, methods, techniques, sequences, and procedures of construction expressly required by the Contract Documents; and (3) Contractor’s safety precautions and programs. Blue Lake Expansion Project – Contract No. 9 Agreement General Construction Page 7 of 10 F. Based on the information and observations referred to in Paragraph 8.01.E above, Contractor does not consider that further examinations, investigations, explorations, tests, studies, or data are necessary for the performance of the Work at the Contract Price, within the Contract Times, and in accordance with the other terms and conditions of the Contract Documents. G. Contractor is aware of the general nature of work to be performed by Owner and others at the Site that relates to the Work as indicated in the Contract Documents. H. Contractor has given RPR written notice of all conflicts, errors, ambiguities, or discrepancies that Contractor has discovered in the Contract Documents, and the written resolution thereof by RPR is acceptable to Contractor. I. The Contract Documents are generally sufficient to indicate and convey understanding of all terms and conditions for performance and furnishing of the Work. 9.0 ARTICLE 9 – CONTRACT DOCUMENTS A. The Contract Documents consist of the following: 1. This Agreement (pages 1 to 10, inclusive). 2. Performance bond (pages 1 to 3, inclusive). 3. Payment bond (pages 1 to 3, inclusive). 4. General Conditions (pages 1 to 40, inclusive). 5. Supplementary Conditions (pages 1 to 24, inclusive). 6. Specifications as listed in the table of contents of these Contract Documents 7. Drawings consisting of [398] sheets with each sheet bearing the following general title: Blue Lake Expansion Project. 8. Addenda (numbers X to X, inclusive). 9. Exhibits to this Agreement (enumerated as follows): a. Contractor’s Bid Form (pages X to X, inclusive). b. Documents submitted by Contract with its Bid c. Documentation submitted by Contractor prior to Notice of Award (pages X to X, inclusive). 10. The following which may be delivered or issued on or after the Effective Date of the Agreement and are not attached hereto: a. Reference Documents that were included as part of the Bidding Documents b. Notice to Proceed (pages X to X, inclusive). c. Work Change Directives. Blue Lake Expansion Project – Contract No. 9 Agreement General Construction Page 8 of 10 d. Change Orders. B. The documents listed in Paragraph 9.01.A are attached to this Agreement (except as expressly noted otherwise above). C. There are no Contract Documents other than those listed above in this Article 9. D. The Contract Documents may only be amended, modified, or supplemented as provided in Paragraph 3.04 of the General Conditions. 10.0 ARTICLE 10 – MISCELLANEOUS 10.01 Terms A. Terms used in this Agreement will have the meanings stated in the General Conditions and the Supplementary Conditions. 10.02 Assignment of Contract A. No assignment by a party hereto of any rights under or interests in the Contract will be binding on another party hereto without the written consent of the party sought to be bound; and, specifically but without limitation, moneys that may become due and moneys that are due may not be assigned without such consent (except to the extent that the effect of this restriction may be limited by law), and unless specifically stated to the contrary in any written consent to an assignment, no assignment will release or discharge the assignor from any duty or responsibility under the Contract Documents. 10.03 Successors and Assigns A. Owner and Contractor each binds itself, its partners, successors, assigns, and legal representatives to the other party hereto, its partners, successors, assigns, and legal representatives in respect to all covenants, agreements, and obligations contained in the Contract Documents. 10.04 Severability A. Any provision or part of the Contract Documents held to be void or unenforceable under any Law or Regulation shall be deemed stricken, and all remaining provisions shall continue to be valid and binding upon Owner and Contractor, who agree that the Contract Documents shall be reformed to replace such stricken provision or part thereof with a valid and enforceable provision that comes as close as possible to expressing the intention of the stricken provision. 10.05 Contractor’s Certifications A. Contractor certifies that it has not engaged in corrupt, fraudulent, collusive, or coercive practices in competing for or in executing the Contract. For the purposes of this Paragraph 10.05: 1. “corrupt practice” means the offering, giving, receiving, or soliciting of anything of value likely to influence the action of a public official in the bidding process or in the Contract execution; Blue Lake Expansion Project – Contract No. 9 Agreement General Construction Page 9 of 10 2. “fraudulent practice” means an intentional misrepresentation of facts made (a) to influence the bidding process or the execution of the Contract to the detriment of Owner, (b) to establish Bid or Contract prices at artificial non-competitive levels, or (c) to deprive Owner of the benefits of free and open competition; 3. “collusive practice” means a scheme or arrangement between two or more Bidders, with or without the knowledge of Owner, a purpose of which is to establish Bid prices at artificial, non-competitive levels; and 4. “coercive practice” means harming or threatening to harm, directly or indirectly, persons or their property to influence their participation in the bidding process or affect the execution of the Contract. Blue Lake Expansion Project – Contract No. 9 Agreement General Construction Page 10 of 10 IN WITNESS WHEREOF, Owner and Contractor have signed this Agreement. Counterparts have been delivered to Owner and Contractor. All portions of the Contract Documents have been signed or have been identified by Owner and Contractor or on their behalf. This Agreement will be effective on _________________ (which is the Effective Date of the Agreement). OWNER CONTRACTOR City and Borough of Sitka, Alaska ____________________________________ By: _________________________ By: ________________________________ Title: City Administrator______ Title: _______________________________ (If Contractor is a corporation, a partnership, or a joint venture, attach evidence of authority to sign.) Attest: _______________________ Attest: ______________________________ Title: _______________________ Title: ______________________________ Address for giving notices: Address for giving notices: City and Borough of Sitka, Alaska ____________________________________ 100 Lincoln Street ____________________________________ Sitka, Alaska 99835 ____________________________________ License No.: _________________________ (Where applicable) (If Owner is a public body, attach evidence of authority to sign and resolution or other documents authorizing execution of this Agreement.) Agent for service of process: ___________________________________ PERFORMANCE AND PAYMENT BONDS EJCDC C-610 Performance Bond Prepared by the Engineers Joint Contract Documents Committee. Page 1 of 3 BLUE LAKE EXPANSION PROJECT CONTRACT NO. 9 – GENERAL CONSTRUCTION PERFORMANCE BOND Any singular reference to Contractor, Surety, Owner, or other party shall be considered plural where applicable. CONTRACTOR (Name and Address): SURETY (Name, and Address of Principal Place of Business): OWNER (Name and Address): City and Borough of Sitka 100 Lincoln St. Sitka, AK 99835 CONTRACT Effective Date of Agreement: Amount: Description (Name and Location): BOND Bond Number: Date (Not earlier than Effective Date of Agreement): Amount: Modifications to this Bond Form: Surety and Contractor, intending to be legally bound hereby, subject to the terms set forth below, do each cause this Performance Bond to be duly executed by an authorized officer, agent, or representative. CONTRACTOR AS PRINCIPAL SURETY (Seal) (Seal) Contractor's Name and Corporate Seal Surety’s Name and Corporate Seal By: By: Signature Signature (Attach Power of Attorney) Print Name Print Name Title Title Attest: Attest: Signature Signature Title Title Note: Provide execution by additional parties, such as joint venturers, if necessary. EJCDC C-610 Performance Bond Prepared by the Engineers Joint Contract Documents Committee. Page 2 of 3 Contractor and Surety, jointly and severally, bind themselves, their heirs, executors, administrators, successors, and assigns to Owner for the performance of the Contract, which is incorporated herein by reference. 1. If Contractor performs the Contract, Surety and Contractor have no obligation under this Bond, except to participate in conferences as provided in Paragraph 2.1. 2. If there is no Owner Default, Surety’s obligation under this Bond shall arise after: 2.1 Owner has notified Contractor and Surety, at the addresses described in Paragraph 9 below, that Owner is considering declaring a Contractor Default and has requested and attempted to arrange a conference with Contractor and Surety to be held not later than 15 days after receipt of such notice to discuss methods of performing the Contract. If Owner, Contractor, and Surety agree, Contractor shall be allowed a reasonable time to perform the Contract, but such an agreement shall not waive Owner’s right, if any, subsequently to declare a Contractor Default; and 2.2 Owner has declared a Contractor Default and formally terminated Contractor’s right to complete the Contract. Such Contractor Default shall not be declared earlier than 20 days after Contractor and Surety have received notice as provided in Paragraph 2.1; and 2.3 Owner has agreed to pay the Balance of the Contract Price to: 1. Surety in accordance with the terms of the Contract; or 2. Another contractor selected pursuant to Paragraph 3.3 to perform the Contract. 3. When Owner has satisfied the conditions of Paragraph 2, Surety shall promptly, and at Surety’s expense, take one of the following actions: 3.1 Arrange for Contractor, with consent of Owner, to perform and complete the Contract; or 3.2 Undertake to perform and complete the Contract itself, through its agents or through independent contractors; or 3.3 Obtain bids or negotiated proposals from qualified contractors acceptable to Owner for a contract for performance and completion of the Contract, arrange for a contract to be prepared for execution by Owner and contractor selected with Owner’s concurrence, to be secured with performance and payment bonds executed by a qualified surety equivalent to the bonds issued on the Contract, and pay to Owner the amount of damages as described in Paragraph 5 in excess of the Balance of the Contract Price incurred by Owner resulting from Contractor Default; or 3.4 Waive its right to perform and complete, arrange for completion, or obtain a new contractor, and with reasonable promptness under the circumstances: 1. After investigation, determine the amount for which it may be liable to Owner and, as soon as practicable after the amount is determined, tender payment therefor to Owner; or 2. Deny liability in whole or in part and notify Owner citing reasons therefor. 4. If Surety does not proceed as provided in Paragraph 3 with reasonable promptness, Surety shall be deemed to be in default on this Bond 15 days after receipt of an additional written notice from Owner to Surety demanding that Surety perform its obligations under this Bond, and Owner shall be entitled to enforce any remedy available to Owner. If Surety proceeds as provided in Paragraph 3.4, and Owner refuses the payment tendered or Surety has denied liability, in whole or in part, without further notice Owner shall be entitled to enforce any remedy available to Owner. 5. After Owner has terminated Contractor’s right to complete the Contract, and if Surety elects to act under Paragraph 3.1, 3.2, or 3.3 above, then the responsibilities of Surety to Owner shall not be greater than those of Contractor under the Contract, and the responsibilities of Owner to Surety shall not be greater than those of Owner under the Contract. To the limit of the amount of this Bond, but subject to commitment by Owner of the Balance of the Contract Price to mitigation of costs and damages on the Contract, Surety is obligated without duplication for: EJCDC C-610 Performance Bond Prepared by the Engineers Joint Contract Documents Committee. Page 3 of 3 5.1 The responsibilities of Contractor for correction of defective Work and completion of the Contract; 5.2 Additional legal, design professional, and delay costs resulting from Contractor’s Default, and resulting from the actions of or failure to act of Surety under Paragraph 3; and 5.3 Liquidated damages, or if no liquidated damages are specified in the Contract, actual damages caused by delayed performance or non-performance of Contractor. 6. Surety shall not be liable to Owner or others for obligations of Contractor that are unrelated to the Contract, and the Balance of the Contract Price shall not be reduced or set off on account of any such unrelated obligations. No right of action shall accrue on this Bond to any person or entity other than Owner or its heirs, executors, administrators, or successors. 7. Surety hereby waives notice of any change, including changes of time, to Contract or to related subcontracts, purchase orders, and other obligations. 8. Any proceeding, legal or equitable, under this Bond may be instituted in any court of competent jurisdiction in the location in which the Work or part of the Work is located, and shall be instituted within two years after Contractor Default or within two years after Contractor ceased working or within two years after Surety refuses or fails to perform its obligations under this Bond, whichever occurs first. If the provisions of this paragraph are void or prohibited by law, the minimum period of limitation available to sureties as a defense in the jurisdiction of the suit shall be applicable. 9. Notice to Surety, Owner, or Contractor shall be mailed or delivered to the address shown on the signature page. 10. When this Bond has been furnished to comply with a statutory requirement in the location where the Contract was to be performed, any provision in this Bond conflicting with said statutory requirement shall be deemed deleted herefrom and provisions conforming to such statutory requirement shall be deemed incorporated herein. The intent is that this Bond shall be construed as a statutory bond and not as a common law bond. 11. Definitions. 11.1 Balance of the Contract Price: The total amount payable by Owner to Contractor under the Contract after all proper adjustments have been made, including allowance to Contractor of any amounts received or to be received by Owner in settlement of insurance or other Claims for damages to which Contractor is entitled, reduced by all valid and proper payments made to or on behalf of Contractor under the Contract. 11.2 Contract: The agreement between Owner and Contractor identified on the signature page, including all Contract Documents and changes thereto. 11.3 Contractor Default: Failure of Contractor, which has neither been remedied nor waived, to perform or otherwise to comply with the terms of the Contract. 11.4 Owner Default: Failure of Owner, which has neither been remedied nor waived, to pay Contractor as required by the Contract or to perform and complete or otherwise comply with the other terms thereof. FOR INFORMATION ONLY – (Name, Address and Telephone) Surety Agency or Broker: Owner’s Representative (Engineer or other party): James Dinley, City Administrator EJCDC C-615 Payment Bond Prepared by the Engineers Joint Contract Documents Committee. Page 1 of 3 BLUE LAKE EXPANSION PROJECT CONTRACT NO. 9 – GENERAL CONSTRUCTION PAYMENT BOND Any singular reference to Contractor, Surety, Owner, or other party shall be considered plural where applicable. CONTRACTOR (Name and Address): SURETY (Name, and Address of Principal Place of Business): OWNER (Name and Address): City and Borough of Sitka 100 Lincoln St. Sitka, AK 99835 CONTRACT Effective Date of Agreement: Amount: Description (Name and Location): Contract No. 9 General Construction BOND Bond Number: Date (Not earlier than Effective Date of Agreement): Amount: Modifications to this Bond Form: Surety and Contractor, intending to be legally bound hereby, subject to the terms set forth below, do each cause this Payment Bond to be duly executed by an authorized officer, agent, or representative. CONTRACTOR AS PRINCIPAL SURETY (Seal) (Seal) Contractor's Name and Corporate Seal Surety’s Name and Corporate Seal By: By: Signature Signature (Attach Power of Attorney) Print Name Print Name Title Title Attest: Attest: Signature Signature Title Title Note: Provide execution by additional parties, such as joint venturers, if necessary. EJCDC C-615 Payment Bond Prepared by the Engineers Joint Contract Documents Committee. Page 2 of 3 1. Contractor and Surety, jointly and severally, bind themselves, their heirs, executors, administrators, successors, and assigns to Owner to pay for labor, materials, and equipment furnished by Claimants for use in the performance of the Contract, which is incorporated herein by reference. 2. With respect to Owner, this obligation shall be null and void if Contractor: 2.1 Promptly makes payment, directly or indirectly, for all sums due Claimants, and 2.2 Defends, indemnifies, and holds harmless Owner from all claims, demands, liens, or suits alleging non-payment by Contractor by any person or entity who furnished labor, materials, or equipment for use in the performance of the Contract, provided Owner has promptly notified Contractor and Surety (at the addresses described in Paragraph 12) of any claims, demands, liens, or suits and tendered defense of such claims, demands, liens, or suits to Contractor and Surety, and provided there is no Owner Default. 3. With respect to Claimants, this obligation shall be null and void if Contractor promptly makes payment, directly or indirectly, for all sums due. 4. Surety shall have no obligation to Claimants under this Bond until: 4.1 Claimants who are employed by or have a direct contract with Contractor have given notice to Surety (at the address described in Paragraph 12) and sent a copy, or notice thereof, to Owner, stating that a claim is being made under this Bond and, with substantial accuracy, the amount of the claim. 4.2 Claimants who do not have a direct contract with Contractor: 1. Have furnished written notice to Contractor and sent a copy, or notice thereof, to Owner, within 90 days after having last performed labor or last furnished materials or equipment included in the claim stating, with substantial accuracy, the amount of the claim and the name of the party to whom the materials or equipment were furnished or supplied, or for whom the labor was done or performed; and 2. Have either received a rejection in whole or in part from Contractor, or not received within 30 days of furnishing the above notice any communication from Contractor by which Contractor had indicated the claim will be paid directly or indirectly; and 3. Not having been paid within the above 30 days, have sent a written notice to Surety (at the address described in Paragraph 12) and sent a copy, or notice thereof, to Owner, stating that a claim is being made under this Bond and enclosing a copy of the previous written notice furnished to Contractor. 5. If a notice by a Claimant required by Paragraph 4 is provided by Owner to Contractor or to Surety, that is sufficient compliance. 6. When a Claimant has satisfied the conditions of Paragraph 4, the Surety shall promptly and at Surety’s expense take the following actions: 6.1 Send an answer to that Claimant, with a copy to Owner, within 45 days after receipt of the claim, stating the amounts that are undisputed and the basis for challenging any amounts that are disputed. 6.2 Pay or arrange for payment of any undisputed amounts. 7. Surety’s total obligation shall not exceed the amount of this Bond, and the amount of this Bond shall be credited for any payments made in good faith by Surety. 8. Amounts owed by Owner to Contractor under the Contract shall be used for the performance of the Contract and to satisfy claims, if any, under any performance bond. By Contractor furnishing and Owner accepting this Bond, they agree that all funds earned by Contractor in the performance of the Contract are dedicated to satisfy obligations of Contractor and Surety under this Bond, subject to Owner’s priority to use the funds for the completion of the Work. EJCDC C-615 Payment Bond Prepared by the Engineers Joint Contract Documents Committee. Page 3 of 3 9. Surety shall not be liable to Owner, Claimants, or others for obligations of Contractor that are unrelated to the Contract. Owner shall not be liable for payment of any costs or expenses of any Claimant under this Bond, and shall have under this Bond no obligations to make payments to, give notices on behalf of, or otherwise have obligations to Claimants under this Bond. 10. Surety hereby waives notice of any change, including changes of time, to the Contract or to related subcontracts, purchase orders, and other obligations. 11. No suit or action shall be commenced by a Claimant under this Bond other than in a court of competent jurisdiction in the location in which the Work or part of the Work is located or after the expiration of one year from the date (1) on which the Claimant gave the notice required by Paragraph 4.1 or Paragraph 4.2.3, or (2) on which the last labor or service was performed by anyone or the last materials or equipment were furnished by anyone under the Contract, whichever of (1) or (2) first occurs. If the provisions of this paragraph are void or prohibited by law, the minimum period of limitation available to sureties as a defense in the jurisdiction of the suit shall be applicable. 12. Notice to Surety, Owner, or Contractor shall be mailed or delivered to the addresses shown on the signature page. Actual receipt of notice by Surety, Owner, or Contractor, however accomplished, shall be sufficient compliance as of the date received at the address shown on the signature page. 13. When this Bond has been furnished to comply with a statutory requirement in the location where the Contract was to be performed, any provision in this Bond conflicting with said statutory requirement shall be deemed deleted herefrom and provisions conforming to such statutory requirement shall be deemed incorporated herein. The intent is that this Bond shall be construed as a statutory Bond and not as a common law bond. 14. Upon request of any person or entity appearing to be a potential beneficiary of this Bond, Contractor shall promptly furnish a copy of this Bond or shall permit a copy to be made. 15. Definitions 15.1 Claimant: An individual or entity having a direct contract with Contractor, or with a first-tier subcontractor of Contractor, to furnish labor, materials, or equipment for use in the performance of the Contract. The intent of this Bond shall be to include without limitation in the terms “labor, materials or equipment” that part of water, gas, power, light, heat, oil, gasoline, telephone service, or rental equipment used in the Contract, architectural and engineering services required for performance of the Work of Contractor and Contractor’s subcontractors, and all other items for which a mechanic’s lien may be asserted in the jurisdiction where the labor, materials, or equipment were furnished. 15.2 Contract: The agreement between Owner and Contractor identified on the signature page, including all Contract Documents and changes thereto. 15.3 Owner Default: Failure of Owner, which has neither been remedied nor waived, to pay Contractor as required by the Contract, or to perform and complete or otherwise comply with the other terms thereof. FOR INFORMATION ONLY – (Name, Address, and Telephone) Surety Agency or Broker: Owner’s Representative (Engineer or other):James Dinley, City Administrator GENERAL CONDITIONS EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. STANDARD GENERAL CONDITIONS OF THE CONSTRUCTION CONTRACT Prepared by ENGINEERS JOINT CONTRACT DOCUMENTS COMMITTEE and Issued and Published Jointly by AMERICAN COUNCIL OF ENGINEERING COMPANIES ______________________ ASSOCIATED GENERAL CONTRACTORS OF AMERICA ______________________ AMERICAN SOCIETY OF CIVIL ENGINEERS _______________________ PROFESSIONAL ENGINEERS IN PRIVATE PRACTICE A Practice Division of the NATIONAL SOCIETY OF PROFESSIONAL ENGINEERS Endorsed by CONSTRUCTION SPECIFICATIONS INSTITUTE EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Copyright © 2007 National Society of Professional Engineers 1420 King Street, Alexandria, VA 22314-2794 (703) 684-2882 www.nspe.org American Council of Engineering Companies 1015 15th Street N.W., Washington, DC 20005 (202) 347-7474 www.acec.org American Society of Civil Engineers 1801 Alexander Bell Drive, Reston, VA 20191-4400 (800) 548-2723 www.asce.org Associated General Contractors of America 2300 Wilson Boulevard, Suite 400, Arlington, VA 22201-3308 (703) 548-3118 www.agc.org The copyright for this EJCDC document is owned jointly by the four EJCDC sponsoring organizations and held in trust for their benefit by NSPE. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page i STANDARD GENERAL CONDITIONS OF THE CONSTRUCTION CONTRACT TABLE OF CONTENTS Page Article 1 – Definitions and Terminology ............................................................................................................................ 1 1.01 Defined Terms ............................................................................................................................................. 1 1.02 Terminology ................................................................................................................................................. 3 Article 2 – Preliminary Matters ........................................................................................................................................... 4 2.01 Delivery of Bonds and Evidence of Insurance .............................................................................................. 4 2.02 Copies of Documents .................................................................................................................................. 4 2.03 Commencement of Contract Times; Notice to Proceed ............................................................................... 4 2.04 Starting the Work ......................................................................................................................................... 4 2.05 Before Starting Construction ........................................................................................................................ 5 2.06 Preconstruction Conference; Designation of Authorized Representatives .................................................... 5 2.07 Initial Acceptance of Schedules ................................................................................................................... 5 Article 3 – Contract Documents: Intent, Amending, Reuse ............................................................................................... 5 3.01 Intent ............................................................................................................................................................ 5 3.02 Reference Standards ..................................................................................................................................... 5 3.03 Reporting and Resolving Discrepancies ....................................................................................................... 6 3.04 Amending and Supplementing Contract Documents ................................................................................... 6 3.05 Reuse of Documents .................................................................................................................................... 6 3.06 Electronic Data ............................................................................................................................................. 7 Article 4 – Availability of Lands; Subsurface and Physical Conditions; Hazardous Environmental Conditions; Reference Points ................................................................................................................................................................. 7 4.01 Availability of Lands ..................................................................................................................................... 7 4.02 Subsurface and Physical Conditions............................................................................................................. 7 4.03 Differing Subsurface or Physical Conditions ................................................................................................ 8 4.04 Underground Facilities ................................................................................................................................. 8 4.05 Reference Points .......................................................................................................................................... 9 4.06 Hazardous Environmental Condition at Site ................................................................................................ 9 Article 5 – Bonds and Insurance ....................................................................................................................................... 11 5.01 Performance, Payment, and Other Bonds .................................................................................................. 11 5.02 Licensed Sureties and Insurers ................................................................................................................... 11 5.03 Certificates of Insurance ............................................................................................................................. 11 5.04 Contractor’s Insurance ............................................................................................................................... 11 5.05 Owner’s Liability Insurance ....................................................................................................................... 12 5.06 Property Insurance ..................................................................................................................................... 12 5.07 Waiver of Rights ......................................................................................................................................... 13 5.08 Receipt and Application of Insurance Proceeds ......................................................................................... 14 5.09 Acceptance of Bonds and Insurance; Option to Replace ........................................................................... 14 5.10 Partial Utilization, Acknowledgment of Property Insurer ........................................................................... 14 Article 6 – Contractor’s Responsibilities ........................................................................................................................... 14 6.01 Supervision and Superintendence .............................................................................................................. 14 6.02 Labor; Working Hours ............................................................................................................................... 15 6.03 Services, Materials, and Equipment ........................................................................................................... 15 6.04 Progress Schedule ...................................................................................................................................... 15 EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page ii 6.05 Substitutes and “Or-Equals” ....................................................................................................................... 15 6.06 Concerning Subcontractors, Suppliers, and Others .................................................................................... 17 6.07 Patent Fees and Royalties ........................................................................................................................... 18 6.08 Permits ....................................................................................................................................................... 18 6.09 Laws and Regulations ................................................................................................................................ 18 6.10 Taxes .......................................................................................................................................................... 19 6.11 Use of Site and Other Areas ....................................................................................................................... 19 6.12 Record Documents .................................................................................................................................... 19 6.13 Safety and Protection ................................................................................................................................. 19 6.14 Safety Representative ................................................................................................................................. 20 6.15 Hazard Communication Programs ............................................................................................................. 20 6.16 Emergencies ............................................................................................................................................... 20 6.17 Shop Drawings and Samples ...................................................................................................................... 20 6.18 Continuing the Work ................................................................................................................................. 22 6.19 Contractor’s General Warranty and Guarantee .......................................................................................... 22 6.20 Indemnification .......................................................................................................................................... 22 6.21 Delegation of Professional Design Services ............................................................................................... 23 Article 7 – Other Work at the Site .................................................................................................................................... 23 7.01 Related Work at Site .................................................................................................................................. 23 7.02 Coordination .............................................................................................................................................. 24 7.03 Legal Relationships .................................................................................................................................... 24 Article 8 – Owner’s Responsibilities ................................................................................................................................. 24 8.01 Communications to Contractor .................................................................................................................. 24 8.02 Replacement of Engineer ........................................................................................................................... 24 8.03 Furnish Data ............................................................................................................................................... 24 8.04 Pay When Due........................................................................................................................................... 24 8.05 Lands and Easements; Reports and Tests .................................................................................................... 24 8.06 Insurance ................................................................................................................................................... 24 8.07 Change Orders ........................................................................................................................................... 24 8.08 Inspections, Tests, and Approvals .............................................................................................................. 24 8.09 Limitations on Owner’s Responsibilities .................................................................................................... 24 8.10 Undisclosed Hazardous Environmental Condition .................................................................................... 25 8.11 Evidence of Financial Arrangements .......................................................................................................... 25 8.12 Compliance with Safety Program ............................................................................................................... 25 Article 9 – Engineer’s Status During Construction ............................................................................................................ 25 9.01 Owner’s Representative ............................................................................................................................. 25 9.02 Visits to Site ................................................................................................................................................ 25 9.03 Project Representative ................................................................................................................................ 25 9.04 Authorized Variations in Work .................................................................................................................. 25 9.05 Rejecting Defective Work .......................................................................................................................... 25 9.06 Shop Drawings, Change Orders and Payments.......................................................................................... 26 9.07 Determinations for Unit Price Work .......................................................................................................... 26 9.08 Decisions on Requirements of Contract Documents and Acceptability of Work ....................................... 26 9.09 Limitations on Engineer’s Authority and Responsibilities ........................................................................... 26 9.10 Compliance with Safety Program ............................................................................................................... 27 Article 10 – Changes in the Work; Claims ........................................................................................................................ 27 10.01 Authorized Changes in the Work ............................................................................................................... 27 10.02 Unauthorized Changes in the Work .......................................................................................................... 27 10.03 Execution of Change Orders ...................................................................................................................... 27 10.04 Notification to Surety ................................................................................................................................. 27 10.05 Claims ........................................................................................................................................................ 27 EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page iii Article 11 – Cost of the Work; Allowances; Unit Price Work ........................................................................................... 28 11.01 Cost of the Work ........................................................................................................................................ 28 11.02 Allowances ................................................................................................................................................ 30 11.03 Unit Price Work ......................................................................................................................................... 30 Article 12 – Change of Contract Price; Change of Contract Times ................................................................................... 30 12.01 Change of Contract Price ........................................................................................................................... 30 12.02 Change of Contract Times .......................................................................................................................... 31 12.03 Delays ........................................................................................................................................................ 31 Article 13 – Tests and Inspections; Correction, Removal or Acceptance of Defective Work ............................................ 32 13.01 Notice of Defects ....................................................................................................................................... 32 13.02 Access to Work .......................................................................................................................................... 32 13.03 Tests and Inspections ................................................................................................................................. 32 13.04 Uncovering Work ...................................................................................................................................... 33 13.05 Owner May Stop the Work ........................................................................................................................ 33 13.06 Correction or Removal of Defective Work ................................................................................................. 33 13.07 Correction Period ....................................................................................................................................... 33 13.08 Acceptance of Defective Work .................................................................................................................. 34 13.09 Owner May Correct Defective Work ......................................................................................................... 34 Article 14 – Payments to Contractor and Completion ...................................................................................................... 35 14.01 Schedule of Values..................................................................................................................................... 35 14.02 Progress Payments ..................................................................................................................................... 35 14.03 Contractor’s Warranty of Title .................................................................................................................... 36 14.04 Substantial Completion .............................................................................................................................. 36 14.05 Partial Utilization ....................................................................................................................................... 37 14.06 Final Inspection .......................................................................................................................................... 37 14.07 Final Payment ............................................................................................................................................ 38 14.08 Final Completion Delayed ......................................................................................................................... 38 14.09 Waiver of Claims ....................................................................................................................................... 38 Article 15 – Suspension of Work and Termination ........................................................................................................... 39 15.01 Owner May Suspend Work ....................................................................................................................... 39 15.02 Owner May Terminate for Cause ............................................................................................................... 39 15.03 Owner May Terminate For Convenience ................................................................................................... 40 15.04 Contractor May Stop Work or Terminate ................................................................................................... 40 Article 16 – Dispute Resolution ........................................................................................................................................ 40 16.01 Methods and Procedures ........................................................................................................................... 40 Article 17 – Miscellaneous ............................................................................................................................................... 41 17.01 Giving Notice ............................................................................................................................................ 41 17.02 Computation of Times ............................................................................................................................... 41 17.03 Cumulative Remedies ................................................................................................................................ 41 17.04 Survival of Obligations ............................................................................................................................... 41 17.05 Controlling Law ......................................................................................................................................... 41 17.06 Headings .................................................................................................................................................... 41 EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 1 of 41 ARTICLE 1 – DEFINITIONS AND TERMINOLOGY 1.01 Defined Terms A. Wherever used in the Bidding Requirements or Contract Documents and printed with initial capital letters, the terms listed below will have the meanings indicated which are applicable to both the singular and plural thereof. In addition to terms specifically defined, terms with initial capital letters in the Contract Documents include references to identified articles and paragraphs, and the titles of other documents or forms. 1. Addenda—Written or graphic instruments issued prior to the opening of Bids which clarify, correct, or change the Bidding Requirements or the proposed Contract Documents. 2. Agreement—The written instrument which is evidence of the agreement between Owner and Contractor covering the Work. 3. Application for Payment—The form acceptable to Engineer which is to be used by Contractor during the course of the Work in requesting progress or final payments and which is to be accompanied by such supporting documentation as is required by the Contract Documents. 4. Asbestos—Any material that contains more than one percent asbestos and is friable or is releasing asbestos fibers into the air above current action levels established by the United States Occupational Safety and Health Administration. 5. Bid—The offer or proposal of a Bidder submitted on the prescribed form setting forth the prices for the Work to be performed. 6. Bidder—The individual or entity who submits a Bid directly to Owner. 7. Bidding Documents—The Bidding Requirements and the proposed Contract Documents (including all Addenda). 8. Bidding Requirements—The advertisement or invitation to bid, Instructions to Bidders, Bid security of acceptable form, if any, and the Bid Form with any supplements. 9. Change Order—A document recommended by Engineer which is signed by Contractor and Owner and authorizes an addition, deletion, or revision in the Work or an adjustment in the Contract Price or the Contract Times, issued on or after the Effective Date of the Agreement. 10. Claim—A demand or assertion by Owner or Contractor seeking an adjustment of Contract Price or Contract Times, or both, or other relief with respect to the terms of the Contract. A demand for money or services by a third party is not a Claim. 11. Contract—The entire and integrated written agreement between the Owner and Contractor concerning the Work. The Contract supersedes prior negotiations, representations, or agreements, whether written or oral. 12. Contract Documents—Those items so designated in the Agreement. Only printed or hard copies of the items listed in the Agreement are Contract Documents. Approved Shop Drawings, other Contractor submittals, and the reports and drawings of subsurface and physical conditions are not Contract Documents. 13. Contract Price—The moneys payable by Owner to Contractor for completion of the Work in accordance with the Contract Documents as stated in the Agreement (subject to the provisions of Paragraph 11.03 in the case of Unit Price Work). 14. Contract Times—The number of days or the dates stated in the Agreement to: (i) achieve Milestones, if any; (ii) achieve Substantial Completion; and (iii) complete the Work so that it is ready for final payment as evidenced by Engineer’s written recommendation of final payment. 15. Contractor—The individual or entity with whom Owner has entered into the Agreement. 16. Cost of the Work—See Paragraph 11.01 for definition. 17. Drawings—That part of the Contract Documents prepared or approved by Engineer which graphically shows the scope, extent, and character of the Work to be performed by Contractor. Shop Drawings and other Contractor submittals are not Drawings as so defined. 18. Effective Date of the Agreement—The date indicated in the Agreement on which it becomes effective, but if no such date is indicated, it means the date on which the Agreement is signed and delivered by the last of the two parties to sign and deliver. 19. Engineer—The individual or entity named as such in the Agreement. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 2 of 41 20. Field Order—A written order issued by Engineer which requires minor changes in the Work but which does not involve a change in the Contract Price or the Contract Times. 21. General Requirements—Sections of Division 1 of the Specifications. 22. Hazardous Environmental Condition—The presence at the Site of Asbestos, PCBs, Petroleum, Hazardous Waste, or Radioactive Material in such quantities or circumstances that may present a substantial danger to persons or property exposed thereto. 23. Hazardous Waste—The term Hazardous Waste shall have the meaning provided in Section 1004 of the Solid Waste Disposal Act (42 USC Section 6903) as amended from time to time. 24. Laws and Regulations; Laws or Regulations— Any and all applicable laws, rules, regulations, ordinances, codes, and orders of any and all governmental bodies, agencies, authorities, and courts having jurisdiction. 25. Liens—Charges, security interests, or encumbrances upon Project funds, real property, or personal property. 26. Milestone—A principal event specified in the Contract Documents relating to an intermediate completion date or time prior to Substantial Completion of all the Work. 27. Notice of Award—The written notice by Owner to the Successful Bidder stating that upon timely compliance by the Successful Bidder with the conditions precedent listed therein, Owner will sign and deliver the Agreement. 28. Notice to Proceed—A written notice given by Owner to Contractor fixing the date on which the Contract Times will commence to run and on which Contractor shall start to perform the Work under the Contract Documents. 29. Owner—The individual or entity with whom Contractor has entered into the Agreement and for whom the Work is to be performed. 30. PCBs—Polychlorinated biphenyls. 31. Petroleum—Petroleum, including crude oil or any fraction thereof which is liquid at standard conditions of temperature and pressure (60 degrees Fahrenheit and 14.7 pounds per square inch absolute), such as oil, petroleum, fuel oil, oil sludge, oil refuse, gasoline, kerosene, and oil mixed with other non-Hazardous Waste and crude oils. 32. Progress Schedule—A schedule, prepared and maintained by Contractor, describing the sequence and duration of the activities comprising the Contractor’s plan to accomplish the Work within the Contract Times. 33. Project—The total construction of which the Work to be performed under the Contract Documents may be the whole, or a part. 34. Project Manual—The bound documentary information prepared for bidding and constructing the Work. A listing of the contents of the Project Manual, which may be bound in one or more volumes, is contained in the table(s) of contents. 35. Radioactive Material—Source, special nuclear, or byproduct material as defined by the Atomic Energy Act of 1954 (42 USC Section 2011 et seq.) as amended from time to time. 36. Resident Project Representative—The authorized representative of Engineer who may be assigned to the Site or any part thereof. 37. Samples—Physical examples of materials, equipment, or workmanship that are representative of some portion of the Work and which establish the standards by which such portion of the Work will be judged. 38. Schedule of Submittals—A schedule, prepared and maintained by Contractor, of required submittals and the time requirements to support scheduled performance of related construction activities. 39. Schedule of Values—A schedule, prepared and maintained by Contractor, allocating portions of the Contract Price to various portions of the Work and used as the basis for reviewing Contractor’s Applications for Payment. 40. Shop Drawings—All drawings, diagrams, illustrations, schedules, and other data or information which are specifically prepared or assembled by or for Contractor and submitted by Contractor to illustrate some portion of the Work. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 3 of 41 41. Site—Lands or areas indicated in the Contract Documents as being furnished by Owner upon which the Work is to be performed, including rights-of-way and easements for access thereto, and such other lands furnished by Owner which are designated for the use of Contractor. 42. Specifications—That part of the Contract Documents consisting of written requirements for materials, equipment, systems, standards and workmanship as applied to the Work, and certain administrative requirements and procedural matters applicable thereto. 43. Subcontractor—An individual or entity having a direct contract with Contractor or with any other Subcontractor for the performance of a part of the Work at the Site. 44. Substantial Completion—The time at which the Work (or a specified part thereof) has progressed to the point where, in the opinion of Engineer, the Work (or a specified part thereof) is sufficiently complete, in accordance with the Contract Documents, so that the Work (or a specified part thereof) can be utilized for the purposes for which it is intended. The terms “substantially complete” and “substantially completed” as applied to all or part of the Work refer to Substantial Completion thereof. 45. Successful Bidder—The Bidder submitting a responsive Bid to whom Owner makes an award. 46. Supplementary Conditions—That part of the Contract Documents which amends or supplements these General Conditions. 47. Supplier—A manufacturer, fabricator, supplier, distributor, materialman, or vendor having a direct contract with Contractor or with any Subcontractor to furnish materials or equipment to be incorporated in the Work by Contractor or Subcontractor. 48. Underground Facilities—All underground pipelines, conduits, ducts, cables, wires, manholes, vaults, tanks, tunnels, or other such facilities or attachments, and any encasements containing such facilities, including those that convey electricity, gases, steam, liquid petroleum products, telephone or other communications, cable television, water, wastewater, storm water, other liquids or chemicals, or traffic or other control systems. 49. Unit Price Work—Work to be paid for on the basis of unit prices. 50. Work—The entire construction or the various separately identifiable parts thereof required to be provided under the Contract Documents. Work includes and is the result of performing or providing all labor, services, and documentation necessary to produce such construction, and furnishing, installing, and incorporating all materials and equipment into such construction, all as required by the Contract Documents. 51. Work Change Directive—A written statement to Contractor issued on or after the Effective Date of the Agreement and signed by Owner and recommended by Engineer ordering an addition, deletion, or revision in the Work, or responding to differing or unforeseen subsurface or physical conditions under which the Work is to be performed or to emergencies. A Work Change Directive will not change the Contract Price or the Contract Times but is evidence that the parties expect that the change ordered or documented by a Work Change Directive will be incorporated in a subsequently issued Change Order following negotiations by the parties as to its effect, if any, on the Contract Price or Contract Times. 1.02 Terminology A. The words and terms discussed in Paragraph 1.02.B through F are not defined but, when used in the Bidding Requirements or Contract Documents, have the indicated meaning. B. Intent of Certain Terms or Adjectives: 1. The Contract Documents include the terms “as allowed,” “as approved,” “as ordered,” “as directed” or terms of like effect or import to authorize an exercise of professional judgment by Engineer. In addition, the adjectives “reasonable,” “suitable,” “acceptable,” “proper,” “satisfactory,” or adjectives of like effect or import are used to describe an action or determination of Engineer as to the Work. It is intended that such exercise of professional judgment, action, or determination will be solely to evaluate, in general, the Work for compliance with the information in the Contract Documents and with the design concept of the Project as a functioning whole as shown or indicated in the Contract Documents (unless there is a specific statement indicating otherwise). The use of any such term or adjective is not intended to and shall not be effective to assign to Engineer any duty or authority to supervise or direct EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 4 of 41 the performance of the Work, or any duty or authority to undertake responsibility contrary to the provisions of Paragraph 9.09 or any other provision of the Contract Documents. C. Day: 1. The word “day” means a calendar day of 24 hours measured from midnight to the next midnight. D. Defective: 1. The word “defective,” when modifying the word “Work,” refers to Work that is unsatisfactory, faulty, or deficient in that it: a. does not conform to the Contract Documents; or b. does not meet the requirements of any applicable inspection, reference standard, test, or approval referred to in the Contract Documents; or c. has been damaged prior to Engineer’s recommendation of final payment (unless responsibility for the protection thereof has been assumed by Owner at Substantial Completion in accordance with Paragraph 14.04 or 14.05). E. Furnish, Install, Perform, Provide: 1. The word “furnish,” when used in connection with services, materials, or equipment, shall mean to supply and deliver said services, materials, or equipment to the Site (or some other specified location) ready for use or installation and in usable or operable condition. 2. The word “install,” when used in connection with services, materials, or equipment, shall mean to put into use or place in final position said services, materials, or equipment complete and ready for intended use. 3. The words “perform” or “provide,” when used in connection with services, materials, or equipment, shall mean to furnish and install said services, materials, or equipment complete and ready for intended use. 4. When “furnish,” “install,” “perform,” or “provide” is not used in connection with services, materials, or equipment in a context clearly requiring an obligation of Contractor, “provide” is implied. F. Unless stated otherwise in the Contract Documents, words or phrases that have a well-known technical or construction industry or trade meaning are used in the Contract Documents in accordance with such recognized meaning. ARTICLE 2 – PRELIMINARY MATTERS 2.01 Delivery of Bonds and Evidence of Insurance A. When Contractor delivers the executed counterparts of the Agreement to Owner, Contractor shall also deliver to Owner such bonds as Contractor may be required to furnish. B. Evidence of Insurance: Before any Work at the Site is started, Contractor and Owner shall each deliver to the other, with copies to each additional insured identified in the Supplementary Conditions, certificates of insurance (and other evidence of insurance which either of them or any additional insured may reasonably request) which Contractor and Owner respectively are required to purchase and maintain in accordance with Article 5. 2.02 Copies of Documents A. Owner shall furnish to Contractor up to ten printed or hard copies of the Drawings and Project Manual. Additional copies will be furnished upon request at the cost of reproduction. 2.03 Commencement of Contract Times; Notice to Proceed A. The Contract Times will commence to run on the thirtieth day after the Effective Date of the Agreement or, if a Notice to Proceed is given, on the day indicated in the Notice to Proceed. A Notice to Proceed may be given at any time within 30 days after the Effective Date of the Agreement. In no event will the Contract Times commence to run later than the sixtieth day after the day of Bid opening or the thirtieth day after the Effective Date of the Agreement, whichever date is earlier. 2.04 Starting the Work A. Contractor shall start to perform the Work on the date when the Contract Times commence to run. No Work shall be done at the Site prior to the date on which the Contract Times commence to run. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 5 of 41 2.05 Before Starting Construction A. Preliminary Schedules: Within 10 days after the Effective Date of the Agreement (unless otherwise speci- fied in the General Requirements), Contractor shall submit to Engineer for timely review: 1. a preliminary Progress Schedule indicating the times (numbers of days or dates) for starting and completing the various stages of the Work, including any Milestones specified in the Contract Documents; 2. a preliminary Schedule of Submittals; and 3. a preliminary Schedule of Values for all of the Work which includes quantities and prices of items which when added together equal the Contract Price and subdivides the Work into component parts in sufficient detail to serve as the basis for progress payments during performance of the Work. Such prices will include an appropriate amount of overhead and profit applicable to each item of Work. 2.06 Preconstruction Conference; Designation of Authorized Representatives A. Before any Work at the Site is started, a conference attended by Owner, Contractor, Engineer, and others as appropriate will be held to establish a working understanding among the parties as to the Work and to discuss the schedules referred to in Paragraph 2.05.A, procedures for handling Shop Drawings and other submittals, processing Applications for Payment, and maintaining required records. B. At this conference Owner and Contractor each shall designate, in writing, a specific individual to act as its authorized representative with respect to the services and responsibilities under the Contract. Such individuals shall have the authority to transmit instructions, receive information, render decisions relative to the Contract, and otherwise act on behalf of each respective party. 2.07 Initial Acceptance of Schedules A. At least 10 days before submission of the first Application for Payment a conference attended by Contractor, Engineer, and others as appropriate will be held to review for acceptability to Engineer as provided below the schedules submitted in accordance with Paragraph 2.05.A. Contractor shall have an additional 10 days to make corrections and adjustments and to complete and resubmit the schedules. No progress payment shall be made to Contractor until acceptable schedules are submitted to Engineer. 1. The Progress Schedule will be acceptable to Engineer if it provides an orderly progression of the Work to completion within the Contract Times. Such acceptance will not impose on Engineer responsibility for the Progress Schedule, for sequencing, scheduling, or progress of the Work, nor interfere with or relieve Contractor from Contractor’s full responsibility therefor. 2. Contractor’s Schedule of Submittals will be acceptable to Engineer if it provides a workable arrangement for reviewing and processing the required submittals. 3. Contractor’s Schedule of Values will be acceptable to Engineer as to form and substance if it provides a reasonable allocation of the Contract Price to component parts of the Work. ARTICLE 3 – CONTRACT DOCUMENTS: INTENT, AMENDING, REUSE 3.01 Intent A. The Contract Documents are complementary; what is required by one is as binding as if required by all. B. It is the intent of the Contract Documents to describe a functionally complete project (or part thereof) to be constructed in accordance with the Contract Documents. Any labor, documentation, services, materials, or equipment that reasonably may be inferred from the Contract Documents or from prevailing custom or trade usage as being required to produce the indicated result will be provided whether or not specifically called for, at no additional cost to Owner. C. Clarifications and interpretations of the Contract Documents shall be issued by Engineer as provided in Article 9. 3.02 Reference Standards A. Standards, Specifications, Codes, Laws, and Regulations 1. Reference to standards, specifications, manuals, or codes of any technical society, organization, or association, or to Laws or Regulations, whether such reference be specific or by implication, shall mean the standard, specification, manual, code, or Laws or Regulations in effect at the time of opening of Bids (or EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 6 of 41 on the Effective Date of the Agreement if there were no Bids), except as may be otherwise specifically stated in the Contract Documents. 2. No provision of any such standard, specification, manual, or code, or any instruction of a Supplier, shall be effective to change the duties or responsibilities of Owner, Contractor, or Engineer, or any of their subcontractors, consultants, agents, or employees, from those set forth in the Contract Documents. No such provision or instruction shall be effective to assign to Owner, Engineer, or any of their officers, directors, members, partners, employees, agents, consultants, or subcontractors, any duty or authority to supervise or direct the performance of the Work or any duty or authority to undertake responsibility inconsistent with the provisions of the Contract Documents. 3.03 Reporting and Resolving Discrepancies A. Reporting Discrepancies: 1. Contractor’s Review of Contract Documents Before Starting Work: Before undertaking each part of the Work, Contractor shall carefully study and compare the Contract Documents and check and verify pertinent figures therein and all applicable field measurements. Contractor shall promptly report in writing to Engineer any conflict, error, ambiguity, or discrepancy which Contractor discovers, or has actual knowledge of, and shall obtain a written interpretation or clarification from Engineer before proceeding with any Work affected thereby. 2. Contractor’s Review of Contract Documents During Performance of Work: If, during the performance of the Work, Contractor discovers any conflict, error, ambiguity, or discrepancy within the Contract Documents, or between the Contract Documents and (a) any applicable Law or Regulation , (b) any standard, specification, manual, or code, or (c) any instruction of any Supplier, then Contractor shall promptly report it to Engineer in writing. Contractor shall not proceed with the Work affected thereby (except in an emergency as required by Paragraph 6.16.A) until an amendment or supplement to the Contract Documents has been issued by one of the methods indicated in Paragraph 3.04. 3. Contractor shall not be liable to Owner or Engineer for failure to report any conflict, error, ambiguity, or discrepancy in the Contract Documents unless Contractor had actual knowledge thereof. B. Resolving Discrepancies: 1. Except as may be otherwise specifically stated in the Contract Documents, the provisions of the Contract Documents shall take precedence in resolving any conflict, error, ambiguity, or discrepancy between the provisions of the Contract Documents and: a. the provisions of any standard, specification, manual, or code, or the instruction of any Supplier (whether or not specifically incorporated by reference in the Contract Documents); or b. the provisions of any Laws or Regulations applicable to the performance of the Work (unless such an interpretation of the provisions of the Contract Documents would result in violation of such Law or Regulation). 3.04 Amending and Supplementing Contract Documents A. The Contract Documents may be amended to provide for additions, deletions, and revisions in the Work or to modify the terms and conditions thereof by either a Change Order or a Work Change Directive. B. The requirements of the Contract Documents may be supplemented, and minor variations and deviations in the Work may be authorized, by one or more of the following ways: 1. A Field Order; 2. Engineer’s approval of a Shop Drawing or Sample (subject to the provisions of Paragraph 6.17.D.3); or 3. Engineer’s written interpretation or clarification. 3.05 Reuse of Documents A. Contractor and any Subcontractor or Supplier shall not: 1. have or acquire any title to or ownership rights in any of the Drawings, Specifications, or other documents (or copies of any thereof) prepared by or bearing the seal of Engineer or its consultants, including electronic media editions; or 2. reuse any such Drawings, Specifications, other documents, or copies thereof on extensions of the Project or any other project without written consent EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 7 of 41 of Owner and Engineer and specific written verification or adaptation by Engineer. B. The prohibitions of this Paragraph 3.05 will survive final payment, or termination of the Contract. Nothing herein shall preclude Contractor from retaining copies of the Contract Documents for record purposes. 3.06 Electronic Data A. Unless otherwise stated in the Supplementary Conditions, the data furnished by Owner or Engineer to Contractor, or by Contractor to Owner or Engineer, that may be relied upon are limited to the printed copies (also known as hard copies). Files in electronic media format of text, data, graphics, or other types are furnished only for the convenience of the receiving party. Any conclusion or information obtained or derived from such electronic files will be at the user’s sole risk. If there is a discrepancy between the electronic files and the hard copies, the hard copies govern. B. Because data stored in electronic media format can deteriorate or be modified inadvertently or otherwise without authorization of the data’s creator, the party receiving electronic files agrees that it will perform acceptance tests or procedures within 60 days, after which the receiving party shall be deemed to have accepted the data thus transferred. Any errors detected within the 60-day acceptance period will be corrected by the transferring party. C. When transferring documents in electronic media format, the transferring party makes no representations as to long term compatibility, usability, or readability of documents resulting from the use of software application packages, operating systems, or computer hardware differing from those used by the data’s creator. ARTICLE 4 – AVAILABILITY OF LANDS; SUBSURFACE AND PHYSICAL CONDITIONS; HAZARDOUS ENVIRONMENTAL CONDITIONS; REFERENCE POINTS 4.01 Availability of Lands A. Owner shall furnish the Site. Owner shall notify Contractor of any encumbrances or restrictions not of general application but specifically related to use of the Site with which Contractor must comply in performing the Work. Owner will obtain in a timely manner and pay for easements for permanent structures or permanent changes in existing facilities. If Contractor and Owner are unable to agree on entitlement to or on the amount or extent, if any, of any adjustment in the Contract Price or Contract Times, or both, as a result of any delay in Owner’s furnishing the Site or a part thereof, Contractor may make a Claim therefor as provided in Paragraph 10.05. B. Upon reasonable written request, Owner shall furnish Contractor with a current statement of record legal title and legal description of the lands upon which the Work is to be performed and Owner’s interest therein as necessary for giving notice of or filing a mechanic’s or construction lien against such lands in accordance with applicable Laws and Regulations. C. Contractor shall provide for all additional lands and access thereto that may be required for temporary construction facilities or storage of materials and equipment. 4.02 Subsurface and Physical Conditions A. Reports and Drawings: The Supplementary Conditions identify: 1. those reports known to Owner of explorations and tests of subsurface conditions at or contiguous to the Site; and 2. those drawings known to Owner of physical conditions relating to existing surface or subsurface structures at the Site (except Underground Facilities). B. Limited Reliance by Contractor on Technical Data Authorized: Contractor may rely upon the accuracy of the “technical data” contained in such reports and drawings, but such reports and drawings are not Contract Documents. Such “technical data” is identified in the Supplementary Conditions. Except for such reliance on such “technical data,” Contractor may not rely upon or make any claim against Owner or Engineer, or any of their officers, directors, members, partners, employees, agents, consultants, or subcontractors with respect to: 1. the completeness of such reports and drawings for Contractor’s purposes, including, but not limited to, any aspects of the means, methods, techniques, sequences, and procedures of construction to be employed by Contractor, and safety precautions and programs incident thereto; or 2. other data, interpretations, opinions, and information contained in such reports or shown or indicated in such drawings; or EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 8 of 41 3. any Contractor interpretation of or conclusion drawn from any “technical data” or any such other data, interpretations, opinions, or information. 4.03 Differing Subsurface or Physical Conditions A. Notice: If Contractor believes that any subsurface or physical condition that is uncovered or revealed either: 1. is of such a nature as to establish that any “technical data” on which Contractor is entitled to rely as provided in Paragraph 4.02 is materially inaccurate; or 2. is of such a nature as to require a change in the Contract Documents; or 3. differs materially from that shown or indicated in the Contract Documents; or 4. is of an unusual nature, and differs materially from conditions ordinarily encountered and generally recognized as inherent in work of the character provided for in the Contract Documents; then Contractor shall, promptly after becoming aware thereof and before further disturbing the subsurface or physical conditions or performing any Work in connection therewith (except in an emergency as required by Paragraph 6.16.A), notify Owner and Engineer in writing about such condition. Contractor shall not further disturb such condition or perform any Work in connection therewith (except as aforesaid) until receipt of written order to do so. B. Engineer’s Review: After receipt of written notice as required by Paragraph 4.03.A, Engineer will promptly review the pertinent condition, determine the necessity of Owner’s obtaining additional exploration or tests with respect thereto, and advise Owner in writing (with a copy to Contractor) of Engineer’s findings and conclusions. C. Possible Price and Times Adjustments: 1. The Contract Price or the Contract Times, or both, will be equitably adjusted to the extent that the existence of such differing subsurface or physical condition causes an increase or decrease in Contractor’s cost of, or time required for, performance of the Work; subject, however, to the following: a. such condition must meet any one or more of the categories described in Paragraph 4.03.A; and b. with respect to Work that is paid for on a unit price basis, any adjustment in Contract Price will be subject to the provisions of Paragraphs 9.07 and 11.03. 2. Contractor shall not be entitled to any adjustment in the Contract Price or Contract Times if: a. Contractor knew of the existence of such conditions at the time Contractor made a final commitment to Owner with respect to Contract Price and Contract Times by the submission of a Bid or becoming bound under a negotiated contract; or b. the existence of such condition could reasonably have been discovered or revealed as a result of any examination, investigation, exploration, test, or study of the Site and contiguous areas required by the Bidding Requirements or Contract Documents to be conducted by or for Contractor prior to Contractor’s making such final commitment; or c. Contractor failed to give the written notice as required by Paragraph 4.03.A. 3. If Owner and Contractor are unable to agree on entitlement to or on the amount or extent, if any, of any adjustment in the Contract Price or Contract Times, or both, a Claim may be made therefor as provided in Paragraph 10.05. However, neither Owner or Engineer, or any of their officers, directors, members, partners, employees, agents, consultants, or subcontractors shall be liable to Contractor for any claims, costs, losses, or damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) sustained by Contractor on or in connection with any other project or anticipated project. 4.04 Underground Facilities A. Shown or Indicated: The information and data shown or indicated in the Contract Documents with respect to existing Underground Facilities at or contiguous to the Site is based on information and data furnished to Owner or Engineer by the owners of such Underground Facilities, including Owner, or by others. Unless it is otherwise expressly provided in the Supplementary Conditions: EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 9 of 41 1. Owner and Engineer shall not be responsible for the accuracy or completeness of any such information or data provided by others; and 2. the cost of all of the following will be included in the Contract Price, and Contractor shall have full responsibility for: a. reviewing and checking all such information and data; b. locating all Underground Facilities shown or indicated in the Contract Documents; c. coordination of the Work with the owners of such Underground Facilities, including Owner, during construction; and d. the safety and protection of all such Underground Facilities and repairing any damage thereto resulting from the Work. B. Not Shown or Indicated: 1. If an Underground Facility is uncovered or revealed at or contiguous to the Site which was not shown or indicated, or not shown or indicated with reasonable accuracy in the Contract Documents, Contractor shall, promptly after becoming aware thereof and before further disturbing conditions affected thereby or performing any Work in connection therewith (except in an emergency as required by Paragraph 6.16.A), identify the owner of such Underground Facility and give written notice to that owner and to Owner and Engineer. Engineer will promptly review the Underground Facility and determine the extent, if any, to which a change is required in the Contract Documents to reflect and document the consequences of the existence or location of the Underground Facility. During such time, Contractor shall be responsible for the safety and protection of such Underground Facility. 2. If Engineer concludes that a change in the Contract Documents is required, a Work Change Directive or a Change Order will be issued to reflect and document such consequences. An equitable adjustment shall be made in the Contract Price or Contract Times, or both, to the extent that they are attributable to the existence or location of any Underground Facility that was not shown or indicated or not shown or indicated with reasonable accuracy in the Contract Documents and that Contractor did not know of and could not reasonably have been expected to be aware of or to have anticipated. If Owner and Contractor are unable to agree on entitlement to or on the amount or extent, if any, of any such adjustment in Contract Price or Contract Times, Owner or Contractor may make a Claim therefor as provided in Paragraph 10.05. 4.05 Reference Points A. Owner shall provide engineering surveys to establish reference points for construction which in Engineer’s judgment are necessary to enable Contractor to proceed with the Work. Contractor shall be responsible for laying out the Work, shall protect and preserve the established reference points and property monuments, and shall make no changes or relocations without the prior written approval of Owner. Contractor shall report to Engineer whenever any reference point or property monument is lost or destroyed or requires relocation because of necessary changes in grades or locations, and shall be responsible for the accurate replacement or relocation of such reference points or property monuments by professionally qualified personnel. 4.06 Hazardous Environmental Condition at Site A. Reports and Drawings: The Supplementary Conditions identify those reports and drawings known to Owner relating to Hazardous Environmental Conditions that have been identified at the Site. B. Limited Reliance by Contractor on Technical Data Authorized: Contractor may rely upon the accuracy of the “technical data” contained in such reports and drawings, but such reports and drawings are not Contract Documents. Such “technical data” is identified in the Supplementary Conditions. Except for such reliance on such “technical data,” Contractor may not rely upon or make any claim against Owner or Engineer, or any of their officers, directors, members, partners, employees, agents, consultants, or subcontractors with respect to: 1. the completeness of such reports and drawings for Contractor’s purposes, including, but not limited to, any aspects of the means, methods, techniques, sequences and procedures of construction to be employed by Contractor and safety precautions and programs incident thereto; or 2. other data, interpretations, opinions and information contained in such reports or shown or indicated in such drawings; or EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 10 of 41 3. any Contractor interpretation of or conclusion drawn from any “technical data” or any such other data, interpretations, opinions or information. C. Contractor shall not be responsible for any Hazardous Environmental Condition uncovered or revealed at the Site which was not shown or indicated in Drawings or Specifications or identified in the Contract Documents to be within the scope of the Work. Contractor shall be responsible for a Hazardous Environmental Condition created with any materials brought to the Site by Contractor, Subcontractors, Suppliers, or anyone else for whom Contractor is responsible. D. If Contractor encounters a Hazardous Environmental Condition or if Contractor or anyone for whom Contractor is responsible creates a Hazardous Environmental Condition, Contractor shall immediately: (i) secure or otherwise isolate such condition; (ii) stop all Work in connection with such condition and in any area affected thereby (except in an emergency as required by Paragraph 6.16.A); and (iii) notify Owner and Engineer (and promptly thereafter confirm such notice in writing). Owner shall promptly consult with Engineer concerning the necessity for Owner to retain a qualified expert to evaluate such condition or take corrective action, if any. Promptly after consulting with Engineer, Owner shall take such actions as are necessary to permit Owner to timely obtain required permits and provide Contractor the written notice required by Paragraph 4.06.E. E. Contractor shall not be required to resume Work in connection with such condition or in any affected area until after Owner has obtained any required permits related thereto and delivered written notice to Contractor: (i) specifying that such condition and any affected area is or has been rendered safe for the resumption of Work; or (ii) specifying any special conditions under which such Work may be resumed safely. If Owner and Contractor cannot agree as to entitlement to or on the amount or extent, if any, of any adjustment in Contract Price or Contract Times, or both, as a result of such Work stoppage or such special conditions under which Work is agreed to be resumed by Contractor, either party may make a Claim therefor as provided in Paragraph 10.05. F. If after receipt of such written notice Contractor does not agree to resume such Work based on a reasonable belief it is unsafe, or does not agree to resume such Work under such special conditions, then Owner may order the portion of the Work that is in the area affected by such condition to be deleted from the Work. If Owner and Contractor cannot agree as to entitlement to or on the amount or extent, if any, of an adjustment in Contract Price or Contract Times as a result of deleting such portion of the Work, then either party may make a Claim therefor as provided in Paragraph 10.05. Owner may have such deleted portion of the Work performed by Owner’s own forces or others in accordance with Article 7. G. To the fullest extent permitted by Laws and Regulations, Owner shall indemnify and hold harmless Contractor, Subcontractors, and Engineer, and the officers, directors, members, partners, employees, agents, consultants, and subcontractors of each and any of them from and against all claims, costs, losses, and damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) arising out of or relating to a Hazardous Environmental Condition, provided that such Hazardous Environmental Condition: (i) was not shown or indicated in the Drawings or Specifications or identified in the Contract Documents to be included within the scope of the Work, and (ii) was not created by Contractor or by anyone for whom Contractor is responsible. Nothing in this Paragraph 4.06.G shall obligate Owner to indemnify any individual or entity from and against the consequences of that individual’s or entity’s own negligence. H. To the fullest extent permitted by Laws and Regulations, Contractor shall indemnify and hold harmless Owner and Engineer, and the officers, directors, members, partners, employees, agents, consultants, and subcontractors of each and any of them from and against all claims, costs, losses, and damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) arising out of or relating to a Hazardous Environmental Condition created by Contractor or by anyone for whom Contractor is responsible. Nothing in this Paragraph 4.06.H shall obligate Contractor to indemnify any individual or entity from and against the consequences of that individual’s or entity’s own negligence. I. The provisions of Paragraphs 4.02, 4.03, and 4.04 do not apply to a Hazardous Environmental Condition uncovered or revealed at the Site. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 11 of 41 ARTICLE 5 – BONDS AND INSURANCE 5.01 Performance, Payment, and Other Bonds A. Contractor shall furnish performance and payment bonds, each in an amount at least equal to the Contract Price as security for the faithful performance and payment of all of Contractor’s obligations under the Contract Documents. These bonds shall remain in effect until one year after the date when final payment becomes due or until completion of the correction period specified in Paragraph 13.07, whichever is later, except as provided otherwise by Laws or Regulations or by the Contract Documents. Contractor shall also furnish such other bonds as are required by the Contract Documents. B. All bonds shall be in the form prescribed by the Contract Documents except as provided otherwise by Laws or Regulations, and shall be executed by such sureties as are named in the list of “Companies Holding Certificates of Authority as Acceptable Sureties on Federal Bonds and as Acceptable Reinsuring Companies” as published in Circular 570 (amended) by the Financial Management Service, Surety Bond Branch, U.S. Department of the Treasury. All bonds signed by an agent or attorney-in-fact must be accompanied by a certified copy of that individual’s authority to bind the surety. The evidence of authority shall show that it is effective on the date the agent or attorney-in-fact signed each bond. C. If the surety on any bond furnished by Contractor is declared bankrupt or becomes insolvent or its right to do business is terminated in any state where any part of the Project is located or it ceases to meet the requirements of Paragraph 5.01.B, Contractor shall promptly notify Owner and Engineer and shall, within 20 days after the event giving rise to such notification, provide another bond and surety, both of which shall comply with the requirements of Paragraphs 5.01.B and 5.02. 5.02 Licensed Sureties and Insurers A. All bonds and insurance required by the Contract Documents to be purchased and maintained by Owner or Contractor shall be obtained from surety or insurance companies that are duly licensed or authorized in the jurisdiction in which the Project is located to issue bonds or insurance policies for the limits and coverages so required. Such surety and insurance companies shall also meet such additional requirements and qualifications as may be provided in the Supplementary Conditions. 5.03 Certificates of Insurance A. Contractor shall deliver to Owner, with copies to each additional insured and loss payee identified in the Supplementary Conditions, certificates of insurance (and other evidence of insurance requested by Owner or any other additional insured) which Contractor is required to purchase and maintain. B. Owner shall deliver to Contractor, with copies to each additional insured and loss payee identified in the Supplementary Conditions, certificates of insurance (and other evidence of insurance requested by Contractor or any other additional insured) which Owner is required to purchase and maintain. C. Failure of Owner to demand such certificates or other evidence of Contractor's full compliance with these insurance requirements or failure of Owner to identify a deficiency in compliance from the evidence provided shall not be construed as a waiver of Contractor’s obligation to maintain such insurance. D. Owner does not represent that insurance coverage and limits established in this Contract necessarily will be adequate to protect Contractor. E. The insurance and insurance limits required herein shall not be deemed as a limitation on Contractor’s liability under the indemnities granted to Owner in the Contract Documents. 5.04 Contractor’s Insurance A. Contractor shall purchase and maintain such insurance as is appropriate for the Work being performed and as will provide protection from claims set forth below which may arise out of or result from Contractor’s performance of the Work and Contractor’s other obligations under the Contract Documents, whether it is to be performed by Contractor, any Subcontractor or Supplier, or by anyone directly or indirectly employed by any of them to perform any of the Work, or by anyone for whose acts any of them may be liable: 1. claims under workers’ compensation, disability benefits, and other similar employee benefit acts; 2. claims for damages because of bodily injury, occupational sickness or disease, or death of Contractor’s employees; EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 12 of 41 3. claims for damages because of bodily injury, sickness or disease, or death of any person other than Contractor’s employees; 4. claims for damages insured by reasonably available personal injury liability coverage which are sustained: a. by any person as a result of an offense directly or indirectly related to the employment of such person by Contractor, or b. by any other person for any other reason; 5. claims for damages, other than to the Work itself, because of injury to or destruction of tangible property wherever located, including loss of use resulting therefrom; and 6. claims for damages because of bodily injury or death of any person or property damage arising out of the ownership, maintenance or use of any motor vehicle. B. The policies of insurance required by this Paragraph 5.04 shall: 1. with respect to insurance required by Paragraphs 5.04.A.3 through 5.04.A.6 inclusive, be written on an occurrence basis, include as additional insureds (subject to any customary exclusion regarding professional liability) Owner and Engineer, and any other individuals or entities identified in the Supplementary Conditions, all of whom shall be listed as additional insureds, and include coverage for the respective officers, directors, members, partners, employees, agents, consultants, and subcontractors of each and any of all such additional insureds, and the insurance afforded to these additional insureds shall provide primary coverage for all claims covered thereby; 2. include at least the specific coverages and be written for not less than the limits of liability provided in the Supplementary Conditions or required by Laws or Regulations, whichever is greater; 3. include contractual liability insurance covering Contractor’s indemnity obligations under Paragraphs 6.11 and 6.20; 4. contain a provision or endorsement that the coverage afforded will not be canceled, materially changed or renewal refused until at least 30 days prior written notice has been given to Owner and Contractor and to each other additional insured identified in the Supplementary Conditions to whom a certificate of insurance has been issued (and the certificates of insurance furnished by the Contractor pursuant to Paragraph 5.03 will so provide); 5. remain in effect at least until final payment and at all times thereafter when Contractor may be correcting, removing, or replacing defective Work in accordance with Paragraph 13.07; and 6. include completed operations coverage: a. Such insurance shall remain in effect for two years after final payment. b. Contractor shall furnish Owner and each other additional insured identified in the Supplementary Conditions, to whom a certificate of insurance has been issued, evidence satisfactory to Owner and any such additional insured of continuation of such insurance at final payment and one year thereafter. 5.05 Owner’s Liability Insurance A. In addition to the insurance required to be provided by Contractor under Paragraph 5.04, Owner, at Owner’s option, may purchase and maintain at Owner’s expense Owner’s own liability insurance as will protect Owner against claims which may arise from operations under the Contract Documents. 5.06 Property Insurance A. Unless otherwise provided in the Supplementary Conditions, Owner shall purchase and maintain property insurance upon the Work at the Site in the amount of the full replacement cost thereof (subject to such deductible amounts as may be provided in the Supplementary Conditions or required by Laws and Regulations). This insurance shall: 1. include the interests of Owner, Contractor, Subcontractors, and Engineer, and any other individuals or entities identified in the Supplementary Conditions, and the officers, directors, members, partners, employees, agents, consultants, and subcontractors of each and any of them, each of whom is deemed to have an insurable interest and shall be listed as a loss payee; 2. be written on a Builder’s Risk “all-risk” policy form that shall at least include insurance for physical loss or damage to the Work, temporary buildings, EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 13 of 41 falsework, and materials and equipment in transit, and shall insure against at least the following perils or causes of loss: fire, lightning, extended coverage, theft, vandalism and malicious mischief, earthquake, collapse, debris removal, demolition occasioned by enforcement of Laws and Regulations, water damage (other than that caused by flood), and such other perils or causes of loss as may be specifically required by the Supplementary Conditions. 3. include expenses incurred in the repair or replacement of any insured property (including but not limited to fees and charges of engineers and architects); 4. cover materials and equipment stored at the Site or at another location that was agreed to in writing by Owner prior to being incorporated in the Work, provided that such materials and equipment have been included in an Application for Payment recommended by Engineer; 5. allow for partial utilization of the Work by Owner; 6. include testing and startup; and 7. be maintained in effect until final payment is made unless otherwise agreed to in writing by Owner, Contractor, and Engineer with 30 days written notice to each other loss payee to whom a certificate of insurance has been issued. B. Owner shall purchase and maintain such equipment breakdown insurance or additional property insurance as may be required by the Supplementary Conditions or Laws and Regulations which will include the interests of Owner, Contractor, Subcontractors, and Engineer, and any other individuals or entities identified in the Supplementary Conditions, and the officers, directors, members, partners, employees, agents, consultants and subcontractors of each and any of them, each of whom is deemed to have an insurable interest and shall be listed as a loss payee. C. All the policies of insurance (and the certificates or other evidence thereof) required to be purchased and maintained in accordance with this Paragraph 5.06 will contain a provision or endorsement that the coverage afforded will not be canceled or materially changed or renewal refused until at least 30 days prior written notice has been given to Owner and Contractor and to each other loss payee to whom a certificate of insurance has been issued and will contain waiver provisions in accordance with Paragraph 5.07. D. Owner shall not be responsible for purchasing and maintaining any property insurance specified in this Paragraph 5.06 to protect the interests of Contractor, Subcontractors, or others in the Work to the extent of any deductible amounts that are identified in the Supplementary Conditions. The risk of loss within such identified deductible amount will be borne by Contractor, Subcontractors, or others suffering any such loss, and if any of them wishes property insurance coverage within the limits of such amounts, each may purchase and maintain it at the purchaser’s own expense. E. If Contractor requests in writing that other special insurance be included in the property insurance policies provided under this Paragraph 5.06, Owner shall, if possible, include such insurance, and the cost thereof will be charged to Contractor by appropriate Change Order. Prior to commencement of the Work at the Site, Owner shall in writing advise Contractor whether or not such other insurance has been procured by Owner. 5.07 Waiver of Rights A. Owner and Contractor intend that all policies purchased in accordance with Paragraph 5.06 will protect Owner, Contractor, Subcontractors, and Engineer, and all other individuals or entities identified in the Supplementary Conditions as loss payees (and the officers, directors, members, partners, employees, agents, consultants, and subcontractors of each and any of them) in such policies and will provide primary coverage for all losses and damages caused by the perils or causes of loss covered thereby. All such policies shall contain provisions to the effect that in the event of payment of any loss or damage the insurers will have no rights of recovery against any of the insureds or loss payees thereunder. Owner and Contractor waive all rights against each other and their respective officers, directors, members, partners, employees, agents, consultants and subcontractors of each and any of them for all losses and damages caused by, arising out of or resulting from any of the perils or causes of loss covered by such policies and any other property insurance applicable to the Work; and, in addition, waive all such rights against Subcontractors and Engineer, and all other individuals or entities identified in the Supplementary Conditions as loss payees (and the officers, directors, members, partners, employees, agents, consultants, and subcontractors of each and any of them) under such policies for losses and damages so caused. None of the above waivers shall extend to the rights that any party making such waiver may have to the proceeds of insurance held by Owner as trustee or otherwise payable under any policy so issued. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 14 of 41 B. Owner waives all rights against Contractor, Subcontractors, and Engineer, and the officers, directors, members, partners, employees, agents, consultants and subcontractors of each and any of them for: 1. loss due to business interruption, loss of use, or other consequential loss extending beyond direct physical loss or damage to Owner’s property or the Work caused by, arising out of, or resulting from fire or other perils whether or not insured by Owner; and 2. loss or damage to the completed Project or part thereof caused by, arising out of, or resulting from fire or other insured peril or cause of loss covered by any property insurance maintained on the completed Project or part thereof by Owner during partial utilization pursuant to Paragraph 14.05, after Substantial Completion pursuant to Paragraph 14.04, or after final payment pursuant to Paragraph 14.07. C. Any insurance policy maintained by Owner covering any loss, damage or consequential loss referred to in Paragraph 5.07.B shall contain provisions to the effect that in the event of payment of any such loss, damage, or consequential loss, the insurers will have no rights of recovery against Contractor, Subcontractors, or Engineer, and the officers, directors, members, partners, employees, agents, consultants and subcontractors of each and any of them. 5.08 Receipt and Application of Insurance Proceeds A. Any insured loss under the policies of insurance required by Paragraph 5.06 will be adjusted with Owner and made payable to Owner as fiduciary for the loss payees, as their interests may appear, subject to the requirements of any applicable mortgage clause and of Paragraph 5.08.B. Owner shall deposit in a separate account any money so received and shall distribute it in accordance with such agreement as the parties in interest may reach. If no other special agreement is reached, the damaged Work shall be repaired or replaced, the moneys so received applied on account thereof, and the Work and the cost thereof covered by an appropriate Change Order. B. Owner as fiduciary shall have power to adjust and settle any loss with the insurers unless one of the parties in interest shall object in writing within 15 days after the occurrence of loss to Owner’s exercise of this power. If such objection be made, Owner as fiduciary shall make settlement with the insurers in accordance with such agreement as the parties in interest may reach. If no such agreement among the parties in interest is reached, Owner as fiduciary shall adjust and settle the loss with the insurers and, if required in writing by any party in interest, Owner as fiduciary shall give bond for the proper performance of such duties. 5.09 Acceptance of Bonds and Insurance; Option to Replace A. If either Owner or Contractor has any objection to the coverage afforded by or other provisions of the bonds or insurance required to be purchased and maintained by the other party in accordance with Article 5 on the basis of non-conformance with the Contract Documents, the objecting party shall so notify the other party in writing within 10 days after receipt of the certificates (or other evidence requested) required by Paragraph 2.01.B. Owner and Contractor shall each provide to the other such additional information in respect of insurance provided as the other may reasonably request. If either party does not purchase or maintain all of the bonds and insurance required of such party by the Contract Documents, such party shall notify the other party in writing of such failure to purchase prior to the start of the Work, or of such failure to maintain prior to any change in the required coverage. Without prejudice to any other right or remedy, the other party may elect to obtain equivalent bonds or insurance to protect such other party’s interests at the expense of the party who was required to provide such coverage, and a Change Order shall be issued to adjust the Contract Price accordingly. 5.10 Partial Utilization, Acknowledgment of Property Insurer A. If Owner finds it necessary to occupy or use a portion or portions of the Work prior to Substantial Completion of all the Work as provided in Paragraph 14.05, no such use or occupancy shall commence before the insurers providing the property insurance pursuant to Paragraph 5.06 have acknowledged notice thereof and in writing effected any changes in coverage necessitated thereby. The insurers providing the property insurance shall consent by endorsement on the policy or policies, but the property insurance shall not be canceled or permitted to lapse on account of any such partial use or occupancy. ARTICLE 6 – CONTRACTOR’S RESPONSIBILITIES 6.01 Supervision and Superintendence A. Contractor shall supervise, inspect, and direct the Work competently and efficiently, devoting such attention thereto and applying such skills and expertise as may be necessary to perform the Work in accordance EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 15 of 41 with the Contract Documents. Contractor shall be solely responsible for the means, methods, techniques, sequences, and procedures of construction. Contractor shall not be responsible for the negligence of Owner or Engineer in the design or specification of a specific means, method, technique, sequence, or procedure of construction which is shown or indicated in and expressly required by the Contract Documents. B. At all times during the progress of the Work, Contractor shall assign a competent resident superintendent who shall not be replaced without written notice to Owner and Engineer except under extraordinary circumstances. 6.02 Labor; Working Hours A. Contractor shall provide competent, suitably qualified personnel to survey and lay out the Work and perform construction as required by the Contract Documents. Contractor shall at all times maintain good discipline and order at the Site. B. Except as otherwise required for the safety or protection of persons or the Work or property at the Site or adjacent thereto, and except as otherwise stated in the Contract Documents, all Work at the Site shall be performed during regular working hours. Contractor will not permit the performance of Work on a Saturday, Sunday, or any legal holiday without Owner’s written consent (which will not be unreasonably withheld) given after prior written notice to Engineer. 6.03 Services, Materials, and Equipment A. Unless otherwise specified in the Contract Documents, Contractor shall provide and assume full responsibility for all services, materials, equipment, labor, transportation, construction equipment and machinery, tools, appliances, fuel, power, light, heat, telephone, water, sanitary facilities, temporary facilities, and all other facilities and incidentals necessary for the performance, testing, start-up, and completion of the Work. B. All materials and equipment incorporated into the Work shall be as specified or, if not specified, shall be of good quality and new, except as otherwise provided in the Contract Documents. All special warranties and guarantees required by the Specifications shall expressly run to the benefit of Owner. If required by Engineer, Contractor shall furnish satisfactory evidence (including reports of required tests) as to the source, kind, and quality of materials and equipment. C. All materials and equipment shall be stored, applied, installed, connected, erected, protected, used, cleaned, and conditioned in accordance with instructions of the applicable Supplier, except as otherwise may be provided in the Contract Documents. 6.04 Progress Schedule A. Contractor shall adhere to the Progress Schedule established in accordance with Paragraph 2.07 as it may be adjusted from time to time as provided below. 1. Contractor shall submit to Engineer for acceptance (to the extent indicated in Paragraph 2.07) proposed adjustments in the Progress Schedule that will not result in changing the Contract Times. Such adjustments will comply with any provisions of the General Requirements applicable thereto. 2. Proposed adjustments in the Progress Schedule that will change the Contract Times shall be submitted in accordance with the requirements of Article 12. Adjustments in Contract Times may only be made by a Change Order. 6.05 Substitutes and “Or-Equals” A. Whenever an item of material or equipment is specified or described in the Contract Documents by using the name of a proprietary item or the name of a particular Supplier, the specification or description is intended to establish the type, function, appearance, and quality required. Unless the specification or description contains or is followed by words reading that no like, equivalent, or “or-equal” item or no substitution is permitted, other items of material or equipment or material or equipment of other Suppliers may be submitted to Engineer for review under the circumstances described below. 1. “Or-Equal” Items: If in Engineer’s sole discretion an item of material or equipment proposed by Contractor is functionally equal to that named and sufficiently similar so that no change in related Work will be required, it may be considered by Engineer as an “or-equal” item, in which case review and approval of the proposed item may, in Engineer’s sole discretion, be accomplished without compliance with some or all of the requirements for approval of proposed substitute items. For the purposes of this Paragraph 6.05.A.1, a proposed item of material or equipment will be considered functionally equal to an item so named if: EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 16 of 41 a. in the exercise of reasonable judgment Engineer determines that: 1) it is at least equal in materials of construction, quality, durability, appearance, strength, and design characteristics; 2) it will reliably perform at least equally well the function and achieve the results imposed by the design concept of the completed Project as a functioning whole; and 3) it has a proven record of performance and availability of responsive service. b. Contractor certifies that, if approved and incorporated into the Work: 1) there will be no increase in cost to the Owner or increase in Contract Times; and 2) it will conform substantially to the detailed requirements of the item named in the Contract Documents. 2. Substitute Items: a. If in Engineer’s sole discretion an item of material or equipment proposed by Contractor does not qualify as an “or-equal” item under Paragraph 6.05.A.1, it will be considered a proposed substitute item. b. Contractor shall submit sufficient information as provided below to allow Engineer to determine if the item of material or equipment proposed is essentially equivalent to that named and an acceptable substitute therefor. Requests for review of proposed substitute items of material or equipment will not be accepted by Engineer from anyone other than Contractor. c. The requirements for review by Engineer will be as set forth in Paragraph 6.05.A.2.d, as supplemented by the General Requirements, and as Engineer may decide is appropriate under the circumstances. d. Contractor shall make written application to Engineer for review of a proposed substitute item of material or equipment that Contractor seeks to furnish or use. The application: 1) shall certify that the proposed substitute item will: a) perform adequately the functions and achieve the results called for by the general design, b) be similar in substance to that specified, and c) be suited to the same use as that specified; 2) will state: a) the extent, if any, to which the use of the proposed substitute item will prejudice Contractor’s achievement of Substantial Completion on time, b) whether use of the proposed substitute item in the Work will require a change in any of the Contract Documents (or in the provisions of any other direct contract with Owner for other work on the Project) to adapt the design to the proposed substitute item, and c) whether incorporation or use of the proposed substitute item in connection with the Work is subject to payment of any license fee or royalty; 3) will identify: a) all variations of the proposed substitute item from that specified, and b) available engineering, sales, maintenance, repair, and replacement services; and 4) shall contain an itemized estimate of all costs or credits that will result directly or indirectly from use of such substitute item, including costs of redesign and claims of other contractors affected by any resulting change. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 17 of 41 B. Substitute Construction Methods or Procedures: If a specific means, method, technique, sequence, or procedure of construction is expressly required by the Contract Documents, Contractor may furnish or utilize a substitute means, method, technique, sequence, or procedure of construction approved by Engineer. Contractor shall submit sufficient information to allow Engineer, in Engineer’s sole discretion, to determine that the substitute proposed is equivalent to that expressly called for by the Contract Documents. The requirements for review by Engineer will be similar to those provided in Paragraph 6.05.A.2. C. Engineer’s Evaluation: Engineer will be allowed a reasonable time within which to evaluate each proposal or submittal made pursuant to Paragraphs 6.05.A and 6.05.B. Engineer may require Contractor to furnish additional data about the proposed substitute item. Engineer will be the sole judge of acceptability. No “or equal” or substitute will be ordered, installed or utilized until Engineer’s review is complete, which will be evidenced by a Change Order in the case of a substitute and an approved Shop Drawing for an “or equal.” Engineer will advise Contractor in writing of any negative determination. D. Special Guarantee: Owner may require Contractor to furnish at Contractor’s expense a special performance guarantee or other surety with respect to any substitute. E. Engineer’s Cost Reimbursement: Engineer will record Engineer’s costs in evaluating a substitute proposed or submitted by Contractor pursuant to Paragraphs 6.05.A.2 and 6.05.B. Whether or not Engineer approves a substitute so proposed or submitted by Contractor, Contractor shall reimburse Owner for the reasonable charges of Engineer for evaluating each such proposed substitute. Contractor shall also reimburse Owner for the reasonable charges of Engineer for making changes in the Contract Documents (or in the provisions of any other direct contract with Owner) resulting from the acceptance of each proposed substitute. F. Contractor’s Expense: Contractor shall provide all data in support of any proposed substitute or “or-equal” at Contractor’s expense. 6.06 Concerning Subcontractors, Suppliers, and Others A. Contractor shall not employ any Subcontractor, Supplier, or other individual or entity (including those acceptable to Owner as indicated in Paragraph 6.06.B), whether initially or as a replacement, against whom Owner may have reasonable objection. Contractor shall not be required to employ any Subcontractor, Supplier, or other individual or entity to furnish or perform any of the Work against whom Contractor has reasonable objection. B. If the Supplementary Conditions require the identity of certain Subcontractors, Suppliers, or other individuals or entities to be submitted to Owner in advance for acceptance by Owner by a specified date prior to the Effective Date of the Agreement, and if Contractor has submitted a list thereof in accordance with the Supplementary Conditions, Owner’s acceptance (either in writing or by failing to make written objection thereto by the date indicated for acceptance or objection in the Bidding Documents or the Contract Documents) of any such Subcontractor, Supplier, or other individual or entity so identified may be revoked on the basis of reasonable objection after due investigation. Contractor shall submit an acceptable replacement for the rejected Subcontractor, Supplier, or other individual or entity, and the Contract Price will be adjusted by the difference in the cost occasioned by such replacement, and an appropriate Change Order will be issued. No acceptance by Owner of any such Subcontractor, Supplier, or other individual or entity, whether initially or as a replacement, shall constitute a waiver of any right of Owner or Engineer to reject defective Work. C. Contractor shall be fully responsible to Owner and Engineer for all acts and omissions of the Subcontractors, Suppliers, and other individuals or entities performing or furnishing any of the Work just as Contractor is responsible for Contractor’s own acts and omissions. Nothing in the Contract Documents: 1. shall create for the benefit of any such Subcontractor, Supplier, or other individual or entity any contractual relationship between Owner or Engineer and any such Subcontractor, Supplier or other individual or entity; nor 2. shall create any obligation on the part of Owner or Engineer to pay or to see to the payment of any moneys due any such Subcontractor, Supplier, or other individual or entity except as may otherwise be required by Laws and Regulations. D. Contractor shall be solely responsible for scheduling and coordinating the Work of Subcontractors, Suppliers, and other individuals or entities performing or furnishing any of the Work under a direct or indirect contract with Contractor. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 18 of 41 E. Contractor shall require all Subcontractors, Suppliers, and such other individuals or entities performing or furnishing any of the Work to communicate with Engineer through Contractor. F. The divisions and sections of the Specifications and the identifications of any Drawings shall not control Contractor in dividing the Work among Subcontractors or Suppliers or delineating the Work to be performed by any specific trade. G. All Work performed for Contractor by a Subcontractor or Supplier will be pursuant to an appropriate agreement between Contractor and the Subcontractor or Supplier which specifically binds the Subcontractor or Supplier to the applicable terms and conditions of the Contract Documents for the benefit of Owner and Engineer. Whenever any such agreement is with a Subcontractor or Supplier who is listed as a loss payee on the property insurance provided in Paragraph 5.06, the agreement between the Contractor and the Subcontractor or Supplier will contain provisions whereby the Subcontractor or Supplier waives all rights against Owner, Contractor, Engineer, and all other individuals or entities identified in the Supplementary Conditions to be listed as insureds or loss payees (and the officers, directors, members, partners, employees, agents, consultants, and subcontractors of each and any of them) for all losses and damages caused by, arising out of, relating to, or resulting from any of the perils or causes of loss covered by such policies and any other property insurance applicable to the Work. If the insurers on any such policies require separate waiver forms to be signed by any Subcontractor or Supplier, Contractor will obtain the same. 6.07 Patent Fees and Royalties A. Contractor shall pay all license fees and royalties and assume all costs incident to the use in the performance of the Work or the incorporation in the Work of any invention, design, process, product, or device which is the subject of patent rights or copyrights held by others. If a particular invention, design, process, product, or device is specified in the Contract Documents for use in the performance of the Work and if, to the actual knowledge of Owner or Engineer, its use is subject to patent rights or copyrights calling for the payment of any license fee or royalty to others, the existence of such rights shall be disclosed by Owner in the Contract Documents. B. To the fullest extent permitted by Laws and Regulations, Owner shall indemnify and hold harmless Contractor, and its officers, directors, members, partners, employees, agents, consultants, and subcontractors from and against all claims, costs, losses, and damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals, and all court or arbitration or other dispute resolution costs) arising out of or relating to any infringement of patent rights or copyrights incident to the use in the performance of the Work or resulting from the incorporation in the Work of any invention, design, process, product, or device specified in the Contract Documents, but not identified as being subject to payment of any license fee or royalty to others required by patent rights or copyrights. C. To the fullest extent permitted by Laws and Regulations, Contractor shall indemnify and hold harmless Owner and Engineer, and the officers, directors, members, partners, employees, agents, consultants and subcontractors of each and any of them from and against all claims, costs, losses, and damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) arising out of or relating to any infringement of patent rights or copyrights incident to the use in the performance of the Work or resulting from the incorporation in the Work of any invention, design, process, product, or device not specified in the Contract Documents. 6.08 Permits A. Unless otherwise provided in the Supplementary Conditions, Contractor shall obtain and pay for all construction permits and licenses. Owner shall assist Contractor, when necessary, in obtaining such permits and licenses. Contractor shall pay all governmental charges and inspection fees necessary for the prosecution of the Work which are applicable at the time of opening of Bids, or, if there are no Bids, on the Effective Date of the Agreement. Owner shall pay all charges of utility owners for connections for providing permanent service to the Work. 6.09 Laws and Regulations A. Contractor shall give all notices required by and shall comply with all Laws and Regulations applicable to the performance of the Work. Except where otherwise expressly required by applicable Laws and Regulations, neither Owner nor Engineer shall be responsible for monitoring Contractor’s compliance with any Laws or Regulations. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 19 of 41 B. If Contractor performs any Work knowing or having reason to know that it is contrary to Laws or Regulations, Contractor shall bear all claims, costs, losses, and damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) arising out of or relating to such Work. However, it shall not be Contractor’s responsibility to make certain that the Specifications and Drawings are in accordance with Laws and Regulations, but this shall not relieve Contractor of Contractor’s obligations under Paragraph 3.03. C. Changes in Laws or Regulations not known at the time of opening of Bids (or, on the Effective Date of the Agreement if there were no Bids) having an effect on the cost or time of performance of the Work shall be the subject of an adjustment in Contract Price or Contract Times. If Owner and Contractor are unable to agree on entitlement to or on the amount or extent, if any, of any such adjustment, a Claim may be made therefor as provided in Paragraph 10.05. 6.10 Taxes A. Contractor shall pay all sales, consumer, use, and other similar taxes required to be paid by Contractor in accordance with the Laws and Regulations of the place of the Project which are applicable during the performance of the Work. 6.11 Use of Site and Other Areas A. Limitation on Use of Site and Other Areas: 1. Contractor shall confine construction equipment, the storage of materials and equipment, and the operations of workers to the Site and other areas permitted by Laws and Regulations, and shall not unreasonably encumber the Site and other areas with construction equipment or other materials or equipment. Contractor shall assume full responsibility for any damage to any such land or area, or to the owner or occupant thereof, or of any adjacent land or areas resulting from the performance of the Work. 2. Should any claim be made by any such owner or occupant because of the performance of the Work, Contractor shall promptly settle with such other party by negotiation or otherwise resolve the claim by arbitration or other dispute resolution proceeding or at law. 3. To the fullest extent permitted by Laws and Regulations, Contractor shall indemnify and hold harmless Owner and Engineer, and the officers, directors, members, partners, employees, agents, consultants and subcontractors of each and any of them from and against all claims, costs, losses, and damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) arising out of or relating to any claim or action, legal or equitable, brought by any such owner or occupant against Owner, Engineer, or any other party indemnified hereunder to the extent caused by or based upon Contractor’s performance of the Work. B. Removal of Debris During Performance of the Work: During the progress of the Work Contractor shall keep the Site and other areas free from accumulations of waste materials, rubbish, and other debris. Removal and disposal of such waste materials, rubbish, and other debris shall conform to applicable Laws and Regulations. C. Cleaning: Prior to Substantial Completion of the Work Contractor shall clean the Site and the Work and make it ready for utilization by Owner. At the completion of the Work Contractor shall remove from the Site all tools, appliances, construction equipment and machinery, and surplus materials and shall restore to original condition all property not designated for alteration by the Contract Documents. D. Loading Structures: Contractor shall not load nor permit any part of any structure to be loaded in any manner that will endanger the structure, nor shall Contractor subject any part of the Work or adjacent property to stresses or pressures that will endanger it. 6.12 Record Documents A. Contractor shall maintain in a safe place at the Site one record copy of all Drawings, Specifications, Addenda, Change Orders, Work Change Directives, Field Orders, and written interpretations and clarifications in good order and annotated to show changes made during construction. These record documents together with all approved Samples and a counterpart of all approved Shop Drawings will be available to Engineer for reference. Upon completion of the Work, these record documents, Samples, and Shop Drawings will be delivered to Engineer for Owner. 6.13 Safety and Protection A. Contractor shall be solely responsible for initiating, maintaining and supervising all safety precautions and programs in connection with the Work. Such EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 20 of 41 responsibility does not relieve Subcontractors of their responsibility for the safety of persons or property in the performance of their work, nor for compliance with applicable safety Laws and Regulations. Contractor shall take all necessary precautions for the safety of, and shall provide the necessary protection to prevent damage, injury or loss to: 1. all persons on the Site or who may be affected by the Work; 2. all the Work and materials and equipment to be incorporated therein, whether in storage on or off the Site; and 3. other property at the Site or adjacent thereto, including trees, shrubs, lawns, walks, pavements, roadways, structures, utilities, and Underground Facilities not designated for removal, relocation, or replacement in the course of construction. B. Contractor shall comply with all applicable Laws and Regulations relating to the safety of persons or property, or to the protection of persons or property from damage, injury, or loss; and shall erect and maintain all necessary safeguards for such safety and protection. Contractor shall notify owners of adjacent property and of Underground Facilities and other utility owners when prosecution of the Work may affect them, and shall cooperate with them in the protection, removal, relocation, and replacement of their property. C. Contractor shall comply with the applicable requirements of Owner’s safety programs, if any. The Supplementary Conditions identify any Owner’s safety programs that are applicable to the Work. D. Contractor shall inform Owner and Engineer of the specific requirements of Contractor’s safety program with which Owner’s and Engineer’s employees and representatives must comply while at the Site. E. All damage, injury, or loss to any property referred to in Paragraph 6.13.A.2 or 6.13.A.3 caused, directly or indirectly, in whole or in part, by Contractor, any Subcontractor, Supplier, or any other individual or entity directly or indirectly employed by any of them to perform any of the Work, or anyone for whose acts any of them may be liable, shall be remedied by Contractor (except damage or loss attributable to the fault of Drawings or Specifications or to the acts or omissions of Owner or Engineer or anyone employed by any of them, or anyone for whose acts any of them may be liable, and not attributable, directly or indirectly, in whole or in part, to the fault or negligence of Contractor or any Subcontractor, Supplier, or other individual or entity directly or indirectly employed by any of them). F. Contractor’s duties and responsibilities for safety and for protection of the Work shall continue until such time as all the Work is completed and Engineer has issued a notice to Owner and Contractor in accordance with Paragraph 14.07.B that the Work is acceptable (except as otherwise expressly provided in connection with Substantial Completion). 6.14 Safety Representative A. Contractor shall designate a qualified and experienced safety representative at the Site whose duties and responsibilities shall be the prevention of accidents and the maintaining and supervising of safety precautions and programs. 6.15 Hazard Communication Programs A. Contractor shall be responsible for coordinating any exchange of material safety data sheets or other hazard communication information required to be made available to or exchanged between or among employers at the Site in accordance with Laws or Regulations. 6.16 Emergencies A. In emergencies affecting the safety or protection of persons or the Work or property at the Site or adjacent thereto, Contractor is obligated to act to prevent threatened damage, injury, or loss. Contractor shall give Engineer prompt written notice if Contractor believes that any significant changes in the Work or variations from the Contract Documents have been caused thereby or are required as a result thereof. If Engineer determines that a change in the Contract Documents is required because of the action taken by Contractor in response to such an emergency, a Work Change Directive or Change Order will be issued. 6.17 Shop Drawings and Samples A. Contractor shall submit Shop Drawings and Samples to Engineer for review and approval in accordance with the accepted Schedule of Submittals (as required by Paragraph 2.07). Each submittal will be identified as Engineer may require. 1. Shop Drawings: a. Submit number of copies specified in the General Requirements. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 21 of 41 b. Data shown on the Shop Drawings will be complete with respect to quantities, dimensions, specified performance and design criteria, materials, and similar data to show Engineer the services, materials, and equipment Contractor proposes to provide and to enable Engineer to review the information for the limited purposes required by Paragraph 6.17.D. 2. Samples: a. Submit number of Samples specified in the Specifications. b. Clearly identify each Sample as to material, Supplier, pertinent data such as catalog numbers, the use for which intended and other data as Engineer may require to enable Engineer to review the submittal for the limited purposes required by Paragraph 6.17.D. B. Where a Shop Drawing or Sample is required by the Contract Documents or the Schedule of Submittals, any related Work performed prior to Engineer’s review and approval of the pertinent submittal will be at the sole expense and responsibility of Contractor. C. Submittal Procedures: 1. Before submitting each Shop Drawing or Sample, Contractor shall have: a. reviewed and coordinated each Shop Drawing or Sample with other Shop Drawings and Samples and with the requirements of the Work and the Contract Documents; b. determined and verified all field measurements, quantities, dimensions, specified performance and design criteria, installation requirements, materials, catalog numbers, and similar information with respect thereto; c. determined and verified the suitability of all materials offered with respect to the indicated application, fabrication, shipping, handling, storage, assembly, and installation pertaining to the performance of the Work; and d. determined and verified all information relative to Contractor’s responsibilities for means, methods, techniques, sequences, and procedures of construction, and safety precautions and programs incident thereto. 2. Each submittal shall bear a stamp or specific written certification that Contractor has satisfied Contractor’s obligations under the Contract Documents with respect to Contractor’s review and approval of that submittal. 3. With each submittal, Contractor shall give Engineer specific written notice of any variations that the Shop Drawing or Sample may have from the requirements of the Contract Documents. This notice shall be both a written communication separate from the Shop Drawings or Sample submittal; and, in addition, by a specific notation made on each Shop Drawing or Sample submitted to Engineer for review and approval of each such variation. D. Engineer’s Review: 1. Engineer will provide timely review of Shop Drawings and Samples in accordance with the Schedule of Submittals acceptable to Engineer. Engineer’s review and approval will be only to determine if the items covered by the submittals will, after installation or incorporation in the Work, conform to the information given in the Contract Documents and be compatible with the design concept of the completed Project as a functioning whole as indicated by the Contract Documents. 2. Engineer’s review and approval will not extend to means, methods, techniques, sequences, or procedures of construction (except where a particular means, method, technique, sequence, or procedure of construction is specifically and expressly called for by the Contract Documents) or to safety precautions or programs incident thereto. The review and approval of a separate item as such will not indicate approval of the assembly in which the item functions. 3. Engineer’s review and approval shall not relieve Contractor from responsibility for any variation from the requirements of the Contract Documents unless Contractor has complied with the requirements of Paragraph 6.17.C.3 and Engineer has given written approval of each such variation by specific written notation thereof incorporated in or accompanying the Shop Drawing or Sample. Engineer’s review and approval shall not relieve Contractor from responsibility for complying with the requirements of Paragraph 6.17.C.1. E. Resubmittal Procedures: EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 22 of 41 1. Contractor shall make corrections required by Engineer and shall return the required number of corrected copies of Shop Drawings and submit, as required, new Samples for review and approval. Contractor shall direct specific attention in writing to revisions other than the corrections called for by Engineer on previous submittals. 6.18 Continuing the Work A. Contractor shall carry on the Work and adhere to the Progress Schedule during all disputes or disagreements with Owner. No Work shall be delayed or postponed pending resolution of any disputes or disagreements, except as permitted by Paragraph 15.04 or as Owner and Contractor may otherwise agree in writing. 6.19 Contractor’s General Warranty and Guarantee A. Contractor warrants and guarantees to Owner that all Work will be in accordance with the Contract Documents and will not be defective. Engineer and its officers, directors, members, partners, employees, agents, consultants, and subcontractors shall be entitled to rely on representation of Contractor’s warranty and guarantee. B. Contractor’s warranty and guarantee hereunder excludes defects or damage caused by: 1. abuse, modification, or improper maintenance or operation by persons other than Contractor, Subcontractors, Suppliers, or any other individual or entity for whom Contractor is responsible; or 2. normal wear and tear under normal usage. C. Contractor’s obligation to perform and complete the Work in accordance with the Contract Documents shall be absolute. None of the following will constitute an acceptance of Work that is not in accordance with the Contract Documents or a release of Contractor’s obligation to perform the Work in accordance with the Contract Documents: 1. observations by Engineer; 2. recommendation by Engineer or payment by Owner of any progress or final payment; 3. the issuance of a certificate of Substantial Completion by Engineer or any payment related thereto by Owner; 4. use or occupancy of the Work or any part thereof by Owner; 5. any review and approval of a Shop Drawing or Sample submittal or the issuance of a notice of acceptability by Engineer; 6. any inspection, test, or approval by others; or 7. any correction of defective Work by Owner. 6.20 Indemnification A. To the fullest extent permitted by Laws and Regulations, Contractor shall indemnify and hold harmless Owner and Engineer, and the officers, directors, members, partners, employees, agents, consultants and subcontractors of each and any of them from and against all claims, costs, losses, and damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) arising out of or relating to the performance of the Work, provided that any such claim, cost, loss, or damage is attributable to bodily injury, sickness, disease, or death, or to injury to or destruction of tangible property (other than the Work itself), including the loss of use resulting therefrom but only to the extent caused by any negligent act or omission of Contractor, any Subcontractor, any Supplier, or any individual or entity directly or indirectly employed by any of them to perform any of the Work or anyone for whose acts any of them may be liable . B. In any and all claims against Owner or Engineer or any of their officers, directors, members, partners, employees, agents, consultants, or subcontractors by any employee (or the survivor or personal representative of such employee) of Contractor, any Subcontractor, any Supplier, or any individual or entity directly or indirectly employed by any of them to perform any of the Work, or anyone for whose acts any of them may be liable, the indemnification obligation under Paragraph 6.20.A shall not be limited in any way by any limitation on the amount or type of damages, compensation, or benefits payable by or for Contractor or any such Subcontractor, Supplier, or other individual or entity under workers’ compensation acts, disability benefit acts, or other employee benefit acts. C. The indemnification obligations of Contractor under Paragraph 6.20.A shall not extend to the liability of Engineer and Engineer’s officers, directors, members, partners, employees, agents, consultants and subcontractors arising out of: EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 23 of 41 1. the preparation or approval of, or the failure to prepare or approve maps, Drawings, opinions, reports, surveys, Change Orders, designs, or Specifications; or 2. giving directions or instructions, or failing to give them, if that is the primary cause of the injury or damage. 6.21 Delegation of Professional Design Services A. Contractor will not be required to provide professional design services unless such services are specifically required by the Contract Documents for a portion of the Work or unless such services are required to carry out Contractor’s responsibilities for construction means, methods, techniques, sequences and procedures. Contractor shall not be required to provide professional services in violation of applicable law. B. If professional design services or certifications by a design professional related to systems, materials or equipment are specifically required of Contractor by the Contract Documents, Owner and Engineer will specify all performance and design criteria that such services must satisfy. Contractor shall cause such services or certifications to be provided by a properly licensed professional, whose signature and seal shall appear on all drawings, calculations, specifications, certifications, Shop Drawings and other submittals prepared by such professional. Shop Drawings and other submittals related to the Work designed or certified by such professional, if prepared by others, shall bear such professional’s written approval when submitted to Engineer. C. Owner and Engineer shall be entitled to rely upon the adequacy, accuracy and completeness of the services, certifications or approvals performed by such design professionals, provided Owner and Engineer have specified to Contractor all performance and design criteria that such services must satisfy. D. Pursuant to this Paragraph 6.21, Engineer’s review and approval of design calculations and design drawings will be only for the limited purpose of checking for conformance with performance and design criteria given and the design concept expressed in the Contract Documents. Engineer’s review and approval of Shop Drawings and other submittals (except design calculations and design drawings) will be only for the purpose stated in Paragraph 6.17.D.1. E. Contractor shall not be responsible for the adequacy of the performance or design criteria required by the Contract Documents. ARTICLE 7 – OTHER WORK AT THE SITE 7.01 Related Work at Site A. Owner may perform other work related to the Project at the Site with Owner’s employees, or through other direct contracts therefor, or have other work performed by utility owners. If such other work is not noted in the Contract Documents, then: 1. written notice thereof will be given to Contractor prior to starting any such other work; and 2. if Owner and Contractor are unable to agree on entitlement to or on the amount or extent, if any, of any adjustment in the Contract Price or Contract Times that should be allowed as a result of such other work, a Claim may be made therefor as provided in Paragraph 10.05. B. Contractor shall afford each other contractor who is a party to such a direct contract, each utility owner, and Owner, if Owner is performing other work with Owner’s employees, proper and safe access to the Site, provide a reasonable opportunity for the introduction and storage of materials and equipment and the execution of such other work, and properly coordinate the Work with theirs. Contractor shall do all cutting, fitting, and patching of the Work that may be required to properly connect or otherwise make its several parts come together and properly integrate with such other work. Contractor shall not endanger any work of others by cutting, excavating, or otherwise altering such work; provided, however, that Contractor may cut or alter others' work with the written consent of Engineer and the others whose work will be affected. The duties and responsibilities of Contractor under this Paragraph are for the benefit of such utility owners and other contractors to the extent that there are comparable provisions for the benefit of Contractor in said direct contracts between Owner and such utility owners and other contractors. C. If the proper execution or results of any part of Contractor’s Work depends upon work performed by others under this Article 7, Contractor shall inspect such other work and promptly report to Engineer in writing any delays, defects, or deficiencies in such other work that render it unavailable or unsuitable for the proper execution and results of Contractor’s Work. Contractor’s failure to so report will constitute an acceptance of such other work as fit and proper for integration with Contractor’s Work except for latent defects and deficiencies in such other work. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 24 of 41 7.02 Coordination A. If Owner intends to contract with others for the performance of other work on the Project at the Site, the following will be set forth in Supplementary Conditions: 1. the individual or entity who will have authority and responsibility for coordination of the activities among the various contractors will be identified; 2. the specific matters to be covered by such authority and responsibility will be itemized; and 3. the extent of such authority and responsibilities will be provided. B. Unless otherwise provided in the Supplementary Conditions, Owner shall have sole authority and responsibility for such coordination. 7.03 Legal Relationships A. Paragraphs 7.01.A and 7.02 are not applicable for utilities not under the control of Owner. B. Each other direct contract of Owner under Paragraph 7.01.A shall provide that the other contractor is liable to Owner and Contractor for the reasonable direct delay and disruption costs incurred by Contractor as a result of the other contractor’s wrongful actions or inactions. C. Contractor shall be liable to Owner and any other contractor under direct contract to Owner for the reasonable direct delay and disruption costs incurred by such other contractor as a result of Contractor’s wrongful action or inactions. ARTICLE 8 – OWNER’S RESPONSIBILITIES 8.01 Communications to Contractor A. Except as otherwise provided in these General Conditions, Owner shall issue all communications to Contractor through Engineer. 8.02 Replacement of Engineer A. In case of termination of the employment of Engineer, Owner shall appoint an engineer to whom Contractor makes no reasonable objection, whose status under the Contract Documents shall be that of the former Engineer. 8.03 Furnish Data A. Owner shall promptly furnish the data required of Owner under the Contract Documents. 8.04 Pay When Due A. Owner shall make payments to Contractor when they are due as provided in Paragraphs 14.02.C and 14.07.C. 8.05 Lands and Easements; Reports and Tests A. Owner’s duties with respect to providing lands and easements and providing engineering surveys to establish reference points are set forth in Paragraphs 4.01 and 4.05. Paragraph 4.02 refers to Owner’s identifying and making available to Contractor copies of reports of explorations and tests of subsurface conditions and drawings of physical conditions relating to existing surface or subsurface structures at the Site. 8.06 Insurance A. Owner’s responsibilities, if any, with respect to purchasing and maintaining liability and property insurance are set forth in Article 5. 8.07 Change Orders A. Owner is obligated to execute Change Orders as indicated in Paragraph 10.03. 8.08 Inspections, Tests, and Approvals A. Owner’s responsibility with respect to certain inspections, tests, and approvals is set forth in Paragraph 13.03.B. 8.09 Limitations on Owner’s Responsibilities A. The Owner shall not supervise, direct, or have control or authority over, nor be responsible for, Contractor’s means, methods, techniques, sequences, or procedures of construction, or the safety precautions and programs incident thereto, or for any failure of Contractor to comply with Laws and Regulations applicable to the performance of the Work. Owner will not be responsible for Contractor’s failure to perform the Work in accordance with the Contract Documents. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 25 of 41 8.10 Undisclosed Hazardous Environmental Condition A. Owner’s responsibility in respect to an undisclosed Hazardous Environmental Condition is set forth in Paragraph 4.06. 8.11 Evidence of Financial Arrangements A. Upon request of Contractor, Owner shall furnish Contractor reasonable evidence that financial arrangements have been made to satisfy Owner’s obligations under the Contract Documents. 8.12 Compliance with Safety Program A. While at the Site, Owner’s employees and representatives shall comply with the specific applicable requirements of Contractor’s safety programs of which Owner has been informed pursuant to Paragraph 6.13.D. ARTICLE 9 – ENGINEER’S STATUS DURING CONSTRUCTION 9.01 Owner’s Representative A. Engineer will be Owner’s representative during the construction period. The duties and responsibilities and the limitations of authority of Engineer as Owner’s representative during construction are set forth in the Contract Documents. 9.02 Visits to Site A. Engineer will make visits to the Site at intervals appropriate to the various stages of construction as Engineer deems necessary in order to observe as an experienced and qualified design professional the progress that has been made and the quality of the various aspects of Contractor’s executed Work. Based on information obtained during such visits and observations, Engineer, for the benefit of Owner, will determine, in general, if the Work is proceeding in accordance with the Contract Documents. Engineer will not be required to make exhaustive or continuous inspections on the Site to check the quality or quantity of the Work. Engineer’s efforts will be directed toward providing for Owner a greater degree of confidence that the completed Work will conform generally to the Contract Documents. On the basis of such visits and observations, Engineer will keep Owner informed of the progress of the Work and will endeavor to guard Owner against defective Work. B. Engineer’s visits and observations are subject to all the limitations on Engineer’s authority and responsibility set forth in Paragraph 9.09. Particularly, but without limitation, during or as a result of Engineer’s visits or observations of Contractor’s Work, Engineer will not supervise, direct, control, or have authority over or be responsible for Contractor’s means, methods, techniques, sequences, or procedures of construction, or the safety precautions and programs incident thereto, or for any failure of Contractor to comply with Laws and Regulations applicable to the performance of the Work. 9.03 Project Representative A. If Owner and Engineer agree, Engineer will furnish a Resident Project Representative to assist Engineer in providing more extensive observation of the Work. The authority and responsibilities of any such Resident Project Representative and assistants will be as provided in the Supplementary Conditions, and limitations on the responsibilities thereof will be as provided in Paragraph 9.09. If Owner designates another representative or agent to represent Owner at the Site who is not Engineer’s consultant, agent or employee, the responsibilities and authority and limitations thereon of such other individual or entity will be as provided in the Supplementary Conditions. 9.04 Authorized Variations in Work A. Engineer may authorize minor variations in the Work from the requirements of the Contract Documents which do not involve an adjustment in the Contract Price or the Contract Times and are compatible with the design concept of the completed Project as a functioning whole as indicated by the Contract Documents. These may be accomplished by a Field Order and will be binding on Owner and also on Contractor, who shall perform the Work involved promptly. If Owner or Contractor believes that a Field Order justifies an adjustment in the Contract Price or Contract Times, or both, and the parties are unable to agree on entitlement to or on the amount or extent, if any, of any such adjustment, a Claim may be made therefor as provided in Paragraph 10.05. 9.05 Rejecting Defective Work A. Engineer will have authority to reject Work which Engineer believes to be defective, or that Engineer believes will not produce a completed Project that conforms to the Contract Documents or that will prejudice the integrity of the design concept of the completed Project as a functioning whole as indicated by the Contract Documents. Engineer will also have EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 26 of 41 authority to require special inspection or testing of the Work as provided in Paragraph 13.04, whether or not the Work is fabricated, installed, or completed. 9.06 Shop Drawings, Change Orders and Payments A. In connection with Engineer’s authority, and limitations thereof, as to Shop Drawings and Samples, see Paragraph 6.17. B. In connection with Engineer’s authority, and limitations thereof, as to design calculations and design drawings submitted in response to a delegation of professional design services, if any, see Paragraph 6.21. C. In connection with Engineer’s authority as to Change Orders, see Articles 10, 11, and 12. D. In connection with Engineer’s authority as to Applications for Payment, see Article 14. 9.07 Determinations for Unit Price Work A. Engineer will determine the actual quantities and classifications of Unit Price Work performed by Contractor. Engineer will review with Contractor the Engineer’s preliminary determinations on such matters before rendering a written decision thereon (by recommendation of an Application for Payment or otherwise). Engineer’s written decision thereon will be final and binding (except as modified by Engineer to reflect changed factual conditions or more accurate data) upon Owner and Contractor, subject to the provisions of Paragraph 10.05. 9.08 Decisions on Requirements of Contract Documents and Acceptability of Work A. Engineer will be the initial interpreter of the requirements of the Contract Documents and judge of the acceptability of the Work thereunder. All matters in question and other matters between Owner and Contractor arising prior to the date final payment is due relating to the acceptability of the Work, and the interpretation of the requirements of the Contract Documents pertaining to the performance of the Work, will be referred initially to Engineer in writing within 30 days of the event giving rise to the question. B. Engineer will, with reasonable promptness, render a written decision on the issue referred. If Owner or Contractor believes that any such decision entitles them to an adjustment in the Contract Price or Contract Times or both, a Claim may be made under Paragraph 10.05. The date of Engineer’s decision shall be the date of the event giving rise to the issues referenced for the purposes of Paragraph 10.05.B. C. Engineer’s written decision on the issue referred will be final and binding on Owner and Contractor, subject to the provisions of Paragraph 10.05. D. When functioning as interpreter and judge under this Paragraph 9.08, Engineer will not show partiality to Owner or Contractor and will not be liable in connection with any interpretation or decision rendered in good faith in such capacity. 9.09 Limitations on Engineer’s Authority and Responsibilities A. Neither Engineer’s authority or responsibility under this Article 9 or under any other provision of the Contract Documents nor any decision made by Engineer in good faith either to exercise or not exercise such authority or responsibility or the undertaking, exercise, or performance of any authority or responsibility by Engineer shall create, impose, or give rise to any duty in contract, tort, or otherwise owed by Engineer to Contractor, any Subcontractor, any Supplier, any other individual or entity, or to any surety for or employee or agent of any of them. B. Engineer will not supervise, direct, control, or have authority over or be responsible for Contractor’s means, methods, techniques, sequences, or procedures of construction, or the safety precautions and programs incident thereto, or for any failure of Contractor to comply with Laws and Regulations applicable to the performance of the Work. Engineer will not be responsible for Contractor’s failure to perform the Work in accordance with the Contract Documents. C. Engineer will not be responsible for the acts or omissions of Contractor or of any Subcontractor, any Supplier, or of any other individual or entity performing any of the Work. D. Engineer’s review of the final Application for Payment and accompanying documentation and all maintenance and operating instructions, schedules, guarantees, bonds, certificates of inspection, tests and approvals, and other documentation required to be delivered by Paragraph 14.07.A will only be to determine generally that their content complies with the requirements of, and in the case of certificates of inspections, tests, and approvals that the results certified indicate compliance with, the Contract Documents. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 27 of 41 E. The limitations upon authority and responsibility set forth in this Paragraph 9.09 shall also apply to the Resident Project Representative, if any, and assistants, if any. 9.10 Compliance with Safety Program A. While at the Site, Engineer’s employees and representatives shall comply with the specific applicable requirements of Contractor’s safety programs of which Engineer has been informed pursuant to Paragraph 6.13.D. ARTICLE 10 – CHANGES IN THE WORK; CLAIMS 10.01 Authorized Changes in the Work A. Without invalidating the Contract and without notice to any surety, Owner may, at any time or from time to time, order additions, deletions, or revisions in the Work by a Change Order, or a Work Change Directive. Upon receipt of any such document, Contractor shall promptly proceed with the Work involved which will be performed under the applicable conditions of the Contract Documents (except as otherwise specifically provided). B. If Owner and Contractor are unable to agree on entitlement to, or on the amount or extent, if any, of an adjustment in the Contract Price or Contract Times, or both, that should be allowed as a result of a Work Change Directive, a Claim may be made therefor as provided in Paragraph 10.05. 10.02 Unauthorized Changes in the Work A. Contractor shall not be entitled to an increase in the Contract Price or an extension of the Contract Times with respect to any work performed that is not required by the Contract Documents as amended, modified, or supplemented as provided in Paragraph 3.04, except in the case of an emergency as provided in Paragraph 6.16 or in the case of uncovering Work as provided in Paragraph 13.04.D. 10.03 Execution of Change Orders A. Owner and Contractor shall execute appropriate Change Orders recommended by Engineer covering: 1. changes in the Work which are: (i) ordered by Owner pursuant to Paragraph 10.01.A, (ii) required because of acceptance of defective Work under Paragraph 13.08.A or Owner’s correction of defective Work under Paragraph 13.09, or (iii) agreed to by the parties; 2. changes in the Contract Price or Contract Times which are agreed to by the parties, including any undisputed sum or amount of time for Work actually performed in accordance with a Work Change Directive; and 3. changes in the Contract Price or Contract Times which embody the substance of any written decision rendered by Engineer pursuant to Paragraph 10.05; provided that, in lieu of executing any such Change Order, an appeal may be taken from any such decision in accordance with the provisions of the Contract Documents and applicable Laws and Regulations, but during any such appeal, Contractor shall carry on the Work and adhere to the Progress Schedule as provided in Paragraph 6.18.A. 10.04 Notification to Surety A. If the provisions of any bond require notice to be given to a surety of any change affecting the general scope of the Work or the provisions of the Contract Documents (including, but not limited to, Contract Price or Contract Times), the giving of any such notice will be Contractor’s responsibility. The amount of each applicable bond will be adjusted to reflect the effect of any such change. 10.05 Claims A. Engineer’s Decision Required: All Claims, except those waived pursuant to Paragraph 14.09, shall be referred to the Engineer for decision. A decision by Engineer shall be required as a condition precedent to any exercise by Owner or Contractor of any rights or remedies either may otherwise have under the Contract Documents or by Laws and Regulations in respect of such Claims. B. Notice: Written notice stating the general nature of each Claim shall be delivered by the claimant to Engineer and the other party to the Contract promptly (but in no event later than 30 days) after the start of the event giving rise thereto. The responsibility to substantiate a Claim shall rest with the party making the Claim. Notice of the amount or extent of the Claim, with supporting data shall be delivered to the Engineer and the other party to the Contract within 60 days after the start of such event (unless Engineer allows additional time for claimant to submit additional or more accurate data in support of such Claim). A Claim for an adjustment in Contract Price shall be prepared in EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 28 of 41 accordance with the provisions of Paragraph 12.01.B. A Claim for an adjustment in Contract Times shall be prepared in accordance with the provisions of Paragraph 12.02.B. Each Claim shall be accompanied by claimant’s written statement that the adjustment claimed is the entire adjustment to which the claimant believes it is entitled as a result of said event. The opposing party shall submit any response to Engineer and the claimant within 30 days after receipt of the claimant’s last submittal (unless Engineer allows additional time). C. Engineer’s Action: Engineer will review each Claim and, within 30 days after receipt of the last submittal of the claimant or the last submittal of the opposing party, if any, take one of the following actions in writing: 1. deny the Claim in whole or in part; 2. approve the Claim; or 3. notify the parties that the Engineer is unable to resolve the Claim if, in the Engineer’s sole discretion, it would be inappropriate for the Engineer to do so. For purposes of further resolution of the Claim, such notice shall be deemed a denial. D. In the event that Engineer does not take action on a Claim within said 30 days, the Claim shall be deemed denied. E. Engineer’s written action under Paragraph 10.05.C or denial pursuant to Paragraphs 10.05.C.3 or 10.05.D will be final and binding upon Owner and Contractor, unless Owner or Contractor invoke the dispute resolution procedure set forth in Article 16 within 30 days of such action or denial. F. No Claim for an adjustment in Contract Price or Contract Times will be valid if not submitted in accordance with this Paragraph 10.05. ARTICLE 11 – COST OF THE WORK; ALLOWANCES; UNIT PRICE WORK 11.01 Cost of the Work A. Costs Included: The term Cost of the Work means the sum of all costs, except those excluded in Paragraph 11.01.B, necessarily incurred and paid by Contractor in the proper performance of the Work. When the value of any Work covered by a Change Order or when a Claim for an adjustment in Contract Price is determined on the basis of Cost of the Work, the costs to be reimbursed to Contractor will be only those additional or incremental costs required because of the change in the Work or because of the event giving rise to the Claim. Except as otherwise may be agreed to in writing by Owner, such costs shall be in amounts no higher than those prevailing in the locality of the Project, shall not include any of the costs itemized in Paragraph 11.01.B, and shall include only the following items: 1. Payroll costs for employees in the direct employ of Contractor in the performance of the Work under schedules of job classifications agreed upon by Owner and Contractor. Such employees shall include, without limitation, superintendents, foremen, and other personnel employed full time on the Work. Payroll costs for employees not employed full time on the Work shall be apportioned on the basis of their time spent on the Work. Payroll costs shall include, but not be limited to, salaries and wages plus the cost of fringe benefits, which shall include social security contributions, unemployment, excise, and payroll taxes, workers’ compensation, health and retirement benefits, bonuses, sick leave, vacation and holiday pay applicable thereto. The expenses of performing Work outside of regular working hours, on Saturday, Sunday, or legal holidays, shall be included in the above to the extent authorized by Owner. 2. Cost of all materials and equipment furnished and incorporated in the Work, including costs of transportation and storage thereof, and Suppliers’ field services required in connection therewith. All cash discounts shall accrue to Contractor unless Owner deposits funds with Contractor with which to make payments, in which case the cash discounts shall accrue to Owner. All trade discounts, rebates and refunds and returns from sale of surplus materials and equipment shall accrue to Owner, and Contractor shall make provisions so that they may be obtained. 3. Payments made by Contractor to Subcontractors for Work performed by Subcontractors. If required by Owner, Contractor shall obtain competitive bids from subcontractors acceptable to Owner and Contractor and shall deliver such bids to Owner, who will then determine, with the advice of Engineer, which bids, if any, will be acceptable. If any subcontract provides that the Subcontractor is to be paid on the basis of Cost of the Work plus a fee, the Subcontractor’s Cost of the Work and fee shall be determined in the same manner as Contractor’s Cost of the Work and fee as provided in this Paragraph 11.01. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 29 of 41 4. Costs of special consultants (including but not limited to engineers, architects, testing laboratories, surveyors, attorneys, and accountants) employed for services specifically related to the Work. 5. Supplemental costs including the following: a. The proportion of necessary transportation, travel, and subsistence expenses of Contractor’s employees incurred in discharge of duties connected with the Work. b. Cost, including transportation and maintenance, of all materials, supplies, equipment, machinery, appliances, office, and temporary facilities at the Site, and hand tools not owned by the workers, which are consumed in the performance of the Work, and cost, less market value, of such items used but not consumed which remain the property of Contractor. c. Rentals of all construction equipment and machinery, and the parts thereof whether rented from Contractor or others in accordance with rental agreements approved by Owner with the advice of Engineer, and the costs of transportation, loading, unloading, assembly, dismantling, and removal thereof. All such costs shall be in accordance with the terms of said rental agreements. The rental of any such equipment, machinery, or parts shall cease when the use thereof is no longer necessary for the Work. d. Sales, consumer, use, and other similar taxes related to the Work, and for which Contractor is liable, as imposed by Laws and Regulations. e. Deposits lost for causes other than negligence of Contractor, any Subcontractor, or anyone directly or indirectly employed by any of them or for whose acts any of them may be liable, and royalty payments and fees for permits and licenses. f. Losses and damages (and related expenses) caused by damage to the Work, not compensated by insurance or otherwise, sustained by Contractor in connection with the performance of the Work (except losses and damages within the deductible amounts of property insurance established in accordance with Paragraph 5.06.D), provided such losses and damages have resulted from causes other than the negligence of Contractor, any Subcontractor, or anyone directly or indirectly employed by any of them or for whose acts any of them may be liable. Such losses shall include settlements made with the written consent and approval of Owner. No such losses, damages, and expenses shall be included in the Cost of the Work for the purpose of determining Contractor’s fee. g. The cost of utilities, fuel, and sanitary facilities at the Site. h. Minor expenses such as telegrams, long distance telephone calls, telephone service at the Site, express and courier services, and similar petty cash items in connection with the Work. i. The costs of premiums for all bonds and insurance Contractor is required by the Contract Documents to purchase and maintain. B. Costs Excluded: The term Cost of the Work shall not include any of the following items: 1. Payroll costs and other compensation of Contractor’s officers, executives, principals (of partnerships and sole proprietorships), general managers, safety managers, engineers, architects, estimators, attorneys, auditors, accountants, purchasing and contracting agents, expediters, timekeepers, clerks, and other personnel employed by Contractor, whether at the Site or in Contractor’s principal or branch office for general administration of the Work and not specifically included in the agreed upon schedule of job classifications referred to in Paragraph 11.01.A.1 or specifically covered by Paragraph 11.01.A.4, all of which are to be considered administrative costs covered by the Contractor’s fee. 2. Expenses of Contractor’s principal and branch offices other than Contractor’s office at the Site. 3. Any part of Contractor’s capital expenses, including interest on Contractor’s capital employed for the Work and charges against Contractor for delinquent payments. 4. Costs due to the negligence of Contractor, any Subcontractor, or anyone directly or indirectly employed by any of them or for whose acts any of them may be liable, including but not limited to, the correction of defective Work, disposal of materials or equipment wrongly supplied, and making good any damage to property. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 30 of 41 5. Other overhead or general expense costs of any kind and the costs of any item not specifically and expressly included in Paragraphs 11.01.A. C. Contractor’s Fee: When all the Work is performed on the basis of cost-plus, Contractor’s fee shall be determined as set forth in the Agreement. When the value of any Work covered by a Change Order or when a Claim for an adjustment in Contract Price is determined on the basis of Cost of the Work, Contractor’s fee shall be determined as set forth in Paragraph 12.01.C. D. Documentation: Whenever the Cost of the Work for any purpose is to be determined pursuant to Paragraphs 11.01.A and 11.01.B, Contractor will establish and maintain records thereof in accordance with generally accepted accounting practices and submit in a form acceptable to Engineer an itemized cost breakdown together with supporting data. 11.02 Allowances A. It is understood that Contractor has included in the Contract Price all allowances so named in the Contract Documents and shall cause the Work so covered to be performed for such sums and by such persons or entities as may be acceptable to Owner and Engineer. B. Cash Allowances: 1. Contractor agrees that: a. the cash allowances include the cost to Contractor (less any applicable trade discounts) of materials and equipment required by the allowances to be delivered at the Site, and all applicable taxes; and b. Contractor’s costs for unloading and handling on the Site, labor, installation, overhead, profit, and other expenses contemplated for the cash allowances have been included in the Contract Price and not in the allowances, and no demand for additional payment on account of any of the foregoing will be valid. C. Contingency Allowance: 1. Contractor agrees that a contingency allowance, if any, is for the sole use of Owner to cover unanticipated costs. D. Prior to final payment, an appropriate Change Order will be issued as recommended by Engineer to reflect actual amounts due Contractor on account of Work covered by allowances, and the Contract Price shall be correspondingly adjusted. 11.03 Unit Price Work A. Where the Contract Documents provide that all or part of the Work is to be Unit Price Work, initially the Contract Price will be deemed to include for all Unit Price Work an amount equal to the sum of the unit price for each separately identified item of Unit Price Work times the estimated quantity of each item as indicated in the Agreement. B. The estimated quantities of items of Unit Price Work are not guaranteed and are solely for the purpose of comparison of Bids and determining an initial Contract Price. Determinations of the actual quantities and classifications of Unit Price Work performed by Contractor will be made by Engineer subject to the provisions of Paragraph 9.07. C. Each unit price will be deemed to include an amount considered by Contractor to be adequate to cover Contractor’s overhead and profit for each separately identified item. D. Owner or Contractor may make a Claim for an adjustment in the Contract Price in accordance with Paragraph 10.05 if: 1. the quantity of any item of Unit Price Work performed by Contractor differs materially and significantly from the estimated quantity of such item indicated in the Agreement; and 2. there is no corresponding adjustment with respect to any other item of Work; and 3. Contractor believes that Contractor is entitled to an increase in Contract Price as a result of having incurred additional expense or Owner believes that Owner is entitled to a decrease in Contract Price and the parties are unable to agree as to the amount of any such increase or decrease. ARTICLE 12 – CHANGE OF CONTRACT PRICE; CHANGE OF CONTRACT TIMES 12.01 Change of Contract Price A. The Contract Price may only be changed by a Change Order. Any Claim for an adjustment in the Contract Price shall be based on written notice submitted by the party making the Claim to the Engineer EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 31 of 41 and the other party to the Contract in accordance with the provisions of Paragraph 10.05. B. The value of any Work covered by a Change Order or of any Claim for an adjustment in the Contract Price will be determined as follows: 1. where the Work involved is covered by unit prices contained in the Contract Documents, by application of such unit prices to the quantities of the items involved (subject to the provisions of Paragraph 11.03); or 2. where the Work involved is not covered by unit prices contained in the Contract Documents, by a mutually agreed lump sum (which may include an allowance for overhead and profit not necessarily in accordance with Paragraph 12.01.C.2); or 3. where the Work involved is not covered by unit prices contained in the Contract Documents and agreement to a lump sum is not reached under Paragraph 12.01.B.2, on the basis of the Cost of the Work (determined as provided in Paragraph 11.01) plus a Contractor’s fee for overhead and profit (determined as provided in Paragraph 12.01.C). C. Contractor’s Fee: The Contractor’s fee for overhead and profit shall be determined as follows: 1. a mutually acceptable fixed fee; or 2. if a fixed fee is not agreed upon, then a fee based on the following percentages of the various portions of the Cost of the Work: a. for costs incurred under Paragraphs 11.01.A.1 and 11.01.A.2, the Contractor’s fee shall be 15 percent; b. for costs incurred under Paragraph 11.01.A.3, the Contractor’s fee shall be five percent; c. where one or more tiers of subcontracts are on the basis of Cost of the Work plus a fee and no fixed fee is agreed upon, the intent of Paragraphs 12.01.C.2.a and 12.01.C.2.b is that the Subcontractor who actually performs the Work, at whatever tier, will be paid a fee of 15 percent of the costs incurred by such Subcontractor under Paragraphs 11.01.A.1 and 11.01.A.2 and that any higher tier Subcontractor and Contractor will each be paid a fee of five percent of the amount paid to the next lower tier Subcontractor; d. no fee shall be payable on the basis of costs itemized under Paragraphs 11.01.A.4, 11.01.A.5, and 11.01.B; e. the amount of credit to be allowed by Contractor to Owner for any change which results in a net decrease in cost will be the amount of the actual net decrease in cost plus a deduction in Contractor’s fee by an amount equal to five percent of such net decrease; and f. when both additions and credits are involved in any one change, the adjustment in Contractor’s fee shall be computed on the basis of the net change in accordance with Paragraphs 12.01.C.2.a through 12.01.C.2.e, inclusive. 12.02 Change of Contract Times A. The Contract Times may only be changed by a Change Order. Any Claim for an adjustment in the Contract Times shall be based on written notice submitted by the party making the Claim to the Engineer and the other party to the Contract in accordance with the provisions of Paragraph 10.05. B. Any adjustment of the Contract Times covered by a Change Order or any Claim for an adjustment in the Contract Times will be determined in accordance with the provisions of this Article 12. 12.03 Delays A. Where Contractor is prevented from completing any part of the Work within the Contract Times due to delay beyond the control of Contractor, the Contract Times will be extended in an amount equal to the time lost due to such delay if a Claim is made therefor as provided in Paragraph 12.02.A. Delays beyond the control of Contractor shall include, but not be limited to, acts or neglect by Owner, acts or neglect of utility owners or other contractors performing other work as contemplated by Article 7, fires, floods, epidemics, abnormal weather conditions, or acts of God. B. If Owner, Engineer, or other contractors or utility owners performing other work for Owner as contemplated by Article 7, or anyone for whom Owner is responsible, delays, disrupts, or interferes with the performance or progress of the Work, then Contractor shall be entitled to an equitable adjustment in the Contract Price or the Contract Times, or both. Contractor’s entitlement to an adjustment of the Contract Times is conditioned on such adjustment being essential EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 32 of 41 to Contractor’s ability to complete the Work within the Contract Times. C. If Contractor is delayed in the performance or progress of the Work by fire, flood, epidemic, abnormal weather conditions, acts of God, acts or failures to act of utility owners not under the control of Owner, or other causes not the fault of and beyond control of Owner and Contractor, then Contractor shall be entitled to an equitable adjustment in Contract Times, if such adjustment is essential to Contractor’s ability to complete the Work within the Contract Times. Such an adjustment shall be Contractor’s sole and exclusive remedy for the delays described in this Paragraph 12.03.C. D. Owner, Engineer, and their officers, directors, members, partners, employees, agents, consultants, or subcontractors shall not be liable to Contractor for any claims, costs, losses, or damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) sustained by Contractor on or in connection with any other project or anticipated project. E. Contractor shall not be entitled to an adjustment in Contract Price or Contract Times for delays within the control of Contractor. Delays attributable to and within the control of a Subcontractor or Supplier shall be deemed to be delays within the control of Contractor. ARTICLE 13 – TESTS AND INSPECTIONS; CORRECTION, REMOVAL OR ACCEPTANCE OF DEFECTIVE WORK 13.01 Notice of Defects A. Prompt notice of all defective Work of which Owner or Engineer has actual knowledge will be given to Contractor. Defective Work may be rejected, corrected, or accepted as provided in this Article 13. 13.02 Access to Work A. Owner, Engineer, their consultants and other representatives and personnel of Owner, independent testing laboratories, and governmental agencies with jurisdictional interests will have access to the Site and the Work at reasonable times for their observation, inspection, and testing. Contractor shall provide them proper and safe conditions for such access and advise them of Contractor’s safety procedures and programs so that they may comply therewith as applicable. 13.03 Tests and Inspections A. Contractor shall give Engineer timely notice of readiness of the Work for all required inspections, tests, or approvals and shall cooperate with inspection and testing personnel to facilitate required inspections or tests. B. Owner shall employ and pay for the services of an independent testing laboratory to perform all inspections, tests, or approvals required by the Contract Documents except: 1. for inspections, tests, or approvals covered by Paragraphs 13.03.C and 13.03.D below; 2. that costs incurred in connection with tests or inspections conducted pursuant to Paragraph 13.04.B shall be paid as provided in Paragraph 13.04.C; and 3. as otherwise specifically provided in the Contract Documents. C. If Laws or Regulations of any public body having jurisdiction require any Work (or part thereof) specifically to be inspected, tested, or approved by an employee or other representative of such public body, Contractor shall assume full responsibility for arranging and obtaining such inspections, tests, or approvals, pay all costs in connection therewith, and furnish Engineer the required certificates of inspection or approval. D. Contractor shall be responsible for arranging and obtaining and shall pay all costs in connection with any inspections, tests, or approvals required for Owner’s and Engineer’s acceptance of materials or equipment to be incorporated in the Work; or acceptance of materials, mix designs, or equipment submitted for approval prior to Contractor’s purchase thereof for incorporation in the Work. Such inspections, tests, or approvals shall be performed by organizations acceptable to Owner and Engineer. E. If any Work (or the work of others) that is to be inspected, tested, or approved is covered by Contractor without written concurrence of Engineer, Contractor shall, if requested by Engineer, uncover such Work for observation. F. Uncovering Work as provided in Paragraph 13.03.E shall be at Contractor’s expense unless Contractor has given Engineer timely notice of Contractor’s intention to cover the same and Engineer has not acted with reasonable promptness in response to such notice. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 33 of 41 13.04 Uncovering Work A. If any Work is covered contrary to the written request of Engineer, it must, if requested by Engineer, be uncovered for Engineer’s observation and replaced at Contractor’s expense. B. If Engineer considers it necessary or advisable that covered Work be observed by Engineer or inspected or tested by others, Contractor, at Engineer’s request, shall uncover, expose, or otherwise make available for observation, inspection, or testing as Engineer may require, that portion of the Work in question, furnishing all necessary labor, material, and equipment. C. If it is found that the uncovered Work is defective, Contractor shall pay all claims, costs, losses, and damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) arising out of or relating to such uncovering, exposure, observation, inspection, and testing, and of satisfactory replacement or reconstruction (including but not limited to all costs of repair or replacement of work of others); and Owner shall be entitled to an appropriate decrease in the Contract Price. If the parties are unable to agree as to the amount thereof, Owner may make a Claim therefor as provided in Paragraph 10.05. D. If the uncovered Work is not found to be defective, Contractor shall be allowed an increase in the Contract Price or an extension of the Contract Times, or both, directly attributable to such uncovering, exposure, observation, inspection, testing, replacement, and reconstruction. If the parties are unable to agree as to the amount or extent thereof, Contractor may make a Claim therefor as provided in Paragraph 10.05. 13.05 Owner May Stop the Work A. If the Work is defective, or Contractor fails to supply sufficient skilled workers or suitable materials or equipment, or fails to perform the Work in such a way that the completed Work will conform to the Contract Documents, Owner may order Contractor to stop the Work, or any portion thereof, until the cause for such order has been eliminated; however, this right of Owner to stop the Work shall not give rise to any duty on the part of Owner to exercise this right for the benefit of Contractor, any Subcontractor, any Supplier, any other individual or entity, or any surety for, or employee or agent of any of them. 13.06 Correction or Removal of Defective Work A. Promptly after receipt of written notice, Contractor shall correct all defective Work, whether or not fabricated, installed, or completed, or, if the Work has been rejected by Engineer, remove it from the Project and replace it with Work that is not defective. Contractor shall pay all claims, costs, losses, and damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) arising out of or relating to such correction or removal (including but not limited to all costs of repair or replacement of work of others). B. When correcting defective Work under the terms of this Paragraph 13.06 or Paragraph 13.07, Contractor shall take no action that would void or otherwise impair Owner’s special warranty and guarantee, if any, on said Work. 13.07 Correction Period A. If within one year after the date of Substantial Completion (or such longer period of time as may be prescribed by the terms of any applicable special guarantee required by the Contract Documents) or by any specific provision of the Contract Documents, any Work is found to be defective, or if the repair of any damages to the land or areas made available for Contractor’s use by Owner or permitted by Laws and Regulations as contemplated in Paragraph 6.11.A is found to be defective, Contractor shall promptly, without cost to Owner and in accordance with Owner’s written instructions: 1. repair such defective land or areas; or 2. correct such defective Work; or 3. if the defective Work has been rejected by Owner, remove it from the Project and replace it with Work that is not defective, and 4. satisfactorily correct or repair or remove and replace any damage to other Work, to the work of others or other land or areas resulting therefrom. B. If Contractor does not promptly comply with the terms of Owner’s written instructions, or in an emergency where delay would cause serious risk of loss or damage, Owner may have the defective Work corrected or repaired or may have the rejected Work removed and replaced. All claims, costs, losses, and damages (including but not limited to all fees and EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 34 of 41 charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) arising out of or relating to such correction or repair or such removal and replacement (including but not limited to all costs of repair or replacement of work of others) will be paid by Contractor. C. In special circumstances where a particular item of equipment is placed in continuous service before Substantial Completion of all the Work, the correction period for that item may start to run from an earlier date if so provided in the Specifications. D. Where defective Work (and damage to other Work resulting therefrom) has been corrected or removed and replaced under this Paragraph 13.07, the correction period hereunder with respect to such Work will be extended for an additional period of one year after such correction or removal and replacement has been satisfactorily completed. E. Contractor’s obligations under this Paragraph 13.07 are in addition to any other obligation or warranty. The provisions of this Paragraph 13.07 shall not be construed as a substitute for, or a waiver of, the provisions of any applicable statute of limitation or repose. 13.08 Acceptance of Defective Work A. If, instead of requiring correction or removal and replacement of defective Work, Owner (and, prior to Engineer’s recommendation of final payment, Engineer) prefers to accept it, Owner may do so. Contractor shall pay all claims, costs, losses, and damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) attributable to Owner’s evaluation of and determination to accept such defective Work (such costs to be approved by Engineer as to reasonableness) and for the diminished value of the Work to the extent not otherwise paid by Contractor pursuant to this sentence. If any such acceptance occurs prior to Engineer’s recommendation of final payment, a Change Order will be issued incorporating the necessary revisions in the Contract Documents with respect to the Work, and Owner shall be entitled to an appropriate decrease in the Contract Price, reflecting the diminished value of Work so accepted. If the parties are unable to agree as to the amount thereof, Owner may make a Claim therefor as provided in Paragraph 10.05. If the acceptance occurs after such recommendation, an appropriate amount will be paid by Contractor to Owner. 13.09 Owner May Correct Defective Work A. If Contractor fails within a reasonable time after written notice from Engineer to correct defective Work, or to remove and replace rejected Work as required by Engineer in accordance with Paragraph 13.06.A, or if Contractor fails to perform the Work in accordance with the Contract Documents, or if Contractor fails to comply with any other provision of the Contract Documents, Owner may, after seven days written notice to Contractor, correct, or remedy any such deficiency. B. In exercising the rights and remedies under this Paragraph 13.09, Owner shall proceed expeditiously. In connection with such corrective or remedial action, Owner may exclude Contractor from all or part of the Site, take possession of all or part of the Work and suspend Contractor’s services related thereto, take possession of Contractor’s tools, appliances, construction equipment and machinery at the Site, and incorporate in the Work all materials and equipment stored at the Site or for which Owner has paid Contractor but which are stored elsewhere. Contractor shall allow Owner, Owner’s representatives, agents and employees, Owner’s other contractors, and Engineer and Engineer’s consultants access to the Site to enable Owner to exercise the rights and remedies under this Paragraph. C. All claims, costs, losses, and damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) incurred or sustained by Owner in exercising the rights and remedies under this Paragraph 13.09 will be charged against Contractor, and a Change Order will be issued incorporating the necessary revisions in the Contract Documents with respect to the Work; and Owner shall be entitled to an appropriate decrease in the Contract Price. If the parties are unable to agree as to the amount of the adjustment, Owner may make a Claim therefor as provided in Paragraph 10.05. Such claims, costs, losses and damages will include but not be limited to all costs of repair, or replacement of work of others destroyed or damaged by correction, removal, or replacement of Contractor’s defective Work. D. Contractor shall not be allowed an extension of the Contract Times because of any delay in the performance of the Work attributable to the exercise by Owner of Owner’s rights and remedies under this Paragraph 13.09. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 35 of 41 ARTICLE 14 – PAYMENTS TO CONTRACTOR AND COMPLETION 14.01 Schedule of Values A. The Schedule of Values established as provided in Paragraph 2.07.A will serve as the basis for progress payments and will be incorporated into a form of Application for Payment acceptable to Engineer. Progress payments on account of Unit Price Work will be based on the number of units completed. 14.02 Progress Payments A. Applications for Payments: 1. At least 20 days before the date established in the Agreement for each progress payment (but not more often than once a month), Contractor shall submit to Engineer for review an Application for Payment filled out and signed by Contractor covering the Work completed as of the date of the Application and accompanied by such supporting documentation as is required by the Contract Documents. If payment is requested on the basis of materials and equipment not incorporated in the Work but delivered and suitably stored at the Site or at another location agreed to in writing, the Application for Payment shall also be accompanied by a bill of sale, invoice, or other documentation warranting that Owner has received the materials and equipment free and clear of all Liens and evidence that the materials and equipment are covered by appropriate property insurance or other arrangements to protect Owner’s interest therein, all of which must be satisfactory to Owner. 2. Beginning with the second Application for Payment, each Application shall include an affidavit of Contractor stating that all previous progress payments received on account of the Work have been applied on account to discharge Contractor’s legitimate obligations associated with prior Applications for Payment. 3. The amount of retainage with respect to progress payments will be as stipulated in the Agreement. B. Review of Applications: 1. Engineer will, within 10 days after receipt of each Application for Payment, either indicate in writing a recommendation of payment and present the Application to Owner or return the Application to Contractor indicating in writing Engineer’s reasons for refusing to recommend payment. In the latter case, Contractor may make the necessary corrections and resubmit the Application. 2. Engineer’s recommendation of any payment requested in an Application for Payment will constitute a representation by Engineer to Owner, based on Engineer’s observations of the executed Work as an experienced and qualified design professional, and on Engineer’s review of the Application for Payment and the accompanying data and schedules, that to the best of Engineer’s knowledge, information and belief: a. the Work has progressed to the point indicated; b. the quality of the Work is generally in accordance with the Contract Documents (subject to an evaluation of the Work as a functioning whole prior to or upon Substantial Completion, the results of any subsequent tests called for in the Contract Documents, a final determination of quantities and classifications for Unit Price Work under Paragraph 9.07, and any other qualifications stated in the recommendation); and c. the conditions precedent to Contractor’s being entitled to such payment appear to have been fulfilled in so far as it is Engineer’s responsibility to observe the Work. 3. By recommending any such payment Engineer will not thereby be deemed to have represented that: a. inspections made to check the quality or the quantity of the Work as it has been performed have been exhaustive, extended to every aspect of the Work in progress, or involved detailed inspections of the Work beyond the responsibilities specifically assigned to Engineer in the Contract Documents; or b. there may not be other matters or issues between the parties that might entitle Contractor to be paid additionally by Owner or entitle Owner to withhold payment to Contractor. 4. Neither Engineer’s review of Contractor’s Work for the purposes of recommending payments nor Engineer’s recommendation of any payment, including final payment, will impose responsibility on Engineer: a. to supervise, direct, or control the Work, or EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 36 of 41 b. for the means, methods, techniques, sequences, or procedures of construction, or the safety precautions and programs incident thereto, or c. for Contractor’s failure to comply with Laws and Regulations applicable to Contractor’s performance of the Work, or d. to make any examination to ascertain how or for what purposes Contractor has used the moneys paid on account of the Contract Price, or e. to determine that title to any of the Work, materials, or equipment has passed to Owner free and clear of any Liens. 5. Engineer may refuse to recommend the whole or any part of any payment if, in Engineer’s opinion, it would be incorrect to make the representations to Owner stated in Paragraph 14.02.B.2. Engineer may also refuse to recommend any such payment or, because of subsequently discovered evidence or the results of subsequent inspections or tests, revise or revoke any such payment recommendation previously made, to such extent as may be necessary in Engineer’s opinion to protect Owner from loss because: a. the Work is defective, or completed Work has been damaged, requiring correction or replacement; b. the Contract Price has been reduced by Change Orders; c. Owner has been required to correct defective Work or complete Work in accordance with Paragraph 13.09; or d. Engineer has actual knowledge of the occurrence of any of the events enumerated in Paragraph 15.02.A. C. Payment Becomes Due: 1. Ten days after presentation of the Application for Payment to Owner with Engineer’s recommendation, the amount recommended will (subject to the provisions of Paragraph 14.02.D) become due, and when due will be paid by Owner to Contractor. D. Reduction in Payment: 1. Owner may refuse to make payment of the full amount recommended by Engineer because: a. claims have been made against Owner on account of Contractor’s performance or furnishing of the Work; b. Liens have been filed in connection with the Work, except where Contractor has delivered a specific bond satisfactory to Owner to secure the satisfaction and discharge of such Liens; c. there are other items entitling Owner to a set-off against the amount recommended; or d. Owner has actual knowledge of the occurrence of any of the events enumerated in Paragraphs 14.02.B.5.a through 14.02.B.5.c or Paragraph 15.02.A. 2. If Owner refuses to make payment of the full amount recommended by Engineer, Owner will give Contractor immediate written notice (with a copy to Engineer) stating the reasons for such action and promptly pay Contractor any amount remaining after deduction of the amount so withheld. Owner shall promptly pay Contractor the amount so withheld, or any adjustment thereto agreed to by Owner and Contractor, when Contractor remedies the reasons for such action. 3. Upon a subsequent determination that Owner’s refusal of payment was not justified, the amount wrongfully withheld shall be treated as an amount due as determined by Paragraph 14.02.C.1 and subject to interest as provided in the Agreement. 14.03 Contractor’s Warranty of Title A. Contractor warrants and guarantees that title to all Work, materials, and equipment covered by any Application for Payment, whether incorporated in the Project or not, will pass to Owner no later than the time of payment free and clear of all Liens. 14.04 Substantial Completion A. When Contractor considers the entire Work ready for its intended use Contractor shall notify Owner and Engineer in writing that the entire Work is substantially complete (except for items specifically listed by Contractor as incomplete) and request that Engineer issue a certificate of Substantial Completion. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 37 of 41 B. Promptly after Contractor’s notification, Owner, Contractor, and Engineer shall make an inspection of the Work to determine the status of completion. If Engineer does not consider the Work substantially complete, Engineer will notify Contractor in writing giving the reasons therefor. C. If Engineer considers the Work substantially complete, Engineer will deliver to Owner a tentative certificate of Substantial Completion which shall fix the date of Substantial Completion. There shall be attached to the certificate a tentative list of items to be completed or corrected before final payment. Owner shall have seven days after receipt of the tentative certificate during which to make written objection to Engineer as to any provisions of the certificate or attached list. If, after considering such objections, Engineer concludes that the Work is not substantially complete, Engineer will, within 14 days after submission of the tentative certificate to Owner, notify Contractor in writing, stating the reasons therefor. If, after consideration of Owner’s objections, Engineer considers the Work substantially complete, Engineer will, within said 14 days, execute and deliver to Owner and Contractor a definitive certificate of Substantial Completion (with a revised tentative list of items to be completed or corrected) reflecting such changes from the tentative certificate as Engineer believes justified after consideration of any objections from Owner. D. At the time of delivery of the tentative certificate of Substantial Completion, Engineer will deliver to Owner and Contractor a written recommendation as to division of responsibilities pending final payment between Owner and Contractor with respect to security, operation, safety, and protection of the Work, maintenance, heat, utilities, insurance, and warranties and guarantees. Unless Owner and Contractor agree otherwise in writing and so inform Engineer in writing prior to Engineer’s issuing the definitive certificate of Substantial Completion, Engineer’s aforesaid recommendation will be binding on Owner and Contractor until final payment. E. Owner shall have the right to exclude Contractor from the Site after the date of Substantial Completion subject to allowing Contractor reasonable access to remove its property and complete or correct items on the tentative list. 14.05 Partial Utilization A. Prior to Substantial Completion of all the Work, Owner may use or occupy any substantially completed part of the Work which has specifically been identified in the Contract Documents, or which Owner, Engineer, and Contractor agree constitutes a separately functioning and usable part of the Work that can be used by Owner for its intended purpose without significant interference with Contractor’s performance of the remainder of the Work, subject to the following conditions: 1. Owner at any time may request Contractor in writing to permit Owner to use or occupy any such part of the Work which Owner believes to be ready for its intended use and substantially complete. If and when Contractor agrees that such part of the Work is substantially complete, Contractor, Owner, and Engineer will follow the procedures of Paragraph 14.04.A through D for that part of the Work. 2. Contractor at any time may notify Owner and Engineer in writing that Contractor considers any such part of the Work ready for its intended use and substantially complete and request Engineer to issue a certificate of Substantial Completion for that part of the Work. 3. Within a reasonable time after either such request, Owner, Contractor, and Engineer shall make an inspection of that part of the Work to determine its status of completion. If Engineer does not consider that part of the Work to be substantially complete, Engineer will notify Owner and Contractor in writing giving the reasons therefor. If Engineer considers that part of the Work to be substantially complete, the provisions of Paragraph 14.04 will apply with respect to certification of Substantial Completion of that part of the Work and the division of responsibility in respect thereof and access thereto. 4. No use or occupancy or separate operation of part of the Work may occur prior to compliance with the requirements of Paragraph 5.10 regarding property insurance. 14.06 Final Inspection A. Upon written notice from Contractor that the entire Work or an agreed portion thereof is complete, Engineer will promptly make a final inspection with Owner and Contractor and will notify Contractor in writing of all particulars in which this inspection reveals that the Work is incomplete or defective. Contractor shall immediately take such measures as are necessary to complete such Work or remedy such deficiencies. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 38 of 41 14.07 Final Payment A. Application for Payment: 1. After Contractor has, in the opinion of Engineer, satisfactorily completed all corrections identified during the final inspection and has delivered, in accordance with the Contract Documents, all maintenance and operating instructions, schedules, guarantees, bonds, certificates or other evidence of insurance, certificates of inspection, marked-up record documents (as provided in Paragraph 6.12), and other documents, Contractor may make application for final payment following the procedure for progress payments. 2. The final Application for Payment shall be accompanied (except as previously delivered) by: a. all documentation called for in the Contract Documents, including but not limited to the evidence of insurance required by Paragraph 5.04.B.6; b. consent of the surety, if any, to final payment; c. a list of all Claims against Owner that Contractor believes are unsettled; and d. complete and legally effective releases or waivers (satisfactory to Owner) of all Lien rights arising out of or Liens filed in connection with the Work. 3. In lieu of the releases or waivers of Liens specified in Paragraph 14.07.A.2 and as approved by Owner, Contractor may furnish receipts or releases in full and an affidavit of Contractor that: (i) the releases and receipts include all labor, services, material, and equipment for which a Lien could be filed; and (ii) all payrolls, material and equipment bills, and other indebtedness connected with the Work for which Owner might in any way be responsible, or which might in any way result in liens or other burdens on Owner's property, have been paid or otherwise satisfied. If any Subcontractor or Supplier fails to furnish such a release or receipt in full, Contractor may furnish a bond or other collateral satisfactory to Owner to indemnify Owner against any Lien. B. Engineer’s Review of Application and Acceptance: 1. If, on the basis of Engineer’s observation of the Work during construction and final inspection, and Engineer’s review of the final Application for Payment and accompanying documentation as required by the Contract Documents, Engineer is satisfied that the Work has been completed and Contractor’s other obligations under the Contract Documents have been fulfilled, Engineer will, within ten days after receipt of the final Application for Payment, indicate in writing Engineer’s recommendation of payment and present the Application for Payment to Owner for payment. At the same time Engineer will also give written notice to Owner and Contractor that the Work is acceptable subject to the provisions of Paragraph 14.09. Otherwise, Engineer will return the Application for Payment to Contractor, indicating in writing the reasons for refusing to recommend final payment, in which case Contractor shall make the necessary corrections and resubmit the Application for Payment. C. Payment Becomes Due: 1. Thirty days after the presentation to Owner of the Application for Payment and accompanying documentation, the amount recommended by Engineer, less any sum Owner is entitled to set off against Engineer’s recommendation, including but not limited to liquidated damages, will become due and will be paid by Owner to Contractor. 14.08 Final Completion Delayed A. If, through no fault of Contractor, final completion of the Work is significantly delayed, and if Engineer so confirms, Owner shall, upon receipt of Contractor’s final Application for Payment (for Work fully completed and accepted) and recommendation of Engineer, and without terminating the Contract, make payment of the balance due for that portion of the Work fully completed and accepted. If the remaining balance to be held by Owner for Work not fully completed or corrected is less than the retainage stipulated in the Agreement, and if bonds have been furnished as required in Paragraph 5.01, the written consent of the surety to the payment of the balance due for that portion of the Work fully completed and accepted shall be submitted by Contractor to Engineer with the Application for such payment. Such payment shall be made under the terms and conditions governing final payment, except that it shall not constitute a waiver of Claims. 14.09 Waiver of Claims A. The making and acceptance of final payment will constitute: EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 39 of 41 1. a waiver of all Claims by Owner against Contractor, except Claims arising from unsettled Liens, from defective Work appearing after final inspection pursuant to Paragraph 14.06, from failure to comply with the Contract Documents or the terms of any special guarantees specified therein, or from Contractor’s continuing obligations under the Contract Documents; and 2. a waiver of all Claims by Contractor against Owner other than those previously made in accordance with the requirements herein and expressly acknowledged by Owner in writing as still unsettled. ARTICLE 15 – SUSPENSION OF WORK AND TERMINATION 15.01 Owner May Suspend Work A. At any time and without cause, Owner may suspend the Work or any portion thereof for a period of not more than 90 consecutive days by notice in writing to Contractor and Engineer which will fix the date on which Work will be resumed. Contractor shall resume the Work on the date so fixed. Contractor shall be granted an adjustment in the Contract Price or an extension of the Contract Times, or both, directly attributable to any such suspension if Contractor makes a Claim therefor as provided in Paragraph 10.05. 15.02 Owner May Terminate for Cause A. The occurrence of any one or more of the following events will justify termination for cause: 1. Contractor’s persistent failure to perform the Work in accordance with the Contract Documents (including, but not limited to, failure to supply sufficient skilled workers or suitable materials or equipment or failure to adhere to the Progress Schedule established under Paragraph 2.07 as adjusted from time to time pursuant to Paragraph 6.04); 2. Contractor’s disregard of Laws or Regulations of any public body having jurisdiction; 3. Contractor’s repeated disregard of the authority of Engineer; or 4. Contractor’s violation in any substantial way of any provisions of the Contract Documents. B. If one or more of the events identified in Paragraph 15.02.A occur, Owner may, after giving Contractor (and surety) seven days written notice of its intent to terminate the services of Contractor: 1. exclude Contractor from the Site, and take possession of the Work and of all Contractor’s tools, appliances, construction equipment, and machinery at the Site, and use the same to the full extent they could be used by Contractor (without liability to Contractor for trespass or conversion); 2. incorporate in the Work all materials and equipment stored at the Site or for which Owner has paid Contractor but which are stored elsewhere; and 3. complete the Work as Owner may deem expedient. C. If Owner proceeds as provided in Paragraph 15.02.B, Contractor shall not be entitled to receive any further payment until the Work is completed. If the unpaid balance of the Contract Price exceeds all claims, costs, losses, and damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) sustained by Owner arising out of or relating to completing the Work, such excess will be paid to Contractor. If such claims, costs, losses, and damages exceed such unpaid balance, Contractor shall pay the difference to Owner. Such claims, costs, losses, and damages incurred by Owner will be reviewed by Engineer as to their reasonableness and, when so approved by Engineer, incorporated in a Change Order. When exercising any rights or remedies under this Paragraph, Owner shall not be required to obtain the lowest price for the Work performed. D. Notwithstanding Paragraphs 15.02.B and 15.02.C, Contractor’s services will not be terminated if Contractor begins within seven days of receipt of notice of intent to terminate to correct its failure to perform and proceeds diligently to cure such failure within no more than 30 days of receipt of said notice. E. Where Contractor’s services have been so terminated by Owner, the termination will not affect any rights or remedies of Owner against Contractor then existing or which may thereafter accrue. Any retention or payment of moneys due Contractor by Owner will not release Contractor from liability. F. If and to the extent that Contractor has provided a performance bond under the provisions of Paragraph 5.01.A, the termination procedures of that bond shall EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 40 of 41 supersede the provisions of Paragraphs 15.02.B and 15.02.C. 15.03 Owner May Terminate For Convenience A. Upon seven days written notice to Contractor and Engineer, Owner may, without cause and without prejudice to any other right or remedy of Owner, terminate the Contract. In such case, Contractor shall be paid for (without duplication of any items): 1. completed and acceptable Work executed in accordance with the Contract Documents prior to the effective date of termination, including fair and reasonable sums for overhead and profit on such Work; 2. expenses sustained prior to the effective date of termination in performing services and furnishing labor, materials, or equipment as required by the Contract Documents in connection with uncompleted Work, plus fair and reasonable sums for overhead and profit on such expenses; 3. all claims, costs, losses, and damages (including but not limited to all fees and charges of engineers, architects, attorneys, and other professionals and all court or arbitration or other dispute resolution costs) incurred in settlement of terminated contracts with Subcontractors, Suppliers, and others; and 4. reasonable expenses directly attributable to termination. B. Contractor shall not be paid on account of loss of anticipated profits or revenue or other economic loss arising out of or resulting from such termination. 15.04 Contractor May Stop Work or Terminate A. If, through no act or fault of Contractor, (i) the Work is suspended for more than 90 consecutive days by Owner or under an order of court or other public authority, or (ii) Engineer fails to act on any Application for Payment within 30 days after it is submitted, or (iii) Owner fails for 30 days to pay Contractor any sum finally determined to be due, then Contractor may, upon seven days written notice to Owner and Engineer, and provided Owner or Engineer do not remedy such suspension or failure within that time, terminate the Contract and recover from Owner payment on the same terms as provided in Paragraph 15.03. B. In lieu of terminating the Contract and without prejudice to any other right or remedy, if Engineer has failed to act on an Application for Payment within 30 days after it is submitted, or Owner has failed for 30 days to pay Contractor any sum finally determined to be due, Contractor may, seven days after written notice to Owner and Engineer, stop the Work until payment is made of all such amounts due Contractor, including interest thereon. The provisions of this Paragraph 15.04 are not intended to preclude Contractor from making a Claim under Paragraph 10.05 for an adjustment in Contract Price or Contract Times or otherwise for expenses or damage directly attributable to Contractor’s stopping the Work as permitted by this Paragraph. ARTICLE 16 – DISPUTE RESOLUTION 16.01 Methods and Procedures A. Either Owner or Contractor may request mediation of any Claim submitted to Engineer for a decision under Paragraph 10.05 before such decision becomes final and binding. The mediation will be governed by the Construction Industry Mediation Rules of the American Arbitration Association in effect as of the Effective Date of the Agreement. The request for mediation shall be submitted in writing to the American Arbitration Association and the other party to the Contract. Timely submission of the request shall stay the effect of Paragraph 10.05.E. B. Owner and Contractor shall participate in the mediation process in good faith. The process shall be concluded within 60 days of filing of the request. The date of termination of the mediation shall be determined by application of the mediation rules referenced above. C. If the Claim is not resolved by mediation, Engineer’s action under Paragraph 10.05.C or a denial pursuant to Paragraphs 10.05.C.3 or 10.05.D shall become final and binding 30 days after termination of the mediation unless, within that time period, Owner or Contractor: 1. elects in writing to invoke any dispute resolution process provided for in the Supplementary Conditions; or 2. agrees with the other party to submit the Claim to another dispute resolution process; or 3. gives written notice to the other party of the intent to submit the Claim to a court of competent jurisdiction. EJCDC C-700 Standard General Conditions of the Construction Contract Copyright © 2007 National Society of Professional Engineers for EJCDC. All rights reserved. Page 41 of 41 ARTICLE 17 – MISCELLANEOUS 17.01 Giving Notice A. Whenever any provision of the Contract Documents requires the giving of written notice, it will be deemed to have been validly given if: 1. delivered in person to the individual or to a member of the firm or to an officer of the corporation for whom it is intended; or 2. delivered at or sent by registered or certified mail, postage prepaid, to the last business address known to the giver of the notice. 17.02 Computation of Times A. When any period of time is referred to in the Contract Documents by days, it will be computed to exclude the first and include the last day of such period. If the last day of any such period falls on a Saturday or Sunday or on a day made a legal holiday by the law of the applicable jurisdiction, such day will be omitted from the computation. 17.03 Cumulative Remedies A. The duties and obligations imposed by these General Conditions and the rights and remedies available hereunder to the parties hereto are in addition to, and are not to be construed in any way as a limitation of, any rights and remedies available to any or all of them which are otherwise imposed or available by Laws or Regulations, by special warranty or guarantee, or by other provisions of the Contract Documents. The provisions of this Paragraph will be as effective as if repeated specifically in the Contract Documents in connection with each particular duty, obligation, right, and remedy to which they apply. 17.04 Survival of Obligations A. All representations, indemnifications, warranties, and guarantees made in, required by, or given in accordance with the Contract Documents, as well as all continuing obligations indicated in the Contract Documents, will survive final payment, completion, and acceptance of the Work or termination or completion of the Contract or termination of the services of Contractor. 17.05 Controlling Law A. This Contract is to be governed by the law of the state in which the Project is located. 17.06 Headings A. Article and paragraph headings are inserted for convenience only and do not constitute parts of these General Conditions. SUPPLEMENTARY CONDITIONS Supplementary Conditions Supplementary Conditions Page 1 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction PART 1 -– GENERAL These Supplementary Conditions amend or supplement the Standard General Conditions of the Construction Contract, EJCDC C-700 (2007 Edition). All provisions which are not so amended or supplemented remain in full force and effect. The terms used in these Supplementary Conditions have the meanings stated in the General Conditions. Additional terms used in these Supplementary Conditions have the meanings stated below, which are applicable to both the singular and plural thereof. PART 2 - MODIFICATIONS OF THE GENERAL CONDITIONS ARTICLE 1 – DEFINITIONS AND TERMINOLOGY SC-1.01 Defined Terms – Delete Sub-Paragraph 1.01. 36, Resident Project Representative and insert the following in its place: 36. Resident Project Representative (RPR) — The authorized representative of Owner who may be assigned to the Site or any part thereof. SC-1.01 Defined Terms – Add the following paragraphs immediately after Paragraph 1.01: 52. 2013 Lake Level Window – The period during 2013 when Owner will operate the Project with the intent of maintaining the lake level at or below El 330. Owner will assume the risk of delays, damage to Contractor’s equipment, and damage to the Work if damage or delay occurs due to lake levels above El 330 during this period, as specified in Section 01012. 53. 2014 Lake Level Window – The period during 2014 when Owner will operate the project with the intent of maintaining the lake level at or below El 302. Owner will assume the risk of delays, damage to Contractor’s equipment, and damage to the Work if damage or delay occurs due to lake levels above El 302 during this period, as specified in Section 01012. 54. As Shown – “as shown” shall mean a specific reference to the Contract Drawings, equivalent to “as shown on the Contract Drawings”. 55. Blue Lake Project – Existing hydro facility that is to be modified by Contractor in its Work. 56. Blue Lake Units (BLU) - Owner’s existing hydro station containing turbine-generating units located near the Project powerhouse site are designated BLU Nos. 1 and 2. The three new hydroelectric units to be installed in the new powerhouse that Contractor is constructing are designated BLU Nos. 3, 4 and 5. 57. Dam Extension – The dam extension from the existing Blue Lake dam, inclusive of the spillway, thrust block, grouting and metalwork. Supplementary Conditions Supplementary Conditions Page 2 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction 58. Drainage Tunnel – The drainage tunnel and drain hole system on the left abutment downstream of the Dam. 59. FERC License Amendment Plans – As described later in Article 6 of these Supplementary Conditions are plans required by the FERC License Amendment that are to be prepared by Owner and submitted to FERC for the construction and operation of the Project. 60. Fish Valve Unit (FVU) – Owner’s small hydro generating unit adjacent to the USFS Sawmill Creek Campground. The existing FVU is referred to as Existing FVU. The new FVU to be installed by Contractor is referred to as FVU. 61. Intake Tunnel – The tunnel that connects the Intake Structure to the Upper Tunnel. 62. Gate House – The building that houses the fixed wheel gate operating equipment, hoist and controls and other electro-mechanical equipment. 63. Gate Shaft – The new vertical shaft for the fixed-wheeled gate and guides located downstream of the Intake Structure. 64. Intake Structure – The structure located at the inlet to the Intake Tunnel. This structure includes trashrack guides, trashracks, bulkhead gate guides and the new bulkhead gate. 65. Generation Outage - The time period extending from final shutdown of the existing BLU generating units until Substantial Completion of the first new BLU generating unit. 66. Lower Portal - the downstream outlet portal of the Lower Tunnel. 67. Lower Tunnel - the lower (downstream) tunnel from the South River Portal at the Sawmill Creek Campground area to the Lower Portal above the powerhouse site). 68. Mean Lower Low Water (MLLW) - sea level datum, MLLW = El 0.00 ft for all project elevation values. 69. North River Portal - the downstream outlet portal of the Upper Tunnel, located to the north of the Sawmill Creek penstock crossing. 70. Point of Destination – the delivery point for Owner furnished materials and equipment that is delivery via barge to Sitka. 71. Sawmill Cove Industrial Park (SCIP) – An industrial park area owned and operated by the City and Borough of Sitka. Specific portions of this area and its buildings will be available for lease by Contractor. Owner will make areas As Shown available for lease to Contractor. 72. Sawmill Creek - Name of the creek extending below Blue Lake Dam to tidewater. Also known as Medvedcha River on the referenced Project drawings. 73. SharePoint – Web-based site to share and manage Project documentation between Contractor, Owner, Engineer and RPR for this Contract. Supplementary Conditions Supplementary Conditions Page 3 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction 74. South River Portal - the upstream portal of the Lower Tunnel, which is south of the Sawmill Creek penstock crossing. 75. Surge Chamber - A vertical shaft excavation in rock above the Lower Portal, that is used to control hydraulic transients on turbine load change. 76. Tailwater Level Window - The periods in 2013 and 2014 when Owner will assume the risk of delays, damage to Contractor’s equipment and damage to the Work if damage or delay occurs due to powerhouse area tailwater levels above el. 16.0 , as specified in Section 01012. 77. Upper Tunnel - the upper (upstream) tunnel from the reservoir intake structure to the North River Portal at the Sawmill Creek Campground. 78. Water Treatment Plant (WTP) – Owner’s existing municipal water treatment plant building near the Lower Portal. 79. Construction Manager – Owner’s representative responsible for management and oversight of Contractor and coordination with the Engineer during construction. The Construction Manager will provide the RPR. ARTICLE 2 – PRELIMINARY MATTERS SC-2.02 Delete Paragraph 2.02. Copies of Documents and insert the following in its place: 2.02 Copies of Documents A. Owner will furnish Contractor up to 1 paper copy of the Contract Documents and three electronic .pdf format copies on discs. Additional paper copies will be furnished upon request at the cost of reproduction. ARTICLE 4 – AVAILABILITY OF LANDS; SUBSURFACE AND PHYSICAL CONDITIONS; HAZARDOUS ENVIRONMENTAL CONDITIONS; REFERENCE POINTS SC-4.02 Add the following new paragraphs immediately after Paragraph 4.02.B: C. The following reports of explorations and tests of subsurface conditions at or contiguous to the Site are known to Owner: 1. Report dated January 15, 2010, prepared by Hatch, entitled: “Technical Memorandum No. 7 – Geotechnical Findings Report, consisting of 58 pages and including 12 figures and nine appendices, Appendix A through I. Note that the memorandum and the figures and appendices are available in .pdf format on Owner’s Electric Department web site: (http://www.cityofsitka.com/government/departments/electric/documents/GeotechInvestTM7.pdf). 2. Report dated January 18, 2011, prepared by Hatch, entitled “Technical Memorandum No. 36. - Assessment of Aggregate Sources, Concrete Production Options and Initial Trial Batch Results. 3. Report dated November 18, 2009, prepared by Hatch, entitled “Technical Memorandum No. 19 - Earthquake Design Parameters”. Supplementary Conditions Supplementary Conditions Page 4 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction 4. Report dated September 10, 2010, prepared by Hatch entitled “Technical Memorandum No. 26 - Updated Earthquake Time Histories”. 5. Report dated March 1954, prepared by the U.S. Bureau of Reclamation entitled “Preliminary Report on the geology of the Blue Lake Project”, which includes drill logs. D. These reports are provided as part of the Reference Documents. E. Owner and Engineer do not represent that the reports show completely all the existing subsurface conditions and do not guarantee any interpretation of facts or opinions in the reports or that the information shown on the Contract Documents will accurately describe the actual subsurface conditions which may be encountered. Bidders and Contractors must assume all responsibility for deductions and conclusions which may be made as to the nature of the materials to be excavated, the difficulties of making and maintaining the required excavation, and of doing other construction affected by subsurface conditions at the site of the construction. F. The following drawings of physical conditions relating to existing surface or subsurface structures at the Site (except Underground Facilities) are known to Owner: 1. Reference Figure PP-01: Existing Dam Survey – Plunge Pool – Plan 2. No reports or drawings related to underground structures at the Site are known to the Owner, other than the as-built drawings of the original dam construction, tunnel construction, as-built drawings of the existing site utilities in the powerhouse area, and other elements of the Blue Lake Project. SC 4.06 Delete Paragraphs 4.06.A and 4.06.B in their entirety and insert the following: A. Reports on lead paint testing of the existing powerhouse are included in the Reference Documents. No other reports or drawings related to Hazardous Environmental Conditions at the Site are known to Owner. B. Not Used ARTICLE 5 – BONDS AND INSURANCE SC-5.01B At the end of paragraph Sc-5.01B insert the following: A Performance Bond shall be provided on EJCDC Form C-610 – Construction Performance Bond. A Payment Bond shall be provided on EJCDC Form C615 – Construction Payment Bond. SC-5.04 Add the following new paragraphs immediately after Paragraph 5.04B: C. The limits of liability for the insurance required by Paragraph 5.04 of the General Conditions shall provide coverage for not less than the following amounts or greater where required by Laws and Regulations: 1. Workers’ Compensation and related coverages under Paragraphs 5.04.A.1 and A.2 of the General Conditions: a. State: Alaska Statutory b. Applicable Federal Supplementary Conditions Supplementary Conditions Page 5 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction (e.g., Longshoreman’s): Statutory c. Employer’s Liability: $ 1,000,000 2. Contractor’s General Liability under Paragraphs 5.04.A.3 through A.6 of the General Conditions which shall include completed operations and product liability coverages and eliminate the exclusion with respect to property under the care, custody and control of Contractor: a. General Aggregate $ 10,000,000 b. Products - Completed Operations Aggregate $ 10,000,000 c. Personal and Advertising Injury $ 1,000,000 d. Each Occurrence (Bodily Injury and Property Damage) $ 10,000,000 e. Property Damage liability insurance will provide Explosion, Collapse, and Under-ground coverages where applicable. f. Excess or Umbrella Liability o Excess or umbrella coverages can be used to satisfy the required insurance coverages and limits. 3. Automobile Liability under Paragraph 5.04.A.6 of the General Conditions: a. Bodily Injury: Each person $ 5,000,000 Each Accident $ 5,000,000 b. Property Damage: Each Accident $ 2,000,000 4. The Contractual Liability coverage required by Paragraph 5.04.B.4 of the General Conditions shall provide coverage for not less than the following amounts: a. Bodily Injury: Each person $ 10,000,000 Each Accident $ 10,000,000 b. Property Damage: Each Accident $ 10,000,000 Annual Aggregate $ 10,000,000 Supplementary Conditions Supplementary Conditions Page 6 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction 5. Inland Marine and Transit Liability coverage shall also be provided as part of the insurance requirements under General Condition Section 5.04.A, as necessary, to cover losses and claims arising from or related Contractor’s activities pertaining to offloading, movement, storage and installation of equipment and materials, for limits not less than $10,000,000 general aggregate and $5,000,000 each occurrence. D. The policies of insurance so required by this Paragraph 5.04 C.2 through 5.04 C 4 inclusive, include as additional insureds (subject to any customary exclusion in respect of professional liability) Owner, Construction Manager, Engineer, their consultants, (including Hatch and Currents Consulting), all of whom shall be listed as additional insureds, and include coverage for the respective officers, directors, partners, employees, agents, and other consultants and subcontractors of each an any of all such additional insureds, using ISO Endorsement CG2032 07 98 or equivalent, and the insurance afforded to these additional insured shall provide primary coverage for all claims covered thereby; E. Contractor shall deliver to Owner, with copies to each additional insured identified in these Supplementary Conditions, certificates of insurance (and other evidence of insurance requested by Owner or any other additional insured) which Contractor is required to purchase and maintain. F. If Owner has any objection to the coverage afforded by or other provisions of the insurance required to be purchased and maintained on the basis of non-conformance with the Contract Documents, Owner shall notify Contractor in writing within 10 days after receipt of the certificates or other evidence required by Paragraph SC-5.04.E. Contractor shall provide such additional information in respect to insurance as Owner shall reasonably request. SC-5.06.A. Delete Paragraph 5.06.A in its entirety and insert the following in its place: A. Contractor shall purchase and maintain property insurance upon the Work at the Site in the amount of the full replacement cost thereof. Contractor shall be responsible for any deductible or self-insured retention. This insurance shall: 1. include the interests of Owner, Contractor, Subcontractors, Construction Manager, Engineer, and the officers, directors, partners, employees, agents and other consultants and subcontractors of any of them, each of whom is deemed to have an insurable interest and shall be listed as an insured or loss payee; 2. be written on a Builder’s Risk “all-risk” policy form that shall at least include insurance for physical loss and damage to the Work, temporary buildings, falsework, and materials and equipment in transit and shall insure against at least the following perils or causes of loss: fire, lightning, extended coverage, theft, vandalism and malicious mischief, earthquake, collapse, debris removal, demolition occasioned by enforcement of Laws and Regulations, water damage (other than that caused by flood), and such other perils or causes of loss as may be specifically required by these Supplementary Conditions. 3. include expenses incurred in the repair or replacement of any insured property (including but not limited to fees and charges of engineers and architects); 4. cover materials and equipment stored at the Site or at another location that was agreed to in writing by Owner prior to being incorporated in the Work, provided that such materials and equipment have been included in an Application for Payment recommended by RPR; Supplementary Conditions Supplementary Conditions Page 7 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction 5. allow for partial utilization of the Work by Owner; 6. Be maintained in effect until final payment is made unless otherwise agreed to in writing by Owner, Contractor, and RPR with 30 days written notice to each other loss payee to whom a certificate of insurance has been issued; and 7. comply with the requirements of Paragraph 5.06.C of the General Conditions. ARTICLE 6 – CONTRACTOR’S REPSONSIBILITIES SC-6.01 Add the following new paragraph immediately after GC-6.01B. C. The initial appointment of the resident superintendent and any removal and subsequent appointment shall be subject to the prior approval of RPR. For reasonable cause, RPR may, upon notice to Contractor, require Contractor to remove (or cause to be removed) and replace the resident superintendent from the Site. Once removed such personnel shall no longer be involved with the Work in any capacity. SC-6.02 Add the following new paragraph immediately after GC-6.02B. C. For reasonable cause, RPR may, upon notice to Contractor, require Contractor to remove (or cause to be removed) any personnel performing any aspect of the Work. Once removed such personnel shall no longer be involved with the Work in any capacity. SC-6.08B Add the following new paragraph immediately after GC-6.08A. B. Owner will obtain and pay for the following specific permits. 1. City and Borough of Sitka Building Permit 2. Alaska Department of Transportation Driveway Permit 3. Alaska Department of Fish and Game Fish Habitat Permit 4. Alaska Department of Fish and Game Scientific Collection Permit 5. Alaska Department of Natural Resources provisional and permanent water rights for Blue Lake and Sawmill Creek. 6. US Army Corps of Engineers Section 10, navigable waters permit 7. US Army Corps of Engineers Section 404, dredge and fill permit 8. US Army Corps of Engineers Section 401, water quality certificate 9. US Forest Service Special Use Permit 10. FERC License Amendment Plans including: • Water Quality Monitoring Plan • Environmental Compliance Monitoring Plan • Cultural Resource Protection Plan • Reservoir Inundation Plan • Reservoir Access Control Plan • Erosion and Sediment Control Plan • Noxious Weed Plan • Supplemental Emergency Action Plan • Bear Safety Plan • Hazardous Material Handling Plan Supplementary Conditions Supplementary Conditions Page 8 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction • Fish Monitoring Plan • Wildlife Monitoring Plan • Wetlands Monitoring Plan • Recreational Monitoring Plan • Scenery Monitoring Plan • Revegetation Plan C. All other permits required for the Work shall be obtained and paid for by Contractor, including: 1. City and Borough of Sitka Business License 2. City and Borough of Sitka Open Burning Permit 3. Alaska Department of Environmental Stormwater Pollution Prevention Plan (SPPP) 4. Alaska Department of Environmental Spill Prevention, Control and Countermeasures Plan (SPCC) 5. Alaska Department of Administration Alaska Business License 6. Alaska Department of Labor Wage and Hour Division Registration for Prevailing Wage 7. Alaska Department of Natural Resources • Temporary Water Use Permit for water taken from Blue Lake or Sawmill Creek • Blasting Permit • Vibration and Noise Management Plan • Soil Disposal Permit • Erosion and Sedimentation Plan 8. Alaska Department of Fish and Game, Title 16 Habitat Permit 9. Corps of Engineers permit for spillway plunge pool work D. Contractor must comply with all of the plans and permits listed in SC-6.08B SC-6.10 Add a new paragraph immediately after Paragraph 6.10.A: B. Owner is exempt from payment of sales and compensating use taxes of the State of Alaska and of cities and counties thereof on all materials to be incorporated into the Work. 1. Owner will furnish the required certificates of tax exemption to Contractor for use in the purchase of supplies and materials to be incorporated into the Work. 2. Owner’s exemption does not apply to construction tools, machinery, equipment, or other property purchased by or leased by Contractor, or to supplies or materials not incorporated into the Work. SC-6.12 Delete Paragraph 6.12.A and replace it with the following: A. Contractor shall maintain in a safe place at the Site one record copy of all Drawings, Specifications, Addenda, Change Orders, Work Change Directives, Field Orders, and written interpretations and clarifications in good order and annotated to show changes made during construction. These record documents together with all approved Samples and a counterpart of all approved Shop Drawings will be available to the RPR for reference. Upon completion of the Work, these record documents, Samples, and Shop Drawings will be delivered to RPR for Owner. Supplementary Conditions Supplementary Conditions Page 9 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction B. At the beginning of the construction, Contractor shall set aside one (1) complete set of full-size prints of the Contract Drawings, upon which it shall record or cause its various subcontractors to record, all deviations in construction, especially pipe and conduit locations, underground utilities and any deviations due to change orders. Notations and changes shall be done in a neat and legible manner in accordance with the RPR’s instructions. Upon completion of project, Contractor shall deliver the set of marked-up prints to the RPR before final payment will be made. SC-6.17 Delete first two sentences of Paragraph 6.17 A and insert the following: A. Contractor shall provide shop drawings and submittals as required by Section 01300 of the Specifications. Delete Item 1 of Paragraph 6.17 A and replace it with the following: 1. Submit electronic and/or paper copies of shop drawings as specified in Section 01300 of the Specifications. SC-6.22 Add the following new paragraph immediately after 6.21E: Contractor and Subcontractor Work force A. Equal Employment Opportunity (EEO) 1. The Contractor and Subcontractors must be an Equal Opportunity Employer (EEO) and that all qualified applications will receive consideration for employment without regard to race, religion, color, national origin, age, physical handicap, sex, marital status, changes in marital status, pregnancy or parenthood. B. Prevailing Wage Rates 1. This contract is subject to the provisions of State of Alaska, Title 36, Minimum Wage Rates and Federal Davis-Bacon Wage Rates. State Wage Rates can be obtained at http://labor.state.ak.us/lss/pamp600.htm 2. Use the State wage rates that are in effect 10 days before Bid Opening. A copy of State Wage rates will be provided on request 3. Contractor may not begin work until he has submitted proof that a “Notice of Work” has been filed with the Alaska Department of Labor. A temporary receipt of the “Notice of Work” date-stamped by Wage & Hour will serve as proof. 4. Contractor shall include with its final pay request a “Notice of Completion of Public Works” from the Alaska Department of Labor showing that all employees’ wages and employment security taxes have been paid to its employees and the employees of its subcontractors (T36 Clearance proved). Final payment will not be released until this has been submitted. C. Alaska Energy Authority (AEA) Grant conditions 1. This Contract is subject to the terms and conditions of the AEA Grant Agreement Number 2195311 and Amendments. A copy of the Grant Agreement and amendments are included in the reference documents. Supplementary Conditions Supplementary Conditions Page 10 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction D. Local Bidder Preference 1. Local bidder preference shall apply to all bids in accordance with Municipal Code Section 3.16.080. 2. Section 3.16.080 is (Reserved) E. IBEW LOCAL 1547 Collective Bargaining Agreement 1. The City and Borough of Sitka Electric Department Employees are represented by the International Brotherhood of Electrical Workers, Local 1547 “IBEW”. The current agreement states the following: Article 22 Subcontracting a. The Employer retains the right to contract and subcontract work at the Utility. b. The Employer may utilize qualified contractors for electrical or communication work, whether new or maintenance work, who have a collective bargaining agreement or letter of assent with the Union, so long as the use of such contractors furthers the Employer’s fiscal responsibility and safety for the citizens and rate payers of the community. Because management retains the right to contract and subcontract the work at the Utility, there is no requirement for union representation by the contractor. This language also does not preclude the Owner from selecting a contractor who may have a collective bargaining agreement or letter of assent with the Union. ARTICLE 7 – COORDINATION SC-7.02, Coordination Delete Paragraph 7.02 and insert the following: A. Owner intends to contract with others for the performance of Contract 8 – Reservoir Debris Management, which will include management and removal of organic debris from Blue Lake during the course of Contractor’s Work. Debris management work will begin during summer 2014 before the Lake fills above El 342 and will continue through the completion of the Work. The Debris Management work primarily involves capture of floating debris, transport of the debris to the upstream (east) end of Blue Lake, followed by burning of the debris at the upstream end of the lake in 2014 and 2015. B. Contractor shall allow the Debris Management contractor regular access along Blue Lake Road to deliver materials, equipment and personnel to the lake. Access shall not be denied for more than 6 hours at a time and the extent of major road outages shall be coordinated with the debris management contractor. C. Owner will identify an individual of the Debris Management contractor’s staff who will have authority and responsibility for coordination of the debris management activities with Contractor. D. Contractor shall coordinate use of the Blue Lake Road, passage through the Dam staging area, and use of the Reservoir Access Road with the Debris Management contractor. Contractor shall not deny the debris management contractor reasonable use of these areas. E. All disputes regarding access and use of Project roads will be resolved by the RPR. Supplementary Conditions Supplementary Conditions Page 11 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction F. Owner intends to complete portions of the electrical and controls construction for the project as described in Specification Section 01550. Contractor shall coordinate with Owner to allow Owner’s reasonable access to work areas, power, building spaces, and utilities within the time frames described in Section 01550. Note that Owner’s work for controls and electrical will require the sequential, coordinated installation of equipment, wiring and controls and will also require coordinated testing by Contractor and Owner of the electrical equipment and controls. ARTICLE 9 – ENGINEER’S AND RPR’S STATUS DURING CONSTRUCTION Delete Article 9 in its entirety and replace it with the following: SC-9.01 Owner’s Representative A. RPR will be Owner’s representative during the construction period. The duties and responsibilities and the limitations of authority of the RPR as Owner’s representative during construction are set forth in the Contract Documents. SC-9.02 Engineer Visits to Site A. Engineer will make visits to the Site at intervals appropriate to the various stages of construction as Owner and RPR deem necessary in order to observe the progress that has been made and the quality of the various aspects of Contractor’s executed Work. Based on information obtained during such visits and observations, Engineer, for the benefit of Owner, will determine, in general, if the Work is proceeding in accordance with the Contract Documents. Engineer will not be required to make exhaustive or continuous inspections on the Site to check the quality or quantity of the Work. Engineer’s efforts will be directed toward providing for Owner a greater degree of confidence that the completed Work will conform generally to the Contract Documents. On the basis of such visits and observations, Engineer will keep Owner informed of the progress of the Work and will endeavor to guard Owner against defective Work. B. During or as a result of Engineer’s visits or observations of Contractor’s Work, Engineer will not supervise, direct, control, or have authority over or be responsible for Contractor’s means, methods, techniques, sequences, or procedures of construction, or the safety precautions and programs incident thereto, or for any failure of Contractor to comply with Laws and Regulations applicable to the performance of the Work. SC-9.03 Project Representative: A. The RPR will be Owner's representative and liaison with Owner, Engineer and Contractor. The RPR or his designated representative will be on site at all times during the Work. The RPR will act as directed by and under the supervision of Owner, and will confer with Engineer as required for interpretation of the design. The RPR's dealings in matters pertaining to the Work in general will be with Owner, Contractor, and Engineer. RPR's dealings with Subcontractors shall be through or with the full knowledge and approval of Contractor. The RPR will: 1. Schedules: Review the progress schedule, schedule of Shop Drawing submittals, and schedule of values prepared by Contractor and if needed consult with Engineer concerning acceptability. Supplementary Conditions Supplementary Conditions Page 12 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction 2. Conferences and Meetings: Attend meetings with Contractor, such as preconstruction conferences, progress meetings, job conferences and other project-related meetings, and prepare and circulate copies of minutes thereof to the Owner. 3. Liaison: a. Serve as Owner’s and Engineer’s liaison with Contractor, working principally through Contractor’s authorized representative, assist in providing information regarding the intent of the Contract Documents. b. Assist in obtaining from Owner additional details or information, when required for proper execution of the Work. 4. Interpretation of Contract Documents: Provide clarifications and interpretations of the Contract Documents as needed and transmit to Contractor. Where required, coordinate with the Engineer to prepare clarifications and interpretations of the Contract Documents. 5. Modifications: Consider and evaluate Contractor’s suggestions for modifications in Drawings or Specifications and report such suggestions, together with RPR’s recommendations, to Engineer as required. Transmit to Contractor in writing decisions as issued by Owner and/or Engineer as required. 6. Review of Work and Rejection of Defective Work: a. Conduct on-Site observations of Contractor’s work in progress and if the quality and quantity of the work and determine if the work is in general proceeding in accordance with the Contract Documents. b. Review for accuracy and accept or reject the weekly report generated by Contractor. c. Coordinate with Engineer, as required, to make field decisions on rock support, borehole locations and quantity, and other geotechnical engineering matters based on field observations as required. 7. Records: All formal records will be kept on SharePoint a. The RPR will maintain files of all project construction correspondence including: From Contractor • Request for Information (RFI) • Formal letters • Submittals schedules • Shop drawings • Request for payments • Claims • Non-Conformance Reports • Change Orders Supplementary Conditions Supplementary Conditions Page 13 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction • Material and Concrete tests • Contractor weekly reports From RPR • Memos for change requests and clarifications of intent of drawings and specifications • Daily reports by Field Inspectors • Laboratory Testing b. Maintain above records for use in preparing Project documentation. 9. Reports: a. Furnish to Owner periodic reports as required of progress of the Work and of Contractor’s compliance with the progress schedule and schedule of Shop Drawing submittals. b. Draft and recommend to Owner proposed Change Orders, Work Change Directives, and Field Orders. Obtain backup material from Contractor. c. Immediately notify Owner of the occurrence of any Site accidents, emergencies, acts of God endangering the Work, damage to property by fire or other causes, or the discovery of any Hazardous Environmental Condition. 10. Payment Requests: Review Applications for Payment with Contractor for compliance with the established procedure for their submission and forward with recommendations to Owner, noting particularly the relationship of the payment requested to the schedule of values, Work completed, and materials delivered at the Site but not incorporated in the Work. 11. Completion: a. Participate in a Substantial Completion inspections, assist in the determination of Substantial Completion and the preparation of lists of items to be completed or corrected. b. Participate in a final inspection in the company of Owner, Contractor, and Engineer (as required) and prepare a final list of items to be completed and deficiencies to be remedied. c. Observe whether all items on the final list have been completed or corrected and make recommendations to Owner concerning acceptance and issuance of the Notice of Acceptability of the Work. SC-9.04 Authorized Variations in Work A. RPR may authorize minor variations in the Work from the requirements of the Contract Documents which do not involve an adjustment in the Contract Price or the Contract Times and are compatible with the design concept of the completed Project as a functioning whole as indicated by the Contract Documents. These may be accomplished by a Field Order and will be binding on Owner and also on Supplementary Conditions Supplementary Conditions Page 14 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction Contractor, who shall perform the Work involved promptly. If Owner or Contractor believes that a Field Order justifies an adjustment in the Contract Price or Contract Times, or both, and the parties are unable to agree on entitlement to or on the amount or extent, if any, of any such adjustment, a Claim may be made therefore as provided in Paragraph 10.05 of the General Conditions. SC-9.05 Rejecting Defective Work A. RPR will have authority to reject Work which the RPR believes to be defective, or that RPR believes will not produce a completed Project that conforms to the Contract Documents or that will prejudice the integrity o f the design concept of the completed Project as a functioning whole as indicated by the Contract Documents. RPR will also have authority to require special inspection or testing of the Work as provided in Paragraph 13.04, whether or not the Work is fabricated, installed, or completed. SC-9.06 Determinations for Unit Price Work A. RPR will determine the actual quantities and classifications of Unit Price Work performed by Contractor. RPR will review with Contractor the RPR’s preliminary determinations on such matters before rendering a written decision thereon (by recommendation of an Application for Payment or otherwise). RPR’s written decision thereon will be final and binding (except as modified by RPR to reflect changed factual conditions or more accurate data) upon Owner and Contractor, subject to the provisions of Paragraph 10.05. SC- 9.07 Decisions on Requirements of Contract Documents and Acceptability of Work A. RPR will be responsible for performance of all claim resolution activities assigned to the Engineer under Section 10.05 of the General Conditions, including determinations relating to interpretation of contract requirements and acceptability of the Work. RPR will consult with the Engineer as required, if the acceptability of the work cannot be readily determined by the RPR. If consulted, Engineer will, with reasonable promptness, render written guidance on the issue referred. If Owner or Contractor believes that any such decision entitles them to an adjustment in the Contract Price or Contract Times or both, a Claim may be made under Paragraph 10.05. The date of RPR’s decision shall be the date of the event giving rise to the issues referenced for the purposes of Paragraph 10.05.B of the General Conditions. B. RPR’s written decision on the issue referred will be final and binding on Owner and Contractor, subject to the provisions of Paragraph 10.05. C. When functioning in a neutral claim resolution function under Section 10.05 of the General Conditions and this SC-9.07, the RPR will act in an independent and neutral manner and will not show partiality or bias toward the Owner or Contractor. The RPR will not be liable in connection with any interpretation or decision rendered in good faith in such capacity. SC-9.08 Limitations on RPR’s Authority and Responsibilities A. RPR will not supervise, direct, control, or have authority over or be responsible for Contractor’s means, methods, techniques, sequences, or procedures of construction, or the safety precautions and programs incident thereto, or for any failure of Contractor to comply with Laws and Regulations Supplementary Conditions Supplementary Conditions Page 15 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction applicable to the performance of the Work. RPR will not be responsible for Contractor’s failure to perform the Work in accordance with the Contract Documents. B. RPR will not authorize any significant deviation from the Contract Documents or substitution of materials or equipment (including “or-equal” items). C. RPR will not be responsible for the acts or omissions of Contractor or of any Subcontractor, any Supplier, or of any other individual or entity performing any of the Work. D. RPR’s review of the final Application for Payment and accompanying documentation and all maintenance and operating instructions, schedules, guarantees, bonds, certificates of inspection, tests and approvals, and other documentation required to be delivered by Paragraph 14.07.A will only be to determine generally that their content complies with the requirements of, and in the case of certificates of inspections, tests, and approvals that the results certified indicate compliance with, the Contract Documents. SC-9.09 Compliance with Safety Program A. While at the Site, RPR and Engineer’s employees and representatives shall comply with the specific applicable requirements of Contractor’s safety programs of which RPR and Engineer have been informed pursuant to Paragraph 6.13.D. B. Contractor shall make its own arrangements for obtaining utility services required during construction as defined in section 01500, which would include: 1. Water Supply – Contractor may obtain water from the river or from Blue Lake and shall provide all necessary temporary pumps, piping and hoses. Municipal treated potable water is available at the SCIP as part of the utilities available for lease. 2. Electric Power – Owner will provide 12,470V power to the dam site. Contractor shall make its own arrangements for electrical power from the Owner utilities and pay all costs for the temporary extension and use of power. 4,160 volts will be available from the City electric system at Blue Lake Powerhouse. Power will be sold at commercial rates. Utility electric power is available at the Sawmill Cove Industrial Park (SCIP) as part of the utilities available with the leased space at the SCIP. Contractor shall arrange for and pay for any utility power supply and consumption at the SCIP. 3. Sanitation – Contractor shall provide its own temporary sanitation facilities as specified in the General Conditions at the Work. Existing permanent sanitary facilities in the SCIP may be used by Contractor as part of any leased space in the SCIP; and 4. Communication – Contractor shall arrange and pay for all communications it may require. ARTICLE 11 – COST OF WORK SC 11.04 – Value Engineering Insert after paragraph 11.03 the following: Supplementary Conditions Supplementary Conditions Page 16 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction This clause applies to Value Engineering Change Proposals (VECP) initiated and developed by the Contractor for changing the drawings, specifications or other requirements of the contract that would result in a savings to the Owner by providing less costly items or methods than those specified without impairing any of their essential functions and characteristics. The VECP clause is a special purpose change clause applicable only to contractor- initiated cost reduction proposals. If approved, the contractor shares in the resultant savings. Until a contract modification is issued by the Owner, or the RPR acting within his authority, the contractor is obligated to perform in accordance with the original contract requirements. Acceptance or rejection of all or part of the VECP by the Owner is final and not subject to the Disputes clause of the contract. However, the terms of the modifications implementing the acceptance are subject to the Disputes clause. (a) General. The Contractor is encouraged to develop, prepare, and submit value engineering change proposals (VECP’s) voluntarily. The Contractor shall share in any instant contract savings realized from accepted VECP’s, in accordance with paragraph (f) of this clause. (b) Definitions. “Collateral costs,” as used in this clause, means Owner costs of operation, maintenance, logistic support, or Owner-furnished property. “Collateral savings,” as used in this clause, means those measurable net reductions resulting from a VECP in the Owner’s overall projected collateral costs, exclusive of acquisition savings, whether or not the acquisition cost changes. “Contractor’s development and implementation costs,” as used in this clause, means those costs the Contractor incurs on a VECP specifically in developing, testing, preparing, and submitting the VECP, as well as those costs the Contractor incurs to make the contractual changes required by Owner acceptance of a VECP. “Owner costs,” as used in this clause, means those Owner costs that result directly from developing and implementing the VECP, such as any net increases in the cost of testing, operations, maintenance, and logistic support. The term does not include the normal administrative costs of processing the VECP. “Instant contract savings,” as used in this clause, means the estimated reduction in Contractor cost of performance resulting from acceptance of the VECP, minus allowable Contractor’s development and implementation costs, including subcontractors’ development and implementation costs (see paragraph (h) of this clause). “Value engineering change proposal (VECP)” means a proposal that— (1) Requires a change to this, the instant contract, to implement; and (2) Results in reducing the contract price or estimated cost without impairing essential functions or characteristics; provided, that it does not involve a change— (i) In deliverable end item quantities only; or (ii) To the contract type only. (c) VECP preparation. As a minimum, the Contractor shall include in each VECP the information described in paragraphs (c)(1) through (7) of this clause. If the proposed change is affected by contractually required configuration management or similar procedures, the instructions in those procedures relating to format, identification, and priority assignment shall govern VECP preparation. The VECP shall include the following: Supplementary Conditions Supplementary Conditions Page 17 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction (1) A description of the difference between the existing contract requirement and that proposed, the comparative advantages and disadvantages of each, a justification when an item’s function or characteristics are being altered, and the effect of the change on the end item’s performance. (2) A list and analysis of the contract requirements that must be changed if the VECP is accepted, including any suggested specification revisions. (3) A separate, detailed cost estimate for (i) the affected portions of the existing contract requirement and (ii) the VECP. The cost reduction associated with the VECP shall take into account the Contractor’s allowable development and implementation costs, including any amount attributable to subcontracts under paragraph (h) of this clause. (4) A description and estimate of costs the Owner may incur in implementing the VECP, such as test and evaluation and operating and support costs. (5) A prediction of any effects the proposed change would have on collateral costs to the Owner. (6) A statement of the time by which a contract modification accepting the VECP must be issued in order to achieve the maximum cost reduction, noting any effect on the contract completion time or delivery schedule. (7) Identification of any previous submissions of the VECP, including the dates submitted, the agencies and contract numbers involved, and previous Owner actions, if known. (d) Submission. The Contractor shall submit VECP’s to the RPR. (e) Owner action. (1) The RPR will notify the Contractor of the status of the VECP within 45 calendar days after the RPR receives it. If additional time is required, the RPR will notify the Contractor within the 45-day period and provide the reason for the delay and the expected date of the decision. The Owner will process VECP’s expeditiously; however, it will not be liable for any delay in acting upon a VECP. (2) If the VECP is not accepted, the RPR will notify the Contractor in writing, explaining the reasons for rejection. The Contractor may withdraw any VECP, in whole or in part, at any time before it is accepted by the Owner. The RPR may require that the Contractor provide written notification before undertaking significant expenditures for VECP effort. (3) Any VECP may be accepted, in whole or in part, by the Owner’s award of a modification to this contract citing this clause. The Owner may accept the VECP, even though an agreement on price reduction has not been reached, by issuing the Contractor a notice to proceed with the change. Until a notice to proceed is issued or a contract modification applies a VECP to this contract, the Contractor shall perform in accordance with the existing contract. The decision to accept or reject all or part of any VECP is a unilateral decision made solely at the discretion of the Owner. (f) Sharing— (1) Rates. The Owner’s share of savings is determined by subtracting Owner costs from instant contract savings and multiplying the result by 50 percent. Supplementary Conditions Supplementary Conditions Page 18 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction (2) Payment. Payment of any share due the Contractor for use of a VECP on this contract shall be authorized by a modification to this contract to— (i) Accept the VECP; (ii) Reduce the contract price or estimated cost by the amount of instant contract savings; and (iii) Provide the Contractor’s share of savings by adding the amount calculated to the contract price or fee. (g) Collateral savings. If a VECP is accepted, the RPR will increase the instant contract amount by 20 percent of any projected collateral savings determined to be realized in a typical year of use after subtracting any Owner costs not previously offset. However, the Contractor’s share of collateral savings will not exceed the contract’s firm-fixed-price or estimated cost, at the time the VECP is accepted. The Owner is the sole determiner of the amount of collateral savings. (h) Subcontracts. The Contractor shall include an appropriate value engineering clause in any subcontract of $55,000 or more and may include one in subcontracts of lesser value. In computing any adjustment in this contract’s price under paragraph (f) of this clause, the Contractor’s allowable development and implementation costs shall include any subcontractor’s allowable development and implementation costs clearly resulting from a VECP accepted by the Owner under this contract, but shall exclude any value engineering incentive payments to a subcontractor. The Contractor may choose any arrangement for subcontractor value engineering incentive payments; provided these payments shall not reduce the Owner’s share of the savings resulting from the VECP. ARTICLE 14 – PAYMENTS TO CONTRATOR AND COMPLETION SC 14: Throughout Article 14, replace “Engineer” with “RPR” SC 14.02A – Progress Payments Revise the first line to read: “On the date established in the” SC 14.02B – Review of Applications Revise the first line to read: “RPR will, within 5 working days after receipt of each” ARTICLE 16 – DISPUTE RESOLUTION SC 16.01 – Methods and Procedures Delete Paragraph 16.01.C is in its entirety and replaced with the following: C. In the event either party believes a critical problem exists which should not or cannot be resolved within the regular timetable of the dispute resolution procedures in this Contract, a senior management representative of either party may contact their counterpart in the other Party to address immediately any critical problem and seek appropriate resolution. D. When a dispute has arisen and negotiations between the parties have reached an impasse, either party may give the other party written notice of the dispute, which notice can occur before or after the RPR’s decision. In the Supplementary Conditions Supplementary Conditions Page 19 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction event such notice is given, the parties shall attempt to resolve the dispute promptly by negotiations between senior management representatives who have authority to settle the controversy and who are at a higher level of management than the persons with direct responsibility for the matter. Within ten (10) days after delivery of the notice, the receiving party shall submit to the other a written response. Thereafter, the representatives shall confer in person or by telephone promptly to attempt to resolve the dispute. All reasonable requests for information made by one party to the other will be honored. Any Contract durations for dispute resolution activities will be extended by the number of days the parties utilize this senior management resolution step. If the dispute has not been resolved by negotiation between the representatives within fifteen (15) days o f the notice, the parties may utilize any dispute resolution remedies or procedures set forth in the Contract. E. Submittal of the dispute to mediation shall operate to suspend obligation to file an arbitration demand under the Contract, until such time as the mediation session is concluded or cancelled by either party. F. All claims, counterclaims, disputes or other matters in question between Owner and Contractor arising out of or relating to the Contract Documents or breach thereof not resolved through negotiation or mediation shall be decided by binding arbitration in accordance with the Construction Industry Arbitration Rules of the American Arbitration Association G. In the event it becomes necessary to enforce any terms of the Contract, the prevailing party shall be entitled to recover all of its reasonable attorneys’ fees, expenses, costs, arbitration fees and arbitrator expenses. H. Senior management of each party will support the development and implementation of conflict avoidance and expedited conflict resolution procedures for this Contract in the event it appears necessary or beneficial to facilitate more effective project performance and communications. As a critical element of these procedures, each party agrees to delegate authority to appropriate staff levels for expedited-decision making during the performance of this Contract. I. If the Claim is not resolved by mediation, RPR’s action under Paragraph 10.05.C or denial pursuant to Paragraphs 10.05.C.3 or 10.05.D shall become final and binding 30 days after termination of the mediation unless, within that time period, Owner or Contractor: 1. elects in writing to invoke any dispute process provided for in the Supplementary Conditions; or 2. agrees with the other party to submit the Claim to another dispute resolution process. SC 16.02 – Partnering Insert after 16.01, the following: The Owner will promote the formation of a "Partnering" relationship with the Contractor in order to effectively complete the contract to the benefit of both parties. The purpose of this relationship will be to maintain cooperative communication and mutually resolve conflicts at the lowest possible management level. The Contractor may request the formation of such a "Partnering" relationship by submitting a request in writing to the RPR after approval of the contract. If the Contractor’s request for "Partnering" is approved by the RPR, scheduling of a "Partnering" workshop, selecting the "Partnering" facilitator and workshop site, and other administrative details shall be as agreed to by both parties. The costs involved in providing a facilitator and a workshop site will be borne by the Owner. The Owner shall pay all compensation for the wages and expenses of the facilitator and of the expenses for obtaining the workshop site. All other costs associated with the "Partnering" relationship will be borne separately by the party incurring the costs. Supplementary Conditions Supplementary Conditions Page 20 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction The establishment of a "Partnering" relationship will not change or modify the terms and conditions of the Contract and will not relieve either party of the legal requirements of the Contract. PART 3 - SUPPLEMENTARY CONDITIONS ARTICLE 18 – OWNER-FURNISHED MATERIAL AND EQUIPMENT SC-18.01: Materials and Equipment A. Description The following materials and equipment will be furnished by the Owner: 1. Fixed wheel gate, bulkhead gate, guides and fixed wheel gate hoist; 2. Bridge crane for BLU powerhouse; 3. Three BLU hydraulic turbines, hydraulic pressure units (HPU), turbine valves, and accessories; 4. Three BLU generators, exciters and accessories; 5. Governors and turbine-generator controls for BLU units; 6. One FVU consisting of turbine and generator and exciter; 7. Steel building for powerhouse superstructure; 8. Penstock and manifold; 9. 480V switchgear; 10. Raw water, station service, and water treatment plant transformers; 11. 12.47 kV Switchgear; Two main 69 kV/12.47 kV transformers and 12. Raw water switchgear. B. Delivery Schedules The Owner furnished materials and equipment will be delivered to Sitka, Alaska as specified hereinafter within the range of delivery dates as follows: Delivery Dates Item Embedded Parts Non-Embedded Parts a. Bulkhead gate and guides January 17, 2013 to February 17, 2013 January 17, 2013 to February 17, 2013 b. Fixed wheel gate, guides and hoist April 17, 2013 to May 17, 2013 April 17, 2013 to May 17, 2013 c. Bridge crane NA May 12, 2012 to September 12, 2012 d. BLU hydraulic turbines January 21, 2013 to April 26, 2013 January 21, 2013 to April 26, 2013 e. BLU turbine governors NA January 21, 2013 to April 26, 2013 Supplementary Conditions Supplementary Conditions Page 21 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction Delivery Dates Item Embedded Parts Non-Embedded Parts f. BLU turbine inlet valves NA January 21, 2013 to April 26, 2013 g. BLU generators and exciters January 21, 2013 to April 26, 2013 January 21, 2013 to April 26, 2013 h. 69 kV/12.47 kV transformers NA October 1, 2013 to December 23, 2013* i. 12.47 kV switchgear NA September 18, 2013 to November 27, 2013* j. Manifold NA Jan 15, 2013 to April 5, 2013 k. Penstock NA Jan 15, 2013 to April 5, 2013 l. Steel Building January 15, 2013 to April 16, 2013 January 15, 2013 to April 16, 2013 *Dates shown represent Owner’s approximated time of delivery. C. Delivery Delivery will be CIF to the barge terminal in Sitka (Point of Destination), Alaska or FAS air-freight terminal at Sitka, Alaska. D. Receiving, handling and storage All Owner-furnished materials and equipment shall be received, handled and stored by Contractor. Receiving, handling and storage of Owner-furnished materials and equipment shall conform to the requirements specified in these Contract Documents. a. Receiving: Contractor shall receive and unload Owner-furnished equipment and materials at the SCIP. Contractor shall check each item received, in the presence of RPR, against shipping lists for shortage and damage. Receiving reports shall be furnished to RPR covering the accepted parts and materials, and the disposition of any parts or materials that are unacceptable due to damage; b. Hauling: Contractor shall, when hauling the equipment from the storage location to the site of the construction comply with all applicable Federal, State, and local regulations for roads and bridges; c. Handling: Contractor shall exercise due care in the handling of equipment, and shall make use of any special lifting or handling devices which form part of Owner-furnished equipment. Care shall be taken not to bend, distort, break, over-stress, or otherwise damage materials and equipment during handling. All handling shall be performed by personnel skilled in this type of work. Proper rigging and slings of adequate strength shall be used. All equipment shall be moved Supplementary Conditions Supplementary Conditions Page 22 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction without impact: slings and rigging shall not mar finished surfaces and anti-chaffing blocks, pads, and similar items shall be used to prevent damage to surfaces of equipment. Contractor shall use manufacture’s lifting points and recommended methods. d. Storage: Owner-furnished materials and equipment shall be stored as specified in these Contract Documents and at locations as approved. Generally, all Owner-furnished materials shall be stored in the SCIP area. All equipment and materials shall be stored as specified until ready for installation. Contractor shall provide satisfactory protection from fire, theft, dirt, moisture, or other damage and loss of all Owner-furnished equipment in its custody. In no case shall articles be stored in such a way that machined or bearing parts will bear on or come in contact with the timber, cribbing, floor, ground or other support on which the article rests. Approved protective coatings on such critical surfaces shall be provided and maintained during storage. e. Inspection: At least one every two months Contractor shall, in the presence of the RPR, inspect all materials and equipment stored in storage areas to determine the condition of such arts, protective coatings, and to correct any deficiencies which may exist. A written report indicating the condition of the equipment shall be made to the RPR within 3 days after each such inspection and shall fully describe the condition of all such parts, protective coatings and storage facilities. Owner furnished materials and equipment that is delivered prior to January 15, 2013 will be received by Owner and stored at SCIP. After the January 14, 2013 the storage and inspection of these materials and equipment shall become the responsibility of Contractor in accordance with the requirements of Paragraphs d and e above. SC-18.02: - Suppliers’ Site Representatives for Owner Furnished Equipment A. Owner, at its discretion, may arrange and pay for one or more Suppliers of the Owner-furnished equipment or materials to furnish competent Site Representatives who are individual technicians or engineers, employed by Suppliers. Site Representatives will be provide advice and assistance and observation of the site installation, erection, testing, and start-up of the following Owner-furnished equipment: i. Fixed-wheel gate hoist; ii. BLU hydraulic turbines, turbine inlet valves, HPUs and accessories; iii. BLU generators, exciters, and accessories; iv. BLU turbine-generator controls; v. Steel building; vi. Bridge crane; vii. 69 kV/12.47 kV transformers; viii. 12.47 kV switchgear; and ix. 480 V station service switchgear. B. Supplier’s Site Representative(s) will provide advice of the installation, testing and commissioning of the Goods that Supplier has furnished to Owner. Contractor shall have overall responsibility for satisfactory installation and testing of Owner-furnished equipment. Contractor shall immediately advise RPR of any disagreement, dispute or misunderstanding between Contractor and Supplier’s Site Representative(s). Supplementary Conditions Supplementary Conditions Page 23 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction C. RPR will advise Contractor in advance when Suppliers’ Site Representative(s) will be at Site. Contractor shall schedule its Work to make effective use of Site Representative(s)’ time. ARTICLE 19 – SITE RESTIRCTIONS SC-19.01: Use of Explosives A. The use of explosives shall be in accordance with all Federal, State and local laws, regulations and ordinances. In addition, blasting operations shall conform to the requirements of the Specifications. Damage to existing features and structures which is caused by blasting operations shall be repaired to their original condition at no additional cost to Owner. B. A comprehensive Blasting Plan must be prepared, submitted, and approved by RPR prior to the delivery of any explosives to the Site. SC-19.02: Fire Prevention and Control A. Contractor, acting independently, shall immediately extinguish without expense to Owner, all uncontrolled fires on or in the vicinity of the project which are caused by Owner, RPR, Engineer, Contractor or its employees whether set directly or indirectly as a result of construction operations. Contractor may be held liable for all damages resulting from fires set or caused by its employees or resulting from its construction operations. If the amount and character of labor, subsistence, supplies and transportation which Contractor is in a position to furnish promptly, for fire suppression, prove inadequate, in Owner’s opinion, Owner will procure such items and services as it may deem necessary and charge the resulting costs to Contractor. SC-19.03: Dust and Spray Control A. Control measures shall be provided to prevent dust and spray from contaminating the site. All control measures shall be satisfactory to the RPR. SC-19.04: Public Use of Blue Lake Dam Access Road and Sawmill Creek Campground The Blue Lake Dam access road and Sawmill Creek Campground are public areas that will be closed to the public during construction of the Work. Any Contractor areas that might present public hazards or attractive nuisance risks shall be barricaded to prevent public entry, as required by the Specifications. The Sawmill Creek Campground area will be closed to public access during construction of the Work. Contractor may use only the designated areas for stockpiling processed rock material, parking and staging of materials near the Fish Valve Unit powerhouse and for its vehicle parking, office trailer and local staging, all within the work area boundary As Shown. SC-19.05: Contractor’s Work Areas Contractor work areas shall be As Shown. SC-19.06: Control of Water, Risk of Spill at Blue Lake Dam Supplementary Conditions Supplementary Conditions Page 24 of 24 Blue Lake Expansion Project – Contract No. 9 General Construction Blue Lake Dam is part of an operating hydroelectric facility. Water levels in Blue Lake are managed by the Owner via releases from the Blue Lake powerhouse, the FVU Powerhouse, the FVU bypass, the Howell Bunger valve at Blue Lake Dam, and by spill of water over the Blue Lake Dam spillway. Flows through the Howell Bunger valve or over the dam’s spillway will put Contractor’s personnel and equipment in the work areas below the dam and downstream of the dam area at risk. Any impending release of flows at the dam will require Contractor to remove its personnel, equipment and materials from the work areas below the dam and downstream of the dam. The risk of spill is described in more detail in Specification Section 01012. SC-19.07 Equipment Isolation and Lockout Procedures Owner will generate and perform all switching orders, equipment isolation, and lockout procedures on Owner’s equipment to secure the electric system and the Blue Lake tunnel. The lockout procedure must be part of Contractor’s overall safety plan and Work Plan, throughout the course of the Work. Contractor shall observe the lockout, place his padlocks on closed valves, electrical breakers and switches or related lockout devices, and sign Owner’s lockout and clearance paperwork. SPECIFICATIONS Blue Lake Expansion Project – Contract No. 9 TOC-1 General Construction May 2012 SPECIFICATIONS TABLE OF CONTENTS PAGE NO. DIVISION 01: GENERAL REQUIREMENTS 01005: GENERAL ........................................................................................... 01005-1 01010: SUMMARY OF WORK ........................................................................ 01010-1 01012: HYDROLOGY AND HYDRAULICS...................................................... 01012-1 01013: GENERATION OUTAGE ..................................................................... 01013-1 01014: EXISTING INTAKE CLOSURE ............................................................ 01014-1 01090: REFERENCE STANDARDS ................................................................ 01090-1 01200: PROJECT ADMINISTRATION ............................................................. 01200-1 01270: MEASUREMENT AND PAYMENT ...................................................... 01270-1 01290: SCHEDULE OF VALUES .................................................................... 01290-1 01300: SUBMITTALS ...................................................................................... 01300-1 01400: QUALITY ASSURANCE ...................................................................... 01400-1 01450: SAFETY .............................................................................................. 01450-1 01500: CONSTRUCTION FACILITIES ............................................................ 01500-1 01550: COORDINATION WITH OWNER PERFORMED WORK ..................... 01550-1 01600: MATERIAL CONTROL ........................................................................ 01600-1 01700: CONTRACT CLOSEOUT, OPERATING AND MAINTENANCE MANUAL AND SPARE PARTS ........................................................... 01700-1 01800: ENVIRONMENTAL CONDITIONS AND CONTROLS .......................... 01800-1 DIVISION 02: SITE WORK 02020: SURVEY CONTROL ........................................................................... 02020-1 02105: DEMOLITION AND SALVAGE ............................................................ 02105-1 02230: CLEARING AND GRUBBING .............................................................. 02230-1 02240: DEWATERING AND WATER CONTROL ............................................ 02240-1 02290: GEOTECHNICAL INSTRUMENTATION AND MONITORING ............. 02290-1 02310 BACKFILL ............................................................................................ 02310-1 02315: ROCK EXCAVATION AND SCALING ................................................. 02315-1 02316: UNCLASSIFIED EXCAVATION ........................................................... 02316-1 02370: EROSION, SEDIMENT AND POLLUTION CONTROL MEASURES ... 02370-1 02400: ROCK TUNNELING, SHAFT EXCAVATION AND SUPPORT ............. 02400-1 02405: DRILLING ............................................................................................ 02405-1 02410: ROCK BOLTS ..................................................................................... 02410-1 02411: ROCK ANCHORS ............................................................................... 02411-1 02413: GROUTED DOWELS .......................................................................... 02413-1 02420: PRESSURE RELIEF DRAINS (WEEPHOLES).................................... 02420-1 02430: FOUNDATION GROUTING ................................................................. 02430-1 02431: CONTACT AND TUNNEL LINER GROUTING .................................... 02431-1 02435: WATER PRESSURE TESTING ........................................................... 02435-1 TABLE OF CONTENTS (Continued) PAGE NO. Blue Lake Expansion Project – Contract No. 9 TOC-2 General Construction May 2012 02440: PRESSURE RELIEF WELLS ............................................................... 02440-1 02465: MICROPILES ...................................................................................... 02465-1 02510: WATER SUPPLY MAINS .................................................................... 02510-1 02530: SANITARY SEWERAGE ..................................................................... 02530-1 02620: SUBDRAINAGE SYSTEM ................................................................... 02620-1 02630 SITE DRAINAGE ................................................................................. 02630-1 02700: GRAVEL SURFACE, BASE AND SUBBASE COURSES .................... 02700-1 02820: FENCES AND GATES ......................................................................... 02820-1 02845: VEHICULAR CONCRETE BARRIERS ................................................ 02845-1 DIVISION 03: CONCRETE 03100: FORMWORK ....................................................................................... 03100-1 03200: CONCRETE REINFORCEMENT ......................................................... 03200-1 03254: CONCRETE WATERSTOPS AND JOINT FILLER .............................. 03254-1 03300: CAST-IN-PLACE CONCRETE ............................................................. 03300-1 03301: CONCRETE INSTRUMENTATION ...................................................... 03301-1 03350: CONCRETE SEALANT ....................................................................... 03350-1 03370: SHOTCRETE ...................................................................................... 03370-1 03480: PRECAST CONCRETE HOLLOW -CORE SLABS ............................... 03480-1 03600: GROUT AND MORTAR PRODUCTS .................................................. 03600-1 03610: DAM CONTRACTION JOINT GROUTING .......................................... 03610-1 DIVISION 05: METALS 05100: STRUCTURAL STEEL ........................................................................ 05100-1 05500: MISCELLANEOUS METALS ............................................................... 05500-1 DIVISION 06: WOOD AND PLASTICS 06066: DECORATIVE PLASTIC LAMINATE ................................................... 06066-1 06100: ROUGH CARPENTRY ........................................................................ 06100-1 06200: MILLWORK ......................................................................................... 06220-1 DIVISION 07: THERMAL AND MOISTURE PROTECTION 07100: DAMPPROOFING AND WATERPROOFING ...................................... 07100-1 07212: BOARD INSULATION.......................................................................... 07212-1 07213: BATT INSULATION ............................................................................. 07213-1 07510: MEMBRANE ROOFING ...................................................................... 07510-1 07900: BUILDING JOINT SEALERS ............................................................... 07900-1 DIVISION 08: DOORS AND WINDOWS 08111: STEEL DOORS ................................................................................... 08111-1 08350: SECTIONAL OVERHEAD DOORS ...................................................... 08350-1 08520: WINDOWS .......................................................................................... 08520-1 08710: DOOR HARDWARE ............................................................................ 08710-1 TABLE OF CONTENTS (Continued) PAGE NO. Blue Lake Expansion Project – Contract No. 9 TOC-3 General Construction May 2012 DIVISION 09: FINISHES 09290: GYPSUM BOARD ............................................................................... 09290-1 09510: ACOUSTICAL PANEL CEILINGS ........................................................ 09510-1 09650: RESILIENT WALL BASE ..................................................................... 09650-1 09772: DECORATIVE FIBERGLASS REINFORCED WALL PANELS ............ 09772-1 09900: PAINTING AND PROTECTIVE COATINGS ........................................ 09900-1 DIVISION 10: SPECIALTIES 10800: BATH ACCESSORIES ........................................................................ 10800-1 DIVISION 13: SPECIAL CONSTRUCTION 13100: PENSTOCK AND MANIFOLD INSTALLATION ................................... 13100-1 13110: TUNNEL STEEL LINERS .................................................................... 13110-1 13120: STEEL BUILDING INSTALLATION ..................................................... 13120-1 13210: INSTALLATION OF OWNER-FURNISHED GATES, GUIDES AND HOISTS ........................................................................ 13210-1 13310: INTAKE TRASHRACK AND SUPPORTS ............................................ 13310-1 DIVISION 14: CONVEYING SYSTEMS 14600: INSTALLATION OF OWNER-FURNISHED BRIDGE CRANE ............. 14600-1 DIVISION 15: MECHANICAL 15020: MECHANICAL GENERAL PROVISIONS ............................................ 15020-1 15061: PIPE HANGERS AND SUPPORTS ..................................................... 15061-1 15131: DRAINAGE PUMPS ............................................................................ 15131-1 15132: VERTICAL TURBINE PUMPS ............................................................. 15132-1 15300: PIPING SYSTEMS .............................................................................. 15300-1 15400: PLUMBING SYSTEM .......................................................................... 15400-1 15405: SANITARY LIFT STATION .................................................................. 15405-1 15415: BACKFLOW PREVENTERS ................................................................ 15415-1 15420: EYE WASH STATION ......................................................................... 15420-1 15440: PLUMBING EQUIPMENT AND FIXTURES ......................................... 15440-1 15480: COMPRESSED AIR SYSTEMS .......................................................... 15480-1 15600: FIRE PROTECTION EQUIPMENT ...................................................... 15600-1 15700: INSTRUMENTATION .......................................................................... 15700-1 15800: HEATING AND VENTILATION SYSTEMS .......................................... 15800-1 15905: AUTOMATIC BACKWASH STRAINER ............................................... 15905-1 15915: RAW WATER INTAKE SCREENS....................................................... 15915-1 DIVISION 16: ELECTRICAL 16020: ELECTRICAL GENERAL PROVISIONS .............................................. 16020-1 TABLE OF CONTENTS (Continued) PAGE NO. Blue Lake Expansion Project – Contract No. 9 TOC-4 General Construction May 2012 16071: FASTENERS, ATTACHMENTS AND SUPPORTING DEVICES ......... 16071-1 16110: RACEWAYS ........................................................................................ 16110-1 16111: EMBEDDED CONDUIT ....................................................................... 16111-1 16114: CABLE TRAY ...................................................................................... 16114-1 16120: WIRE AND CABLE .............................................................................. 16120-1 16131: EXPOSED CONDUIT – WET LOCATIONS ......................................... 16131-1 16132: INTERIOR RACEWAYS, FITTINGS AND ACCESSORIES ................. 16132-1 16133: EXPOSED CONDUIT .......................................................................... 16133-1 16134: OUTLET, JUNCTION AND PULL BOXES ........................................... 16134-1 16138: ELECTRIC MANHOLES ...................................................................... 16138-1 16221: MOTOR AND MOTOR CONTROLLERS ............................................. 16221-1 16223: LOW VOLTAGE STATION SERVICE SWITCHGEAR ......................... 16223-1 16232: 125V DC BATTERY AND CHARGING SYSTEM ................................. 16232-1 16233: UNINTERRUPTIBLE POWER SUPPLY SYSTEM (DUAL INVERTERS AND STATIC TRANSFER SWITCH) .................. 16233-1 16272: TRANSFORMERS – DRY TYPE, UNDER 600 V ................................ 16272-1 16273: TRANSFORMERS – OIL FILLED TYPE, OVER 600 V ........................ 16273-1 16275: MAIN SUBSTATION TRANSFER INSTALLATION .............................. 16275-1 16335: SWITCHGEAR INSTALLATION .......................................................... 16335-1 16414: AUTOMATIC TRANSFER SWITCH ..................................................... 16414-1 16442: PANELBOARDS .................................................................................. 16442-1 16450: GROUNDING ...................................................................................... 16450-1 16480: RAW WATER PUMP ELECTRICAL SYSTEM ..................................... 16480-1 16500: LIGHTING AND RECEPTACLES ........................................................ 16500-1 16622: STANDBY DIESEL-GENERATOR....................................................... 16622-1 16721: FIRE ALARM SYSTEMS ..................................................................... 16721-1 16723: FIBER OPTIC CABLE SYSTEM .......................................................... 16723-1 DIVISION 20: TURBINE AND GENERATOR EQUIPMENT 20100: TURBINE AND GENERATOR EQUPMENT INSTALLATION .............. 20100-1 APPENDIX A – MILESTONE SCHEDULE DIVISION 01 GENERAL REQUIREMENTS Blue Lake Expansion Project – Contract No. 9 01005-1 General Construction May 2012 SECTION 01005 GENERAL PART 1 GENERAL 1.01 OWNER A. Unless otherwise agreed, all correspondence and project documentation sent to Owner shall be addressed: Mr. Dean Orbison City and Borough of Sitka 105 Jarvis Street Sitka, AK 99835 Telephone: 907-747-1827 Fax: 907-747-3208 Email: deano@cityofsitka.com B. Unless otherwise agreed, all correspondence and project documentation sent to Resident Project Representative (RPR) shall be addressed: Mr. Richard Linden City and Borough of Sitka 105 Jarvis Street Sitka, AK 99835 Telephone: To Be Determined at Notice to Proceed Fax: To Be Determined at Notice to Proceed Email: Richard.Linden@mcmillen-llc.com 1.02 PROJECT REPRESENTATIVES A. Owner will maintain a Resident Project Representative (RPR), as well as a staff of inspectors and office engineer on-site for the duration of the project. Refer to the Supplemental Conditions for the duties of the RPR. B. Project Documents shall be sent to the Resident Project Representative with a copy to Owner’s Project Manager. C. Contractor’s Manager shall be responsible for successful completion of the Work in accordance with the Contract. 1.03 PROJECT NAME A. The project name shall appear on all project documentation as follows: City and Borough of Sitka Blue Lake Expansion Project Contract No. 9 General Construction 1.04 PROJECT LOCATION Blue Lake Expansion Project – Contract No. 9 01005-2 General Construction May 2012 A. The Project is located in the Borough of Sitka, Alaska approximately five miles east of the City of Sitka. The expansion of the existing facility includes a new intake structure and gatehouse located at the southwest end of Blue Lake, an 83 ft high raise of the existing dam, a new powerhouse on Sawmill Creek in the vicinity of Eastern Channel Silvery Bay, and associated new tunnel and penstock sections interconnecting these locations. 1.05 PUBLIC ACCESS A. The new powerhouse is adjacent to the existing powerhouse which can be easily accessed from Sawmill Creek Road. There are campgrounds and scenic natural features in the vicinity of the some of the expansion project work areas that the public utilizes. Take appropriate action at all times to ensure the safety and well being of the public near their work area. Appropriate security precautions shall also be taken by Contractor to protect the Site, and the personnel and the equipment that are brought to the site to perform the W ork (see Section 01500). 1.06 PERFORMANCE OF WORK A. Contractor shall confine its equipment, operations, and material to the work areas As Shown, or required as directed by RPR. B. Contractor shall employ only competent and skillful workers on the Work. RPR may notify Contractor if an employee of the Contractor has been observed to: be incompetent, refuse to carry out provisions of the Contract Documents, exhibit disorderly behavior, use threatening or abusive language to any person on the Work including the Owner, RPR, Engineer, or other representatives of the Owner, does not follow prescribed safety measures required in their job or, in general, not perform their work satisfactorily. Upon Contractor's receipt of such notice, such employee identified shall be subject to disciplinary action up to and including potential immediate discharge from the Work and shall not be employed again on the project, except with the written permission of Owner. C. Contractor shall not hire employees of Owner, others in contract with Owner, or their subcontractors without written release from such employer. Contractor shall be solely responsible for employees leaving his employ for any reason until such employee has left the site. D. Contractor shall be completely responsible for notifying his subcontractors and others engaged in the Work on his behalf of all requirements under the Contract Documents. END OF SECTION Blue Lake Expansion Project – Contract No. 9 01010-1 General Construction May 2012 SECTION 01010 SUMMARY OF WORK PART 1 GENERAL 1.01 GENERAL DESCRIPTION OF PROJECT A. Existing Project 1. Owner’s electric system is an isolated electric grid, located on Baranof Island, Alaska. All electric energy consumed on the island is locally generated on the island by two hydroprojects and 12 MW of diesel generators. The existing 7.54 MW Blue Lake Hydroelectric Facility is located between Blue Lake and Silver Bay, along Sawmill Creek, 5 miles southeast of the community of Sitka, in the City and Borough of Sitka, Alaska. 2. The Blue Lake facility was commissioned in 1961. It has three powerhouses, including the 6 MW two unit Blue Lake Powerhouse, the 0.67 MW Fish Valve Unit (FVU) and the 0.87 MW Pulp Mill Feeder Unit (PMFU). Water originates from the Blue Lake reservoir and is used for hydroelectric generation, in-stream flow needs, municipal water use and bulk water sales. In addition to the powerhouses and the reservoir, the project is comprised of a 149-ft-high, 256-ft long concrete arch dam equipped with a 140-ft-long spillway and a release valve, impounding the 1,255-acre Blue Lake reservoir, a submerged intake structure, tunnels, penstocks, transmission lines and access roads. B. Project Background 1. Blue Lake hydro project was constructed from 1959 through 1960, developed as a 6.0 MW hydroelectric facility to supply the City of Sitka and for supply of water to a pulp mill that was located at the present-day Sawmill Cove Industrial Park (SCIP). Initially, about one third of the Blue Lake inflows were used by the pulp mill and the remaining water was used for electric generation or was spilled over Blue Lake dam. The hydro project supplied much of Sitka’s electric energy needs since their commissioning in 1961. The hydro project remains largely unmodified since construction. The Alaska Pulp Co (APC) ceased operation in 1993. 2. In 1982 the Owner completed the 16 MW Green Lake hydro project, located about 8 miles east of Blue Lake. The combined generation output of Blue Lake hydro project and Green Lake hydro project was used to supply Owner’s electric system, along with surplus energy sales to the APC mill until the time of the mill closure. Currently, Blue Lake and Green Lake hydro projects supply the vast majority of the electric energy needs on Baranof Island. C. Blue Lake Expansion Project : 1. The Blue Lake Expansion Project includes increasing the height of the Blue Lake Dam by 83 ft, modifying waterways from the dam to the powerhouse, and constructing a new powerhouse with three 5.3 MW (nominal capacity) generating units. Blue Lake Expansion Project – Contract No. 9 01010-2 General Construction May 2012 2. The dam extension provides an increase in the overall maximum gross head on the plant from 329 ft to 413 ft, a 25% increase in head. 3. In addition, the project includes modification to the existing switchyard, relocation of the existing Sitka electric system control center to the new Blue Lake powerhouse, and replacement of the Fish Valve Unit with a new unit designed for higher operating head. 4. The Substantial Completion date for the Blue Lake Expansion Project and this Contract No. 9 is February 1, 2015. 1.02 WORK UNDER THIS CONTRACT A. The Work covered under these Specifications and As Shown consists of performing all operations required for the Blue Lake Expansion Project, Contract No. 9 – General Construction. The contract drawings are divided into twelve primary features. General project implementation requirements and the primary features of the Blue Lake Expansion Project include the items of work described below. B. General Project Implementation 1. Preliminary Progress Schedule. 2. Work Plan including Progress Schedule and, as required to reflect the Contractor’s proposed approach to the Work, elaboration and refinement to Owner prepared FERC License Amendment Plans. 3. Furnishing a detailed construction plan and schedule for the orderly completion of the W ork as specified. Submittal format shall conform to Div 1, Section 01300. 4. Furnishing of a detailed site specific Health and Safety Plan (HASP) to satisfy the requirements of the Occupational Safety and Health Administration (OSHA) Standard 29 CFR 1910. Submittal shall conform to Div 1, Section 01450. 5. Implementation of FERC License Amendment Plans. 6. Furnishing of all documents required by these specifications including drawings, data, and calculations on materials, methods, equipment, and installation procedures and drawings. Submittal format shall conform to Div 1, Section 01300. 7. Furnishing and maintaining required temporary facilities for construction including power, lighting, water, sanitary facilities, and field offices during the duration of the contract as herein specified in Section 01500. 8. Maintain driveable surfacing on Project Site. 9. Mobilizing to and demobilize from the Site to begin and end construction activities. 10. Field verifying all field conditions prior to installation, including location of all underground utilities. Blue Lake Expansion Project – Contract No. 9 01010-3 General Construction May 2012 11. Providing all necessary labor, equipment, materials and supervision to supply and install all components as specified on the drawings and in the specifications, including, the construction of components listed in Section 1.02 B. 12. Providing and implement a QA/QC program, per Section 01400. 13. Providing all project documentation, procedures, manuals and drawings including as-built drawings as required by these technical specifications. 14. Furnishing all labor, materials and equipment to establish and maintain a site office and laydown areas as needed to perform the work. The site shall be restored at the completion of the Work in accordance with the drawings and specifications. 15. Providing all required notices and permits including payment of associated fees and perform all work in accordance with issued construction permits, except as noted in Section 1.03 A below. 16. Furnishing and installing all materials As Shown, including all required demolition, clearing and grubbing, excavation, grading, backfill, geotextile, new fencing, fencing repair and installing miscellaneous items as indicated herein. If any soils or other excavated materials are stockpiled, they are to be surrounded by silt fencing to prevent erosion. 17. Removing and disposing of all excess materials and debris. 18. Providing all construction survey and layout including horizontal and vertical control. 19. Abatement of any hazardous materials that may be encountered during the performance of the Work. 20. Any required staging and work areas and access roads to the various construction site areas. This shall include regrading of the Blue Lake Road from the Sawmill Creek Road to the dam site and construction of the dam staging areas at the right abutment dam site. 21. Clearing and grubbing of all site areas as specified. 22. Providing all site restoration for areas disturbed by Contractor’s activities. C. Blue Lake Dam Extension (Feature 20) 1. Right and left abutment rock support. 2. Left abutment tunnel drainage system, and rock block anchor installation. 3. Raising the height of the existing dam structure by 83 ft including demolition work, preparation of the top surface of the existing dam as specified, consolidation grouting, and construction of the extended structure with new spillway and left abutment thrust block cut-off wall, curtain grouting, parapet wall and vertical construction joint grouting. Blue Lake Expansion Project – Contract No. 9 01010-4 General Construction May 2012 4. Instrumentation and control systems including dam instrumentation, piezometer monitoring wells and the sluice gate operating system. 5. Extending ladders that provide access to the Howell-Bunger valve 6. Walkway under the new spillway that provides access to the left abutment of the dam. 7. Extending hydraulic lines to slide gate upstream of Howell-Bunger valve. 8. Providing debris boom and anchor points as required to prevent debris from entering the intake. (Feature 06) 9. Pressure relief wells. 10. Spillway plunge pool scour wall. D. Drainage Tunnel (Feature 23) 1. Temporary staging, work areas and temporary access roads and site restoration as required or specified. 2. Installing erosion and sediment control measures. 3. Tunnel portal excavation and support. 4. Tunnel excavation and support. 5. Spoils removal and disposal. 6. Excavated rock support systems including rock bolts, steel sets, and other miscellaneous associated materials. 7. Drilling all geotechnical exploratory percussion and cored holes. 8. Providing drainage measurement weir. E. Intake Tunnel (Feature 24) 1. Excavating reservoir access road and rock support 2. Portal excavation and rock support 3. Intake tunnel excavation and rock support F. Gate Shaft Excavation, Rock Support and Intake Structure (Feature 25) 1. Excavating (i.e., removal) rock cofferdam used for construction of the new intake tunnel. 2. Permanent closure and sealing of existing intake gate structure 3. Foundation preparation for new intake structure. Blue Lake Expansion Project – Contract No. 9 01010-5 General Construction May 2012 4. Intake structure including intake tunnel portal. 5. Providing trashracks and guides. 6. Installing Owner-furnished bulkhead gate guides. 7. Installing adjusting and testing Owner-furnished intake bulkhead gate. 8. Providing the bulkhead gate slot cover. 9. Embedding piping for water level and trashrack pressure sensing and air bubbler system. 10. Sealing and abandonment of the existing intake structure G. Gate Shaft (Feature 26) 1. New gate shaft including gate chamber, Owner-furnished fixed-wheel gate, gate guides, gate frame and hoist installation, gatehouse structure and architectural features, mechanical and electrical systems, and instrumentation. 2. Concrete lining of the intake tunnel from the intake structure to and including the bottom of the gate shaft. 3. Installation of Owner-furnished fixed wheel gate frame and guides. 4. Construction of gatehouse access road and crane access area adjacent to gatehouse. 5. Supply and installation of pad mount transformer, power cable and conduit from dam site junction pedestal to gatehouse and all electrical, mechanical and instrumentation services in the gatehouse and at the dam. H. Tunnel Modifications and Surge Chamber (Feature 30) 1. Restoring Filter Plant Access Road, as required, from Sawmill Creek Road to the PMFU and site restoration as required or specified. 2. Intake tunnel tie-in to existing upper tunnel, including excavation of the remaining rock plug between new and existing tunnel, spoil disposal, and construction of a concrete plug in the existing tunnel just upstream of the tunnel tie-in to isolate the existing intake from the waterway. 3. All required dewatering and water control for completion of the contract work. 4. Steel liner installation at the north river, south river, and lower portals. 5. Adit and surge shaft and chamber construction. 6. Adit tunnel concrete plug with manhole entryway. I. Penstock and Penstock Drain (Features 31 and 32) 1. Penstock modifications including required demolition of a portion of the existing lower penstock (sta. 2+58 to sta. 4+12), timber crib wall modifications and Blue Lake Expansion Project – Contract No. 9 01010-6 General Construction May 2012 construction of an approximate 380 ft of new penstock section including anchor blocks, penstock drain and associated features as specified. 2. Work shall include installation of Owner-furnished penstock and manifold from Sta. 4+12, reconnection of 20-inch line to City water treatment plant, and construction of a 24-inch diameter penstock drain line with fixed-cone valve energy dissipater and structure. J. Water Treatment Plant (Feature 33) 1. Replacing strainers and pressure regulators in existing Water Treatment Plant As shown. 2. Installing pressure reducing valve in the SCIP fire line located in the metering building. K. Powerhouse (Feature 45) 1. Constructing access road from Sawmill Creek Road to the powerhouse. 2. All site work. 3. Foundations, afterbay, weir, metal work and associated building architectural work . 4. All associated mechanical and electrical equipment, systems, instrumentation and services as specified for the new powerhouse. 5. Raw water supply system including pump station structure, pumps, valves, controls, intake screens and piping; industrial water pumped from tailrace; and an industrial water tap on the 42” bulk water line. 6. Potable water supply to powerhouse 7. Sewer force main and lift station 8. Erecting Owner-furnished pre-engineered powerhouse superstructure including structural steel, anchors, precast concrete wall panels, metal roof panels, crane runway, crane rails, end stops. 9. Installing of Owner-furnished turbine and generator equipment including turbines, HPUs, turbine inlet valves, generators, exciters and control panels with governors as described in Section 20100 10. Installation of Owner-furnished 12.47 kV powerhouse switchgear and 480V station service switchgear. 11. Installation of Owner-furnished bridge crane. 12. Supplying and installing station service generator. L. Fish Value Unit Powerhouse (Feature 46) Blue Lake Expansion Project – Contract No. 9 01010-7 General Construction May 2012 1. Fish valve unit (FVU) powerhouse modifications consisting of demolition and salvage of existing turbine and generator, concrete pad demolition and reconstruction, and installation of Owner-furnished FVU turbine and generator equipment including turbine, gate positioner, generator, exciter and turbine inlet valve. M. Switchyard (Feature 55) 1. Constructing transformer support pads and spill containments. 2. Installing Owner-furnished 69 kV main transformers. 3. All associated tie-ins and connections as defined in section 01550. 4. Providing security fences and gates. 5. Provide conduit As Shown N. Existing Blue Lake Powerhouse (Feature 90) 1. Rerouting the water transmission main with new 24-inch diameter pipe around new powerhouse site (the tie-in valves will be installed in advance by Owner). 2. Providing temporary sewer lift station and power to the building. 3. Provide and connect power, control wiring, water and sewer at east wall of powerhouse. 1.03 SERVICES PROVIDED BY OTHERS A. Property and Onsite Services Supplied by Owner are: 1. The property As Shown. 2. Office space, laydown, construction camp area is available for lease at the Sawmill Cove Industrial Park owned by the Owner adjacent to the Powerhouse site. 3. Use of limited laydown areas and SCIP. 4. Electrical power at designated onsite locations (see Section 01500, 1.03). B. Supplier Site Representatives for Owner-furnished equipment and Goods (to be Installed by Contractor) will be provided (at Owner’s discretion) for the equipment in: 1. Item G1 (fixed wheel gate hoist only) 2. Items K8 (pre-engineered powerhouse superstructure), 3. Item K9 (turbine-generator equipment), 4. Item K10 (switchgear), LV & MV 5. Item K11 (bridge crane), Blue Lake Expansion Project – Contract No. 9 01010-8 General Construction May 2012 6. Item L1 (FVU turbine-generator equipment), and 7. Item N2 (69 kV main transformers) C. Interface Points and Work by Others: 1. Owner will provide a distribution circuit from the FVU road intersection area to the dam area, including a construction transformer for construction power at the dam and intake work area. 2. Owner will provide fiberoptic cable from the Blue Lake Powerhouse to the dam site transformer pedestal location and from the Blue Lake Powerhouse control room to the FVU. Contractor can make arrangements with communications providers for telephone and internet services, using some of these fibers. 3. Owner will furnish stoplogs for the FVU tailrace. 4. Owner will provide all SCADA and control equipment in BLU powerhouse, including SCADA terminations at the BLU control panels, the switchyard, the station service panel and ac power panels, using Contractor supplied and installed conduit and cable tray. 5. Contractor will provide power cables from the transformers in the switchyard to the circuit breakers in the BLU powerhouse, using Contractor provided and installed embedded conduit and cable tray. 6. Contractor will provide control cables from the transformers in the switchyard to the switchyard control building, using Contractor provided and installed embedded conduit and cable tray. 7. Owner will terminate the control cables from the switchyard to the Blue Lake switchyard control building located in the switchyard using contractor supplied and installed embedded conduit. 8. Interface points for water mains and sewer force main piping are as follows: a. Industrial Water Supply Discharge: Right bank of Sawmill Creek Truss Bridge connecting into existing 42” diameter HDPE Bulk Water pipeline. b. Emergency Water Supply Discharge: Between existing penstock and Water Treatment Plant, new connection into existing ductile iron Raw Water pipeline. c. Potable Water Supply Source: Existing valve at intersection of existing powerhouse access road and Sawmill Creek Road. d. Water Transmission bypass main source: At new tie-in, to be constructed by others (CH2MHill design), in existing 30” Water Transmission main near Water Treatment Plant. e. Water Transmission bypass main discharge: At new tie-in, to be constructed by others (CH2MHill design), in existing 30” Water Transmission main at intersection of existing powerhouse access road and Sawmill Creek Road. Blue Lake Expansion Project – Contract No. 9 01010-9 General Construction May 2012 f. Sewer Main discharge: Existing force main at intersection of existing powerhouse access road and Sawmill Creek Road. 9. Owner will assist with unwatering the tunnel and penstock at the start of the generation outage period. Contractor will seal and decommission the existing gates and intake structure. D. As part of the Work Plan, create site specific plans necessary for obtaining permits and approvals. These site specific plans will elaborate and suggest refinements to Owner acquired permits, certificates and plans including FERC License Amendment Plans. 1.04 OWNER’S REFERENCE INFORMATION A. Owner’s reference information is identified in specification and the notes on the Drawings. 1.05 WORK BY OTHERS A. Work to be done by others will include: 1. Dewatering and rewatering of the power tunnel for generation outage work. 2. Owner will acquire all necessary permits and approvals from all federal, state and local agencies as noted in the Supplemental Conditions, paragraph SC- 6.08B. 3. Contractor will be required to comply with the Owner’s FERC License Amendment Plans and develop their own plans as required to obtain construction permits. END OF SECTION Blue Lake Expansion Project – Contract No. 9 01012-1 General Construction May 2012 SECTION 01012 HYDROLOGY AND HYDRAULICS PART 1 GENERAL 1.01 OVERVIEW A. This Section describes: hydraulic capacities of the existing project facilities; the hydrologic setting of the existing Blue Lake hydro project; Owner’s planned operation of the existing project during construction of the Blue Lake Expansion; and Owner’s specific assumption of risk related to high inflows, high lake levels, and high tailwater conditions during construction. B. Owner will assume responsibility for maintaining specific Lake Level Windows and powerhouse Tailwater Level Windows as described herein. Owner will reimburse Contractor for its additional costs suffered, if water levels exceed the level windows described herein, provided that Contractor suffers damage to plant, equipment, permanent works or delay as a result of high water in excess of the window levels described herein. C. This section presents Owner’s plan for management of lake levels during construction. Owner will operate the Blue Lake hydro project to maximize energy generation during much of the construction period. However Owner expects to partner with the Contractor in managing lake levels and scheduling the Work as the Work progresses and inflows occur. Owner anticipates deviating from the plans described in this Section, as needed, in response to the actual Blue Lake inflows from late 2012 through December 2014. Owner seeks to achieve the most expeditious and cost efficient construction effort that inflows allow, while maintaining power generation during construction, in cooperation with Contractor. 1.02 PROJECT OPERATIONS A. Owner’s electric system is an isolated electric grid, located on Baranof Island, Alaska. All electric energy consumed on the island is locally generated on the island by two hydroprojects and 12 MW of diesel generators. B. Blue Lake hydro project was constructed from 1959 through 1960, developed as a 6.0 MW hydroelectric facility to supply the City of Sitka and for supply of water to a pulp mill that was located at the present-day Sawmill Cove Industrial Park (SCIP). Initially, about one third of the Blue Lake inflows were used by the pulp mill and the remaining water was used for electric generation or was spilled over Blue Lake dam. The Blue Lake hydro project supplied much of Sitka’s electric energy needs since its commissioning in 1961. The hydro project remains largely unmodified since construction. The Alaska Pulp Co (APC) ceased operation in 1993. C. In 1982 Owner completed the 16 MW Green Lake hydro project, located about 8 miles east of Blue Lake. The combined generation output of the Blue Lake hydro project and the Green Lake hydro project was used to supply Owner’s electric system, along with surplus energy sales to the APC mill until the time of the mill closure. Currently, Blue Lake and Green Lake hydro projects supply the vast majority of the electric energy needs on Baranof Island. Blue Lake Expansion Project – Contract No. 9 01012-2 General Construction May 2012 D. In 1987 Owner developed Blue Lake as a source of unfiltered municipal water for the Sitka community, by construction of a water supply pipeline from the Blue Lake powerhouse area to the city. Municipal water consumption accounts for an average 5 cfs diversion of pressurized water to the city. Note that municipal water quality requirements take precedence over any construction activity, as specified in the Supplementary Conditions. E. The Fish Valve Unit (FVU) powerhouse was constructed in 1991 to generate energy from the instream flow release Owner discharges into Sawmill Creek at the Sawmill Creek penstock crossing. The FVU currently operates with a continuous discharge, which varies from 50 cfs to 70 cfs, depending on the time of year. F. From the time of completion of the Green Lake hydro project until the summer of 2011, Owner has enjoyed surplus energy generating capacity, where the available hydro resources have been greater than Owner’s electric loads. Owner has seen a significant growth in electric energy demand since 2008 as customers have been switching from oil and kerosene heat to electric heat. In 2011 Owner had to operate its diesel generating resources to meet electric energy demand (in a non- emergency situation) for the first time since 1982. At present, Owner expects that it may have to use its diesel generating resources to meet a portion of its system energy needs in the 2012 to 2014 time frame. G. One foot of water storage in Blue Lake, at El 330 water level, contains 1,210 ac-ft of water. This water volume can generate approximately 275,000 kWH of energy in the Blue Lake powerhouse. At the current retail electric rate (9 cents per kWH not including diesel surcharge costs), this foot of storage has a value of $24,800 in energy sales. At the current cost of diesel generation (55 cents per kWH), this foot of storage is has a value of $151,000 in avoided diesel-fired generation costs. These are significant costs to Owner and its approximate 3,000 electric utility customers. Owner intends to maximize the Blue Lake hydro generation during the construction of the Blue Lake expansion, to the extent possible. 1.03 FLOW RATING CURVES AND CONSTRUCTION RESTRICTIONS A. The following rating curves, operating data, and restrictions are provided for Contractor’s reference. Note that Owner will restrict Contractor’s activities in some cases, as described below, to allow operation of the hydro projects. B. Existing Blue Lake Dam Spillway Rating Curve and Construction Restrictions. 1. The existing spillway rating curve is shown in Figure 01012-1, below. The new spillway will have essentially the same relative head vs. discharge relationship and a similar rating curve. 2. As noted later in this Section, Owner anticipates there is a 40% probability that Blue Lake will fill in the fall of 2013 and spill over the dam crest at El 342.0. Protection of the spillway plunge pool area from excessive erosion is required during the 2013 and 2014 construction seasons. Owner anticipates this will be achieved by maintaining operation of the existing dam spillway through the fall and winter of 2013 to 2014. 3. Protection of Contractor’s temporary facilities around the dam from spill flows over the dam, including cranes, equipment in the plunge pool area, partial construction and equipment in the exploratory tunnel and plunge pool weir areas and any other equipment or temporary works below the dam are Contractor’s responsibility. Construction of the left abutment drainage tunnel, Blue Lake Expansion Project – Contract No. 9 01012-3 General Construction May 2012 pressure relief wells and plunge pool scour wall should be completed outside the expected 2013-2014 spill season. Owner will not compensate Contractor by a change in Contract Price or Contract Times for any damage to partially completed project features below the dam, or damage to construction plant or equipment below the dam that occur due to spill over Blue Lake dam in the 2013-2014 spill season. 4. The existing spillway acts to throw spill flows downstream of the dam a sufficient distance to avoid regular erosion of the existing timber crib and loose rock materials that are immediately adjacent to the downstream face of the dam in the plunge pool. Extensive analysis by Engineer (see Technical Memorandum No. 28 in the Reference Documents) indicates that the timber crib and loose materials in this area of the plunge pool are stable and will not move with spill flows up to about 11,500 cfs (a flood flow with a 1 in 40 year recurrence interval). 5. If operation of the existing Blue Lake spillway is maintained between September 1, 2013 and December 15, 2013 (the “2013 Spill Window”), Owner will not hold Contractor responsible for any damage to the plunge pool area due to spill over the dam, including large flood events. 6. Construction Restriction: In the non-overflow sections of the dam crest (the crest on either side of the spillway), Contractor shall maintain the height of the existing dam parapet walls (El 351.0), or an equivalent new raised block section of the dam higher than El 351, from September 1, 2013 until December 15, 2013. Contractor shall not create any opening along the dam crest between these dates that would allow flow over the non-overflow crest areas of the dam, for reservoir water levels of El 351 or lower. 7. Construction Restriction: Contractor shall not begin the dam raise work in the existing spillway area until after December 15, 2013. 8. Construction Restriction: Contractor shall not restrict flows approaching the existing spillway from the reservoir and shall not impair the flow capacity of the existing spillway between September 1, 2013 and December 15, 2013. Blue Lake Expansion Project – Contract No. 9 01012-4 General Construction May 2012 Figure 01012-1A Existing Blue Lake Spillway Rating Curve C. Howell Bunger Valve Rating Curve and Operating Requirements. 1. The 42 inch Howell Bunger valve, located at El 233.75 in Blue Lake Dam was replaced with a new valve in 2006 and is fully operational. This valve is rarely operated. Owner’s primary use of this valve is to provide instream flows to Sawmill Creek when the project tunnel is dewatered. 2. This valve will be used during the generation outage to supply water down Sawmill Creek for instream flow. The Howell Bunger valve might also be used by Owner to help control water levels in Blue Lake during the 2013 and 2014 construction seasons. This will only occur if high inflows occur and the Owner is well assured that both Blue Lake and Green Lake reservoirs will fill in the October-November time frame of each year. The effect of any such operation on lake levels will be small, as the valve’s discharge capacity is small relative to inflows during wet years. 3. Note that the Howell Bunger valve inlet is constrained by head losses in its trashrack, its sharp-edged pipe entry on the upstream side of the dam and debris in front of the valve inlet trashrack. The maximum discharge capacity of the valve is approximately 450 cfs at reservoir level El 316. A flow discharge rating curve for the valve is provided in the Reference Documents. 4. Construction Restriction: Contractor shall not locate any crane or other hard to move construction equipment in the discharge area of the Howell Bunger valve As Shown. The valve shall remain operable during the full Expansion Project construction period. Owner will operate the valve only during the generation outage and possibly as needed to aid in managing reservoir levels, in cooperation with Contractor. 340 342 344 346 348 350 352 354 356 358 360 0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000Elevation (ft)Discharge (cfs) Blue Lake Expansion Project – Contract No. 9 01012-5 General Construction May 2012 D. Spillway Plunge Pool Tailwater Rating Curve 1. The plunge pool water level with no flow over the spillway is typically about El 190, which is about 10 feet below the creek channel just downstream of the pool. The plunge pool water level varies with spillway flow as shown in the curve below. Note that the invert of the drainage tunnel portal is approximately El 210. Figure 01012-1B Existing Plunge Pool Stage/Discharge Rating Curve E. The FVU turbine hydraulic capacity is approximately 70 cfs. The FVU will operate throughout the construction work, except for the generation outage period and the time when the existing FVU generating equipment is being salvaged and the new FVU generating equipment is being installed. The flow discharge from the FVU will vary between 50 cfs and 70 cfs, depending on the time of year, as needed to meet the instream flow requirements in Sawmill Creek. F. The FVU building is potentially subject to flooding in the event of very high spillway flows at Blue Lake dam during any time that the FVU building doors are open. Owner will assume the risk of loss due to a flood affecting the FVU building, provided Contractor does not remove the watertight door to the FVU building until after the beginning of the generation outage and provided that Contractor re- installs the door before December 15, 2014. G. The two existing Blue Lake turbines can discharge a combined flow of about 370 cfs with both machines operating at overload (3.5MW), with Blue Lake at El 342. 195 200 205 210 215 220 225 230 0 5,000 10,000 15,000 20,000 25,000 30,000Elevation (ft)Discharge (cfs) Blue Lake Expansion Project – Contract No. 9 01012-6 General Construction May 2012 Owner will operate these units during the construction work to help manage the Blue Lake water level, while meeting system generation requirements. If high inflow conditions occur and lake level operating targets are met, the Owner will operate the Blue Lake turbines at continuous overload to help control the Blue Lake water level. H. Powerhouse Tailwater Rating Curve 1. The tailwater level at the existing and new powerhouse locations is a function of both tidal variations in Silver Bay (just downstream of the powerhouse) and the flow in Sawmill Creek adjacent to the powerhouse, as well as debris bockage at the bridge piers downstream on the Blue Lake powerhouse. Owner will assume the risk of high tailwater levels at the powerhouse, if the Contractor provides cofferdam protection during the Tailwater Level Window as described below. 2. Tidal variations in Silver Bay at the SCIP are described by Southeast Alaska tide tables published by NOAA for the Sitka area. Note that the high tide of record is El 12.5’. Historical tide data is shown in Figure 01012-2 below: 3. High flows in Sawmill Creek at the powerhouse are driven by spill flows over Blue Lake dam. The drainage area below the dam and above the powerhouse is about 10% of the 39 square mile drainage area feeding Blue Lake. As a result, high tailwater conditions at the powerhouse almost always involve a combination of high spill flows and high tides. The historic record that conservatively approximates the frequency, stage and flow of Sawmill Creek at the Blue lake powerhouse is available by obtaining the record of USGS Gage No. 15088000. This gage was reinstalled about 100 yds upstream of the powerhouse to record the stage on a continuous basis since 2000. In order to adjust to the project datum, Gage readings need to be adjusted upwards by 1.42 feet (e.g. a Gage reading of El 13 ft would be adjusted to an actual water surface El of 14.42 ft, MLLW datum.). For convenience, the tailwater rating curve of the gauge is shown in Figure 01012-3 below. The staging level would appear to be about 3 to 4 feet higher at this gauge location than the water level at the powerhouse location; however, as noted in Figure 01012-2, tidal influences as well as storm surges could increase the tailwater to a higher location at the powerhouse than 3 to 4 feet from the USGS tailwater rating curve. Blue Lake Expansion Project – Contract No. 9 01012-7 General Construction May 2012 Figure 01012-3 – USGS Stream Gauge Rating Curve Upstream of Powerhouse Site The following Figures 01012-4 and 01012-5 present hydrographs of flow that have historically occurred at the powerhouse from 2001 through 2011. Figure 01012-4 – Hydrograph of Flows at Powerhouse (2001-2006) Blue Lake Expansion Project – Contract No. 9 01012-8 General Construction May 2012 Figure 01012-5 – Hydrograph of Flows at Powerhouse (2007-2011) 1.04 PROJECT HYDROLOGY RECORDS A. The USGS maintained a stream monitoring gage (USGS Gage No. 15088000) in Sawmill Creek near the outlet of Blue Lake from 1929 through 1957 (a 28 year record). The average, maximum and minimum daily flows in this USGS record are shown below in Table 01012-1. Since construction of Blue Lake dam, daily flow records have been sporatically maintained, and the pulp mill diversion were not accurately measured. As a result, accurate inflow records or estimates are not available for the period after 1957 until the gage was reinstalled in 2000. Owner uses the 28-year hydrologic flow record which is available, for planning project operations and predicting future reservoir levels. Table 01012-1.Average, Minimum, and Maximum Daily Flows, 1929 – 1957 (cfs) Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Avg 186 176 137 218 575 763 708 683 773 764 515 271 Min 24 28 21 34 57 308 311 200 144 84 50 35 Max 2270 2410 1250 1050 1640 1780 2170 4940 4980 5500 4430 3770 B. The 15 largest floods of record are listed in Table 01012-2. Engineer completed an analysis of historical floods and has predicted the maximum flood flow that might occur at the Project, as described in Technical Memorandum No. 34 in the Reference Documents. Blue Lake Expansion Project – Contract No. 9 01012-9 General Construction May 2012 Table 01012-2 – Floods of Record, 1929 – Present Date Annual Peak Streamflow Oct 22, 1937 4,840 Aug 19, 1939 4,290 Nov 12, 1946 6,190 Sep 08, 1948 7,100 Nov 09, 1948 4,900 Oct 30, 1949 4,430 Sep 14, 1952 6,380 Sep 20, 1954 5,670 Dec 16, 1954 6,230 Sep 30, 1957 4,630 Nov 1993 11,100 Aug 2002 7,280 Oct 2002 5,680 Dec 2004 7,210 Nov 2005 11,500 1.05 OWNER’S OPERATING PLANS FOR 2012 THROUGH 2014 A. Blue Lake water levels are driven heavily by rain events which Owner cannot predict in advance. The hydraulic capacity of the existing Blue Lake powerhouse is small relative to inflows from rainfall events in the Blue Lake basin. B. Owner plans to operate the Blue Lake Project in its existing configuration on the established reservoir rule curve to obtain maximum generation during the construction period. Construction activities shall be scheduled to facilitate this requirement. As part of its normal operation, Blue Lake dam may spill in the September to November timeframe, depending on reservoir inflows. C. Owner plans to operate the Blue Lake project to achieve target reservoir levels in Blue Lake, as follows: 1. November 2012 to October 31, 2013 – Operate Blue Lake hydro plant in coordination with Green Lake hydro plant to maximize energy generation and to hold Blue Lake water levels below El 330 during the 2013 Lake Level Window period. (Lake Level Window periods are described later in this section). Owner will try to hold the lake surface below this elevaton to allow excavation and construction activities in the intake tunnel and intake structure areas. 2. November 1, 2013 to start of generation outage (assumed to start September 1, 2014) – Operate Blue Lake in coordination with Green Lake through about May 2014 to maximize generation. After about May, 2014, operate Blue Lake at maximum hydraulic capacity (maximum generation) as needed to help hold the lake below El. 302 during the 2014 Lake Level Window. This window is provided so that Contractor can complete construction of the intake structure, at which point the intake bulkhead can be installed and work behind the bulkhead in the tunnel can safely continue as the lake rises above El 302. After installation of the intake bulkhead gate, Owner will reduce generation at Blue Blue Lake Expansion Project – Contract No. 9 01012-10 General Construction May 2012 Lake to aid in filling the lake so that the lake level will be high enough for testing the turbine-generators at the end of the generation outage. 3. Generation Outage (assumed duration: September 1 to October 31, 2014) – Blue Lake powerhouse and FVU will not be operating while the generation outage construction work takes place. The Howell Bunger valve at the dam will release water continuously for the instream flow requirement. During the generation outage, Blue Lake water levels will rise. Owner projects that, by the end of this period, the lake will rise to about El 350, which is sufficient to begin commissioning tests of the new Blue Lake turbine-generators. 4. Project Testing and Commissioning (assumed to start November 1, 2014) – Functional testing, acceptance testing and commissioning of the new Blue Lake turbine-generators will take place. As soon as the first generating unit at Blue Lake is declared Substantially Complete, this unit will begin continuous generating operation. This milestone constitutes the end of the generation outage, see Section 01013. 5. The second and third new Blue Lake units will be commissioned in sequence after the first unit is tested. Salvage of the existing FVU turbine-generator and installation of the new FVU unit will begin during the generation outage, as Contractor’s resources allow. Work at the FVU will continue until completed after the generation outage. 1.06 OPERATIONS MODEL AND PREDICTED LAKE LEVELS A. In the 1990’s, the Owner developed an Operations Model for the coordinated operation of Blue Lake and Green Lake projects. This model is used by Owner for day-to-day planning of hydro and diesel generation in the Sitka electric system. The model is an Excel based spreadsheet tool, that schedules hydro generation to meet system electric loads on a daily basis using estimated or historical project inflows. B. Owner has configured this model to predict lake levels in Blue Lake during the operating periods described above for the Blue Lake hydro project, beginning on November 1, 2012 and extending through December 2014. In this model configuration, the expected 2013-2014 electric loads are included along with the available hydrology record for 1929 through 1957 and 1995 through 2003. The model simulates the Blue Lake hydro project operation using 36 different three-year hydrologic records. The first record include in sequence, years 1929, 1930, and 1931. The second three-year record is 1930, 1931, and 1932, and so on. The final three-year record includes inflows from 2001 followed by 2002, and 2003. C. Owner believes that this model, as configured for the Blue Lake Expansion Project construction period, is the best tool for predicting reservoir levels. Historical lake levels are not useful for predicting 2012 to 2014 levels, as historical generation and flows through the project facilities are considerably different than both present-day operation and the projected operation during construction of the Expansion Project. D. The complete set of 36 three-year runs of the operations model is shown in Figure 01012-6. This chart shows the predicted Blue Lake lake levels with each of the 36 3-year hydrologic records. This figure illustrates the cloud of reservoir elevations possible based on historic inflow data. This figure assumes no diesel generaton in any year. Owner will generate with diesel fuel, if low inflows occur. Contractor should not assume that lake levels below about EL 330 will persist through the winter of 2013 to 2014. Note that MS Excel output files with the detailed ouput from the model are included with the Reference documents, for Contractor’s use. Blue Lake Expansion Project – Contract No. 9 01012-11 General Construction May 2012 E. Owner will maintain this computer model throughout the construction of the Blue Lake Expansion and will run the model when requested by Contractor to help estimate future lake levels and spills. All results will be shared with Contractor to aid in a cooperative planning of future reservoir operation and construction activities. The model can be run beginning on any day after November 1, 2012, using the actual Blue Lake water level on the start date and based on a variety of inflow assumptions. The inflow assumptions which can be used include percentages of average inflow, any historical year’s inflow record, and the full 39- year suite of inflow records. Figure 01012-6 – Simulated Blue Lake Water Levels during Construction 1.07 OWNER’S ASSUMPTION OF RISK FOR LAKE AND TAILWATER WATER LEVELS. A. Owner will assume the risk of certain high flows and high water level conditions during the Blue Lake Expansion Project construction. For the Level Windows described below, Owner will pay Contractor’s additional costs if the water levels exceed those described for the Level Window and if Contractor suffers damage or delay, during the “window” dates defined herein. Owner will pay for damage to Contractor’s equipment, materials, permanent construction and temporary construction facilities if the Work herein is damaged by water levels exceeding the limit described, during the “window’s” duration. Owner will pay for pumping, restoration of temporary facilities, and cleanup. Owner will also pay for schedule Blue Lake Expansion Project – Contract No. 9 01012-12 General Construction May 2012 acceleration, extra shift work or other additional costs, if required to restore the project schedule, for delays directly related to flooding of work areas or loss of working time within the dates described here for the Level Windows. Specific Level Windows for work in the intake area and at the powerhouse are described below. B. Figure 01012-7 shows predicted lake levels in 2013, based on the 36 3-year stream records simulated in the model. As shown in this figure, Owner will assume the risk of flooding or lost time in the intake area, for a water level window from January 26, 2013 to August 19, 2013 for Blue Lake water levels in excess of EL 330 ft. Figure 01012-7 – Predicted Blue Lake Water Levels during 2013 C. Figure 01012-8 shows predicted lake levels in 2014 based on the simulation model. As shown in the figure, Owner will assume the risk of flooding or lost time in the intake area, for water levels that exceed El 302 from March 14, 2014 to July 4, 2014. Figure 01012-8 – Predicted Blue Lake Water Levels, February thru August, 2014 Blue Lake Expansion Project – Contract No. 9 01012-13 General Construction May 2012 D. Figure 01012-9 presents the model output in a different format, showing the probability of various water levels by date. The 2013 and 2014 Lake Level Windows are repeated in this figure. This Figure also shows the risk of spill over Blue Lake Dam. There is at least a 10% probability of spill over the dam between September 9, 2013 and December 2, 2013. Owner will assume no risk for any spill events over the dam at any time during the Project Work that affect Contractor’s work at the dam or in the Sawmill Creek area downstream of the dam, extending to the FVU building. Contractor shall be responsible for all high water risks that might affect Work at the dam and in the Sawmill Creek channel, downstream to the FVU building. Blue Lake Expansion Project – Contract No. 9 01012-14 General Construction May 2012 Figure 01012-9 – Probability of Various Blue Lake Water Levels by Date E. Based on the historic record of USGS gage 15088000 Owner will assume the risk of flooding or lost time in the powerhouse area for Sawmill Creek water levels that exceed el. 16.0 in the powerhouse area from December 15, 2012 to September 9, 2013 and from December 2, 2013 to December 31, 2014 (the “Tailwater Windows”). The Contractor shall accept the risk of flooding above el. 16.0 in the powerhouse area outside of these two Tailwater Level windows (i.e., during the period from September 9, 2013 to December 2, 2013). 1.08 SITKA AREA WEATHER A. Precipitation varies throughout the year with the highest average monthly precipitation during October and the lowest during June. The average rainfall in the City of Sitka for each month is as follows. Note that precipitation in the Blue Lake basin is approximately 2 times greater than at the City of Sitka. Note also that the Generation Outage must occur when both inflows and lake levels are highest at Owner’s hydro plants, thus in the fall of 2014. Blue Lake Expansion Project – Contract No. 9 01012-15 General Construction May 2012 Table 01012-3 Average Sitka Precipitation and Temperature Records, with Average Monthly Inflows to Blue Lake Month Precipitation (inches) Temperature (F°) High Low Blue Lake ave inflow, cfs January 8.80 38 27 176 February 7.37 42 28 173 March 6.68 45 30 132 April 5.60 50 34 212 May 4.86 55 39 567 June 3.82 59 44 772 July 4.20 62 49 708 August 6.40 63 49 684 September 12.38 60 44 774 October 15.60 51 38 756 November 10.16 43 32 502 December 10.20 39 29 278 B. Temperature and other weather conditions at the site vary throughout the year and should be carefully factored into the construction work. Contractor shall comply with all applicable cold weather construction practices and requirements. 1.09 COFFERDAM AND DESIGN WATER LEVELS DURING CONSTRUCTION A. The Engineer’s design for cofferdams in Blue Lake and tailrace stoplog systems at the powerhouse will accommodate the following water levels: Location Design Water Level Overflow Level Intake Structure rock cofferdam El. 330.0 El. 330.5 Intake Structure (for 2013 season)EL. 302.0 El. 305.0 Powerhouse Tailrace Stoplogs EL. 14.7 El. 14.7 B. The tailrace stoplog design level provides no freeboard above the design level and flooding of the Work behind the stoplogs will begin as soon as the design water level is reached. Contractor shall plan its Work as needed to provide adequate time for safe evacuation of personnel and removal of equipment, if the Contractor relies on the stoplogs for protection of the Work and if overtopping of the stoplogs is imminent. C. The Powerhouse stoplogs are designed as a permanent feature of the Project. Contractor may complete these stoplogs and use them for cofferdam protection of the powerhouse area to provide a cofferdam system up to el. 14.7. D. The intake structure design level for the 2014 season represent Owner’s estimated maximum water level allowable for construction of the intake structure (following removal of the rock cofferdam). Note that the lowest point of the intake foundation concrete is el. 305.0. Also note that some trim excavation of the rock hillside in front of the intake is required down to el. 298. E. Contractor shall take into account the above design and overflow levels in planning and scheduling construction activities. Provisions for all cofferdam and stoplog protection deemed necessary during construction shall be Contractor’s responsibility. Blue Lake Expansion Project – Contract No. 9 01012-16 General Construction May 2012 PART 2 PRODUCTS Not used. PART 3 EXECUTION 3.01 CONSTRUCTION PLANNING AND SCHEDULING A. Contractor shall take account the above described hydrology, hydraulic design, Lake Level Windows, Tailrace Level Window and weather conditions when planning and scheduling all construction activities. Contractor shall ensure the work is carried out in a safe manner, protected from damage, and in accordance with standard accepted construction practice. As described herein, Owner will assume the risk of high water levels at the intake and powerhouse, during the Water Level Windows specified. END OF SECTION Blue Lake Expansion Project – Contract No. 9 01013-1 General Construction May 2012 SECTION 01013 GENERATION OUTAGE PART 1 GENERAL 1.01 OVERVIEW A. Work includes Owner’s requirements for the Generation Outage and the construction restrictions that will be placed on Contractor as part of the Generation Outage Work. Requirements for Contractor’s submittals, including work plan and schedule for the outage are described in this Section. B. The Generation Outage includes the time extending from final shutdown of the existing Blue Lake Powerhouse turbine-generators until the time when Substantial Completion is reached for the first new powerhouse turbine generator. Substantial Completion for the first generating unit includes the requirement that this unit shall be able to continuously generate power at a minimum 75% gate (approximately 75% load). 1.02 LAKE LEVELS AND OWNER’S PLAN FOR GENERATION OUTAGE A. August, September, and October are typically the highest rainfall and highest inflow months of the year. In these months Owner’s two reservoirs, Blue Lake and Green Lake, typically fill the fastest compared to any other season in the year. Generally, the highest lake levels occur in November of any given year. Owner has scheduled the Generation Outage for the fall of 2014 (approximately September 1st through mid October) to ensure that: 1) the Blue Lake water level will rise high enough during the outage to submerge the new intake structure to provide adequate head to test the new Blue Lake generating equipment at the end of the outage; and 2) to provide adequate head and flow at the Green Lake hydro plant to meet the Owner’s electric system demand during the outage. B. The new Blue Lake intake structure shall be completed and the intake bulkhead gate installed by the Milestone Date defined in the Agreement, in order to allow filling of the lake in anticipation of the Generation Outage (see Agreement and Section 01012). If the intake is not finished and the bulkhead is not installed prior to the Blue Lake water level reaching el. 308 and prior to July 4, 2014, the Generation Outage may need to be postponed by one year, to the fall of 2015. C. The Generation Outage work shall begin on or before September 1, 2014. If the outage starts later than September 1, the outage may extend past November to the extent that the Owner’s other hydroelectric facility, Green Lake, will not have sufficient water to supply the Owner’s generating needs, even with operation of the Owner’s diesel electric generators. D. The Green Lake project does not have adequate generating capacity to meet Owner’s electric loads by itself. As a result, Owner expects to operate its diesel generators to meet loads during the Generation Outage. If the Generation Outage extends longer than about 55 days (assuming average inflows and a September 1, 2014 outage start date), Owner will have to run its diesel generators near their full capacity to supply the electric system. A Generation Outage that extends past October 30 will likely result in Owner not having sufficient generating capacity to meet its electric loads. Owner has approximately 12 MW of diesel generating capacity, when all of the approximately 35-year old machines are operable. The expected Green Lake full gate capacity towards the end of the Generation Blue Lake Expansion Project – Contract No. 9 01013-2 General Construction May 2012 Outage (with lower than normal December lake levels) is about 12 MW. Owner’s peak electric system loads in December are often above 25 MW. 1.03 CONTRACT MILESTONES A. Contract Milestone Dates are given in Article 4 of the Agreement. Milestone dates related to the Generation Outage include: 1. Milestone No. 3 – Completion of intake structure and placement of intake bulkhead gate. 2. Milestone No. 4 – Project sufficiently complete to allow start of Generation Outage. 3. Milestone No. 5 – Substantial Completion of the first generating unit to the point where this unit can continuously generate electric power at 75% gate. B. Details of these milestone dates including incentive payments and liquidated damages are included in the Agreement. 1.04 SUBMITTALS A. Generation Outage Work Plan. Contractor shall submit a comprehensive work plan for the Generation Outage that includes: 1. Narrative description of work sequence at each work location during the Generation Outage 2. Description of control of water, personnel access, equipment access, power and ventilation at each work location. 3. Description of equipment, crews, productivity and work shifts planned for each work location. 4. Alternatives for acceleration of work, if required to maintain schedule. B. Generation Outage Schedule. Submit a detailed schedule for the Generation Outage, as a stand-alone schedule with more detailed work activities than the overall Project Schedule. Provide an hourly or shift-based schedule if needed to adequately describe the sequence of work. Submit updates of this schedule each week, during the Generation Outage. C. The Generation Outage Work Plan shall be submitted with the overall Project Work Plan, as specified in Section 01200. 1.05 GENERAL SEQUENCE OF GENERATION OUTAGE A. The following list of work activities includes most of the general activities and work elements required during the Generation Outage. Contractor shall revise and expand this list to suit its approach to the Project and to ensure that the work can be completed in the time required. This list is provided to aid Contractor in planning the work and to help define the Construction Restrictions described later in this Section. This list is not intended to be a comprehensive listing of all activities during the Generation Outage. The Generation Outage will include the following general steps: 1. Owner’s approval of Milestone No. 4 – Project sufficiently complete to begin Generation Outage. Blue Lake Expansion Project – Contract No. 9 01013-3 General Construction May 2012 2. Owner’s shutdown of generation at Blue Lake Powerhouse. 3. Owner’s startup of an alternate municipal water supply. 4. Owner operates Howell Bunger valve at Dam to establish instream flow release into Sawmill Creek (note that Contractor shall complete work activities in plunge pool area and Sawmill Creek stream reach below Dam to allow flow release from Howell Bunger valve, before the start of Generation Outage). 5. Owner’s shutdown of generation at FVU. 6. Owner’s shutdown of municipal water withdrawal from penstock. 7. Lock-out and tag-out of all water release points from penstock (approx 9 points) jointly, Contractor and Owner. 8. Owner’s operation of existing tunnel fixed wheel gate and existing bypass gate, to close gates and shut off flow to tunnel. 9. Sealing of existing intake gates (see Section 01014). 10. Release of safety tags at FVU bypass and existing tunnel drain valve. 11. Owner’s dewatering of tunnel, using FVU bypass and tunnel drain valve. 12. Begin care of water and sediment control for leakage through intake structures and tunnel leakage along the length of tunnel (see Section 01014). 13. Open tunnel access at manholes (North, South and Lower portals). 14. Open tunnel access as needed for North and South Portal liner installation. 15. Remove and salvage penstock sections below Lower Portal, begin access into tunnel at Lower Portal. 16. Complete intake tunnel (drill, shoot and muck rock plug) and make connection to existing tunnel. 17. Install tunnel steel liners in North and South Portals (section 13110). Grout liners. 18. Excavate existing tunnel concrete liner at Lower Portal and install Lower Portal steel liner, grout liner 19. Install concrete plug in existing intake tunnel (see section 01014). After concrete cures, grout plug-to-rock interface and complete final closure of plug. 20. Excavate riser shaft connection (drill, shoot and muck rock plug) between lower tunnel and surge chamber adit. (Note that the adit tunnel concrete plug shall be in place prior to starting the Generation Outage). Install concrete curb in adit tunnel. 21. Demolish existing penstock support pedestals and pads, excavate for penstock anchor block no. 5. 22. Install penstock pipe sections 7 through 10. Blue Lake Expansion Project – Contract No. 9 01013-4 General Construction May 2012 23. Construct penstock anchor block no. 5. 24. Install penstock pipe section 11, bolt new loose flange to existing flange at upstream end of penstock pipe section 11, weld up new flange to pipe section 11, install sleeve coupling at connection to pipe section 10. 25. Remove and salvage the existing FVU turbine inlet valve. Install the new FVU turbine inlet valve. Test this valve in the dry and then lock in the closed position. Note that removal of the existing FVU turbine and generator is not required during the Generation Outage. 26. Repair penstock and tunnel liner interior coatings. 27. Complete installation of the municipal water supply valve, pressure reducing valves and strainers. Complete dry testing of the strainers. 28. Complete installation of the fire water supply pressure regulator. 29. Close all access points into tunnel, reinstall existing penstock section near FVU. 30. Wait sufficient time before watering up tunnel for curing of interior paint coatings on liners and penstock 31. Water up tunnel between the bulkhead gate and fixed wheel gate using fill valve on bulkhead gate 32. Remove bulkhead gate from intake structure, place cover over bulkhead slot. 33. Water up the remainder of the tunnel by cracking the fixed wheel gate. (This is expected to take up to approximately six hours). 34. Wet test of new fixed wheel gate, test gate closure against flow of new penstock drain valve (approx 20 cfs). 35. Wet test opening of new fixed wheel gate, test gate opening of gate to tunnel fill position and filling of partially dewatered tunnel. Move fixed wheel gate to its normal park position, with operator and all controls fully functional. 36. Initiate wet testing of first generating unit in new powerhouse. (all dry testing of this unit to be complete before start of Generation Outage) 37. Complete wet testing of the municipal water supply valve and strainer. Begin commercial operation of strainer. 38. Owner will start up the water treatment building operation and shut down the Indian River municipal water treatment plant. 39. Complete mechanical bearing runs, function tests, and operational tests of first generating unit. 40. Demolish and dispose of existing fixed wheel gate engine hoist and bypass gate hydraulic system (as time permits and before reservoir reaches el. 340). 41. Plug existing tunnel intake structure air vent (if lake water level might exceed el. 342 before the existing intake tunnel is completely plugged). Blue Lake Expansion Project – Contract No. 9 01013-5 General Construction May 2012 42. Operate first generating unit at minimum 75% gate for a minimum 12 hours uninterrupted. 43. Provide written approval of turbine-generator’s technical site representatives that the first turbine generator is ready for continuous operation. 44. Turn the first generating unit over to Owner for Partial Acceptance with the capability to operate continuously at 75% gate or higher. This achieves Substantial Completion of the first generating unit and the requirements for Milestone No. 5. 45. As time and Contractor resources permit, perform the following (note that these activities should not be started and/or should be interrupted, if they could delay Contractor’s meeting Milestone date No. 5): a) Perform dry and wet testing on the second and third generating units at Blue Lake Powerhouse. b) Begin salvage of the existing FVU turbine generator and installation of the new FVU turbine-generator. c) Salvage and remove the second group of 4.16kV-69kV transformers in the switchyard, install the second new drainage sump, transformer foundation, and second 12.47kV-69kV transformer in the switchyard. d) Any other construction activities. 1.06 CONSTRUCTION RESTRICTIONS A. Contractor shall comply with the following restrictions on construction activities during the Generation Outage work: 1. Contractor shall not move through or operate any equipment in Sawmill Creek in order to reach the South Portal of the tunnel without obtaining appropriate permits. Access to the South Portal shall be by the Sawmill Creek campground area footbridge over Sawmill Creek or by air. If a temporary bridge to the South Portal area is required by the Contractor, the Contractor shall obtain and pay for the necessary permits and special use permits. 2. Operation of the existing tunnel water control gates and valves (existing fixed wheel gate, intake bypass gate, Howell Bunger valve, FVU turbine inlet valve, FVU bypass valve, PMFU supply valve, municipal water root valve, existing powerhouse valves, tunnel drain valve, etc) will be provided by Owner. Provide 24 hours notice for requests for Owner’s operation of existing valves and gates. 3. Once operational, the new fixed wheel gate, hoist, and control system shall be in continuous normal operation, with the gate parked in its normal position, just above the gate frame. The gate, controls, and communication system shall allow manual closure of the gate from the gate house and/or remote manual closure of the gate from the powerhouse. 4. Owner expects to not allow dewatering of the tunnel following startup of the water treatment building. The tunnel will be dewatered after the water treatment building resumes operation only if there are serious concerns related to the tunnel performance, leakage, or other issues in the tunnel, penstock and powerhouse systems. Blue Lake Expansion Project – Contract No. 9 01013-6 General Construction May 2012 5. Contractor shall not perform any electrical switching operations in the switchyard, at the FVU or at the power feed to the dam area, or any other direct connection to Owner’s transmission or distribution electrical system. Provide 24 hours advance notice for requests for switching operation by Owner’s staff. PART 2 PRODUCTS Not used. PART 3 EXECUTION 3.01 OUTAGE CONSTRUCTION PLANNING AND SCHEDULING A. Contractor shall take into account the restrictions on tunnel access and the required crew sizes and equipment needs in planning the Generation Outage work. B. In planning and executing the work, Contractor shall consider the possible leakage through the existing intake structure and the resulting requirements for care of water in the tunnel below the intake (see Section 01014). C. During the Generation Outage, Contractor shall participate in daily meetings at the start of each day, with Owner and RPR, to review work accomplished and the work plan going forward. D. An updated schedule for the Generation Outage shall be submitted weekly as described in this Section. END OF SECTION Blue Lake Expansion Project – Contract No. 9 01014-1 General Construction May 2012 SECTION 01014 EXISTING INTAKE CLOSURE PART 1 GENERAL 1.01 OVERVIEW A. This Section describes requirements for Contractor’s inspection, temporary closure and permanent sealing of the existing Blue Lake intake structure and tunnel. If Contractor’s inspection of the existing intake reveals the intake will likely not provide an adequate temporary closure against flow, Owner will accept the risk and cost of modifications of the existing intake as required to achieve an adequate temporary closure, as described herein. B. The Intake Closure work includes: 1. Removal and inspection of the existing intake bulkhead gate. 2. Underwater inspection of the intake structure area, including the bulkhead gate seal surfaces. 3. Providing inspection reports. 4. Reinstallation of the bulkhead gate. 5. Temporary sealing of the intake air vent. 6. Construction of the permanent intake tunnel concrete plug, As Shown. C. Construction restrictions that Contractor shall work within are specified herein. Requirements for Contractor’s submittals, including work plan and schedule for the intake closure are described in this Section. D. Owner will operate the existing fixed wheel gate hoist and bypass gate operator, as requested by Contractor, during the Work. Contractor shall provide any lifting and handling mechanisms, cranes, blocking, etc, for removal, reinstallation and blocking in position the existing bulkhead gate. E. Note that the time required for the intake closure work must be included as part of the Generation Outage schedule, as specified in Section 01013. 1.02 REFERENCE DOCUMENTS A. As-Built drawings of the existing intake structure are included in the Reference Drawings. These include: Series 5714 Carey and Kramer drawings for the original project construction; Series 716 RW Beck drawings for the 1983 era rehabilitation work; and a Series M group of KCM drawings for the 1995 bypass gate replacement work. B. The Reference Documents include video files and photographs of historical tunnel inspections which show the intake structure from inside the tunnel. The reference Blue Lake Expansion Project – Contract No. 9 01014-2 General Construction May 2012 documents also include a group of narrated video files taken of Owner’s physical model of the intake structure. These narrated videos describe: the physical arrangement of the structure; Owner’s knowledge of current underwater conditions at the intake; the historical problems with bulkhead gate sealing at the intake; diver access to the intake; and debris clearing work conducted in 2006. Contractor shall review and become familiar with these Reference Documents related to the existing intake structure and gates. C. The Owner’s physical model of the intake structure will be made available to Contractor during the Work, to aid in planning and prosecution of the Work. 1.03 HISTORICAL INTAKE LEAKAGE – RISK ASSUMED BY OWNER A. The Reference Documents provide information on historical gate leakage at the existing intake. In past tunnel dewatering efforts, the intake structure total leakage ranged from about 4 cfs to 12 cfs (1,800 gpm to 5,400 gpm), where virtually all of this leakage was passing around the edges of the bulkhead gate. This leakage has always been retarded to less than 400 gpm by placing visqueen, peat moss or shredded paper in front of the gate. In past inspections from inside the tunnel, no leakage has typically been observed through the air vent system or the bypass gate. Limited leakage, possibly 20 gpm or less has been observed through the fixed wheel gate seals. It is not known if the bulkhead gate has ever been pulled from its slot since the original project construction in 1959 – 1960 and only limited underwater inspections have been made of this gate. B. Diver inspections and recent reviews by Owner suggest that the bulkhead gate is being held off its sealing surface by rock and gravel debris that has traveled down the slope above the intake and has become wedged between the gate and the concrete structure. See Reference Drawing series 5714, in particular sheets 5714- 26C, -28C and -32C. C. Owner believes, and will take the risk that, effective temporary closure of the bulkhead gate can be achieved by removing the bulkhead gate to allow removal of the debris at the gate seals, followed by reinstallation of the gate and blocking the gate in place against its seats. D. If the bulkhead gate removal, inspection and reinstallation sequence describe in this Section is completed, Owner will assume the risk of any repairs required to restore the sealing functionality of the bulkhead gate and its embedded seal plates. If distortion, erosion or other damage to the bulkhead gate or its seal plates is discovered, Owner will reimburse Contractor for repairs to the bulkhead gate and/or its embedded seal plates and surrounding concrete. Any and all repairs shall be completed according to a repair plan approved by Owner. E. Owner will accept the risk of leakage flows through the existing intake in excess of 200 gpm. If leakage flows above 200 gpm occur following Contractor’s initial repair and sealing of the existing intake, Owner will reimburse the Contractor for additional work to seal the existing intake and/or to handle leakage in excess of 200 gpm. Note that this leakage rate does not include any leakage through the new intake and gate shaft and that the Contractor’s additional work shall be defined in a leakage reduction plan approved by Owner. Blue Lake Expansion Project – Contract No. 9 01014-3 General Construction May 2012 F. Owner will not extend the Contract Times or pay for any schedule acceleration related to any potential repairs to the bulkhead gate or embedded seal plates and concrete. The inspection work described in this Section, and any subsequent gate repairs shall be planned and scheduled by Contractor at an early enough date to ensure that this gate work does not delay the Generation Outage or Completion of the Work. 1.04 SUBMITTALS A. Submit the following in accordance with Section 01300: 1. Detailed plan for inspection of existing intake and bulkhead gate, which shall include: a) Initial underwater inspection of existing intake and gates. b) Removal and above-water inspection of bulkhead gate. c) Dimensional check of bulkhead gate sealing surfaces and out-of-plane tolerances. d) Underwater inspection of bulkhead gate seal frames and surrounding concrete. e) Reinstallation of bulkhead gate. f) Wedging or blocking of bulkhead gate in closed position. 2. Inspection report for intake and bulkhead gate inspection including: a) Narrative report with photographs of bulkhead gate. b) Narrated underwater video report of intake and bulkhead gate sealing surfaces. c) Dimensional drawing of the bulkhead gate only, showing shape of gate sealing surfaces and any deviation from a true plane. 3. If damage or distortion of the bulkhead gate or bulkhead gate embedded sealing surfaces is found, submit a preliminary proposal for repairs. 4. Proposed work sequence for temporary sealing of the existing intake, including: a) Narrative description of Contractor’s proposed work sequence for temporary sealing of the intake, followed by permanent sealing of the tunnel. b) Gate operation and other work that Contractor requests Owner to provide. c) Description of control of water, personnel access, equipment access, power and ventilation required following dewatering of the tunnel and prior to completing the final closure. d) Schedule for temporary and permanent closure work. Blue Lake Expansion Project – Contract No. 9 01014-4 General Construction May 2012 e) Contingency plan if leakage through the existing intake exceeds 200 gpm. f) Generation Outage Schedule. As specified in Section 01013, include the existing intake closure work and tunnel permanent closure work as tasks in the overall Generation Outage schedule. 1.05 CONSTRUCTION RESTRICTIONS A. Contractor shall comply with the following restrictions on construction activities related to the existing intake closure: 1. Contractor shall complete the bulkhead gate removal and inspection work no later than May 1, 2014. This is required to allow sufficient time before the Generation Outage for planning and completion of any gate or intake structure repairs that are identified in the inspections. Note that April and May are typically the months with the lowest water levels in Blue Lake. 2. Contractor shall schedule all underwater work, including any diver or ROV work, with Owner at least 14 days in advance. This is to allow Owner to arrange for alternative power generation sources and water system operating support. These are required to allow underwater work to take place with either no flow, or municipal water flow only (about 5 cfs) through the intake. 3. Intake structure outages with no flow shall be limited to 4 hours maximum duration of the closure to reopening of the 20 inch municipal water valve. This restriction is based on the maximum time allowed for shutdown of the municipal water withdrawal from the Blue Lake penstock. During such outages the City of Sitka water treatment system valve on the Blue Lake penstock will be shut off and the City’s municipal water will be supplied from limited-capacity storage tanks in town. 4. After removal of the bulkhead gate to the surface, Contractor shall reinstall the gate within seven days of its removal. Owner will extend this time, if gate repairs are required. 5. Operation and lockout of the existing tunnel water control gates and valves (existing fixed wheel gate, intake bypass gate, Howell Bunger valve, FVU turbine inlet valve, FVU bypass valve, PMFU supply valve, municipal water root valve, existing powerhouse valves, tunnel drain valve, etc) will be provided by the Owner. Contractor shall observe the lockout procedure and apply a lock to the lock box. Provide 72 hours notice for requests for Owner’s operation of existing valves and gates. PART 2 PRODUCTS Not used. PART 3 EXECUTION 3.01 INTAKE STRUCTURE UNDERWATER INSPECTION Blue Lake Expansion Project – Contract No. 9 01014-5 General Construction May 2012 A. Contractor shall complete an underwater inspection of the existing intake structure, including trashracks, fixed wheel gate, bulkhead gate, bypass gate and air vent piping. This inspection shall confirm the overall condition of the gates, gate access, extent of debris, and activities required to lift the bulkhead gate to the surface of the lake. B. Underwater inspection shall include narrated video of the gates and structures, with written report that describes overall findings for each gate and structure and identifies DVD hour-minute mark for various portions of the video record. A summary written document that describes major and unexpected findings shall accompany the video record. The written inspection report and video shall be submitted to Owner within three days of completing the underwater inspection. 3.02 BULKHEAD GATE ABOVE WATER INSPECTION AND CLEANUP A. Contractor shall rig a new lifting cable or wire rope to the bulkhead gate capable of maintaining proper gate alignment and lifting it above the surface of the lake for inspection. Note that there are stop angles at the top of the bulkhead gate guides which must be removed to lift the gate, see Reference Drawing 5714-32C. B. Small gravel and rocks may be wedged between the bulkhead gate and concrete surfaces. These gravels and rocks may need to be removed before lifting the gate, and/or Contractor’s lifting system shall be adequate to overcome the resisting force of these gravels and rocks. The lifting system shall also provide alignment control of the gate so that the gate guides are not damaged while removing and replacing the gate. C. Contractor shall raise the bulkhead gate to the surface and inspect it, on a barge, float or on the shore. The gate shall be pressure washed with a minimum 2500 psi water pressure washer to allow a detailed inspection of the gate. D. The overall condition of the gate shall be inspected and noted in the report. Areas of corrosion greater than 1/8 inch deep, any cracks in the steel structure, and any missing or deformed parts shall be noted. Photographs of all damage, cracks, missing parts, deformation or other areas of interest shall be included in the report. E. The condition of the bronze bearing plate on the gate shall be assessed, including the screw connections of the plates to the gate, the condition of the face of the bearing plate, and measurement of whether the face of the bearing plate lays in a uniform plane. The face measurement shall determine the true position of the bearing plate relative to a common plane, with measurements taken on 18 inch centers to an accuracy of 1/16” (offset from the theoretical plane). Measurements shall be made by an optical or laser system or, as a minimum, by a piano wire grid and cross-corner system that establishes a reference plane. F. Contractor shall sand or file away any raised burrs or local deformations on the face of the bearing plate and shall tighten the flat head screw fasteners (if they are loose and can be tightened with a slotted screw driver - ratchet tool). G. Gouges of the bearing plate deeper than 1/4inch, missing or corroded fasteners, and a bearing plate face that deviates from a common plane by more than 3/16inch total Blue Lake Expansion Project – Contract No. 9 01014-6 General Construction May 2012 on the gate, or 0.020 inches in 3 feet shall be documented in Contractor’s inspection report. H. Contractor shall submit a report for the above-water bulkhead gate inspection within 3 days of lifting the gate above the lake surface. 3.03 BULKHEAD GATE REINSTALLATION AND INTAKE UNDERWATER WORK A. Contractor shall clear loose debris from the intake structure above the gate lintel prior to re-installation of the bulkhead gate, to prevent debris falling between the gate and the bearing surface during installation and impeding gate sealing. B. Contractor shall reinstall the bulkhead gate in its guides, bearing on the support brackets below the gate’s intake opening. Care shall be taken to ensure that the gate rests directly on the support brackets with no debris in the bracket contact area or between the gate bearing plates and their corresponding stainless steel embedded seal plates. C. Contractor shall develop and implement a system to wedge the gate against the face of the intake to assure that new debris raveling down the slope of the intake area does not have the opportunity fall between the gate and the concrete structure and then interfere with proper sealing of the gate. The wedges shall force the gate against its seal plates in a manner that assures the gate and wedges will remain in place during the summer of 2014 and continuing through the Generation Outage. A minimum of four wedges shall be installed, near the top and bottom corners of the gate. D. The bulkhead gate stop angles do not need to be replaced. The bulkhead gate lifting cable shall be left accessible for possible use during the initial dewatering of the tunnel. E. Any trashrack sections that were removed for access by divers or ROVs shall be replaced. The replaced rack sections shall be adequately secured to ensure they remain in the up position until the Generation Outage begins. 3.04 BULKHEAD GATE AND UNDERWATER SEAL SURFACES REPAIRS A. If the underwater inspection of the intake structure, or the above-water inspection of the bulkhead gate reveals damage that needs correction, Contractor shall prepare and submit a repair plan for review and approval of the RPR and Owner. Any such approved repairs will be paid for on a Force-Account basis or by a Change Order issued to Contractor. B. Contractor shall pursue development of any required repair plan and shall complete the repairs expeditiously, to keep the gate and intake repairs off the critical path for the Generation Outage. Owner will not pay for any delays or schedule acceleration related to repairs to the existing intake structure or bulkhead gate. 3.05 CLOSURE OF EXISTING INTAKE A. Owner will open the Howell Bunger valve at the dam to maintain instream flow requirements, shut down Owner’s generating and flow releases from the Blue Lake Penstock and will operate the fixed wheel gate hoist system to lower the fixed wheel Blue Lake Expansion Project – Contract No. 9 01014-7 General Construction May 2012 gate and close the intake, and close the bypass valve in accordance with lockout procedures, all as part of the early steps in the Generation Outage described in Section 01013. B. Following Owner’s dewatering of the tunnel, Contractor shall cap or seal the existing tunnel air vent pipe to ensure a rising lake level does not allow water entry to the tunnel through the air vent system. This cap or seal may be applied to the vent pipe at a location above water, using a standard pipe cap or blind flange assembly. C. Contractor shall initiate control of water leakage flowing from the existing and new intakes into the tunnel, to allow work in the tunnel as described in Sections 01013 and Section 13110. D. Contractor shall demolish and salvage equipment and materials at the existing intake, as specified in Section 02105. E. The bulkhead hoist cable, fixed wheel hoist cables, fixed wheel gate lifting system and bypass gate operating system shall all remain in an operable condition, until the temporary closure of the intake is approved by the RPR and the Generation Outage work is underway. END OF SECTION Blue Lake Expansion Project – Contract No. 9 01090-1 General Construction May 2012 SECTION 01090 REFERENCE STANDARDS PART 1 GENERAL 1.01 REQUIREMENTS INCLUDED A. This Section covers abbreviations and acronyms used in this Specification to identify reference standards. B. Contractor shall obtain copies of referenced standards when needed for proper performance of Work or when required for submittal by these Specifications. 1.02 QUALITY ASSURANCE A. When a standard is specified by reference, Contractor shall comply with the requirements and recommendations stated in that standard, except when requirements are modified by these Specifications or applicable codes establish stricter standards. 1.03 ABBREVIATIONS AND NAMES OF ORGANIZATIONS A. The following is a list of standard abbreviations for organizations: 1. AAMA American Architectural Manufacturers Association 2. AASHTO American Association of State Highway &Transportation Officials 3. AATCC American Association of Textile Chemists and Colorists 4. ACI American Concrete Institute 5. ACDE Association of Commercial Diving Educators 6. ADC Air Diffusion Council 7. ADCI Association of Dive Contractors International 8. ADEC Alaska Department of Environmental Conservation 9. ADNR Alaska Department of Natural Resources 10. AHRI Air Conditioning, Heating, & Refrigeration Institute 11. AISC American Institute of Steel Construction 12. AISI American Iron & Steel Institute 13. Alaska DOT & PF Alaska Department of Transportation and Public Facilities 14. ASPMC Alaska State Plumbing & Mechanical Codes 15. AMCA Air Movement and Control Association Blue Lake Expansion Project – Contract No. 9 01090-2 General Construction May 2012 16. ANSI American National Standards Institute 17. ARI Air-Conditioning and Refrigeration Institute 18. ASCE American Society of Civil Engineers 19. ASHRAE American Society of Heating, Refrigerating and Air-Conditioning Engineers 20. ASME American Society of Mechanical Engineers 21. AI Asphalt Institute 22. ASTM American Society for Testing and Materials 23. AWPA American Wood Protection Association 24. AWPB American Wood Preservers Bureau 25. AWS American Welding Society 26. AWWA American Water Works Association 27. BHMA Builders Hardware Manufacturers Association 28. CFR Code of Federal Regulations 29. CLFMI Chain Link Manufacturers Institute 30. CISCA Ceilings & Interior Systems Construction Association 31. CMAA Crane Manufacturers Association of America 32. COE U.S. Army Corps of Engineers 33. CPMB Concrete Plant Manufacturers Bureau 34. DHI Door Hardware Institute 35. EIA Electronic Industries Association 36. FCWA Federal Clean Water Act 37. FM Factory Mutual 38. FS Federal Specifications 39. GA Gypsum Association 40. HIS Hydraulic Institute Standards 41. IBC International Building Code 42. IBPMC International Building Plumbing and Mechanical Codes Blue Lake Expansion Project – Contract No. 9 01090-3 General Construction May 2012 43. ICC-ES International Code Council-Evaluation Services 44. ICEA Insulated Cable Engineers Association 45. IEC International Electrotechnical Commission 46. IEEE Institute of Electrical & Electronics Engineers 47. IMC International Mechanical Code 48. IPC International Plumbing Code 49. ISEE International Society of Explosives Engineers 50. ISO International Organization for Standardization 51. MIL Military Specifications 52. MSHA Mining Safety and Health Administration Standards 53. NAAMM National Association of Architectural Metal Manufacturers 54. NDS National Design Specification for Wood Construction 55. NEC National Electrical Code 56. NECA National Electrical Contractors Association 57. NEMA National Electrical Manufacturer’s Association 58. NESC National Electrical Safety Code 59. NETA National Electrical Testing Association 60. NFoPA National Forest Products Association 61. NFPA National Fire Protection Association 62. NIST National Institute of Standards Technology 63. NRMCA National Ready Mix Concrete Association 64. NSF National Sanitation Foundation 65. OSHA Occupational Safety and Health Administration 66. PCI Precast/Prestressed Concrete Institute 67. PTI Post-Tensioning Institute 68. PS Product Standard 69. SAE Society for Automobile Engineers Blue Lake Expansion Project – Contract No. 9 01090-4 General Construction May 2012 70. SDI Steel Door Institute 71. SMACNA Sheet Metal & Air Conditioning Contractors’ National Association 72. SSPC Society for Protective Coatings 73. TIA Telecommunications Industry Association 74. TMMB Truck Mixer Manufacturers Bureau 75. UBC Uniform Building Code 76. UFC Uniform Fire Code 77. UL Underwriter’s Laboratory, Inc. 78. USBR United States Bureau of Reclamation 79. USFWS United States Fish and Wildlife Service 80. USFS United States Forest Service 81. WAQTC Western Alliance for Quality Transportation Construction END OF SECTION Blue Lake Expansion Project – Contract No. 9 01200-1 General Construction May 2012 SECTION 01200 PROJECT ADMINISTRATION PART 1 GENERAL 1.01 WORK INCLUDED A. Work includes, but is not limited to, requirements for the Contractor’s Progress Schedule, Work Plan, Progress Meetings, Daily Reporting, and Monthly Reporting. The section also includes descriptions of the Contractor’s responsibilities for coordination of work, site access and employee identification, and licenses and permits that involve the Owner. B. General: Notice of Award, if award is made, will be given after approval to proceed with the Blue Lake Expansion Project is received from Owner, City and Borough of Sitka. 1.02 RELATED SECTIONS A. Section 01270: Measurement and Payment B. Section 01290: Schedule of Values C. Section 01300: Submittals D. Section 01400: Quality Assurance E. Section 01450: Safety F. Section 01800: Environmental Conditions and Controls 1.03 Submittals A. Submit under provisions of Section 01300 for review. B. Contractor shall prepare a Work Plan that is a revision and adds detail to the Preliminary Work Plan, which was provided as part of the Contractor’s bid. The Work Plan shall be prepared using project management software such as Primavera P6 Microsoft Project etc. and the Work Plan must be issued to the RPR in pdf format. The Work Plan shall consist of the following: 1. A Progress Schedule shall be submitted as required by Sections 2.05 and 2.07 of the General Conditions as well as Part 2, Article 2 of the Supplemental Conditions. The Progress Schedule should include a delivery schedule for key items and provides manpower loading, equipment spread, shifts per day, hours per shift, and number of work days per week to accomplish the schedule. Additional items to be part of the Progress Schedule shall consist of the following: a) A Critical Path Milestone (CPM) schedule that identifies major tasks and subtasks. All tasks shall be broken down to activities of less than two weeks in duration. The CPM will identify the anticipated duration of the Blue Lake Expansion Project – Contract No. 9 01200-2 General Construction May 2012 estimated work force by craft for each activity and/or task. In addition, each activity shall be given an alphanumeric designation. i. The use of a construction scheduling and management system is required. The submission of a Flow Chart, with connections to preceding and succeeding tasks, is required. b) Contains a narrative logic, incorporating the alphanumeric activity designations, describing the relationship of the above activities, and tasks in the scheduling of work (e.g., placing rebar [E-7] will precede placing concrete in placement of 1D [E 8]). c) Identifies a proposed schedule for obtaining necessary environmental and construction permits, including submittal dates. i. Identifies all activities which may not begin until permit approval. d) Identifies all activities which may not begin without some approval by RPR or Owner (such as submittals, hold and witness points, etc.). e) Identifies work items whose progress is subject to river flow and lake level conditions, such as powerhouse excavations and tunnel intake. f) Identifies major equipment that will be used for each activity. g) Identifies all subcontractors to be used for each activity. h) Incorporates the delivery, unloading, and installation of Owner furnished materials and equipment i) Identifies all activities at the beginning of which equipment furnished by Owner will be required. j) Identifies completed pay item quantities associated with each activity. 2. Detailed Work Descriptions and Plans a) General descriptions with proposed strategies for accomplishing the work activities described in the Progress Schedule. b) Site Management Plan c) FERC License Amendment Plans: Elaborate on and amend FERC License Amendment Plans that were prepared by the Owner to reflect the Contractor’s approach to the work. d) Site-Specific Health and Safety Plan e) Water Control and Dewatering Plan f) Spill Prevention, Control and Countermeasures (SPCC) Plan g) Survey Control and Structural Monitoring Plan h) Demolition and Removal Plan Blue Lake Expansion Project – Contract No. 9 01200-3 General Construction May 2012 i) Rock Excavation Plan j) Erosion and Sediment Control Plan/Stormwater Pollution Prevention Plan (ESCP/SWPPP) k) Rock Tunnelling Plan l) Grouting Plan (includes foundation grouting, dam vertical contraction joint and tunnel liner grouting plans.) m) Mass Concrete Placement Lift Plan n) Structural Steel Installation and Erection Plan o) Penstock Installation Plan p) Sample Progress Reports. 3. Within 14 calendar days of receipt of the Work Plan, the Engineer in consultation with the RPR will review and comment on the Work Plan. C. Periodic Work Plan Updates and Reporting 1. Provide an updated Progress Schedule on a monthly basis. 2. Provide a transmittal form with a description of schedule changes and concerns. Report any anticipated changes to the Work Plan 1.04 PROJECT REVIEW MEETINGS A. Schedule regular, periodic meetings; one per week minimum at a time agreed upon with the RPR. B. Hold additional meetings as required by progress of the Work or as requested by the RPR. C. Location of Meetings: Hold meetings on or off site as approved by the RPR. D. Suggested Project Meeting Agenda Items 1. Review and approve minutes of previous meeting. 2. Review work progress since previous meeting relative to Project Schedule. 3. Field observations 4. Problems and conflicts. 5. Coordination with other contracts. 6. Review of delivery schedules. 7. Corrective measures and procedures to regain projected schedule. 8. Revisions to the Project Schedule. Blue Lake Expansion Project – Contract No. 9 01200-4 General Construction May 2012 9. Review of submittal preparation status. 10. Review of submittal review status. 11. Review of any proposed changes and possible effect on Progress Schedule and completion date. 12. Present any changes that appear to require a change order affecting the contract amount. 13. Identify significant decisions and specific action items. D. Draft Project Meeting Agenda and provide to RPR for review along with Meeting Minutes. Incorporate RPR’s suggested edits and distribute to Project Meeting attendees a minimum of 1 day in advance of meeting. E. Meeting Minutes: Recap discussion under each agenda item and document significant decisions and action items. Prepare and distribute meeting minutes for each project meeting within 5 working days of the next meeting. 1.05 DAILY REPORTING A. Prepare and submit a “Daily Report”. Submit to the RPR no later than 12:00 PM the next workday. B. Include topics shown in the sample report form attached to this specification section. C. Edit daily report as necessary to facilitate its efficient and timely completion while maintaining, at a minimum, the information indicated on the attached sample report. 1.06 MONTHLY REPORTING A. Prepare and submit a “Monthly Report” to the RPR with the monthly Request for Progress Payment. B. This report shall include information on the following site activities: 1. Safety 2. Environment 3. Quality 4. Construction Progress 5. Updated schedule (if requested by RPR) 6. Outstanding RFI’s, Non-Conformance Reports, etc. 7. Photographs (6 to 10) depicting general site conditions and overall progress. 1.07 SITE COORDINATION Blue Lake Expansion Project – Contract No. 9 01200-5 General Construction May 2012 A. Contractor is responsible for the coordination of his own work with the work of his subcontractors. RPR will be responsible for coordinating Contractors’ activities with all other entities involved with the project. B. Contractor will be required to have a qualified (eligible to sit for an Alaskan State Professional Engineering license in the Civil Engineering Field plus four years field experience in construction) engineer or technician (10 years experience as a field technician or assistant superintendent) on site at all times throughout the term of the contract. C. Contractor will be required to have a licensed State of Alaska Professional Land Surveyor who will be responsible for all surveying, quality control and mapping required by the contract and their qualifications will be subject to review and approval by RPR. Additional surveying requirements are addressed in Section 02020. D. Contractor, including all key Contractor personnel, are responsible to attend all necessary pre-construction meetings requested by Owner in Sitka, Alaska. 1.08 COOPERATION WITH OTHER CONTRACTORS A. Coordinate and cooperate with all other contractors performing Work on behalf of Owner or any Work in the vicinity of the Site. Contractor shall not delay or interfere with the Work or storage of materials and equipment of Owner or other contractors. 1.09 PLANT AND EQUIPMENT A. Provide sufficient plant and equipment of adequate capacity and efficiency to accomplish the Work on schedule and in a safe and workmanlike manner. All plant and equipment shall be maintained in good working order. Owner reserves the right to prohibit the use of any plant and/or equipment by Contractor, the use of which, in Owner’s opinion, would adversely affect the quality of the Work, and/or the safety of life and property or contravene permit requirements. 1.10 CONDUCT AND IDENTIFICATION OF CONTRACTOR’S EMPLOYEES A. Prevent employees of Contractor from entering Owner’s premises unless and until they shall have identified themselves in the manner and to the extent agreed upon between Owner and Contractor. Owner reserves the right to require all Contractor employees to identify themselves with photo ID badges provided by Contractor before they enter upon Owner’s premises unless another manner of identification is agreed upon between Owner and Contractor. Implement a system for all personnel to sign into the job site each day prior to the start of work. B. Upon admission to Owner’s premises, implement a policy to assure that Contractor’s employees shall comply with directions of Owner’s employees and guards while on the premises. Contractor’s employees shall also be subject to Owner’s car inspection upon entering and leaving the premises of Owner. C. Assign the Contractor’s Site Superintendent or his designated appointee, to serve as a “Security Liaison” that will be available on a 24/7 basis for the duration of the project to address any security related issues. Maintain a daily log of all Contractor personnel, including subcontractors, equipment operators and visitors at all Work Sites related to the project. Provide the daily log to Owner monthly in an electronic format approved by Owner. Owner reserves the right to deny or to revoke access Blue Lake Expansion Project – Contract No. 9 01200-6 General Construction May 2012 onto the site or sites to any Subcontractor, temporary or short-term Contractor personnel or visitor at any time. D. Issue instructions to his employees covering the foregoing requirements and he undertakes that he will at all times cooperate with Owner to the extent necessary to bring about compliance therewith. 1.11 ACCESS BY OTHERS A. At no time shall Contractor restrict the movement of Owner’s authorized personnel and equipment in the performance of their Work at Site. B. Cooperate with other contractors performing Work for Owner and to coordinate and arrange the sequence of his Work to conform to the progressive operations of the Work already under Contract or to be put under Contract. Cooperation and adjustments with other contractors engaged in work on the Site is essential to properly coordinate the construction efforts of all contractors. END OF SECTION Project Name Project No. Location Safety Schedule Carryover Quality Issues Weather temp sky wind Precip. 7:00 AM 70 clear 10 NE 12:00 PM 70 clear 10 NE 5:00 PM 70 clear 10 NE 0 First Aid's 0 0 Medical Aid 0 0 Near Misses Reported 0 0 Vehicle damage 0 0 Theft / Vandalism 0 0 Property damage 0 0 Environmental (Spills)0 Today's Manpower Count 0 Weather comments comment here Contractor Incidents: comment here other other other other other other Delays, Difficulties, Stoppages, or Downtime, etc. Instruction Issued, and Changes Requested or Authorized (State by Whom and if Verbal or Written) other other Equipment and Material Received, General Comments Other Activities Today: Activities Today Observations DAILY REPORT day of week Prepared By: Report No.: Workforce DATE: Other visitors on-site today: Contractor Representatives on-site today: other comment here Blue Lake Expansion Project – Contract No. 9 01270-1 General Construction May 2012 SECTION 01270 MEASUREMENT AND PAYMENT PART 1 GENERAL 1.01 SECTION INCLUDES A. Measurement and payment descriptions for the Bid Items. 1.02 RELATED SECTIONS A. Section 01200: Project Administration B. Section 01290: Schedule of Values C. Section 01300: Submittals D. Section 01400: Quality Assurance 1.03 DESCRIPTION A. Payment will be made in accordance with the Bid Items and the provisions of the General Conditions, Supplementary Conditions, Schedule of Values and provisions requirements given in this section. B. All Bid Items are for supply and installation, unless otherwise noted. 1.04 MEASUREMENT AND PAYMENT FOR THE BID ITEMS A. Bid Items with their associated measurement and payment provisions are as follows (note that these are general descriptions of the required work and the details for the work are as further described on the drawings and as detailed in the specifications): Item 1.01 – Work Plan 1. Measurement for this item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs associated with the preparation and design of an acceptable W ork Plan as specified in Section 01200 of the Specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. Work includes, but is not limited to: a) Preparation of Progress Schedule. i. General descriptions of proposed strategies for accomplishing the work activities described in the Progress Schedule. b) Detailed Work Plans and Descriptions (must be completed and accepted prior to any work being performed): Blue Lake Expansion Project – Contract No. 9 01270-2 General Construction May 2012 i. Site Management Plan ii. FERC License Amendment Article Plans iii. Site-Specific Health and Safety Plan iv. Quality Control and Inspection Plan (QCIP) v. Water Control and Dewatering Plan vi. Spill Prevention, Control and Countermeasures (SPCC) Plan vii. Survey Control Plan viii. Erosion and Sediment Control Plan/Stormwater Pollution Prevention Plan (ESCP/SWPPP) c) Detailed Work Plans and Descriptions (must be completed and accepted prior to associated work being performed) i. Demolition and Removal Plan ii. Rock Excavation Plan iii. Rock Tunnelling Plan iv. Vibration and Noise Management Plan v. Grouting Plan vi. Mass Concrete Placement Lift Plan vii. Structural Steel Installation and Erection Plan viii. Penstock Installation Plan Item 1.02 – Mobilization 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be not more than 5% of the total contract price. Payment will be for all direct and indirect costs for mobilizing to the Site with all necessary personnel, equipment and materials to start W ork according to the approved Work Plan and as specified in the Contract Documents. Mobilization shall include all required office facilities, equipment and support facilities, controls, maintenance and protection of traffic, and all required submittals. Payment for accepted work will be lesser of 60% of the Bid Item LS or 3% of the total Contract Price for the first progress payment and the lesser of 40% of the Bid Item LS or 2% of the total Contract Price for the second progress payment. Item 1.03 – Performance and Payment Bonds 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Item will be paid after accepted delivery of Performance and Payment Bonds, in the amount necessary to guarantee the completion of the Project. Item 1.04 – Erosion, Sediment and Pollution Control Measures 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work includes the design of ESCP, SPPP and SPCC, and the supply, installation and maintenance of all approved erosion, sediment and pollution control measures on the Site. The Work also includes the removal of all temporary control measures and all collected materials from the Site. Item 1.05 – Contract Closeout Blue Lake Expansion Project – Contract No. 9 01270-3 General Construction May 2012 1. Measurement for this Item will be Lump Sum (LS) equal to not less than one hundred and fifty thousand dollars $150,000.00) , which shall be paid after completing contract closeout. 2. The Bid Item Lump Sum Price for this Item will be for all direct and indirect costs for, and be full compensation for contract closeout. a) Contract closeout includes all labor, equipment, materials or subcontracted services necessary for providing record drawings complete and approved by RPR with associated field marked-up records, manuals, guarantees, warranties, including all Contractor-provided media and any required corrections or collection of data necessary to render a complete record of the Work as actually constructed. Payment will be made only for the entire, integrated drawing and document set; no payment will be made for completed individual drawings and/or documents. Item 1.06 – Reservoir Access Road, Gate House Access Road, and Improvements to Blue Lake Road and Dam Staging Area 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for the construction of the Reservoir Access Road; the Gate House Access Road and Parking Area, improvements to existing Blue Lake Road, the dam staging and turnaround areas at El 462 ft, any associated crane pads, and construction of any temporary access roads As Shown and as detailed in the specifications or as considered necessary by the Contractor. The Schedule of Values breakdown will detail payment for work items completed and accepted. 3. Work Includes but is not limited to: a) Surveying, scaling, clearing and grubbing, unclassified excavation, rock excavation, drainage structures, backfilling, grading, spoiling, placement of subbase, base, surface courses, concrete infill, and initial and final regrading and resurfacing of the entire Blue Lake Road and final site restoration. Item 1.07(a) – Place Crushed Rock Material at Campground 1. Measurement for this Item will be per Cubic Yard (CY). 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for furnishing, loading, hauling, placing, grading and compacting crushed rock at the campground As Shown and as detailed in the specifications. Item 1.07(b) – Stockpile Crushed Rock Material at Campground 1. Measurement for this Item will be per Cubic Yard (CY). 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for stockpiling crushed rock at a campground location as designated by the RPR, including furnishing, loading, hauling, and stockpiling. Blue Lake Expansion Project – Contract No. 9 01270-4 General Construction May 2012 Item 1.08 – 1” Diameter Rock Bolts in Tunnels 1. Measurement for this Item will be per Lineal Foot (LF) of rock bolts installed. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for installation of 1” diameter (#8) rock bolts in the Intake Tunnel, Adit Tunnel and Drainage Tunnel as shown on the drawings and as detailed in the specifications. This Item does not include wire mesh, shotcrete, or pressure relief holes. 3. Work includes but is not limited to: a) Procuring, delivering, and storing rock bolts, bearing plates, nuts, flat and bevelled washers, all other hardware, and encapsulation materials. b) Drilling holes for rock bolts. c) Installing and grouting rock bolts. d) Testing and locking-off rock bolts and providing test reports to RPR. Item 1.09 – 1” Diameter Rock Bolts in Shafts 1. Measurement for this Item will be per Lineal Foot (LF) of rock bolts installed. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for installation of 1” diameter (#8) rock bolts in the Gate Shaft and Surge Shaft As Shown and as detailed on the specifications. This item does not include wire mesh, shotcrete, or pressure relief holes. 3. Work includes but is not limited to: a) Procuring, delivering, and storing rock bolts, bearing plates, nuts, flat and bevelled washers, all other hardware, and encapsulation materials. b) Drilling holes for rock bolts. c) Installing and grouting rock bolts. d) Testing and locking-off rock bolts and providing test reports to RPR. Item 1.10 – 1” Diameter Rock Bolts in Locations Other Than Tunnels and Shafts 1. Measurement for this Item will be per Lineal Foot (LF) of rock bolts installed. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for installation of 1” diameter (#8) rock bolts in the locations other than tunnels and shafts As Shown and as detailed on the specifications. This Item does not include rock bolts for the tunnel portal areas, nor does this Item include wire mesh, shotcrete, or pressure relief holes. 3. Work includes but is not limited to: e) Procuring, delivering, and storing rock bolts, bearing plates, nuts, flat and bevelled washers, all other hardware, and encapsulation materials. Blue Lake Expansion Project – Contract No. 9 01270-5 General Construction May 2012 f) Drilling holes for rock bolts. g) Installing and grouting rock bolts. h) Testing and locking-off rock bolts and providing test reports to RPR. Item 1.11 – Drilled Drain Holes 1. Measurement for this Item will be per Lineal Foot (LF) of drains installed. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for drilling slope drain holes and tunnel drain holes, and installing drains As Shown and as detailed on the specifications. This Item does not include consolidation grouting. 3. Work includes but is not limited to: a) Drilling drain holes and installation of drain materials. Item 1.12 – Drilled Tunnel Pre-Excavation Grout Holes 1. Measurement for this Item will be per Lineal Foot (LF) of hole drilled. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for drilling 2-½” diameter grout holes. This Unit Price includes furnishing drilling equipment and labor, and positioning and orientation of the equipment in preparation for drilling. This Unit Price also includes installation of casing, stand pipes and packers as necessary. Note that “feeler” holes required as a part of the excavation will not be measured and paid for under this Item as the cost of such holes is deemed to be incidental to the cost of the excavation, irrespective of whether such holes are subsequently used to inject grout. Item 1.13 – Injecting Grout in Tunnels 1. Measurement for this Item will be per hour (Hour) of grouting. 2. Time for this Item shall not be measured for payment when the grouting operation is delayed by delivery of materials, downtime of equipment on which the grouting operation is dependent, shift changes, meetings, filling holes not used for grouting, clean-up of grout spills, and removal of unused materials and supplies. 3. The Bid Item Unit Price for this Work will be for all direct and indirect costs including all tunnel crews, equipment, and plant and direct support labor, equipment, and plant during the period that grout is actually injected. This Item includes mobilization and demobilization of the grout pump equipment in preparation for tunnel grouting. This Item shall be comprised of continuous, uninterrupted pumping sessions for any grouting session beginning with the mobilization of the grout plant spread, followed by the injection of grout into a hole or group of holes, to the time that grout plant spread is demobilized and excavation operations can proceed. This Item does not include the cost of cement for grouting. 4. Indirect costs associated with any extension of the Contract Time due to the performance of the grouting work performed under this Item will be compensated separately if measurable and documented properly. Any such Blue Lake Expansion Project – Contract No. 9 01270-6 General Construction May 2012 indirect costs would be restricted to field overhead labor, equipment, plant, and support services; as well as home office G&A costs during the extension of Contract Time due to the grouting work performed under this Item. 5. The RPR shall determine, no more frequently than monthly, whether or not the grouting performed under this Item was on the Critical Path, and therefore warranting an extension of Contract Time. Item 1.14 – Drilled Grout Holes in Shafts 1. Measurement for this Item will be per Lineal Foot (LF) of hole drilled. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for drilling up to 50 foot long 2-½” diameter grout holes through shaft walls at 8 to 20 degree angles from vertical. This Item includes furnishing drilling equipment and labor, equipment supports in shaft, and positioning and orientation of equipment in preparation for drilling . This Item also includes installation of casing, stand pipes and packers as necessary. Item 1.15 – Injecting Grout in Shafts 1. Measurement for this Item will be per hour (Hour) of grouting. 2. Time for this Item shall not be measured for payment when the grouting operation is delayed by delivery of materials, downtime of equipment on which the grouting operation is dependent, shift changes, meetings, filling holes not used for grouting, clean up of grout spills, and removal of unused materials and supplies. 3. The Bid Item Unit Price for this Work will be for all direct and indirect costs including all tunnel crews, equipment, and plant during the period that grout is actually injected. This Item includes mobilization and demobilization of equipment in preparation for shaft grouting. This Item shall be comprised of continuous, uninterrupted pumping sessions for any grouting session beginning with the mobilization of the grout plant spread, followed by the injection of grout into a hole or group of holes, to the time that the grout plant spread is demobilized and excavation/normal work operations can proceed. This Item does not include the cost of cement for grouting. 4. Indirect costs associated with any extension of the Contract Time due to the performance of the grouting work performed under this Item will be compensated separately if measurable and documented properly. Any such indirect costs would be restricted to field overhead labor, equipment, plant, and support services; as well as home office G&A costs during the extension of Contract Time due to the grouting work performed under this Item. 5. The RPR shall determine, no more frequently than monthly, whether or not the grouting performed under this Item was on the Critical Path, and therefore warranting an extension of Contract Time. Item 1.16 – Tunnel and Shaft Grout Materials 1. Measurement for this Item will be per bag (Bag) of cement. The bag shall be considered the standard size bag (94 pounds avoirdupois) of cement that is used in the industry. Blue Lake Expansion Project – Contract No. 9 01270-7 General Construction May 2012 2. The quantity approved for payment shall be based on the weight of grout material placed, which will include cement and admixtures (dispersants, superplasticizers, bentonite, or other approved materials). 3. The Bid Item Unit Price for this Work will be for all materials required for grouting mixed and ready for placement during a grouting operation. No payment will be made for material wasted because of equipment failure, or for materials rejected because of defective mixing or defective placement. Item 1.17 – Steel Sets in Tunnels and at Portals 1. Measurement for this Item will be for Each (EA) steel set installed. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for the installation of the steel sets As Shown and as detailed on the specifications. 3. Work includes, but is not limited to: a) Preparation and submittal of shop drawings depicting fabricated dimensions and details of bolted connections and foot blocks. b) Delivering and storing steel sets and all necessary hardware (foot blocks; hardware for bolted flange connections; collar pipes; tie rods and hardware) on Site. c) Installation of steel sets. d) Rock bolts and hardwood blocks and wedges to shim and stabilize steel sets. Item 1.18 – Shotcrete (3” Thick) and Wire Mesh in Tunnels and Shafts 1. Measurement for this Item will be per Square Foot (SF) of 3” thick shotcrete and wire mesh installed. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for the supply and installation of wire mesh and shotcrete in tunnels and shafts As Shown and as detailed on the specifications. 3. Work includes, but is not limited to: a) Supply and installation of wire mesh As Shown for shotcrete application. b) Supply and installation of shotcrete. Item 1.19 – Shotcrete (4” Thick) and Wire Mesh in Tunnels 4. Measurement for this Item will be per Square Foot (SF) of 4” thick shotcrete and wire mesh installed. 5. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for the supply and installation of wire mesh and shotcrete in tunnels and shafts As Shown and as detailed on the specifications. 6. Work includes, but is not limited to: Blue Lake Expansion Project – Contract No. 9 01270-8 General Construction May 2012 a) Supply and installation of wire mesh As Shown for shotcrete application. b) Supply and installation of shotcrete. Item 1.20 – Hydraulic Liners in Tunnels 1. Measurement for this Item will be per Lineal Foot (LF) of reinforced concrete hydraulic liner installed. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for the installation of reinforced concrete tunnel liners As Shown, and as detailed on the specifications. 3. Work includes, but is not limited to: a) Rock excavation, Type 1 rock support (steel sets, rock bolts, mesh, and shotcrete), site preparation for concrete placement, formwork, reinforcing steel, and furnishing, placing, finishing, curing, and protection of concrete. Item 1.21 – Powerhouse, Penstock, and Access Road Excavation 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for the excavation and preparation of the site for installation of the new penstock and construction of the powerhouse As Shown, and as detailed on the specifications. This Bid Item also includes the excavation for the Powerhouse Access Road, Filter Plant Access Road, and associated parking areas. 3. Work includes, but is not limited to: a) Surveying, scaling, clearing and grubbing, cofferdams, care of water, unclassified excavation, rock excavation, disposal of rock material, salvage and demolition of existing penstock sections, valves, couplings, thrust blocks and penstock accessories placement of subbase, base, surfacing courses, initial and final regrading and resurfacing of the entire associated roads and parking areas, and final site restoration. Item 1.22 – Powerhouse Area Backfill 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for all backfill work in the Powerhouse area and for construction of the Powerhouse Access Road, Water Treatment Plant Road, Filter Plant Access Road, and associated parking areas As Shown and as detailed on the specifications. The Schedule of Values breakdown will detail payment of the work items completed and accepted. 3. Work includes, but is not limited to: Surveying and layout Blue Lake Expansion Project – Contract No. 9 01270-9 General Construction May 2012 a) Backfill and grading for the powerhouse, penstock, nearby roads and parking areas b) Concrete block walls for the Water Treatment Plant Access Road and for the penstock backfill c) Preparing excavated surfaces for placement of fill materials d) Placement of subbase, base and surfacing courses for the Powerhouse Access Road, Water Treatment Plant Road and Filter Plant Access Road and associated parking areas in conformity with the lines, grades, thicknesses and typical sections e) Supply and installation of concrete barriers f) Supply and installation of all site drainage and stormwater management systems g) Site restoration in the powerhouse area Item 1.23 – Utilities Protection and Relocation 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for completion of site utility services As Shown and detailed in the specifications. Site utilities include new 24” water supply transmission main, potable water service, pumped NSRAA industrial water supply, pumped emergency water supply, and sewer force main service outside of 5 feet from the powerhouse foundation. Site utility demolition work includes all areas. Owner will isolate all utility services for Contractor to perform utility Work. The Schedule of Values breakdown will detail payment for the work items completed and accepted. 3. Work includes, but is not limited: a) Survey, clearing and grubbing, unclassified excavation, rock excavation, care of ware, trenching, shoring, pipework, backfilling, and site restoration. b) Protecting, maintaining, and restoring all existing buildings, access routes, roads, water power generation, and utility service to allow for continuous, normal operations of facilities by the Owner except where service disruptions are authorized in writing elsewhere. c) Demolition and removal of existing septic field and service lines where it interferes with construction. d) Demolition and removal of portions of the existing 30” diameter water transmission main, where it interferes with construction. Item 1.24 – Chain Link Fence 1. Measurement for this Item will be per Lineal Foot (LF) of fence installed. Blue Lake Expansion Project – Contract No. 9 01270-10 General Construction May 2012 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for procurement and installation of galvanized steel chain link fences and gates As Shown. and as detailed on the specifications. 3. Work includes, but is not limited to: a) Chain link fencing and gates. b) Posts, hardware, bracing, ties, and anchors. c) Concrete footings. Item 20.01 – Dam Extension 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for extension of the Blue Lake Dam as shown on the drawings and as detailed on the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. 3. Work includes, but is not limited to: a) Surveying and layout, demolition, clearing and grubbing, foundation excavation, consolidation grouting, backfill and grading, disposal of unclassified and rock material, dam survey monitoring, preparing concrete contact surfaces for concrete placement, formwork, reinforcement, embedded items, placing concrete, finishing, protecting, and curing concrete a) Supply and installation of ladder, guardrail, and walkway system b) Relocation of sluice gate operating system to temporary location and then permanent modification and installation c) Supply and installation of staff gage Item 20.02 – Left Abutment Thrust Block and Cut-Off Wall 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for construction of the left abutment thrust block and cut-off wall. 3. Work includes, but is not limited to: a) Surveying and layout, clearing and grubbing, scaling, unclassified excavation, rock excavation, disposal of unclassified and rock materials, preparation of excavated rock faces for concrete placement, and site drainage features b) Formwork, reinforcement, concrete placement, finishing, protecting, and curing. Item 20.03 – Abutment Piezometer Blue Lake Expansion Project – Contract No. 9 01270-11 General Construction May 2012 1. Measurement for this Item will be per Lineal Foot (LF) of hole drilled. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for procurement and installation of one piezometer in the left abutment As Shown. and as detailed on the specifications. 3. This Work will include the drilling and construction of the monitoring well and associated instrumentation. Item 20.04 – Plunge Pool Pressure Relief Wells and Monitoring System. 1. Measurement for this Item will be Lineal Foot (LF) of hole drilled. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for providing the plunge pool pressure relief wells and monitoring system As Shown. and as detailed on the specifications. 3. Work includes, but is not limited to: a) Surveying and layout of pressure relief wells using horizontal and vertical control. b) Core drilling holes, recover cores, and facilitate inspection. c) Water pressure testing of holes. d) Grouting of the pressure relief wells. e) Placement of all fill, well protection, and reinforced concrete materials. f) Installation and removal of temporary casings. g) Supply and installation of borehole manually read pressure gauges. h) Supply and installation of piezometer. Item 20.05 – Left Abutment Rock Anchors – 1-3/8” Diameter, 31’ to 50’ Length 1. Measurement for this Item will be per Lineal Foot (LF) of rock anchors installed. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for supply and installation of 1-3/8” diameter rock anchors, 31 to 50 feet long, in the left abutment As Shown. and as detailed on the specifications. 3. Work includes, but is not limited to: a) Supplying rock anchors and associated materials. b) Drilling holes for rock anchors. c) Installation and testing of rock anchors. Item 20.06 – Foundation Grouting – Drill Holes Blue Lake Expansion Project – Contract No. 9 01270-12 General Construction May 2012 1. Measurement for this Item will be per Lineal Foot (LF) of holes drilled. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for drill setup and drilling holes in rock for foundation grouting including drill setups As Shown. and as detailed on the specifications. Item 20.07 – Foundation Grouting – Cement for Foundation Grouting 1. Measurement for this Item will be per 94 pound Bag (BAG) of cement supplied and used. 2. The Bid Item Unit Price for this Work will be for the cement supplied and used at the mixer for foundation grouting. Work performed and quantity used will be in consultation with Engineer. Item 20.08 – Foundation Grouting – Plasticizer 1. Measurement for this Item will be per Gallon (GAL) of plasticizer supplied and used. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for supply of plasticizer used for the foundation grouting. Item 20.09 – Foundation Grouting – Water Tests 1. Measurement for this Item will be for Each (EA) test performed. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for performing water tests on the foundation grouting. Item 20.10 – Foundation Grouting – Grout Pipe 1. Measurement for this Item will be per Pound (LB) of pipe installed. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for supply and installation of grout pipe for foundation grouting operations. Item 20.11 – Dam Contraction Joint Grouting 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for grouting contraction joints in the dam As Shown. and as detailed on the specifications. 3. Work includes, but is not limited to: a) Maintaining dam mass concrete monitoring instrumentation, including joint meters and thermocouples b) Facilitating and assisting Engineer with monitoring and inspection of dam concrete during curing c) Grout hook-ups, including: tubing, fittings, connections, and cover plates Blue Lake Expansion Project – Contract No. 9 01270-13 General Construction May 2012 d) Pressure grouting. Item 22.01 – Spillway Plunge Pool Scour Wall Concrete Head Beam 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for construction of the plunge pool scour wall reinforced concrete including protective steel plate As Shown and as detailed on the specifications. The Schedule of Values breakdown will detail payment for items completed and accepted. This Item does not include rock bolts to be embedded in the concrete head beam. 3. Work includes, but is not limited to: a) Dewatering of the plunge pool; surveying and layout; scaling; removal of timber and organic debris; unclassified excavation; rock excavation; formwork, reinforcing steel concrete placing, finishing, protecting, and curing b) Installation of protective steel plate. Item 22.02 – Spillway Plunge Pool Scour Wall Riprap Protection 1. Measurement for this Item will be Cubic Yard (CY). 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for providing riprap upstream of the concrete head beam plate As Shown. and as detailed on the specifications. 3. Work includes, but is not limited to: a) Removal of timber and organic debris from riprap placement areas. b) Furnishing and placement of Class II, III and IV riprap. Item 22.03 – Spillway Plunge Pool Scour Wall Micropiles 1 thru 29 1. Measurement for this bid item will be per Lineal Foot (LF) of micro-piling. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for providing micro piles. This Item includes grouting and rock dowels As Shown and as detailed on the specifications. 3. Work includes but is not limited to: a) Survey and layout of micropiles b) Drilling and installing micropile casing c) Drilling and installing rock anchors d) Grouting bond length of rock anchors e) Test and lock -off of grouted rock anchors that are included with micropiles. Blue Lake Expansion Project – Contract No. 9 01270-14 General Construction May 2012 Item 22.04 – Spillway Plunge Pool Scour Wall Micropiles 30 thru 38 (Optional) 1. Measurement for this bid item will be per Lineal Foot (LF) of micro-piling through alluvial material including grouting and rock dowels As Shown. and as detailed on the specifications. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for providing micro piles. Work includes, but is not limited to: a) Survey and layout of micropiles b) Drilling and installing micropile casing c) Drilling and installing rock anchors d) Grouting bond length of rock anchors e) Test and lock-off of grouted rock anchors that are included with micropiles. Item 22.05 – Spillway Plunge Pool Scour Wall Micropiles 39 thru 43 1. Measurement for this bid item will be Lineal Foot (LF) of micro-piling. 2. The Bid Item Unit Price for this Work will be for all direct and indirect costs required for providing micro piles. This Item includes grouting and rock dowels as shown on the drawings and as detailed on the specifications. 3. Work includes, but is not limited to: a) Surveying and layout of micropiles b) Drilling and installation of micropile casing c) Drilling and installation of rock anchors d) Grouting bond length of rock anchors e) Testing and lock-off of grouted rock anchors that are included with micropiles. Item 22.06 – Spillway Plunge Pool Scour Wall Grouting of Grout Piles 30 thru 38 (Optional) 1. Measurement for this item will be Cubic Yard (CY) of grouting. 2. The Bid Item Prices for this Work will be for all direct and indirect costs required for providing micro piles. This Item includes all alluvial material including grouting and rock dowels As Shown and as detailed on the specifications. 3. Work includes but is not limited to: a) Survey and layout of grout piles b) Drilling of grout holes Blue Lake Expansion Project – Contract No. 9 01270-15 General Construction May 2012 c) Installation of any temporary casings d) Grouting of the alluvial material. Item 23.01 – Drainage Tunnel 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for performing tunnel excavation. The price shall include the tunnel access road; tunnel portal excavation and support; tunnel excavation; preparation and equipment set-up for installation of excavation support; maintaining excavation support; furnishing, installing, and maintaining temporary utilities and ventilation; and all other incidental work required to develop and maintain the drainage tunnel during construction. This Item does not include drilling and grouting for ground and groundwater control or installation of tunnel excavation rock support. 3. Work includes, but is not limited to: a) Survey and layout of site features using horizontal and vertical control. b) Rock excavation, scaling, and support for the drainage tunnel access road and portal. c) Contractor designed temporary retaining wall to support temporary road fill. d) Drainage tunnel rock excavation. e) Facilitating and assisting in periodic inspection of exposed rock face by RPR to identify ground support type. f) Drilling of “feeler” holes to assess rock quality and conditions in advance of tunnel excavation. g) Drilling, blasting and mucking out of excavated rock. h) Design and provide access road retaining wall and fill materials. Remove all materials following completion of tunnel. i) Provide v-notch seepage weir. j) Transport and disposal of excavated material. Item 23.02 – Exploratory Cored Holes 1. Measurement for this Item will be per Lineal Foot (LF) of holes cored from the inside the drainage tunnel. Holes will in length As Shown and as detailed on the specifications. 2. The Bid Item Unit Price for this Work will be all direct and indirect costs for all labor, equipment, and materials necessary for core drilling of minimum 3 inch diameter exploratory cored holes from inside the drainage tunnel As Shown and as detailed on the specifications. 3. Work includes but is not limited to: Blue Lake Expansion Project – Contract No. 9 01270-16 General Construction May 2012 a) Core drilling. b) Removal, identification, transportation and storage of cores. Facilitate RPR inspection of cores. c) Flushing and cleaning core drilled holes. d) Water pressure testing over the entire length of the borehole with a single packer set at the collar of each borehole. e) “Downhole”-oriented optical televiewer surveying of each borehole or as directed by RPR. Item 23.03 – Exploratory Holes 1. Measurement for this Item will be per Lineal Foot (LF) of holes drilled from inside the drainage tunnel. Holes will vary in length As Shown and as detailed in the specifications. 2. The Bid Item Unit Price for this Work will be all direct and indirect costs for all labor, equipment, and materials necessary for the drilling of minimum 3-inch diameter exploratory holes from inside the drainage tunnel As Shown and as detailed on the specifications. 3. Work includes but is not limited to: a) Drilling. b) Flushing and cleaning drilled holes. c) “Downhole”-oriented optical televiewer surveying of the first 30 feet of each borehole, or as directed by RPR. Item 23.04 – Water Pressure Packer Tests 1. Measurement for this Item will be per Each (EA) test performed. 2. The Bid Item Unit Price for this Work will be all direct and indirect costs for all labor, equipment, and materials necessary to perform water pressure packer testing As Shown and as detailed in the specifications and as may be required to locate permeable rock joints. Item 24.01 – Intake Tunnel Excavation 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for performing tunnel excavation. The price shall include the tunnel excavation; preparation and equipment set-up for installation of excavation support; installation of rock trap near end of tunnel; maintaining excavation support; furnishing, installing, and maintaining temporary utilities and ventilation; groundwater collection and transport out of tunnel, and all other incidental work required to develop and maintain the intake tunnel during construction As Shown and as detailed in the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. Blue Lake Expansion Project – Contract No. 9 01270-17 General Construction May 2012 This Item does not include Installation of tunnel excavation support, and drilling and grouting for ground and groundwater control. 3. This Work includes, but is not limited to: a) Survey and layout of tunnel. b) Dewatering of tunnel and control of water. c) Tunnel rock excavation. d) Drilling of “feeler” holes to assess rock quality and conditions in advance of tunnel excavation. e) Drilling, blasting and mucking out of excavated rock. f) Cleaning of excavated tunnel surfaces. g) Transporting and disposal of excavated material. h) Facilitating and assisting in periodic inspection of exposed rock face by Engineer to identify ground support type. i) Excavation and erection of rock trap, including structural steel framing, connection hardware, lumber decking and personnel grating. Item 25.01 – Intake Excavation 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for excavation of the intake As Shown and as detailed on the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. If deemed necessary by the Contractor the Intake Portal Access Road as shown in the drawings will be included in this item. 3. Work includes, but is not limited to: a) Survey and layout, demolition and salvage of equipment and structures at the existing tunnel intake, cofferdam (if necessary), control of water, unclassified excavation, rock excavation, scaling, preparation of excavated surfaces for concrete, disposal of excavated materials, and removal of cofferdam (if used). Item 25.02 – Intake Structure 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for construction of the new intake structure As Shown and as detailed on the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. 3. Work includes, but is not limited to: Blue Lake Expansion Project – Contract No. 9 01270-18 General Construction May 2012 a) Survey, formwork, reinforcement, and concrete for the intake including finishing, protecting, and curing concrete, facilitating and assisting in concrete sampling and testing by RPR if requested, concrete quality control and inspection b) Furnish and install trashracks, guides, and temporary supports including on site testing c) Install Owner furnished equipment (Contract 3) bulkhead gate and bulkhead gate guides, associated embedded metals, field adjustments, field coating repair, site testing and commissioning d) Piping for reservoir level and bubbler systems. Item 26.01 – Gate Chamber, Gate Shaft, and Gatehouse Structures 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for the excavation and construction of the gate chamber structure, gate shaft structure, and gate house structure intake As Shown and as detailed in the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. This Item does not include installation of excavation support, drilling and grouting, and ground and groundwater control. 3. Work includes, but is not limited to: a) Survey and layout, unclassified excavation, and rock excavation, site preparation for concrete placement, formwork, reinforcement and embedments, concrete including finishing, protecting, and curing concrete, grouting b) Construction in gatehouse area including retaining walls, handrails and accessories for parking area As Shown and as detailed on the specifications. c) Construction of gate shaft collar. d) Facilitating and assisting in concrete and grout sampling and testing by RPR if requested. e) Installation and testing of Owner furnished equipment (Contract 3) including fixed wheel gate, gate guides, and hoist. f) Piping systems. g) Providing mechanical and electrical equipment, fixtures, outlets, and accessories, including all electrical site work in the vicinity of the dam, dam staging area, and gate house. h) Providing all architectural items: roofing, miscellaneous metal items, roof accessories, coatings and finishes. i) Reservoir debris boom, boom anchorages and related work. Blue Lake Expansion Project – Contract No. 9 01270-19 General Construction May 2012 Item 30.01 – Temporary and Permanent Sealing of Existing Intake 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for temporary and permanent sealing of the existing intake As Shown and as detailed in the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. 3. Work includes, but is not limited to: a) Plan and design of temporary and permanent sealing. b) Remove existing bulkhead gate and perform inspection. c) Underwater inspection of the intake structure area. d) Prepare inspection reports. e) Reinstallation of the bulkhead gate and trashracks. f) Temporary sealing of the intake air vent. g) Diversion and care of water in the tunnels and shaft. h) Site preparation for concrete tunnel plug placement, including rock excavation for the plug. i) Supply, installation and stripping of formwork. j) Supply and installation of concrete reinforcing steel and embedments including grout pipe. k) Supply and placement of concrete. l) Facilitating and assisting in concrete sampling and testing by RPR if requested. m) Concrete quality control and inspection. n) Supply and installation of tunnel plug drain pipe and valve. o) Consolidation grouting. p) Tunnel plug contact grouting. Item 30.02 – Tunnel Steel Liners 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for supply and installation of steel tunnel liners at the North, South, and Lower Portals As Shown and as detailed in the specifications. The Blue Lake Expansion Project – Contract No. 9 01270-20 General Construction May 2012 Schedule of Values breakdown will detail payment for work items completed and accepted. 3. Work includes, but is not limited to: a) Design and supply of steel liner segments. b) Unloading and storing steel tunnel liner segments on site. c) Diversion and care of tunnel seepage and gate leakage from the existing and new intakes. d) Demolition and removal of existing tunnel concrete. e) Installation of liners including welding and weld testing. f) Placement of grout and concrete around liners and grout collars. g) Application of liner coating and repair of penstock coating. h) Closure of access points. i) Site restoration of access points. Item 30.03 – Adit Tunnel and Surge Chamber 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for performing adit tunnel excavation, surge shaft and chamber excavation, and construction of surge shaft top portal structure. The price shall include the adit tunnel portal excavation and support; tunnel excavation; shaft and chamber excavation; preparation and equipment set-up for installation of tunnel and shaft excavation support; maintaining excavation support; furnishing, installing, and maintaining temporary utilities and ventilation; groundwater collection and transport out of tunnel; and all other incidental work required to develop and maintain the tunnel, shaft, and chamber during construction. The price shall also include the chamber top portal structure and foundation and rock trap at the base of the shaft As Shown and as detailed in the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. This Item does not include installation of tunnel, shaft, and chamber excavation support, drilling and grouting for ground and groundwater control in tunnel and shaft. 3. Work includes, but is not limited to: a) Survey and layout of tunnel including horizontal and vertical control. b) Facilitating and assisting in periodic inspection of exposed rock face by Engineer to identify ground support type. c) Clearing and grubbing. d) Scaling of existing vegetation and loose material. Blue Lake Expansion Project – Contract No. 9 01270-21 General Construction May 2012 e) Unclassified excavation. f) Rock excavation. g) Drilling of “feeler” holes to assess rock quality and conditions in advance of tunnel excavation. h) Drilling, blasting and mucking out of excavated rock. i) Diversion and care of tunnel seepage. j) Cleaning of excavated surfaces. k) Construction of reinforced concrete wall at base of surge chamber. l) Construction of the surge chamber top portal structure. m) Construction of gated adit tunnel closure at the portal. n) Transport and disposal of excavated material. Item 30.04 – Adit Tunnel Concrete Plug and Connection to Existing Tunnel 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for connecting the surge shaft to the existing tunnel and plugging the adit tunnel with reinforced concrete As Shown and as detailed in the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. 3. Work includes, but is not limited to: a) Rock excavation for the tunnel connection. b) Facilitating and assisting in inspection of exposed rock face by RPR to confirm rock support plans. c) Transportation and disposal of rock materials. d) Provide miscellaneous metals, inclusive of manhole and 36-inch steel pipe for adit plug. e) Site preparation for concrete placement. f) Supply, installation and stripping of formwork. g) Supply and installation of concrete reinforcing steel and embedments. h) Supply and placement of concrete. i) Consolidation grouting. j) Contact grouting. Blue Lake Expansion Project – Contract No. 9 01270-22 General Construction May 2012 k) Facilitating and assisting in concrete sampling and testing by RPR if requested. l) Concrete quality control and inspection. Item 31.01 – Timber Crib Wall – Demolition, Excavation, and Grading 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for demolition, excavation, and grading of the timber crib wall. Work includes, but is not limited to: a) Demolition and removal of existing timber crib retaining wall. b) Transportation and disposal of unclassified material. Item 31.02 – Install Owner Furnished Penstock and Manifold 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for installation of the penstock and manifold As Shown and as detailed in the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. This Item does not include backfill of the penstock which should be included in Bid Item 1.14 Powerhouse Area Backfill. 3. Work includes, but is not limited to: a) Construction As Shown and as detailed in the specifications. b) Installation and welding of Owner furnished penstock, sleeve couplings and other associated components. Item 32.01 – Penstock Drain System 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for construction of the 24 inch penstock drain system. This Item does not include backfill. 3. Work includes, but is not limited to: a) Furnish and install 24 inch drain line with couplings and accessories. b) Construct energy dissipating structure, including all appurtenances. c) Furnish, install and test shutoff valve and 24 inch fixed cone valve. Item 33.01 – Water Treatment Building Modifications 1. Measurement for this Item will be Lump Sum (LS). Blue Lake Expansion Project – Contract No. 9 01270-23 General Construction May 2012 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for salvage of existing equipment and supply and installation of new piping and equipment in the existing Water Treatment Building As Shown and as detailed on the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. 3. Work includes, but is not limited to: a) Salvage of two existing strainers and flow control valves. b) Furnish and install new strainers and pressure reducing valves and associated piping and controls. c) Furnish and install new piping, fitting and valves within the building for the water supply from the penstock and the municipal water supply pumps. d) Furnish and install 20”valve and raw water line from penstock to water treatment building Item 45.01 – Powerhouse Concrete 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for concrete construction for the Blue Lake powerhouse, including the afterbay, raw water sump, and miscellaneous concrete structures near the powerhouse As Shown and as detailed in the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. This item does not include the penstock drain concrete structures or the penstock concrete anchor blocks. 3. Work includes, but is not limited to: a) Construction As Shown and as detailed in the specifications. b) Formwork, reinforcing, embedded metals, concrete placing, finishing, curing, protecting, concrete (including but not limited to those furnished by Owner under Contract 1 and Contract 7) according to supplier’s requirements prior to concrete placement. Item 45.02 – Erect Owner Furnished Powerhouse Structure 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for erection and installation of the Owner furnished pre- fabricated, powerhouse structure As Shown and as detailed in the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. 3. Work includes, but is not limited to: a) Storing of materials on Site. Blue Lake Expansion Project – Contract No. 9 01270-24 General Construction May 2012 b) Installation of all Owner furnished steel building materials (furnished under supply contract 7). c) Supply and installation of joint sealers specified by steel building supplier. d) Performing touch-up painting as needed. Item 45.03 – Powerhouse Interior Build-Out 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for interior build-out of the Blue Lake powerhouse As Shown and as detailed in the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. 3. Work includes, but is not limited to, a) Interior precast hollow-core concrete slabs, including cast-in-place concrete topping courses. b) Interior steel structural members. c) Miscellaneous galvanized metals, such as walkways, stairways, ladders and handrails. d) Doors, roll-up doors, windows, and louvers. e) Gypsum wall board. f) Batt insulation, resilient channel, and acoustic sealant g) Suspended acoustic ceiling tile. h) Fiberglass reinforced plastic panels. i) Countertops and cabinets. j) Bathroom partitions and accessories. k) Plumbing fixtures. l) Finish carpentry. m) Supply and application of paint at interior walls. n) Supply and application of concrete sealant on powerhouse floor. Item 45.04 – Powerhouse Electrical Equipment and Services 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for supply and installation of electrical equipment and services in the Blue Lake powerhouse As Shown and as detailed in the specifications. The Blue Lake Expansion Project – Contract No. 9 01270-25 General Construction May 2012 Schedule of Values breakdown will detail payment for work items completed and accepted. 3. Work includes, but is not limited to: a) 125V DC electrical system. b) Grounding system. c) Embedded conduit, exposed conduit, and cable trays. d) Low and medium voltage cable, control cable, and signal cable. e) Install raw water electrical 480V MCC RWP and local panels. f) Installation, commissioning and testing for 480V transformers SST1, SST2 & RWPT3 (transformers furnished by Owner). g) Lighting and receptacles. h) Fire alarm and security systems. i) Supply and installation of 200 kW standby diesel engine and generator, accessory components and controls, safety devices, and field testing and commissioning. Item 45.05 – Powerhouse Mechanical Equipment and Services 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for supply and installation of mechanical equipment and services in the Blue Lake powerhouse As Shown and as detailed in the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. 3. Work includes, but is not limited to: a) Sumps and sump pumps. b) Fire protection system. c) Raw water pumping system. d) Raw water intake screens. e) Sanitary lift station and station drainage/treatment system. f) Service and potable water system. g) Compressed air system. h) Heating and ventilation systems, including generator exhaust ducts. Blue Lake Expansion Project – Contract No. 9 01270-26 General Construction May 2012 Item 45.06 – Install Owner Furnished BLU Turbine and Generator Equipment, Bridge Crane and 12.47kV Switchgear 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for installation of turbines, generators, associated equipment, bridge crane, and switchgear at the powerhouse As Shown and as detailed in the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. 3. Work includes, but is not limited to: a) Unloading the turbines, generators, and auxiliary equipment (furnished under procurement contract 1). b) Installation and testing of turbines and generators (furnished under procurement contract 1). c) Installation and testing of 12.47 kV switchgear (furnished under procurement contract 2). d) Installation and testing of bridge crane (furnished under procurement contract 6). e) Crane overhaul and repair of protective coatings. f) Performing field adjustments and facilitating site testing of all equipment. g) Providing an installation report, which includes all measurements taken during installation and testing of the turbines, generators, crane, and switchgear equipment. h) Installation of Owner-furnished 480V switchgear (furnished under procurement contract 2). Item 46.01 – Demolition and Salvage of Existing FVU Turbine and Generator Equipment 1. Measurement for this item will be as Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for salvage and demolition of the existing Fish Valve Unit (FVU) As Shown and as detailed in the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. 3. Work includes, but is not limited to: a) Removal of existing turbine, generator, exciter, and concrete. Transportation of salvaged and removed materials to SCIP. b) Removal of generator terminal box for reinstallation on new FVU. c) Transportation and disposal of material. Blue Lake Expansion Project – Contract No. 9 01270-27 General Construction May 2012 d) Providing inspection report with inventory of parts. e) Protect and repair damaged conduit for reuse by the Owner. Item 46.02 – Install Owner Furnished Turbine & Generator Equipment 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for installation the 1.6 MW Fish Valve Unit As Shown and as detailed in the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. 3. Work includes, but is not limited to: a) Unloading the turbine, inlet valve, and generator equipment. b) Preparing foundation and rock faces for concrete placement. c) Formwork, reinforcing steel and embedded materials to be positioned according to supplier’s requirements, furnishing, placing, curing, and protection of concrete. d) Installation of turbine, valve, generator and accessories. e) Mechanical and electrical systems in the powerhouse. f) Performing field adjustments and facilitating site testing. g) Providing assistance during commissioning. Item 55.01 – Switchyard Foundation Structures and Buried Conduit 1. Measurement for this Item will be Lump Sum (LS). 2. The Bid Item Lump Sum Price for this Work will be for all direct and indirect costs required for construction of the new Blue Lake switchyard As Shown and as detailed in the specifications. The Schedule of Values breakdown will detail payment for work items completed and accepted. 3. Work includes, but is not limited to: a) Removal and salvage of existing main transformers. b) Demolition and removal of foundations of main transformers. c) Unclassified excavation, transportation and disposal of unclassified materials, site preparation for concrete placement, formwork, reinforcing steel, embedments, and furnishing, placing, finishing, curing, and protection of concrete foundations. d) Installation of embedded conduit and cable tray from Blue Lake powerhouse to Blue Lake switchyard. e) Installation of embedded conduit in switchyard. Blue Lake Expansion Project – Contract No. 9 01270-28 General Construction May 2012 f) Installation of Owner furnished 69kV transformers, including cable, wiring, and grounding tie-ins to the existing switchyard systems. END OF SECTION Blue Lake Expansion Project – Contract No. 9 01290-1 General Construction May 2012 SECTION 01290 SCHEDULE OF VALUES PART 1 GENERAL 1.01 INTENT The intent of the schedule of values is to provide a metric to quantify the work performed for use in making accurate progress payments and establish a metric that may be applied to change orders. 1.02 WORK INCLUDED Prepare Schedule of Values, based on the Contractors Estimate and Work Plan, for review by RPR. Participate in meetings to negotiate and finalize a mutually acceptable Schedule of Values to allow for accurate progress payments during the course of the work. 1.03 RELATED SECTIONS A. Section 00004: Instructions to Bidders B. Section 00005: Bid Form C. Section 01270: Measurement and Payment D. Section 2.05.A.3: General Conditions E. Section 2.07.A: General Conditions F. Section 14.01: General Conditions 1.04 REFERENCE STANDARDS Not used. 1.05 SUBMITTALS A. Submit initial Schedule of Values for review under provisions of Section 01300. B. Resubmit Schedule of Values for review as requested during negotiations. C. Prepare final Schedule of Values for review and approval of RPR. 1.06 FORMAT AND CONTENT Blue Lake Expansion Project – Contract No. 9 01290-2 General Construction May 2012 A. The Schedule of Values shall be used as a basis for determining progress payments on a lump sum bid item. The Schedule of Values shall be a schedule of cost loaded construction activities equal, in total, to the bid and shall be in such form and sufficient detail to correctly represent a reasonable apportionment of the lump sum. The breakdown of the lump sum item shall be reasonably sized, discrete in nature, and appropriate to thoroughly represent the work. Additional break down may be by location, discipline, division, cost type, etc. B. Each lump sum bid item on the Bid Form, as set forth in the bid must be broken down separately. The breakdown of each lump sum bid item must cover the cost of construction required by the Contract Drawings and Contract Documents for that item. The sum of the values for the construction activities, within a bid item, must equal the total bid amount for that item. Use the Bid Form as a basis to develop the Schedule of Values. The highest level of the Schedule will be the feature number. The second highest level will be the bid item number. Use additional break down to show estimated quantities and unit prices for each lump sum bid item. Include line items for the unit price bid items. C. The Schedule of Values shall be broken down into units that facilitate measurement of work progress that include quantities and unit price values for the Work. Units may include; cubic yards, pounds, lineal ft, square ft, each, etc. D. Feature level Schedule of Value items include the following: 1. General and Multiple – Feature Payment Items 2. Dam Extension 3. Spillway Plunge Pool Scour Wall 4. Drainage Tunnel 5. Intake Tunnel 6. Intake Structure 7. Gate Shaft 8. Tunnel Modifications 9. Penstock 10. Penstock Drain 11. Water Treatment Building 12. Powerhouse 13. Fish Valve Unit 14. Switch Yard Modifications E. Suggested Third Tier Schedule of Value Activities Blue Lake Expansion Project – Contract No. 9 01290-3 General Construction May 2012 1. Access roads and parking areas, placement of fill and surfacing materials 2. As-Built drawings 3. Backfill, type D1 and C1 4. Backfill, native material 5. Bridge crane, furnish and installation 6. Chain link fencing and gates 7. Clearing and Grubbing 8. Cast in place concrete 9. Contact grouting 10. Consolidation grouting 11. Reinforcing steel 12. Dam monitoring system 13. Dam extension, vertical contraction joint grouting 14. Demolition 15. Architectural work 16. Rock excavation 17. Unclassified Excavation 18. Excavation, in Tunnels 19. Excavation, in Shafts 20. Ground support (steel sets, rock bolts, wire mesh, shotcrete, etc.) 21. Riprap 22. Fixed wheel gate, guides and hoist installation 23. Trashrack and guides 24. Miscellaneous metal supply and installation 25. Mobilization (including subcontractors, plant and facilities) 26. Penstock installation 27. Penstock, painting Blue Lake Expansion Project – Contract No. 9 01290-4 General Construction May 2012 28. Powerhouse perimeter drainage 29. Permits/Bonds/Insurances 30. Plumbing, fixtures 31. Plumbing, rough-in 32. Electrical, 125V DC electrical system 33. Electrical, 200 kW standby diesel engine and generator 34. Electrical, conduit and cable trays 35. Electrical, fire alarm and security systems 36. Electrical, grounding system 37. Electrical, installation of 480V transformers 38. Electrical, lighting and receptacles 39. Electrical, low and medium voltage cable, control cable, and signal cable 40. Mechanical, compressed air system 41. Mechanical, drainage sumps and sump pumps 42. Mechanical, fire protection system 43. Mechanical, heating and ventilation system 44. Mechanical, raw water pumping system and intake screens 45. Mechanical, sanitary lift station 46. Mechanical, service and potable water system 47. Mechanical, valves and governors 48. Pre-engineered building, erect steel superstructure 49. Pre-engineered building, install precast concrete exterior wall panels and metal roof panels 50. Punch list and closeout documents 51. Roofing, accessories 52. Steel fabrications, miscellaneous 53. Tunnel liner material supply Blue Lake Expansion Project – Contract No. 9 01290-5 General Construction May 2012 54. Tunnel liner installation 55. Work Plans 56. General Conditions 57. Salvage of Owner equipment 58. Survey and Layout 59. Switchgear, 12.47kV installation 60. Switchgear, 480V installation 61. Electrical, raw water electrical 480V MCC, RWP, and local panels installation 62. Timber crib wall, demolition and excavation 63. Turbine-generator, installation 64. Turbine-generator, testing PART 2 PRODUCTS Not Used. PART 3 EXECUTION A. Contractor to prepare a Schedule of Values using suggested items listed above. Include in the Schedule of Values any additional items or breakdown of items that the Contractor believes will assist in quantification or valuation of appropriate portions of the Work. B. The Schedule of Values must be broken into unit pricing wherever possible. Provide a quantity, unit price and total where possible. C. Where unit pricing is not an appropriate metric. Contractor may use % complete with a full description of the scope. D. Submit initial proposed Schedule of Values for review. Submittal will be reviewed for content, and balance. E. Participate in meeting(s) to negotiate changes to the Schedule of Values. Based on these discussions, resubmit the Schedule of Values for additional review and approval. F. The RPR may, after further review of the Schedule of Values, ask for an additional revision and re-submittal of the final Schedule of Values so that it better reflects costs for specific parts of the Work and provides more equitable means of periodic payment. END OF SECTION Blue Lake Expansion Project – Contract No. 9 01300-1 General Construction May 2012 SECTION 01300 SUBMITTALS PART 1 GENERAL 1.01 WORK INCLUDED A. Work includes, but is not limited to, the submittal of: certificates of compliance, shop drawings, product information, parts or equipment lists, MSDS sheets, plans, schedules, samples, test reports, surveys, mix designs, and other documents produced by the Contractor. 1. The “Attachment A – Submittal List” included in this Section provides a table of the required Contractor submittals. The table includes a submittal description, the respective Section of the Specifications, the type of submittal, and the due date. 1.02 PRELIMINARY SCHEDULES AND PRECONSTRUCTION CONFERENCE A. Submit a Preliminary Progress Schedule, a Preliminary Submittal Schedule, and a Preliminary Schedule of Values, in accordance with Paragraph 2.05 of the General Conditions. Schedules shall be submitted in both .mpp and .pdf format. B. Before any Work at the Site is started, a Preconstruction Conference will take place in accordance with Paragraph 2.06 of the General Conditions. During this conference, the preliminary schedules will be reviewed in accordance with Paragraph 2.07 of the General Conditions. The preliminary Work Plan that was submitted with the winning Bid (see Article 15 of Instructions to Bidders) may also be reviewed at this conference. C. At the Preconstruction Conference, Owner will provide Contractor with details of the submittal protocol and Owner will provide Contractor with an appropriate username and password for access to the SharePoint website. 1.03 SUBMITTAL PROCESS A. The issue and transfer of submittals between Contractor, RPR and Engineer shall be done electronically using Owner’s Microsoft SharePoint file sharing software. Contractor shall follow Owner’s project specific submittal numbering protocol, which is not intended to conflict with Contractor’s normal drawing number process. Submit to the RPR. B. Submit all drawings as PDF files, configured for printing at 11 inch by 17 inch size. Provide other documents also as PDF files, with 8 ½ inch x 11 inch size, or 11 inch by 17 inch size as appropriate. C. Contractor and Owner shall agree on a formal protocol for issuing and return of submittals, at the Preconstruction Conference, to take place as specified in General Conditions Paragraph 2.06. 1.04 WORK PLAN AND PROGRESS REPORTS Blue Lake Expansion Project – Contract No. 9 01300-2 General Construction May 2012 A. Submit a Work Plan as specified in Section 1200 of the Specifications. Follow the Progress Report format as included in the reviewed Work Plan. B. Weekly progress reports shall be submitted by the Contractor for the duration of the project. Provide weekly reports by 8 am on Tuesday of the week following the subject week. Submit reports in paper and PDF format. The weekly progress report will be reviewed and signed by the RPR after noting any discrepancies. C. Within five days following the end of each month, Contractor shall submit a monthly progress report summarizing work completed in the previous month and describing any changes to the schedule of the Work. The monthly progress report shall include color photographs and illustrate progress of the Work. 1.05 CONTRACTOR-PREPARED DRAWINGS AND DOCUMENTS A. Submit to RPR the drawings and documents listed in Attachment A, attached to this Section. B. Check for accuracy and completeness and approve all drawings prior to issue. Review drawings from subcontractors and certify in writing that such drawings are correct and approved before submitting such drawings to RPR. Contractor and subcontractor drawings not processed in this manner will be returned immediately without review by RPR. C. Disorganized submittals that do not meet the requirements of the Contract Documents shall be returned without review. D. Except as may otherwise be indicated, the RPR shall return prints of each submittal to the Contractor with comments noted thereon, within 30 Days following receipt by the RPR. It is considered reasonable that the Contractor shall make a complete and acceptable submittal to the RPR by the first resubmittal on an item. The RPR reserves the right to withhold monies due to the Contractor to cover additional costs of the RPR’s review beyond the first resubmittal. The RPR's maximum review period for each submittal or resubmittal shall be 30 Days. Thus, for a submittal that requires 2 resubmittals before it is complete, the maximum review period could be 90 Days. E. If a submittal is returned to the Contractor marked "NO EXCEPTIONS TAKEN," formal revision and resubmission shall not be required. F. If a submittal is returned marked "MAKE CORRECTIONS NOTED," Contractor shall make the corrections on the submittal, but formal revision and resubmission shall not be required. G. If a submittal is returned marked "AMEND-RESUBMIT," the Contractor shall revise it and shall resubmit the required number of copies. Re-submittal of portions of multi- page or multi-drawing submittals shall not be allowed. For example, if a Shop Drawing submittal consisting of 10 drawings contains one drawing noted as "AMEND - RESUBMIT," the submittal as a whole is deemed "AMEND - RESUBMIT," and 10 drawings are required to be resubmitted. H. If a submittal is returned marked "REJECTED-RESUBMIT," it shall mean either that the proposed material or product does not satisfy the specification, the submittal is so incomplete that it cannot be reviewed, or is a substitution request not submitted in accordance with General Conditions Paragraph 6.05 Substitutes and “Or-Equals”. Blue Lake Expansion Project – Contract No. 9 01300-3 General Construction May 2012 The Contractor shall prepare a new submittal and shall submit the required number of copies. I. Re-submittal of rejected portions of a previous submittal shall not be allowed. Every change from a submittal to a resubmittal or from a resubmittal to a subsequent resubmittal shall be identified and flagged on the resubmittal. J. Fabrication of an item may commence only after the Owner has reviewed the pertinent submittals and returned copies to the Contractor marked either "NO EXCEPTIONS TAKEN" or "MAKE CORRECTIONS NOTED." Corrections indicated on submittals shall be considered as changes necessary to meet the requirements of the Contract Documents and shall not be taken as changes to the contract requirements. K. Submittals shall be carefully reviewed by an authorized representative of the Contractor prior to submission to the RPR. Each submittal shall be dated and signed by the Contractor as being correct and in strict conformance with the Contract Documents. In the case of Shop Drawings, each sheet shall be so dated and signed. Any deviations from the Contract Documents shall be noted on the transmittal sheet. The RPR shall only review submittals that have been so verified by the Contractor. Non-verified submittals shall be returned to the Contractor without action taken by the RPR, and any delays caused thereby shall be the total responsibility of the Contractor. L. Corrections or comments made on the Contractor's Shop Drawings during review do not relieve the Contractor from compliance with Contract Drawings and Specifications. Review is for conformance to the design concept and general compliance with the Contract Documents only. The Contractor is responsible for confirming and correlating quantities and dimensions, fabrication processes and techniques, coordinating Work with the trades, and satisfactory and safe performance of the Work. 1.06 SAMPLES A. The Contractor shall submit the number of samples indicated by the Specifications. If the number is not indicated, submit not less than 3 samples. Where the amount of each sample is not indicated, submit such amount as necessary for proper examination and testing by the methods indicated. B. Samples shall be individually and indelibly labeled or tagged, indicating the salient physical characteristics and manufacturer's name. Upon acceptance by the RPR, one set of the samples shall be stamped and dated by the RPR and returned to the Contractor, one set of samples shall be retained by the RPR, and one set shall remain at the Site in the RPR’s field office until completion of the Work. C. Unless indicated otherwise, the Owner shall select colors and textures from the manufacturer's standard colors and standard materials, products, or equipment lines. If certain samples represent non-standard colors, materials, products, or equipment lines that shall require an increase in Contract Times or Price, the Contractor shall clearly state so on the transmittal page of the submittal. D. The Contractor shall schedule sample submittals such that: Blue Lake Expansion Project – Contract No. 9 01300-4 General Construction May 2012 1. Sample submittals for color and texture selection are complete so the Owner has 45 Days to assemble color panels and select color and texture dependent products and materials without delay to the construction schedule, and 2. After the Owner selects colors and textures, the Contractor has sufficient time to provide the products or materials without delay to the construction schedule. The Contract Times shall not be extended for the Contractor's failure to allow enough review and approval or selection time, failure to submit complete samples requiring color or texture selection, or failure to submit complete or approvable samples. 1.07 TECHNICAL MANUAL A. The Contractor shall submit technical operation and maintenance information for each item supplied by the Contractor of mechanical, electrical, and instrumentation equipment, precluding Owner furnished equipment which will be supplied by the Owner, in an organized manner in the Technical Manual. It shall be written so that it can be used and understood by the Owner's operation and maintenance staff. B. The Technical Manual shall be subdivided first by specification section number; second, by equipment item; and last, by "Category." The following "Categories" shall be addressed (as applicable): 1. Category 1 - Equipment Summary a. Summary: A table shall indicate the equipment name, equipment number, and process area in which the equipment is installed. b. Form: The Owner shall supply an Equipment Summary Form for each item of mechanical, electrical, and instrumentation equipment in the Work The Contractor shall fill in the relevant information on the form and include it in Part 1. The Contractor shall provide cut sheets and manufacturer information for each piece of equipment and include it in Part 1 and organized into sections that correlate to the table above. 2. Category 2 - Operational Procedures a. Procedures: Manufacturer-recommended procedures on the following shall be included in Part 2: 1) Installation 2) Adjustment 3) Startup 4) Location of controls, special tools, equipment required, or related instrumentation needed for operation 5) Operation procedures 6) Load changes 7) Calibration Blue Lake Expansion Project – Contract No. 9 01300-5 General Construction May 2012 8) Shutdown 9) Troubleshooting 10) Disassembly 11) Reassembly 12) Realignment 13) Testing to determine performance efficiency 14) Tabulation of proper settings for pressure relief valves, low and high pressure switches, and other protection devices 15) List of all electrical relay settings including alarm and contact settings 3. Category 3 - Preventive Maintenance Procedures a. Procedures: Preventive maintenance procedures shall include manufacturer- recommended procedures to be performed on a periodic basis, both by removing and replacing the equipment or component, and by maintaining the equipment in place. b. Schedules: Recommended frequency of preventive maintenance procedures shall be included. Lubrication schedules, including lubricant SAE grade, type, and temperature ranges, shall be covered. 4. Category 4 - Parts List a. Parts List: A complete parts list shall be furnished, including a generic description and manufacturer's identification number for each part. Addresses and telephone numbers of the nearest supplier and parts warehouse shall be included. b. Drawings: Cross-sectional or exploded view drawings shall accompany the parts list. Part numbers shall appear on the drawings with arrows to the corresponding part. 5. Category 5 - Wiring Diagrams a. Diagrams: Category 5 shall include complete internal and connection wiring diagrams for electrical equipment items. 6. Category 6 - Shop Drawings a. Drawings: This category includes approved shop or fabrication drawings with RPR comments and corrections incorporated, complete with dimensions. 7. Category 7 - Safety Blue Lake Expansion Project – Contract No. 9 01300-6 General Construction May 2012 a. Procedures: This category describes the safety precautions to be taken when operating and maintaining the equipment or working near it. 8. Category 8 - Documentation: a. Equipment warranties, affidavits, certifications, calibrations, laboratory test results, etc. required by the Technical Specifications shall be placed in this category. C. Format 1. Each Technical Manual shall be bound in standard size 3 ring hardcover binders labeled on the spine and cover with project name, Owner's project number, specification section number, equipment name, and equipment identification number 2. Each Binder shall contain its own detailed table of contents at the front, plus a summary level table of contents information for the other binders in a multi-binder set. 3. Documents in binders shall be 3 hole punched, no text shall be punched out, and pages larger than 8-1/2 by 11 shall be folded to 8-1/2 by 11. 4. Each final set of Technical Manuals shall include a CD with electronic files: a. Project specific files created in Microsoft Office 2010, Auto Cad version 2010, Adobe Acrobat portable document format, or other software required by the specifications. b. Manufacturer literature in Adobe Acrobat portable document format. D. Review Process 1. The Contractor shall furnish 2 draft Technical Manuals for each Specification Section that requires a Manual. The RPR shall retain one copy and shall return one copy to the Contractor with review comments. 2. The Contractor shall incorporate comments into the draft and submit 3 identical copies of the final Manual for acceptance plus one electronic copy with each hard copy. E. Except where indicated otherwise, manuals shall be submitted in final form to the RPR not later than the 75 percent of construction completion date. Discrepancies found by the RPR shall be corrected by the Contractor within 30 Days from the date of written notification by the RPR. F. Work under this Contract involves start-up and commissioning of equipment in multiple areas of the facility at independent times within the project schedule. Manuals shall be complete for each piece of equipment prior to placing equipment into service final acceptance of the equipment by the RPR training of the Owner's personnel. Except where indicated otherwise, manuals shall be submitted for review in final form a minimum of 30 Days prior to pre-commissioning and commissioning the start of performance testing for each piece of equipment. Discrepancies found Blue Lake Expansion Project – Contract No. 9 01300-7 General Construction May 2012 by the RPR shall be corrected within 30 Days from the date of written notification by the RPR. G. Manuals that are incomplete or unacceptable at the schedule criterion above shall constitute sufficient justification for the Owner to retain the amount in paragraph “Technical Manual Submittals" of Section 01 70 00 – Contract Closeout, Operations and Maintenance Manuals, and Spare Parts, from any monies due the Contractor. 1.08 SPARE PARTS LIST A. The Contractor shall furnish to the RPR one identical sets of spare parts information for mechanical, electrical, and instrumentation equipment. The spare parts list shall include those spare parts that each manufacturer recommends be maintained by the Owner in inventory. 1. Sources and Pricing: The spare parts list shall include a current list price of each spare part. Each manufacturer or supplier shall indicate the name, address, and telephone number of its nearest outlet of spare parts to assist the Owner in ordering. 2. Format: The Contractor shall cross-reference spare parts lists to the equipment numbers designated in the Contract Documents. The spare parts lists shall be bound in standard size, 3 ring, loose-leaf, vinyl plastic hard cover binders suitable for bookshelf storage. Binder ring size shall not exceed 2-1/2 inches. Each copy of the spare parts lists shall be accompanied by a CD containing the lists in electronic format, in files created under Microsoft Office 2010, all documents shall be in .pdf format. 1.09 RECORD DRAWINGS A. The Contractor shall maintain one set of Drawings at the Site for the preparation of record drawings. On these, it shall mark every project condition, location, configuration, and any other change or deviation which may differ from the Contract Drawings at the time of award, including buried or concealed construction and utility features that are revealed during the course of construction. Special attention shall be given to recording the horizontal and vertical location of buried utilities that differ from the locations indicated, or that were not indicated on the Contract Drawings. Said record drawings shall be supplemented by any detailed sketches as necessary or as Contractor is directed, to fully indicate the Work as actually constructed. These record drawings are the Contractor's representation of as-built conditions, shall include revisions made by addenda and change orders, and shall be maintained up- to-date during the progress of the Work. Red ink shall be used for alterations and notes. Notes shall identify relevant Change Orders by number and date. B. In the case of those drawings that depict the detail requirement for equipment to be assembled and wired in the factory, such as motor control centers and the like, the record drawings shall be updated by indicating those portions which are superseded by change order drawings or final Shop Drawings, and by including appropriate reference information describing the change orders by number and the Shop Drawings by manufacturer, drawing, and revision numbers. C. Disorganized or incomplete record drawings shall not be accepted. The Contractor shall revise them and resubmit within 10 Days. Blue Lake Expansion Project – Contract No. 9 01300-8 General Construction May 2012 D. Record drawings shall be accessible to the RPR during the construction period. E. Final payment shall not be acted upon until the record drawings have been completed and delivered to the RPR. Said up-to-date record drawings shall be in the form of a set of prints with carefully plotted information overlaid and an electronic form under Microsoft Office 2010, Auto Cad Version 2010, or other software required by the Specifications. F. Information submitted by the Contractor shall be assumed to be correct, and the Contractor shall be responsible for the accuracy of such information 1.10 QUALITY CONTROL (QC) SUBMITTALS A. Quality control submittals are defined as those required by the Specifications to present documentary evidence to the RPR that the Contractor has satisfied certain requirements of the Contract Documents. B. Unless otherwise indicated, QC submittals shall be submitted as follows: 1. Before delivery and unloading, for the following types of submittals: a. Manufacturers' installation instructions b. Manufacturers' and Installers' experience qualifications c. Concrete mix delivery tickets d. Design calculations e. Affidavits and manufacturers' certification of compliance with indicated product requirements f. Laboratory analysis results g. Factory test reports 2. Within 30 Days of the event documented for the following types of submittals: a. Manufacturers' field representative certification of proper installation b. Field measurement c. Field test reports d. Receipt of permit e. Receipt of regulatory approval C. The RPR shall record the date that a QC submittal was received and review it for compliance with submittal requirements, but the review procedures above for Shop Drawings and samples shall not apply. 1.11 INFORMATIONAL SUBMITTALS Blue Lake Expansion Project – Contract No. 9 01300-9 General Construction May 2012 A. Informational submittals formalize the flow of information between the Contractor and the RPR. Forms shall be employed for such purpose. B. The RPR shall supply the required forms for the project in the appropriate format. The Contractor shall utilize the RPR’s forms and submittal process documenting the Work including utilizing Owner provided Share Point Website. 1.12 CONSTRUCTION PHOTOGRAPHS A. Starting when the W ork begins and continuing for as long as the Work is in progress, not less than 12 exposures at intervals no more than 1 week apart, consisting of different subjects or angles or view at different locations of progress on the Site. Digital electronic copies shall be furnished to the RPR within 1 week after exposure. Prints shall become sole property of the Owner upon submittal by the Contractor. PART 2 -- PRODUCTS (NOT USED) PART 3 -- EXECUTION (NOT USED) - END OF SECTION - Page 1 of 4 Attachment A - Submittal List Category Code Category Description C certificates of compliance D drawings I product information L parts or equipment list M Material Safety Data Sheet (MSDS) O&M operating and maintenance manual P plan or procedure S schedule T tests or reports U survey X mix design misc letters, lists of documents or subs, permits, qualifications & resumes, samples, unpriced contracts, warranty info. No.Specification Section Submittal Title and Description Submittal Categories Due Date: 1 01013 Generation Outage Work Plan P with Work Plan 2 01013 Generation Outage Schedule S with Work Plan 3 01013 Generation Outage Schedule Updates S Weekly During Outage 4 01014 Inspection Plan for Existing Intake and Bulkhead Gate P, S 30 days before planned work 5 01014 Inspection Report T Within 1 week of inspection 6 01014 Preliminary Proposal for Repairs of Damage P as needed 7 01014 Plan for Sealing Existing Intake P,S 14 days before work 8 01200 Work Plan and Progress Schedule P, S 30 days after award 9 01200 Meeting Agenda P, S At Least 1 day prior 10 01200 Meeting Minutes T Within 5 days of next meeting 11 01200 Daily Reports T Following work day 12 01200 Monthly Reports T Incl. with Request for Payment 13 01270 Request for Payment Misc No later than 5th day of each month 14 01270 Final Request for Payment Misc Within 15 Days of Completion 15 01270 Schedule of Values Misc with Work Plan 16 01300 Preliminary Progress Schedule, Preliminary Submittal Schedule S 15 days after award 17 01300 Weekly Progress Reports T Following Tuesday 18 01450 Discipline Policy misc with Work Plan 19 01450 Site Specific Health and Safety Plan misc 14 days before work 20 01500 Material Disposal Permits misc Before material is removed from Site 21 01700 Checklist of Completed Work misc Within 5 days of completion 22 01700 Record Drawings D Upon Substantial Completion 23 01700 O&M Manuals O&M Upon Substantial Completion 24 02020 Survey Control and Structural Monitoring Plan P with Work Plan 25 02105 Demolition Plan P with Work Plan 26 02105 Structural Verification Survey U As needed, prior to installation 27 02105 Chain of custody letter for off-site disposal misc 1 day after work 28 02240 Dewatering and Water Control Plan P with Work Plan 29 02290 Geotechnical Instrumentation Plan P 30 days before work 30 02290 Operating Instructions O&M Upon Receipt of Equipment 31 02310 Backfill Grading Test Reports T Prior to Work 32 02310 Backfill Batch Ticket T Upon Delivery 33 02315 Rock Excavation Plan P with Work Plan 34 02315 Scaling Records D Available upon request 35 02315 Pre-Blast Survey U 14 days before work 36 02316 Chain of custody letter for off-site disposal misc As needed, See Section 02105 37 02370 Erosion & Sediment Control Plan P with Work Plan 38 02370 Stormwater Pollution Prevention Plan P with Work Plan 39 02370 Spill Prevention Control and Countermeasures Plan P with Work Plan 40 02400 Rock Tunnelling and Shaft Excavation Plan P with Work Plan 41 02400 Tunnelling Records T 1 day after work 42 02405 Exploratory Drilling and Borehole Documentation Plan P with Work Plan 43 02410 Rock Bolt and Epoxy and/or Grout Product Data I Prior to Ordering 44 02410 Rock Bolt Mill Certifications C Prior to Shipment 45 02410 Tensioning jacks calibration certificates C 7 days before work 46 02411 Rock anchor installation plan & mill certs P, C 30 days before work 47 02411 Rock anchor embedment grout and mix design X 30 days before work 48 02411 Rock Anchor Test jacks calibration curve C 7 days before work 49 02411 Stress test data forms T 30 days before work 50 02411 Rock Anchor Shop Drawings D 30 days before work 51 02411 Stress test results T Immediately after work 52 02411 Grout cube and embedment grout test results T 1 day after work 53 02413 Grouted Dowel Shop Drawings D 30 days before work 54 02413 Grouted Dowel Test Results T Upon delivery 55 02430 Grouting Plan P 30 days before work 56 02430 Cement certifications and test reports C, T 14 days before work 57 02430 Plasticizer information I 14 days before work 58 02430 Completed and signed grouting records T 1 day after work 59 02431 Tunnel Liner Grouting Plan P, L, I, misc 30 days before work 60 02431 Grout Mix Design X 30 days before work 61 02431 Cement certifications and test reports C, T 14 days before work 62 02431 Additives information I 14 days before work 63 02431 Completed and signed grouting records T 1 day after work 64 02435 Water pressure testing equip. list, schematic, and record sheets L, P, T 14 days before work 65 02435 Completed and signed water pressure test records T 1 day after readings 66 02440 Pressure Relief Well Plan P, S with Work Plan 67 02440 Pressure Relief Well Installation Records P, S 1 day after work Page 2 of 4 Attachment A - Submittal List Category Code Category Description C certificates of compliance D drawings I product information L parts or equipment list M Material Safety Data Sheet (MSDS) O&M operating and maintenance manual P plan or procedure S schedule T tests or reports U survey X mix design misc letters, lists of documents or subs, permits, qualifications & resumes, samples, unpriced contracts, warranty info. No.Specification Section Submittal Title and Description Submittal Categories Due Date: 68 02465 Micropile Installation Plan P, S, misc with Work Plan 69 02465 Micropile reinforcement, pipe casing, spacers, and grout certifications I, C 30 days before work 70 02465 Micropile Installation Records T 1 day after work 71 02465 Micropile Reinforcement Load Test Results T Immediately after work 72 02510 Water Supply Mains Plan C, I, L, P, S 30 days before work 73 02510 Water Main Backfill materials and piping certifications C Prior to Installation 74 02510 Water Main Record Drawings D 14 days after work 75 02510 Water Main Pressure Testing Records T 1 day after work 76 02530 Sanitary Connection Plan P, D, S 30 days before work 77 02530 SanitaRY Piping product data I Prior to Installation 78 02530 Sanitary Piping Certifications C Upon Delivery 79 02530 Sanitary Record Drawings D 14 days after work 80 02530 Sanitary Pressure Testing Records T 1 day after work 81 02620 Subdrainage system product data I 14 days before work 82 02630 Site drainage system product data I 14 days before work 83 02630 Site drainage system certifications C Upon delivery 84 02700 Backfill test reports T Prior to Work 85 02700 Backfill batch tickets T Upon delivery 86 02820 Fences and gates shop drawings D, I 14 days before work 87 02845 Vehicular Barriers Data I 14 days before work 88 02845 Vehicular Barriers Bill of Materials misc Upon delivery 89 03100 Concrete forms: boards, accessories, and coatings I 21 days before work 90 03100 Formwork drawings D 21 days before work 91 03100 Exterior wall color system and seal I 21 days before work 92 03200 Reinforcing steel, certified test reports T Upon delivery 93 03200 Mechanical splices: method and equipment P 21 days before work 94 03200 Concrete reinforcing steel shop drawings D 21 days before work 95 03254 Waterstop shop drawings D 21 days before work 96 03254 Waterstop certification of compliance C Upon delivery 97 03254 Waterstop sample misc 21 days before work 98 03300 Concrete mix design, materials list, product data X, L, I 60 days before work 99 03300 Thermocouple & Concrete Temperature Monitoring System I 45 days before work 100 03300 Concrete Conveying equipment & placement procedures I, P 45 days before work 101 03300 Concrete Placement Lift Plan and Drawings P, D 45 days before work 102 03300 Concrete Weather Placinf Procedures P, D 45 days before work 103 03300 Hydrophilic Waterstop anchorage details & sample I, misc 45 days before work 104 03300 Concrete Weather placing procedures P 45 days before work 105 03300 Concrete mix test reports T 60 days before work 106 03300 Finishing, curing and concrete protection procedures P 45 days before work 107 03300 Concrete certificates of compliance C 30 days before work 108 03300 Concrete batching plant, equipment, and methods I, P 45 days before work 109 03300 Concrete Pre-Placement Form misc 45 days before work 110 03300 Concrete Batch Tickets T Upon Delivery 111 03301 Thrermocouples Installation Plan P 45 days before work 112 03301 Crack Meters Installation Plan P 45 days before work 113 03301 Joint Meters Installation Plan P 45 days before work 114 03350 Concrete sealant information and installation procedure I, P 14 days before work 115 03370 Shotcrete materials test reports and certificates of compliance T, C 14 days before work 116 03370 Shotcrete plant and equipment L 14 days before work 117 03370 Shotcrete mix design X 21 days before work 118 03370 Shotcrete Test Results T 7 days after work 119 03480 HC Slab Shop Drawings D 30 days before work 120 03480 HC Slab Analyses and Calculations misc 30 days before work 121 03480 HC Slab Erection Drawings D 30 days before work 122 03480 HC Slab Mix Design X 30 days before work 123 03480 HC Slab Joint Sealer Data misc 30 days before work 124 03480 HC Slab Test Results T 7 days before shipment 125 03600 Nonshrink grout data sheets, mix design, installation procedure I, X, P 30 days before work 126 03600 Epoxy grout data sheets, mix design, installation procedure I, X, P 30 days before work 127 05100 Structural steel shop drawings D 30 days before fab 128 05100 Structural steel certifications C 7 days before shipment 129 05500 Miscellaneous metals shop drawings D 30 days before fab 130 05500 Miscellaneous metals certifications C 7 days before shipment 131 06066 Plastic laminate product data, sample board, MSDS sheets, and shop drawings D, I, M, misc 30 days before work 132 06100 Rough carpentry product data and material certificates I, C 30 days before fab 133 06200 Millwork product data and finish samples I, misc 30 days before work Page 3 of 4 Attachment A - Submittal List Category Code Category Description C certificates of compliance D drawings I product information L parts or equipment list M Material Safety Data Sheet (MSDS) O&M operating and maintenance manual P plan or procedure S schedule T tests or reports U survey X mix design misc letters, lists of documents or subs, permits, qualifications & resumes, samples, unpriced contracts, warranty info. No.Specification Section Submittal Title and Description Submittal Categories Due Date: 134 07100 Dampproofing product data, test reports, and warranty I, T, misc 30 days before work 135 07100 Dampproofing storage, handling, and installation instructions P 14 days before work 136 07212 Board insulation product data, instructions, and certificates I, P, C 14 days before work 137 07213 Batt insulation product data I 14 days before work 138 07510 Membrane Roofing product data, design drawings, and warranty I, D, misc 14 days before work 139 07900 Building Joint Sealers product data I 14 days before work 140 08111 Standard steel doors product data, sample board, shop drawings, installation instructions, and certificates I, misc, D, P, C 30 days before fab 141 08350 Manual sectional overhead doors product data, sample board, certificates, shop drawings, maintenance data and warranty info I, misc, C, D, P 30 days before fab 142 08520 Window shop drawings, product data and samples D, I, misc 30 days before fab 143 08710 Door hardware product data and materials list I, L 30 days before fab 144 09290 Gypsum board product data and certificate I, C 14 days before work 145 09510 Acoustic panel ceiling product data, shop drawings and certifications I, D, C 14 days before work 146 09650 Resilient wall base product data, sample board and warranty I, misc 14 days before work 147 09772 Decorative wall panel product data, sample board, MSDS and warranty I, misc, M 14 days before work 148 09772 Decorative wall panel shop drawings D 30 days before work 149 09900 Painting and coating product data, MSDS, and procedures QC checklist I, M, P, T 30 days before work 150 10800 Bath accessories product data and warranty I, misc 14 days before work 151 13100 Penstock shop drawings D 60 days before work 152 13100 Penstock coating information I, misc 60 days before work 153 13100 Penstock installation procedures, before and after Outage P 60 days before work 154 13100 Penstock welder certifications C 60 days before work 155 13100 Penstock elastomeric material data I 60 days before work 156 13100 Penstock welding procedures P 60 days before work 157 13100 Penstock welding corrections misc 5 days after work 158 13100 Penstock NDT records T 5 days after work 159 13100 Penstock As-Built Drawings D Upon Substantial Completion 160 13110 Tunnel steel liner shop drawings D 60 days before fab 161 13110 Tunnel steel liner coating information I 60 days before fab 162 13110 Tunnel steel liner certifications C 60 days before fab 163 13110 Tunnel steel liner installation drawings and procedures D, P 60 days before fab 164 13120 Steel building modifications misc as needed 165 13120 Steel building welder certifications C 14 days before work 166 13210 Gate installation procedure and schedule P, S 60 days before work 167 13210 Gate installation, testing and commissioning report T 21 days after work 168 13310 Trashrack shop drawings, installation procedures and schedule D, P 60 days before fab 169 13310 Trashrack welding procedures and certifications P, C 60 days before fab 170 13310 Trashrack material data I 60 days before fab 171 13310 Trashrack NDT results T 14 days before work 172 14600 Powerhouse bridge crane installation procedure P 60 days before work 173 14600 Powerhouse bridge crane testing and commissioning T 14 days before work 174 14600 Powerhouse bridge crane testing after final recondioning T 14 days before work 175 15020 General mechancal - testing and commissioning results T 7 days after work 176 15061 Pipe hangers and supports D, I 30 days before work 177 15131 Drainage pump drawings, product data, test certificate D,I, T Before equipment order 178 15131 Drainage pump installation, start-up/commissioning instructions P 14 days after equipment order 179 15131 Drainage pump O&M and spare parts list O&M, L 7 days after work 180 15132 Raw water pump drawings, product data, test certificate D,I, T Before equipment order 181 15132 Raw water pump installation, start-up/commissioning instructions P 14 days after equipment order 182 15132 Raw water pump O&M and spare parts list O&M, L 7 days after work 183 15300 Piping product data, certificate of compliance and welder certificates I,C 14 days before work 184 15400 Plumbing product data, certificate of compliance, O&M manuals I,C, O&M 30 days before work 185 15405 Sanitary lift station drawings, product data, certificate of compliance, O&M manuals D, I, P 30 days before work 186 15405 Sanitary lift station installation, start-up and commissioning instructions, O&M manuals P, O&M 60 days after equipment order 187 15415 Backflow preventer product data I Before equipment order 188 15415 Backflow preventer O&M, test results, test kit O&M,T, misc 14 days after work 189 15420 Eye wash station product data I Before equipment order 190 15440 Plumbing equipment product data I Before equipment order 191 15440 Plumbing equipment O&M O&M 14 days after work 192 15480 Compressed air system product data I Before equipment order 193 15480 Compressed air system O&M and parts list O&M,L 14 days after work 194 15600 Fire extinguisher product data I Before equipment order 195 15600 Fire hose station drawings and calculations D, misc 60 days before work Page 4 of 4 Attachment A - Submittal List Category Code Category Description C certificates of compliance D drawings I product information L parts or equipment list M Material Safety Data Sheet (MSDS) O&M operating and maintenance manual P plan or procedure S schedule T tests or reports U survey X mix design misc letters, lists of documents or subs, permits, qualifications & resumes, samples, unpriced contracts, warranty info. No.Specification Section Submittal Title and Description Submittal Categories Due Date: 196 15600 Fire protection O&M misc 14 days after work 197 15700 Instrumentation product data I Before equipment order 198 15700 Instrumentation O&M misc 14 days after work 199 15800 Heating and ventilation product data, diffuser/grille schedule I, misc Before equipment order 200 15800 Heating and ventilation O&M O&M 14 days after work 201 15905 Automatic backwash strainer product data I Before equipment order 202 15905 Automatic backwash strainer drawings, installation instructions D, P Before equipment order 203 15905 Automatic backwash strainer O&M, spare parts O&M, misc 14 days after work 204 15915 Raw water intake screens product data, drawings, calculations, qualification data I,D, misc 120 days before sump concrete placement 205 15915 Raw water intake screen installation instructions, O&M manuals P,misc, O&M 60 days before work 206 16020 Electric equipment general provisions P, T 60 days before work 207 16071 Fasteners, attachments and supporting devices D 60 days before work 208 16110 Raceways D,I 60 days before work 209 16111 Embedded conduit I 60 days before work 210 16114 Cable tray I 60 days before work 211 16120 Wire and cable I 60 days before work 212 16131 Exposed conduit - wet locations I 60 days before work 213 16132 Interior raceways fittings and accessories I,P 60 days before work 214 16133 Exposed conduit I 60 days before work 215 16134 Outlet, Junction and Pull Boxes I,P 61 days before work 216 16138 Electric manholes D,I,P 60 days before work 217 16221 Motor and motor controllers D,I,O&M,P 60 days before work 218 16232 125V dc battery and charging system D,I,O&M,P 60 days before work 219 16233 Uninterruptable power system D,I,O&M,P 60 days before work 220 16272 Transfomers - dry type, under 600V D,I,O&M,P 60 days before work 221 16273 Transfomers - oil filled, over 600V D,I,O&M,P 60 days before work 222 16275 Substation main transformer installation procedure P 60 days before work 223 16335 Switchgear installation procedure P 60 days before work 224 16414 Automatic transfer switch I,D,O&M,P 60 days before work 225 16442 Panelboards D,I,O&M,P 60 days before work 226 16450 Grounding I 60 days before work 227 16480 Pump control system installation procedure P 60 days before work 228 16500 Lighting and receptacles I 60 days before work 229 16222 Standby diesel generator D,I,O&M,P 60 days before work 230 16721 Fire alarm D,I,O&M,P 60 days before work 231 16723 Fibre optic cable system I, D, T 60 days before work 232 20100 Blue Lake Unit (BLU) installation procedure P 90 days before work 233 20100 Blue Lake Unit (BLU) testing and commissioning results T 21 days after completion of commissioning of each unit 234 20100 Fish Valve Unit (FVU) installation procedure P 90 days before work 235 20100 Fish Valve Unit (BLU) testing and commissioning results T 21 days after completion of commissioning Blue Lake Expansion Project – Contract No. 9 01400-1 General Construction May 2012 SECTION 01400 QUALITY ASSURANCE PART 1 GENERAL 1.01 DESCRIPTION A. When referenced herein, the term “Owner” may include at Owner’s discretion, Engineer or RPR. The term “Contractor” shall include subcontractors, suppliers, sub-suppliers, and sellers. B. The requirements for Quality as outlined in this Section and elsewhere in these documents shall apply to Contractor as well as its subcontractors or to any tier of supplier who shall furnish material, components or services as part of the Work covered by these documents. C. All materials and Work activities covered by the drawings and specifications will be subject to inspection and acceptance by Owner. D. Owner’s inspection program will include a system for controlling materials and work which are found to be in non-conformance with the drawings and/or specifications. This program will include the use of Non-Conformance Reports (NCR) to document non-conformances and their resolution. E. Inspections performed or witnessed by Owner or his designated representative shall not relieve Contractor and all subcontractors of their responsibility to satisfy the requirements of these specifications and all applicable referenced codes and standards. F. Whenever disputes may occur during the course of the Contract, Owner will be the sole judge of the acceptability of the materials and the workmanship for the Work provided by Contractor. G. All tests performed by Contractor or his subcontractors may be witnessed by Owner at Owner’s discretion. Copies of all test reports shall be given without delay to Owner prior to further fabrication or installation, for inclusion in their inspection reports. All tests required shall be at the expense of Contractor. 1.02 PROCUREMENT QUALITY A. General: These requirements pertain to inspections and tests necessary to substantiate product conformance to contractual requirements. B. Description: 1. Contractor shall allow Owner access to his premises for the purpose of quality surveillance and verification. Contractor shall also arrange for access to subcontractors/suppliers facilities at Owner’s request. 2. Contractor shall notify Owner at least five working days prior to the date of the following, except as noted: Blue Lake Expansion Project – Contract No. 9 01400-2 General Construction May 2012 a. When the order has been released to manufacturing for fabrication. b. At in-process inspection/test “Witness” points pre-identified by Owner. c. At inspection/test “Hold” points pre-identified by Owner. d. Material or equipment is ready for final or witness inspection test. Failure to do so may be cause for rejection and/or repetition of the activity at Contractor’s expense. e. Those points designated “Hold” are mandatory for Owner’s witnessing, unless waived in writing. Those points designated “Witness” will be witnessed at the convenience of Owner and Contractor is not obligated to delay his inspection/test or subsequent processing at “Witness” points. To date, Engineer has identified the performance testing of each vertical lift gate as “hold points.” Engineer will review Contractor’s CPM for witness and hold points. 3. Contractor shall ensure that documentation controlling the Work, such as drawings, procedures, purchase orders, and specifications are readily available at the location where the Work is performed. 4. Contractor’s personnel performing and/or interpreting inspections and tests shall be qualified under all applicable codes, standards, or specifications. Personnel qualifications shall be available to Owner upon request. 5. Contractor shall provide Owner with documented notification of all deviations from contractual requirements, such as deviations from specifications, codes, and drawings and shall undertake repair only after concurrence by Owner. 6. Owner, or his designated representative, may periodically monitor Contractor’s (and/or his subcontractor’s) conduct of work to assure compliance with this specification and applicable procurement documents. 7. Material, equipment, and services shall be subjected to all tests and inspections required by the applicable codes and standards in addition to those explicitly called for in this specification and applicable procurement documents. 8. Owner or his representative may inspect the Work at Contractor’s and/or Owner’s facility for compliance with the specification and applicable procurement documents. Deficiencies noted during this inspection may be cause for rejection of the Work and its return to Contractor at Contractor’s expense. 9. Inspections performed by Owner or his representative do not relieve Contractor or his subcontractors of their obligation to maintain an adequate test, inspection, and documentation program of their own. 10. Contractor shall be responsible to assure that applicable quality and technical requirements specified in the procurement documents are passed on to and implemented by subcontractors. 11. Contractor is responsible to review and determine that all sub-vendor procedures for special fabrication and testing meet the applicable requirements. Blue Lake Expansion Project – Contract No. 9 01400-3 General Construction May 2012 12. Items shipped to another contractor en route to Owner shall be accompanied by specific instructions as to the required maintenance, storage, handling, shipping, installation, operation, preservation, and packaging of the items during this transient period. 1.03 CONSTRUCTION QUALITY A. General: Owner’s Inspection Program for the construction phase of the project may include documented inspections in the areas of material receiving, storage, installation, and testing activities associated with the Work. B. Description: 1. Representatives of Owner may visit and inspect the Work at all times during its progress, and Contractor shall provide all proper access facilities that may be necessary for a complete and safe inspection. 2. Owner shall have the right to order the cessation or modification of Work whenever in his judgment such work is contrary to the terms of the Contract or is, or may become, a danger, provided, however, that neither the presence nor absence of Owner’s Representative(s), nor any action or failure to act on their part, shall relieve Contractor of any obligation or liability elsewhere imposed in the Contract. 3. Work and materials which are found to be in non-conformance with the drawings and/or specifications will be reported by Non-Conformance Reports (NCR) to Owner for disposition. The NCR will include Contractor’s recommended disposition of the nonconforming condition, i.e., “Reject,” “Repair,” or “Rework.” Contractor’s recommended disposition must be accepted by Owner in writing prior to its implementation. If Contractor’s recommended disposition is unacceptable, Owner will specify the required disposition and Contractor shall implement this disposition. Such nonconforming materials will be identified by colored “QC Hold” tags traceable to the PAR and use of the materials will not be permitted until the QC Hold is removed by RPR. Owner may require that nonconforming materials be segregated from acceptable materials or removed from the Site to prevent their inadvertent use in the Work. In the event that the disposition of materials or completed Work is “Rejected”, the nonconforming condition shall be classified as “defective work” and promptly replaced in accordance with this specification. 4. Colored tags will be removed by RPR only after completed repair or rework has been re-inspected and accepted in writing by Owner. 5. Prior to concrete production, concrete batching facilities shall be certified and approved by Owner. 1.04 CONTRACTOR REQUIREMENTS A. Contractor’s responsibilities for quality shall include, but not be limited to, the following: 1. Ensure that materials received by Contractor or his subcontractors for use in the Work conforms to the requirements of the drawings and/or specifications and purchase order. Blue Lake Expansion Project – Contract No. 9 01400-4 General Construction May 2012 2. Ensure that all Work conforms to the requirements of the drawings and/or specifications. 3. A system for collecting and filing QA records. Submit QA documents in accordance with Section 01300. 4. Assignment of individuals directly responsible for 1, 2, and 3 above. 5. Contractor shall allow RPR free access to all areas of the Work at Site or in the shops where the Work is being performed. 6. Contractor shall indicate on all of his contracts and purchase orders that “This order is subject to inspection by City and Borough of Sitka or its authorized representative.” 7. Contractor shall promptly remove from the Work all materials (whether or not already incorporated into any installation of the Work) and any part or parts of the Work condemned by RPR or by any federal, state, or municipal agency having authority in respect thereof, as failing to conform to the requirements of the Contract. Contractor shall thereupon promptly replace such materials and re-execute such part or parts of the Work. PART 2 PRODUCTS Not Used. PART 3 EXECUTION Not Used. END OF SECTION Blue Lake Expansion Project – Contract No. 9 01450-1 General Construction May 2012 SECTION 01450 SAFETY PART 1 GENERAL 1.01 SAFETY - GENERAL A. Worker safety and protecting the environment is a high priority. Contractor shall strictly enforce adherence to training and safety rules. B. Contractor shall comply with any safety program required by Federal, State, Local, Owner, Engineer and Contractor safety policies. Where there is a difference between policies, the more stringent rule shall govern. The program shall also include filing of all accident and injury reports with RPR and Contractor’s Project Manager. Contractor shall arrange weekly safety meetings at his construction facilities. Attendance at the weekly safety meetings is mandatory for RPR and Contractor’s supervisory personnel. Attendance of daily (per shift) “tailboard” meetings with RPR and Contractor personnel is required. The safety program shall also comply with the requirements of Section 01800. C. All Contractor personnel training records, calibration data and recorded data are subject to review/audit by Owner. D. It is the responsibility of Contractor to supply his own employees with all necessary personal protective equipment (PPE). E. Contractor shall designate a project site staff member as its Project Safety Inspector for each work area in operation during this project. The Project Safety Inspector shall have current, validated first-aid and safety training and shall be in control of all safety related issues, in their area of responsibility, throughout the project. F. One of the active Safety Inspectors shall be designated as the lead safety person and shall be in control of all safety related issues throughout the project. G. Contractor shall provide and maintain air horns for emergency use for all his personnel. 1.02 FIRST AID A. Provide and maintain a fully stocked first-aid equipment center, sufficient to address first-aids and medical emergencies, at the work site. Contractor shall provide for the treatment of minor injuries to his employees. Contractor will not be required to provide such treatment to employees of other contractors or of Owner unless an emergency occurs. B. Designate personnel with qualifications to administer first aid. Contractor shall notify RPR of all injuries and first aids within 24 hours that the injury occurs. In the event of an injury requiring off-site medical attention, Contractor is required to notify Owner immediately. Contractor shall be responsible for making prompt Blue Lake Expansion Project – Contract No. 9 01450-2 General Construction May 2012 arrangements with local ambulance/rescue team services and hospitals for transportation and treatment of employees with major injuries. C. Procure, maintain, and display on Site, a list of local first aid and medical services which includes services’ phone numbers. 1.03 COMMUNICATION AT SITE A. Contractor’s lead person onsite shall have direct communication with RPR. RPR shall be responsible in the daily oversight of the Blue Lake water level. If Contractor deems that work conditions are unsafe at any time during the work period due to the rate of rising lake level and meteorological forecasts such that a spill event is pending within 48 hours, he/she shall have full authority to stop all work in the river and order personnel to evacuate the river area immediately. 1. Contractor may check out and use an Owner supplied radio for direct communication with Blue Lake Dam Duty Operator for 24-hr communication with Owner’s operating staff. B. Contractor lead person shall have a long-range digital pager and/or cell phone and/or radio with him at all times for emergency contact purposes. Contractor’s key personnel (Site Engineer, Lead Foreman, etc.) shall have cell phones and/or radios with them at Site. Note that there is no cell phone service at Blue Lake intake and dam areas C. Provide emergency home and office phone list of all its senior site personnel to Owner prior to commencing Site Work. D. Provide and maintain a constant and reliable form of communication to all personnel within the underground excavation and between all operations at each access point during all Work tasks so that constant communication with the Contractor’s safety personnel can be maintained at all times. E. Contractor is responsible to provide and maintain a constant and reliable form of communication to RPR and with Contractor’s Safety Inspectors. 1.04 NOISE MONITORING A. Contractor is responsible to provide, maintain and calibrate, per manufacturer’s recommendations, noise monitoring equipment. Contractor is responsible to monitor noise around all work areas and react according to OSHA’S Hearing Conservation Guidelines. B. Contractor is required to record all readings and maintain on job site for review by RPR. 1.05 CONTRACTOR DISCIPLINE POLICY A. Contractor is required to provide and submit a copy of Contractor’s discipline policy as it relates to employee conduct and safety. 1.06 SUBMITTALS A. Submit under provisions of Section 01300 for review. Blue Lake Expansion Project – Contract No. 9 01450-3 General Construction May 2012 B. Site-Specific Health and Safety Plan: This plan must be reviewed and approved prior to the beginning of any work and include the following: 1. A temporary EAP that describes in detail the evacuation of workers and equipment from Work areas whenever overtopping or failure of any water control system is imminent. 2. Project Safety Inspectors for each work area as well as the Safety Inspector who will serve as the lead safety person. 3. List of minimum PPE to be worn at all time on the project as well as specific PPE for each phase of work. 4. A list of first aid equipment and the locations of first aid equipment centers. 5. List of local first aid and medical services. 6. If underwater or in-water work is planned, identify all proposed equipment and personnel for water work including all safety response equipment. 7. Communications equipment for communications between Contractor personnel, RPR and Blue Lake Dam Duty Operator. 8. List of emergency home and office phone numbers for all senior site personnel. 9. A copy of Contractor’s discipline policy. PART 2 PRODUCTS Not Used. PART 3 EXECUTION Not Used. END OF SECTION Blue Lake Expansion Project – Contract No. 9 01500-1 General Construction May 2012 SECTION 01500 CONSTRUCTION FACILITIES PART 1 GENERAL 1.01 TEMPORARY WATER A. Provide and maintain adequate water for domestic use by its work force. B. Non-potable water will be available at powerhouse, FVU, and lower portal sites, except during the generation outage. Water at the dam site will have to be pumped from the reservoir elevation. Potable water will be available at the Sawmill Creek Industrial Park (SCIP) and the BLU powerhouse site following installation of the potable water line to be installed by Contractor. 1.02 TEMPORARY SANITARY FACILITIES A. Provide and maintain adequate temporary sanitary facilities for Owner personnel and contractor’s work force. The sanitary facilities shall comply with all applicable health codes. Sanitary facilities will be necessary at each work area location. 1.03 TEMPORARY ELECTRICAL POWER A. Owner will provide a limited source of electric power to Contractor at the following site locations, which will be charged at published rates, which currently are about $0.09/kWh 1. 12470 VAC at the dam site 2. 4160 VAC at the BLU powerhouse site 3. 12470 VAC at SCIP 4. 240 VAC or 4160 VAC at FVU B. Contractor is responsible to discuss with Owner and provide power requirements. 1.04 TEMPORARY HEATING A. Contractor shall provide and maintain temporary heating as required to maintain temperatures in work areas during progress of the Work as specified in other Sections of these documents. 1. Owner does not allow open flame for heating in the trailers, or unventilated areas. If open flame heating is proposed in ventilated areas, air monitoring equipment shall be required at the expense of Contractor. 1.05 TEMPORARY LIGHTING A. Provide, install and maintain temporary artificial lighting for areas where natural light does not meet the minimum requirements for construction work. The lighting Blue Lake Expansion Project – Contract No. 9 01500-2 General Construction May 2012 equipment shall be standard products meeting UL standards. This includes lighting to facilitate access and performance of the work inside of the tunnel. 1. Contractor is responsible to provide and maintain dusk to dawn lighting for personnel safety and job site security at the laydown areas as a minimum. Proposed lighting locations need to be reviewed and approved by RPR. 1.06 FIELD OFFICE A. Provide and maintain a field office for his own use. Contractor shall maintain in his field office, one copy of all drawings and specifications, Material Safety Data Sheets (MSDS), local, state, and federal permits and licenses, a copy of the Site- Specific Health and Safety Plan (See Section 01450), and other pertinent information relating to the Work. Such information shall be available to RPR during construction and shall be delivered to him upon acceptance of the Work. B. Provide and maintain telephones and fax machines in his field office and all necessary connections to local communication providers for his own use. Contractor shall be responsible to arrange for the installation of a temporary phone line to the field trailer with local telephone service provider. C. Provide a reference table, telephone facilities, and a conference table with 10 chairs for project meetings with climate control. D. Contractor shall have the ability to reproduce 11” x 17” drawings with dimensions to scale. E. Owner has building space available for Contractor lease to use for field offices at SCIP. Contractor would be responsible for upgrading the building as needed for his office. 1.07 BREAK TRAILER A. Contractor is responsible to provide break/change trailer, if necessary, for Contractor personnel. 1.08 FIRE PROTECTION A. Contractor shall be responsible for fire protection in his Work, office and staging areas and shall supply and maintain all necessary fire protection equipment. The type of equipment and its relative position to the Work areas shall be in conformance with all regulations and to RPR’s satisfaction. Contractor personnel must be trained in operation/used of fire extinguishers. Fire-fighting equipment shall be maintained in operable condition at all times. B. In general, the applicable practices of the National Fire Protection Association shall form the basis of the fire safety requirements for the project. Contractor’s fire protection system shall include the use of water. 1.09 SHOP AND STORAGE FACILITIES A. Contractor shall provide and maintain shop facilities for his own use. Contractor shall furnish storage space as specified in Section 01600. B. Contractor may lease limited covered storage area at SCIP from the Owner. Blue Lake Expansion Project – Contract No. 9 01500-3 General Construction May 2012 C. All Contractor petroleum products stored on-site shall have a containment structure equal in volume to the product’s container and stored in a container specific for the product. Refer to Section 02370. D. Contractor may use the PMFU building for secure storage of explosives provided the Owner may operate the facility and be allowed access under escort by the Contractor. 1.10 STAGING AREA A. Contractor shall be responsible for constructing the required staging and work areas as indicated on the contract drawings and as required to perform the Work. Contractor shall also be responsible for temporary works, including: 1. Security 2. Lighting 3. Additional electric 4. Additional utilities 5. Road maintenance 6. Snow removal 7. Housekeeping 8. Any modification necessary to keep site in the same or better condition than at start of project. B. The Contractor may lease staging area and area for a construction camp at SCIP from the Owner. Power, water and sewer are available. 1.11 HANDLING OF MATERIALS A. Contractor shall receive, unload, store, and handle all materials to be used or installed in the Work, all in accordance with supplier recommendations and with Section 01600. 1.12 PROTECTION OF PROPERTIES, STRUCTURES AND UTILITIES A. Contractor shall be responsible for providing and maintaining proper protection from all damage resulting from the performance of the Work as specified and/or carried out for all properties, structures, underground and overhead utilities which are within or adjacent to either Work area (Blue Lake Expansion Project) or to the staging areas. Any damage resulting from lack of proper protection of the Work shall be repaired at the expense of Contractor and be subject to the acceptance of Owner. B. Public access will be granted to the public roadways, adjacent to the work areas. Contractor shall take appropriate action at all times to ensure the safety and well being of the public near their work area. Appropriate security precautions shall be taken by Contractor to protect the site, the personnel and the equipment that are brought to the site to perform the work. The Blue Lake Road may be closed on a Blue Lake Expansion Project – Contract No. 9 01500-4 General Construction May 2012 temporary basis with authorization from the USFS. Public safety would be considered a legitimate reason to close the road. C. Contractor’s equipment working in the vicinity of overhead lines shall at all times be grounded to protect persons and property. D. All utilities, equipment, and structures adjacent to the Work shall be kept clear of all debris and Contractor’s equipment at all times, except by prior agreement with Owner. E. Caution shall be exercised in the movement of construction equipment and personnel under, around, and over existing lines and structures in the immediate Work area. Where it is unsafe for Contractor to perform the Work because of inadequate clearances from transmission and distribution lines, Contractor shall notify RPR in writing, at least two weeks in advance of commencing work, for RPR to arrange for lines to be temporarily removed from service and/or relocated. All Work performed under these conditions shall be in accordance with scheduling and arrangements, as mutually agreed upon by Contractor prior to the commencement of related operations. Contractor shall comply with the instruction of RPR in all matters dealing with Work in the vicinity of energized or de-energized lines. F. Contractor shall at all times protect and preserve all materials, supplies and equipment of every description (including property which may be Owner-furnished or owned), and all Work performed. For this purpose, Contractor shall provide all protection against deterioration and damage as required to the satisfaction of Engineer. Protection shall specifically include, but not be limited to, air-tight protection against demolition debris, dust , welding and cutting sparks, and slag, for all existing and new (installed or stored) electrical and mechanical equipment. All reasonable requests of RPR to enclose or specifically protect such property shall be complied with. If, as determined by Owner or RPR, material, equipment, supplies and Work performed are not adequately protected by Contractor, such property may be protected by Owner and the cost thereof may be charged to Contractor or deducted from any payments due. This protection shall include perimeter fencing, locked gates and 24 hour lighting for site security at the staging areas. G. Wherever in this Specification Contractor is required to provide protection for materials, equipment, property or completed or partially completed Work, it shall be understood that such protection shall include protection from vandalism or other related acts as well as protection from damage resulting from the performance of the Work. 1.13 GRADES, LINES AND LEVELS A. Prior to commencement of the Work, Owner will establish permanent monuments As Shown. Contractor shall protect the monuments and benchmarks from damage throughout the course of the Work. B. Contractor shall be responsible for all other reference lines and benchmarks required for controlling his Work. C. Contractor shall preserve all monuments, markers, benchmarks and survey lines. In the event of destruction or damage through his own cause, Contractor shall immediately re-establish the survey to the satisfaction of RPR and at no additional cost to Owner. Under these circumstances, Contractor shall also be responsible Blue Lake Expansion Project – Contract No. 9 01500-5 General Construction May 2012 for delays, errors, and damage which may be caused by such destruction of the survey. D. Contractor shall cooperate with RPR in making the results of all survey work available for review and in assisting RPR in the verification of all survey work. All survey notes shall be recorded in hard-bound field books. 1.14 DISPOSAL OF MATERIALS A. All steel, metals and alloys for disposal shall remain at the property of Owner. The above materials must be deposited at SCIP or Recycle Center as directed by the RPR. All other material from required demolition, clearing and grubbing and any other debris shall become property of Contractor and shall be disposed of offsite. 1. All unclassified excavation may be disposed of at the Green Lake Road Disposal Area, which is approximately 2.3 miles east of the SCIP along Green Lake Road. Refer to Owner’s ESCP approved with the FERC licence Amendment Application in the reference documents. B. Contractor shall obtain all necessary permits and shall also obtain written permission from the property owner on whose property the disposal is to be made and shall send the permits, or copies to RPR before any material is removed from the Site. The location of the disposal site and the manner of disposal will be subject to the prior acceptance by RPR. In addition, Contractor shall obtain from the property owner, upon completion, a written statement of acceptance of this disposal work. A copy of this statement shall also be sent to RPR. See also Section 2050 – Demolition. C. Contractor shall comply with any/all requirements of Section 02370. 1.15 NATURAL ENVIRONMENT A. Contractor shall comply with all state and federal laws, rules, and regulations pertaining to the preservation and protection of the natural environment, and bear fully all civil and/or criminal penalties that may arise from the Work or operations of Contractor, whether such penalties are assessed against Owner or Contractor. Contractor further agrees that he shall promptly restore and repair, at his own expense, any damage inflicted upon the natural environment during the course of his operations. The determination as to what constitutes damage to the natural environment shall be within the sole discretion of Owner or applicable agencies. Contractor further agrees to indemnify and hold Owner free from all liability for damage inflicted upon the natural environment by Contractor, regardless of whether the damage is negligently or intentionally caused. 1.16 CONTRACTOR’S WORK AND OPERATING AREAS A. Contractor’s operation areas are those areas assigned by Owner to Contractor for his various operational activities AS Shown. They will encompass all of his areas of construction activity, including work areas, shop, temporary spoil and storage areas, and field office. B. Contractor shall, under regulations prescribed by Owner, use only established roads on Owner’s premises or construct and use such temporary roadways as may be authorized in writing by Owner. When it is necessary to cross curbs and sidewalks, Contractor shall provide protection against damage and shall be Blue Lake Expansion Project – Contract No. 9 01500-6 General Construction May 2012 obligated to replace or repair any damaged roads, curbing, and walkways at his expense. C. Contractor shall be allowed to provide all temporary modifications to any of Owner’s facilities or structures to facilitate work on this project only after submittal in writing of any such proposed changes is made to and approved in writing by Owner. The cost to make any of these changes shall be included in this item and be available for detailed scrutiny by Owner before approval is given to proceed with the temporary change. All temporary changes shall be restored to original condition or left in place for future work as directed by Owner at no cost to Owner. D. Contractor shall provide and maintain adequate barricades, metal signs, and personnel for the proper protection and control of his operations. E. The removal of snow and ice from all Work areas, laydown areas, access roadways, parking lots, and walks during the progress of the Work, shall be provided by Contractor. F. Contractor shall be responsible for dust control at Site, and underground work, during the progress of the Work. G. Access to the Work areas by Owner and authorized contractors shall be maintained at all times. 1.17 SECURITY AT SITE A. Contractor shall be responsible for security of his own plant and equipment. 1.18 ACCESS ROADS A. Contractor shall be responsible for maintenance and repair of the Blue Lake Road and other access roads. At the completion of the Work, Contractor shall patrol the permanent roads to leave them in a condition equal to or better to that at the start of the construction. 1.19 PARKING A. Contractor shall provide parking for all construction personnel in the designated work areas. Contractor is responsible to transport employees to designated work site from parking area. 1.20 GARBAGE COLLECTION A. Contractor shall provide garbage collection services to include all construction- related debris. B. Contractor is responsible to collect and properly dispose of all trash generated by Contractor personnel. PART 2 PRODUCTS Not Used. PART 3 EXECUTION Blue Lake Expansion Project – Contract No. 9 01500-7 General Construction May 2012 Not Used. END OF SECTION Blue Lake Expansion Project – Contract No. 9 01550-1 General Construction May 2012 SECTION 01550 COORDINATION WITH OWNER PERFORMED WORK PART 1 GENERAL 1.01 WORK INCLUDED A. This Section describes: Contractor coordination and interface with Owner performed work and Contractor’s work required to support Owner performed work. B. The Owner will be performing work for portions of the Blue Lake Expansion Project that must interface with the work and schedule of the Contractor. The work performed by the Owner includes: 1. Electrical work on Fish Valve Unit controls. 2. Install Blue Lake switchyard control building and panel. 3. 69kV connections to Main Transformers in Blue Lake Switchyard. 4. Control wiring between Main Transformers and switchyard control building. 5. Replace existing dam feeder transformer in Blue Lake switchyard. 6. Provide and install all SCADA interfaces between the Contractor’s work and the Blue Lake control room. 7. Provide utility connection points for water, sewer, and electrical service to the existing Blue Lake powerhouse (external to the existing powerhouse building). C. Owner’s work will generally consist of: wire, control cable and control panel installation; wiring checkout and testing; control system testing; and software testing. D. The Contractor shall cooperate with the Owner to ensure that the work performed under this section is completed prior to the generation outage or the appropriate milestone defined in the schedule. The Contractor shall install the building features, equipment and material necessary for the Owner to perform his work in a timely fashion. The Contractor shall allow adequate time for Owner’s work to ensure that sufficient time remains for the Contractor to complete his work, while allowing both parties adequate time to check out and test the systems prior to commissioning. E. The work sequences and schedule information provided in this Section are the Owner’s estimates of a logical sequence of work and appropriate timing for the Work. Contractor may adjust the sequence and timing of tasks to suit its Work Plan and schedule, provided adequate time is provided to the Owner to complete Owner’s work and provided that all construction required to allow completion of Owner’s work have been completed in advance of the time scheduled for Owner’s work tasks. 1.02 SITE ACCESS AND SUPPORT SERVICES Blue Lake Expansion Project – Contract No. 9 01550-2 General Construction May 2012 A. While the Contractor is on site, he shall provide the Owner, or his representative, safe work area access, ventilation, electric power, lighting, and support services during Owner’s work. B. Contractor provided support services shall include: intermittent power-up or shutdown of Contractor installed systems which are connected to Owner-installed equipment; all lock-out and tag-out activities required for Contractor’s safety; intermittent support by Contractor staff to make Contractor-installed equipment ready for checkout and testing. 1.03 RELATED SECTIONS A. Section 01300: Submittals PART 2 PRODUCTS NOT USED PART 3 EXECUTION 3.01 GENERAL A. The Contractor shall cooperate with the Owner to complete the work necessary for installation or reinstallation and testing of Owner furnished equipment. 3.02 FISH VALVE UNIT CONTROLS A. Interface 1. Owner will salvage and remove electrical equipment and wiring at the FVU for reinstallation with the new FVU equipment. Contractor shall remove and salvage existing FVU equipment, followed by installation of new FVU equipment and extension or addition of conduit. Owner will furnish and install new wiring and cable for the FVU controls and will reinstall salvaged materials and equipment described herein. Contractor and Owner shall work jointly with the FVU equipment Site Representative to commission the new FVU generating equipment. B. Owner’s Scope 1. Owner will shutdown, de-energize and lockout the FVU. 2. Owner will salvage control wiring, high voltage cabling, actuator control cabinet, Fenwall bearing temperature gauges, neutral grounding reactor, and high voltage termination cabinet. 3. Owner will re-install actuator control cabinet, the Fenwall temperature gauges, high voltage termination cabinet, and the neutral grounding reactor. 4. Owner will furnish, install, and terminate conduit and control wiring on the FVU Unit and in the existing switchgear and control cabinet. Blue Lake Expansion Project – Contract No. 9 01550-3 General Construction May 2012 5. Owner will reconnect high voltage conduit to the termination cabinet. The Owner will furnish, install, and terminate new high voltage cabling from the FVU switchgear to the generator terminals and the neutral grounding reactor. 6. Owner will test wiring prior to commissioning and will assist the Contractor and the FVU supplier’s Site Representative in commissioning of the FVU. C. Contractors Scope 1. Contractor’s scope for salvage of the existing FVU and installation of the new FVU equipment shall be as specified in Sections 02105 and 20100. 2. The sequence of Contractor’s work shall be scheduled to allow work by Owner, as specified in this section. D. Sequence of Construction 1. Owner will shutdown, de-energize, and lockout the Fish Valve Unit in cooperation with the Contractor. Station service power will remain energized to provide power for construction activities. 2. Owner will remove the control wiring, high voltage cabling, actuator control cabinet, Fenwal bearing temperature gauges, neutral grounding reactor, and high voltage termination cabinet from the existing FVU just prior to the Contractor removing the existing FVU. 3. Contractor shall salvage the existing FVU and demolish the supporting concrete base and other parts of the structure As Shown. The Contractor shall take care to protect the existing in floor conduit so that it may be reused with the new Owner-furnished FVU equipment (supplied under Contract 1). 4. Contractor shall extend the existing conduit as far as required to keep the conduits useable and above the new concrete work 5. Contractor shall construct the concrete pad and all other demolition and concrete work, then install the new FVU Turbine Generator, connect the turbine water supply piping, install the isolation valve hydraulic controls, and draft tube. 6. Owner will re-install the actuator control cabinet, the Fenwall temperature gauges, high voltage termination cabinet, and the neutral grounding reactor. The Fenwal gauge sensors must be installed in the bearing housings prior to filling the bearings with oil. 7. Owner will furnish, install, and terminate conduit and control wiring on the FVU Unit and in the existing switchgear and control cabinets. 8. Owner will reconnect high voltage conduit to the termination cabinet. The Owner will furnish, install, and terminate new high voltage cabling from the FVU switchgear to the generator terminals and the neutral grounding reactor. 9. Owner will test wiring prior to commissioning of FVU by Contractor. The Owner will obtain the Contract No. 1 Site Representative’s written acceptance of the wiring installed by the Owner, prior to commissioning of FVU. Blue Lake Expansion Project – Contract No. 9 01550-4 General Construction May 2012 10. Contractor and Contract No. 1 Site Representative shall work jointly to commission the new FVU. Owner will provide support for the commissioning work, as needed for all Owner-provided work. E. Schedule: 1. Contractor shall provide Owner a minimum of 14 calendar days prior to beginning of concrete demolition to allow the Owner to remove equipment and wiring. The Contractor shall provide access for Owner’s staff re-mount equipment, connect conduits, pull wire, terminate, and begin checkout of control equipment. Contractor shall provide Owner a minimum of 14 calendar days to complete this work. The Contractor, the Contract 1 Site Representative, and the Owner will then jointly commission the Fish Valve Unit. 2. Owner anticipates that the final shutdown of the existing FVU, prior to its removal, salvage, and replacement, will take place during the Generation Outage. 3. Owner furnished Inlet Valve must be installed by Contractor during the Generation Outage 3.03 BLUE LAKE SWITCHYARD CONTROL BUILDING AND CONTROL PANEL A. Interface: 1. The Owner will provide and install a local control panel for the Blue Lake switchyard. This local control panel will contain all of the switchyard local controls and protective relays, including the main transformer protective relays and the transmission distance relays. The control panel will also contain a SCADA PLC that will communicate with relays and controls within the switchyard and communicate with the new Blue Lake control room through fiber based ethernet. The switchyard control panel will be located in a modular building provided by the Owner located in the switchyard As Shown. The Owner will provide the building excavation, foundation, and install the building. The Contractor shall provide conduit to connect the switchyard control building with devices in the switchyard and powerhouse. Owner provided and Contractor provided conduit and wire runs are defined As Shown. B. Owner’s Scope: 1. Owner will furnish and install the switchyard control building and install the local control panel inside this building. Owner will expand the gravel pad for the new control building. All conduit and wire internal to the building will be furnished and installed by the Owner. 2. Owner will provide conduit stubs as shown outside the switchyard control building foundation, for continuation by the Contractor, to the particular switchyard device. 3. After the Contractor provides the conduit to the appropriate devices, pulls and labels the control conductors, the Owner will, terminate and test the low voltage and control cables at both the control panel and at the device. C. Contractor’s Scope: Blue Lake Expansion Project – Contract No. 9 01550-5 General Construction May 2012 1. The Contractor shall provide the conduit from the switchyard control building foundation stub-out to the appropriate devices in the switchyard or powerhouse. Contractor shall provide all necessary demolition, excavation, conduit, cable tray, concrete, backfill and related construction to complete these conduit and cable tray runs beyond the switchyard control building, As Shown. 2. The Contractor provides, pulls, and labels the control conductors, the Owner will terminate and test the low voltage and control cables at both the control panel, the new power plant, and at the switchyard device. The Owner will furnish the fiber optic cable and the Contractor will install the fiber optic cable from the new powerhouse control room to the switchyard control panel. 3. Sequence of Construction: The Contractor shall provide the conduit from the switchyard control building foundation stubs to the appropriate devices in the switchyard or powerhouse. Contractor shall provide all necessary demolition, excavation, conduit, cable tray, concrete, backfill and related construction to complete these conduit and cable tray runs beyond the switchyard control building As Shown. 4. The Contractor provides, pulls, and labels the control conductors, the Owner will, terminate and test the low voltage and control cables at both the control panel, the new power plant, and at the switchyard device. This work will include the fiber optic cable from the new powerhouse control room to the switchyard control panel. The Owner will furnish the fiber optic cable. D. The sequence of construction for the switchyard control building and control panel is to be integrated into the sequence of construction for the Blue Lake switchyard as described later in this Section. 3.04 REPLACE EXISTING FVU AND DAM FEEDER TRANSFORMER IN BLUE LAKE SWITCHYARD A. Interface: 1. The existing 4160V/12470V FVU feeder transformer located in the Blue Lake switchyard will be replaced with a 12,470V/12,470V transformer during the generation outage. The Dam site and FVU power will be shut off during the period of time that this work is done. The Contractor shall allow a minimum 12- hour power outage for the Owner to replace the dam feeder transformer T4. 2. Note that primary power from the 69kV transmission system must be cut over to the first new 69kV/12.47kV main transformer before the dam feeder transformer can be replaced. B. Owner’s Scope: 1. Furnish new 12470V/12470V FVU and dam feeder transformer including all foundation hardware, bushings, terminations, and any new wire and cable. 2. Remove existing transformer. 3. Install and test new transformer, test and adjust transformer relay protection and controls within new power plant MV switchgear. 4. Commission and connect new transformer, providing power to the dam feeder, FVU, gatehouse and dam area. Blue Lake Expansion Project – Contract No. 9 01550-6 General Construction May 2012 C. Contractor’s Scope: 1. Provide access into Blue Lake switchyard for Owner’s removal and replacement of the transformer. 2. Provide whatever temporary power sources are needed for Contractor’s work at the FVU, gatehouse and dam areas, during the transformer replacement. D. Sequence of Construction 1. The sequence of construction for replacing the dam feeder transformer in the Blue Lake switchyard is to be integrated into the sequence of construction for the Blue Lake switchyard as described later in this Section. 2. INSTALL 3.05 INSTALL NEW 12.47kV to 69KV MAIN TRANSFORMERS IN BLUE LAKE SWITCHYARD A. Sequence of Construction: The sequence of construction for removing the existing main transformers and installing the new main transformers in the Blue Lake switchyard is to be integrated into the sequence of construction for the Blue Lake switchyard as described later in this Section. 3.06 SEQUENCE OF CONSTRUCTION IN BLUE LAKE SWITCHYARD A. General: The work tasks sequenced below include work for the switchyard control building, control panel, dam feeder transformer, and main transformer replacements. All of this work is to be completed in sequence in the Blue Lake switchyard, generally as described below. B. Sequence of Construction for Blue Lake Switchyard 1. Owner: Expand the gravel pad and install the new switchyard control building and panel. 2. Owner: install control conduits for all three 69 kV breakers on their existing pads. 3. Owner: install control conduits for the two new 69kV main transformers. Stub and cap conduit for connection by the Contractor during construction of the transformer foundation and containment. 4. Contractor: Install cable runs from medium voltage switchgear and powerhouse control room for the following runs: a) across to old Blue Lake power house, along the wall in cable tray, b) one circuit up the tower for the creek crossing, c) a 480 circuit, hardwire and fiber optic control to the new switch yard control building, and d) all the circuits running along the creek side of the switchyard to feed the new 69kV main transformers and the new fish valve and dam feeder transformer T4. 5. Owner: power up control building and panel temporarily from the existing blue lake powerhouse to provide 120/208 3 phase service for lights, heat, and battery charger. Blue Lake Expansion Project – Contract No. 9 01550-7 General Construction May 2012 6. Owner: Furnish and install Ethernet connection to the existing SCADA control room to temporarily communicate with the new switchyard control panel. 7. Owner: replace all switchyard 69kV circuit breakers. 8. Owner: connect power, monitoring, and controls, to new switchyard control panel. Set up and put in service protective relays. 9. Owner: move 69kV potential transformers from their existing pedestals and perhaps temporarily mount them on the switchyard structure. Furnish and install temporary conduit and control cable to connect PT signals to the new substation control panel. 10. Owner: disconnect No. 2 transformer bank from 69kV and 4160 V bus. 11. Contractor: Remove the No. 2 transformer bank on the north end of the switchyard. Demolish the existing containment, foundations, and PT pedestals. Demolish No. 2 4160V bus. Construct new containment structure, transformer foundation, and PT pedestals on No. 2 side. Run control conduit from new foundation to the stub out from Substation Control Building. 12. Contractor: Move new 69 kV main transformer T2 into place on new foundation. Terminate and connect the medium voltage cables to the transformer 12.5 kV terminals. Note that MV Switchgear should be in place in the new powerhouse and MV cables terminated in the new powerhouse. 13. Contractor: Connect control conduits from the switchyard control panel and from the Blue Lake Powerhouse to the transformer control cabinet. 14. Contractor: Run all conductors for cabinet heat, CT and PT connections, protective sensors and relays, low oil level, sudden pressure, etc. between the transformer #2 control cabinet and the switchyard control panel. 15. Owner: Terminate wiring in the transformer control cabinet and in the switchyard control panel. 16. Owner: Move 69 kV PT’s and pedestals on No 2 transformer bank to foundation old transformer As Shown, make permanent wiring connections and re-connect to 69 kV bus. 17. Owner: Connect main transformer T2 69 kV bushings to 69 kV bus. Energize main transformer T2 from the 69 kV side. 18. Contractor: Rack in MV Transformer Breaker in the new power house and close, energizing the MV switchgear within the new power house. 19. Contractor: Rack in and close the station service transformer breakers. 20. Contractor: Close Station service breakers to energize the station service bus. 21. Owner: Replace the FVU and dam feeder transformer with a new 12,470V x 12,470V transformer T4. 22. Contractor: Connect feed to the new fish valve and dam feeder from the new powerhouse. Rack in the fish valve & dam feeder breaker, energizing the fish valve and dam feeder transformer T4. Blue Lake Expansion Project – Contract No. 9 01550-8 General Construction May 2012 23. Contractor: After generation outage, and after the first new powerhouse generating unit is operational, the second existing switchyard 4160V No. 1 transformer bank will be removed, foundations and containment replaced as described above. Contractor shall then set the 69 kV main transformer T1 and the Owner will wire in the controls, similar to the 69 kV main transformer T2. The sequence of work and the Contractor’s scope of work for the T1 transformer bank shall be similar to that described above for the T2 bank. C. Schedule: 1. As part of the Contractor’s Work Plan, provide a schedule and sequence of construction for work in the Blue Lake switchyard. This schedule and sequence must consider the multiple work activities that will be completed by the Owner and the Contractor and the need to maintain operation of the switchyard during construction. 2. As part of the Work Plan and Schedule, provide a written schedule that identifies the date and times that will be provided for the Owner’s work in the switchyard. 3. Provide a 12 hour window for Owner’s replacement of the Dam Feeder transformer. No electric power will be provided by the Owner to the FVU, gatehouse, and dam areas during this time. 4. Provide 5 day window for Owner’s connection of control wiring to the T2 main transformer. 5. Provide Owner at least 5 days written notice of any construction window that will be provided for Owner to complete work in the switchyard, including notice of connection of main transformers to 69 kV bus and energization of those transformers. 3.07 FURNISH AND INSTALL SCADA SYSTEM BETWEEN CONTRACTOR’S WORK AND THE BLUE LAKE CONTROL ROOM A. General: 1. The Owner will be designing and providing a SCADA Control Center that will replace the existing Blue Lake Control Center located in the old plant. This new Center will interface with all of the Owner and Contractor provided equipment. The SCADA control system will enable the generation, distribution, transmission, and switchyard equipment to be operated in remote or supervisory mode. The equipment controlled by the SCADA system is As Shown on Control Block Diagram 109-45-115. 2. The SCADA control center will be located in the Blue Lake Powerhouse control room. The control room equipment and software will be tested by the Owner in an off-site location (the Owner’s Jarvis St. substation) prior to installation in the powerhouse. 3. Each equipment supply contract entered into by the Owner (Contract 1 – Supply of Turbine and Generator Equipment, Contract 2 – Switchgear, Contract 3 – Supply of Gates and Hoist; and Contract 5 – Supply of Main Transformers) defines the control interface between the equipment and SCADA. Blue Lake Expansion Project – Contract No. 9 01550-9 General Construction May 2012 4. Equipment provided by the Contractor shall also define the control interface between that equipment and SCADA, which may be as complex as fiber optic based Ethernet and as simple as alarm, start, and stop, dry contacts. 5. The Owner will provide and terminate the fiber based ethernet communication cables between each of the SCADA controlled devices and the SCADA equipment located in the control room. The Owner will route the communication cable through contractor supplied conduit and cable tray As Shown. The Contractor shall provide and route hard wire control circuits and terminate at device end only. All work by both the Owner and the Contractor shall be complete prior to the generation outage. The Blue Lake control room, SCADA room, conduit, cable trays, and SCADA controlled devices must in place with adequate time for the Owner to install, and terminate the communication cables and test the SCADA system prior to the generation outage. B. Owner’s Scope: 1. Provide design of SCADA system. 2. Provide SCADA equipment not included in procurement contracts. 3. Provide programming of SCADA system using addressing defined in each procurement contract. 4. Provide and install fiber based Ethernet communication cables between all SCADA controlled devices. 5. Test SCADA system against all controlled and monitored devices. C. Contractor’s Scope: 1. Provide definition of control system interface with SCADA system, for all Contractor-furnished equipment. Definition shall include primarily dry contact and analog signal values and connection point information 2. Provide conduit and cable tray As Shown for routing optic fiber communication cables, dry contact, and analog signal wiring 3. Provide a central terminal strip in each contractor supplied control panel for termination of SCADA cabling. 4. Provide addressing and programming for Contractor supplied control panels. 5. Provide powerhouse control room construction complete for Owner’s use, as described herein, at least 60 days prior to start of Generation Outage. 6. Contractor supplied control panels a. Stand-by generator – start/stop dry contact b. Battery chargers and inverters – alarm dry contact c. Station service air compressor control panels – dry contact – tank pressure 4-20 ma. d. Service Water strainers – differential pressure alarm dry contact Blue Lake Expansion Project – Contract No. 9 01550-10 General Construction May 2012 e. Gate house control panel with air compressor and intake/trashrack pressure indication – alarm dry contact, 4-20 ma signals to Gate house PLC (PLC panel is Owner furnished). f. Inlet screen air backflush system- alarm dry contacts g. Sump pump duplex control panel – alarm dry contacts h. Sump alarm panel - alarm dry contacts i. Sanitary sewer lift station – dry contact alarm j. HVAC controls D. Schedule: 1. Contractor shall schedule work to provide use of and access to the control room 60 calendar days prior to the start of the generation outage. Architectural finishes, including wall covering, flooring, ceilings, doors and windows shall be complete before the start of this period. Contractor shall provide heating, ventilation, lighting, 120V ac power and 125V DC power in the control room for the Owner’s use during this time, for 12 hours each day from 7 am to 7 pm. The intent is to allow the Owner to install the new SCADA Control Center in the control room, connect it to the existing SCADA controlled equipment and test 2. Contractor shall schedule work to provide the use of and access to cable trays and conduit required by the Owner for fiber optic cable connection between the SCADA Control Center in the new control room and all SCADA controlled equipment related to the new generation plant and substation. This will allow testing and commissioning of the SCADA as related to all new system generation and substation equipment 30 calendar days in advance of the start of the generation outage. Conduit and cable tray runs to specific equipment, such as the Turbine Generator Control Panels, Station Service panel, and medium voltage switchgear panel, must be accessible for Owner connection and testing 30 days prior to the generation outage. 3.08 PROVIDE UTILITY CONNECTION POINTS FOR WATER, SEWER, AND ELECTRICAL SERVICE TO THE EXISTING BLUE LAKE POWER HOUSE A. General: 1. The Owner will provide utility connection points for the existing Blue Lake powerhouse external to the existing powerhouse on the south wall. The Contractor shall interface with these points to provide utilities to the old powerhouse. B. Owner’s Scope: 1. Provide 480V, 600 amp, 3 phase fused disconnect on the external wall of the existing powerhouse for Contractor connection of power from the new station service panel. Install a dry type step down transformer within the existing powerhouse and all connections within that facility. 2. Provide 2” pipe connection on existing sewer treatment plant for contractor to provide a gravity drain to the sewer lift station. Blue Lake Expansion Project – Contract No. 9 01550-11 General Construction May 2012 3. Provide 4” 150 psi flange for connection of potable water system. C. Contractor’s Scope: 1. Provide cable and conduit from 480V station service bus breaker CB-SSB11 to the fused disconnect on the external wall of the existing blue lake powerhouse As Shown. 2. Provide 2” gravity drain sewer line from existing treatment plant to sewer lift station As Shown. 3. Provide 4” potable water line branch and valve from Contractor provided potable water line As Shown. D. Schedule: 1. Contractor shall schedule work to provide these connections 30 calendar days in advance of the start of the generation outage. END OF SECTION Blue Lake Expansion Project – Contract No. 9 01800-3 General Construction May 2012 1.09 DUST AND FUME CONTROL A. Accomplish effective control of potentially harmful dusts, fumes, mists, gases, smoke, sprays or vapor, by accepted engineering control measures, for example, enclosure or confinement of the operation, ventilation and substitution of less toxic materials. 1.10 NOTIFICATION AND SAFETY PROCEDURES FOR ENVIRONMENTALLY SUSPICIOUS SUBSTANCES A. Notify RPR immediately if any environmentally suspicious substance is encountered during demolition, excavation or other construction activities. B. Prepare to properly handle, transfer and containerize any impacted media (i.e., rock, cement, groundwater, sediment, etc.) in the Blue Lake Expansion Project area, in accordance with the Owner’s FERC License Amendment Plans including the ESCP. PART 2 PRODUCTS NOT USED PART 3 EXECUTION NOT USED END OF SECTION Blue Lake Expansion Project – Contract No. 9 01700-1 General Construction May 2012 SECTION 01700 CONTRACT CLOSEOUT, OPERATING AND MAINTENANCE MANUALS AND SPARE PARTS PART 1 GENERAL 1.01 CLEANUP A. Contractor shall at all times keep the premises free from accumulations of waste materials or rubbish caused by his employees or Work and shall remove from Owner’s property and from all public and private property, at its own expense, all rubbish and waste materials resulting from its operations B. At the completion of all items of the Work and prior to final inspection, Contractor shall remove all temporary structures; all rubbish and waste from and about the Work area; and all its tools, scaffolding, and surplus materials, leaving his Work "clean," ready for immediate use. Restoration of grade, topsoil, shrubbery or small trees, along with reseeding of grassy areas, will be required if pre-existing items were damaged during construction. 1.02 ACCEPTANCE A. Acceptance of the Work shall be in accordance with Article 14 of the General Conditions. 1.03 PROJECT RECORD DOCUMENTS A. Contractor shall provide documentation in the form of a checklist, signed by Contractor's Superintendent, proving completed inspection for each phase of the Work such as after excavation, demolition, placement of reinforcement, placement of bolts/dowels, placement of forms, and placement of concrete. B. Record Drawings: Contractor shall keep in his field office and maintain one complete set of accurate Record Drawings as specified in section 01300. Upon completion of the Work, Contractor shall submit Record Drawings to RPR along with any other drawings and documents that show actual construction of the Work under this Contract. It is Owner’s intention that Engineer will transfer Record Drawing information onto the "Issued for Construction" drawings to generate “Conformed to Construction Record”. Contractor shall assist Engineer in this Work to ensure that the information is transferred accurately and reflects actual construction Work. These drawings shall be considered the As-Built set of drawings. 1.04 OPERATING AND MAINTENANCE MANUALS A. The Contractor shall furnish three complete bound Operation and Maintenance (O&M) Manuals as separate volumes, plus a DVD with electronic files in Adobe PDF format, covering all equipment furnished under this Contract as specified in section 01300. B. After acceptance three copies of each volume of O&M Manuals shall be bound with Chicago screws, with cloth faced hardboard covers. The front cover shall be imprinted with the title of the project, the name of Owner, the name of Engineer, Construction Manager, and the name of Contractor. The back edge shall be Blue Lake Expansion Project – Contract No. 9 01700-2 General Construction May 2012 imprinted with the name of the project, Owner and the year of completion of the project. C. After acceptance, five electronic copies of each volume of O&M Manuals shall be provided on DVD disk in Adobe PDF file format. These .pdf files shall be bookmarked by manual section, equivalent to the table of contents for each bound O&M document. 1.05 SPARE PARTS A. Contractor shall provide spare parts as specified in section 01300. B. Spare parts shall be adequately labelled and securely packaged for long-term storage at Site. All spare parts shall be interchangeable with, and of the same materials and workmanship as, the corresponding parts of the equipment covered by these Specifications. C. In addition to the spare parts mentioned in paragraph A above, Contractor shall provide sufficient consumables, as would prudently be expected for testing and commissioning of the Work. Contractor shall provide, in a timely manner, new spare parts to replace any spare parts used during start-up and commissioning. END OF SECTION Blue Lake Expansion Project – Contract No. 9 01600-1 General Construction May 2012 SECTION 01600 MATERIAL CONTROL PART 1 GENERAL 1.01 HANDLING OF MATERIALS A. Receive, handle, systematically document, and store Contractor furnished and Owner furnished materials and equipment and in accordance with Supplier’s recommendations and in a manner that will protect such items from damage or deterioration. B. Store materials and equipment off the ground on blocking or pallets. Protect from vandalism and weather damage. 1.02 STORAGE AND PROTECTION AT SITE A. Owner will provide property at SCIP for outside storage of Owner-furnished components. Owner will also lease the Boat Building at SCIP for dry storage of Owner-furnished components requiring dry storage. Contractor may store Contractor-furnished goods in this building if space is available, at no charge. Contractor may lease additional property at SCIP for outside storage of Contractor- furnished components. B. The amount of material stored and its location shall be subject to approval of RPR in Owner supplied areas. C. Contractor shall be responsible for repair of any damages which Contractor has caused to Owner's storage area. END OF SECTION Blue Lake Expansion Project – Contract No. 9 01800-1 General Construction May 2012 SECTION 01800 ENVIRONMENTAL CONDITIONS AND CONTROLS PART 1 GENERAL 1.01 WORK INCLUDED A. The Work covered by this Section consists of the design of all necessary temporary and permanent environmental control features required for project construction activities. 1.02 RELATED WORK A. Section 01200: Project Administration B. Section 02370: Erosion and Sediment Control Measures 1.03 ENVIRONMENTAL CONDITIONS AND CONTROLS A. The Owner will employ an Environmental Compliance Monitor (ECM) as required by the FERC licence amendment to observe and monitor compliance with environmental protection plans. Contractor to provide adequate access for ECM inspections. B. Strictly enforce adherence to all environmental policies, and be cognizant of the environmental conditions discussed in this Section for all phases of work performed as part of this project. Notify RPR and ECM immediately upon discovery of potential environmental impacts or conditions. C. Provide approved control measures as required by the Owner-prepared FERC Amendment Plans, and Contractor’s site-specific ESCP, SWPPP, and SPCC (See Section 02370). Maintain these control measures as ordered by RPR or ECM during the life of the Contract to control erosion, water pollution, and water runoff or other forms of site contamination. All site stormwater drainage features shall be protected and maintained free flowing and free of debris. All roadways shall be maintained free of debris. D. In the event of conflict between these specification requirements and pollution control laws, rules or regulations of other Federal, State or local agencies, the more restrictive laws, rules or regulations shall apply. 1.04 RESOURCE PROTECTION AND MONITORING PLANS A. Adhere to FERC Amendment Plans and License Articles (See Reference Documents). B. Notify RPR and ECM with any suggested modifications to these plans. 1.05 PROTECTION OF WATER RESOURCES Blue Lake Expansion Project – Contract No. 9 01800-2 General Construction May 2012 A. Blue Lake reservoir is the Owner’s primary and unfiltered drinking water source. The reservoir will be utilized for drinking water before during and after construction. Utmost care must be taken to prevent contamination of the reservoir. B. Protect all water resources (i.e. ground and surface waters), including all drains, from leaching and /or run-off of chemical pollutants, solid wastes and construction site debris. C. Maintain on site, sufficient quantities of absorbent materials for use in case of chemical or oil spills. In the event of any actual or suspected spill of any chemical, petroleum product, or waste water, Contractor shall immediately notify RPR and ECM and immediately take all measures necessary to control the spread of the spilled material, and to remove and properly dispose of the spilled material. D. Storage and/or use of chemicals, fuels, oils, greases, bituminous materials, solids, waste washings, and cement shall be handled appropriately as to prevent leaching or surface run-off into public waters or drains. All approved storage areas for these materials must be diked and protected from precipitation. E. Disposal of any waste materials on the construction site is prohibited. F. Do not directly discharge water resulting from or contaminated by construction operations into any bodies of water or drainage systems. G. Do not discharge suspended and/or settle-able solids in amounts that cause visible contrast to natural conditions. 1.06 DEWATERING A. Perform construction activities in such a manner that the site is effectively drained. Provide gravity drainage wherever possible. Additional means shall be utilized when necessary and shall include pumping and bailing. B. Do not directly discharge water resulting from or contaminated by construction operations into any water bodies or drain systems. Handle water discharged from pumps and associated equipment prevent ponding, sediment runoff, and creating hazardous conditions on paved surfaces. 1.07 FLOOR DRAIN AND CATCH BASIN PROTECTION A. Keep drains open during the duration of the work and rendered fully operational by Contractor at the completion of the project. B. Discharge of any liquids or solids into Owner's storm water piping system is prohibited unless specifically authorized in writing by RPR. C. Protect all exterior drains and catch basins within or adjacent to work areas or grounds disturbed by Contractor’s activities from sediment runoff. 1.08 EROSION AND SEDIMENT CONTROL A. Comply with all applicable Federal, State and Local regulations and laws. In the event of a discharge to streams, rivers, lakes or canals that causes a visible plume in the receiving water body, Contractor shall immediately notify the RPR and ECM. See Section 02370 for further requirements. DIVISION 02 SITE WORK Blue Lake Expansion Project – Contract No. 9 02020-1 General Construction May 2012 SECTION 02020 SURVEY CONTROL PART 1 GENERAL 1.01 WORK INCLUDED A. Establish survey control, set benchmarks, and provide temporary structural monitoring systems for all work for the Blue Lake Expansion Project As Shown. B. Provide temporary survey controls to monitor construction of the dam extension, exploratory tunnel, surge chamber, tunnel modifications, penstock demolition, penstock installation, penstock anchor blocks, intake, powerhouse area excavations, and other aspects of the work. C. Provide permanent dam extension survey systems As Shown, working with Owner’s surveyor and RPR. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 01500: Construction Facilities C. Section 01700: Contract Closeout D. Section 02105: Demolition and Salvage E. Section 02240: Dewatering and Water Control F. Section 02290: Geotechnical Instrumentation and Monitoring G. Section 02310: Backfill H. Section 02315: Rock Excavation and Scaling I. Section 02400: Rock Tunnelling J. Section 02405: Drilling K. Section 02430: Foundation Grouting L. Section 02465: Micropiles M. Section 02510: Water Supply Mains N. Section 02530: Sanitary Sewerage O. Section 02620: Subdrainage System P. Section 02630: Site Drainage Blue Lake Expansion Project – Contract No. 9 02020-2 General Construction May 2012 Q. Section 02700: Gravel Surface, Base and Subbase Courses R. Section 03300: Cast-In-Place Concrete S. Section 03301: Concrete Instrumentation T. Section 05100: Structural Steel U. Section 05500: Miscellaneous Metals V. Section 13100: Penstock Installation W. Section 13120: Steel Building Installation X. Section 13210: Installation of Intake Fixed-Wheel Gate, Guides and Hoist Y. Section 13310: Intake Trashrack and Supports Z. Section 13450: Installation of Bulkhead Gate and Guides 1.03 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submit Survey Control and Structural Monitoring Plan that includes details for establishing additional benchmarks and details of a temporary structural monitoring system during construction for existing structures and portions of existing structures to remain. 1. As a minimum, include a description of the equipment, material and methods required to establish the monitoring system; equipment, materials, methods and procedures to execute periodic monitoring surveys; sketch/location of all survey control points; and demonstrate that equipment and methods can provide accuracy and precision required. Submittal shall include example of record data sheets that will identify date/time of survey, names of survey personnel, weather/ambient conditions, station or monument number, survey measurement, datum used, difference or change from previous measurement, difference or change from baseline measurement, and other information that will assist in interpretation. 2. Identify the Licensed Land Surveyor (LLS) for performing the survey tasks. The LLS shall employ the services of an Alaska State Licensed Land Surveyor and an Alaska State Licensed Professional Engineer. Contractor shall provide necessary credentials to as part of plan. LLS must be capable of recommending, developing and executing Structural Monitoring System and providing other survey support as required. Licensed Professional Engineer must be capable of interpreting structural implications of day-to-day readings from the structural monitoring system. 3. Provide access to survey control information to facilitate periodic surveys by Owner’s surveyor. PART 2 PRODUCTS Blue Lake Expansion Project – Contract No. 9 02020-3 General Construction May 2012 Not Used PART 3 EXECUTION 3.01 BENCHMARKS A. Provide equipment, materials, labor and survey to facilitate installations of any additional benchmarks or reference points beyond those As Shown. B. Take all necessary precautions to protect existing control points, monuments, pins, etc. from disruption/disturbance during execution of the Work. C. Should any such survey points be destroyed, altered or disrupted in any manner, immediately notify RPR. Contractor will be responsible for correcting and/or replacing such survey points at no additional cost to Owner. Contractor also responsible for correcting and/or replacing components/materials incorrectly installed from disturbed survey/benchmark points, at no additional cost to Owner. D. Perform construction surveying as necessary to maintain accurate alignment and elevations of work items. 3.02 TEMPORARY STRUCTURAL MONITORING SYSTEM A. Protect existing monuments, permanent and temporary, unless their removal and replacement is part of the structural monitoring plan. B. Establish monuments, control points, foresights, back sights, offsets, etc. as necessary to monitor for vertical and horizontal movements of key project structures. C. Keep temporary structural monitoring system as simple as practicable to avoid or minimize the introduction of measurement error. Wherever possible use single, direct line-of-sight; offsets, if required, shall be as few and short as possible; no horizontal angles; use same equipment/personnel to ensure accuracy and consistency of duplication of measurements. D. Determine threshold limits for structural systems being monitored. Thresholds should represent a departure from expected structural behavior that requires the work to be suspended and inspected. Provide structural monitoring systems that give accuracy sufficient to detect that a threshold value has been exceeded. E. If threshold requirements for specific structural systems do not require greater accuracy, the suggested minimum accuracy requirements for the structural monitoring system are as follows: 1. Vertical measurements .......... 0.02 feet 2. Horizontal measurements ..... L/5000, L = instrument to target distance F. The structural monitoring system shall include a minimum of two control points established at locations sufficiently distant from any construction activities or other disruption and may be considered as stable reference datum. Blue Lake Expansion Project – Contract No. 9 02020-4 General Construction May 2012 G. Contractor’s LLS shall repeat monitoring surveys a minimum of at least every week, where work is performed, during the construction schedule and as required by RPR. H. Contractor shall have personnel adequately trained and skilled to conduct monitoring surveys on a regular or periodic basis not exceeding daily during demolition or as directed by RPR. I. Contractor’s lead surveyor(s) who responsible for monitoring surveys, shall have as a minimum a 4-year civil engineering college degree plus 4 years field experience or 10 years of field experience and can demonstrate adequate surveying skills to RPR's satisfaction. Should unusual measurements be recorded, Contractor shall immediately notify Owner. 1. Owner’s LLS may be called out to conduct verification survey as required by RPR at no additional cost to Owner to clarify unusual measurements. J. Contractor shall provide copies of monitoring records to RPR within 24 hours after completion of monitoring survey. 3.03 DAM SURVEY MONITORING SYSTEM A. Install survey pedestals SP1 and SP2, and prism targets T1 through T5 during or within one week of dam extension construction completion prior to final of grouting vertical contraction joints. Coordinate installation with RPR. B. Install survey pedestal SP3, and collimation survey targets CT1 and CT2 within one week after completing final grouting of vertical contraction joints. Install according to approved plan in coordination with RPR and Engineer. C. Facilitate implementation of monitoring system by RPR after surveys systems are installed. 3.04 PROJECT RECORD DRAWINGS A. Document permanent survey control information on project record drawings. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02105-1 General Construction May 2012 SECTION 02105 DEMOLITION AND SALVAGE PART 1 GENERAL 1.01 WORK INCLUDED A. Perform all for demolition and salvage for project features As Shown. B. Demolition and salvage shall include, but is not limited to, removal, salvage, and/or disposal of materials and equipment, followed by site restoration, as specified for the following: 1. Intake Area a) Demolition and salvage work to decommission and abandon existing intake structure gate hoist system. 2. Dam Area demolition and salvage work to allow extension of the dam, including: a) Parapet wall removal b) Removal of portions of spillway wall c) Removal of concrete on the abutments at the dam crest d) Dam crest roughening e) Removal of right abutment access ladder (above dam crest) f) Removal of existing handrail at dam crest g) Removal and temporary re-location of the hydraulic slide gate controls. 3. Tunnel a) Demolition of portions of concrete liner. 4. Sawmill Creek Penstock Crossing/Fish Valve Unit a) Removal and salvage of the existing Fish Valve Unit (FVU) turbine generator. 5. Powerhouse Area a) Removal and salvage of a portion of the existing penstock, 84” valve and air release valve. b) Demolition of existing penstock support saddles and foundations. c) Demolition of the timber crib wall near at the lower portal. Blue Lake Expansion Project – Contract No. 9 02105-2 General Construction May 2012 d) Removal and salvage of two banks of 4160V-69kV transformers (Seven total transformers) and accessory electrical equipment in the switchyard. e) Demolition and disposal of transformer foundations, conduit, and oil containment systems under the existing main transformers in the switchyard. i. Note: BKR 33 is a gas breaker and required no oil containment. f) Demolition of portions of fencing. g) Demolition of metal garage. 6. Septic drain field demolition and disinfection. 7. Water Transmission main, fittings, and valves demolition, removal, salvage and disposal. 8. Water Treatment Plant (WTP) - Replacement and salvage of existing strainers and salvage and relocation of piping. 9. Note: No demolition or salvage is required inside the existing Blue Lake Unit or at the Pulp Mill Feeder Unit Powerhouse. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 01450: Safety C. Section 01800: Environmental Conditions and Controls D. Section 02020: Survey Control E. Section 02315: Rock Excavation and Scaling F. Section 02316: Unclassified Excavation G. Section 02370: Erosion and Sediment Control Measures 1.03 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Contractor shall submit a demolition plan as part of the Work Plan, which describes the following: 1. Proposed sequence of operations. 2. Proposed equipment and methods to be used for each operation. 3. Proposed measures to protect structures and services which are to remain in place, including temporary shoring, bracing, and supports. 4. Proposed measures to prevent demolition debris and sediment from entering the lake and creek. Blue Lake Expansion Project – Contract No. 9 02105-3 General Construction May 2012 5. Salvage plan for FVU. C. Contractor shall, after completion of demolition and prior to installing materials, make a survey of structures which are to remain and interface with the new work. Any deviations from the dimensions and elevations shown on the drawings which would affect fabrication and construction shall be noted and resolved to the satisfaction of Owner before proceeding with the Work. D. "Chain-of -Custody" letter for offsite disposal of demolished materials. Refer to Section 3.01(L). PART 2 PRODUCTS 2.01 PRODUCTS A. Concrete repairs: All products installed for concrete repairs are to be supplied by Sika Corporation, 201 Polito Avenue, Lyndhurst, NJ 07071, ph: 201-933-8800, http://usa.sika.com/ or approved equal. PART 3 EXECUTION 3.01 GENERAL A. Contractor is responsible for obtaining any applicable permits prior to demolition commencement. B. Contractor shall demolish structures in a safe, orderly manner, which includes the use of temporary rails, barricades and nets in accordance with applicable federal, state, and local regulations; and shall protect all adjacent structures, utilities, and services during demolition. Note: If water is necessary for any demolition or surface preparation that could have the potential to introduce leachate into the adjacent water bodies, wastewater control features shall be provided as part of the demolition work and in accordance with approved ESCP, SPPP and SPCC (See Section 02370). Contractor shall notify RPR prior to commencement of the work. Contractor is responsible for prevention of non-stormwater run-off entering the adjacent water bodies. C. Precautions shall be taken to prevent damage to existing work which is to remain in place, be reused or remain the property of Owner and to any new work constructed or installed under this contract. Any damage to such work shall be repaired or replaced as approved by Owner at no additional cost to Owner. Contractor shall ensure that structural elements are not overloaded as a result of the demolition work. Shoring, bracing, and supports shall be installed and maintained, as required. D. Where existing equipment is to be salvaged, the equipment shall be removed in a manner that retains the integrity and function of the equipment and the equipment bases and supports. Equipment shall be un-bolted from any embedded foundation plates or bolts and carefully lifted free of its foundations. Flame or abrasive cutting of equipment bases will not be permitted. Embedded bolts, anchors, frames and foundation plates may be demolished and disposed of. Blue Lake Expansion Project – Contract No. 9 02105-4 General Construction May 2012 E. Where existing equipment is to be salvaged, electrical, mechanical, and piping connections shall be disconnected at fittings, flanges, conductor terminations and joints, in a manner that avoids cutting of pipe, mechanical devices, wire and electrical conductors. Wiring connections shall be unfastened and the connecting wires pulled out of junction boxes and terminal boxes in a manner that avoids damage to wiring insulation and wire marking. F. Follow approved plan for salvage and reuse of existing mechanical supports, electrical conduit, and wiring at the FVU. G. Dust resulting from demolition shall be controlled to avoid creation of a nuisance in the surrounding area. The use of water will not be permitted when it would result in or create hazardous or objectionable conditions, such as erosion, transport of sediments into adjacent water bodies, pollution, flooding or ice. H. The burning of refuse and debris on the project site will not be permitted without a burning permit. I. The use of explosives for demolition will not be permitted unless approved by RPR. J. Demolished materials shall be removed and disposed of as the work progresses. Debris shall not be allowed to accumulate in any work/staging areas, as required by local, state and federal regulation. K. Uncontaminated demolished materials shall be disposed of off-site at a regulated landfill facility. Care shall be taken to prevent refuse and debris from falling into the river or reservoir. Any debris or refuse which falls into a water body shall be removed promptly. L. Offsite disposal of demolished materials and waste shall be documented by a "Chain-of-Custody" letter (or form). This letter will be initiated by Contractor for each load of demolition debris hauled offsite, and shall record and account for each successive handler/possessor of this debris including the party responsible for accepting the debris for final disposition. The Chain-of-Custody letter (form) will include: 1. Project name and number. 2. Originator’s name and signature. 3. Date and location of origination. 4. Estimated quantity of debris. 5. Brief description/type of debris. 6. Name of intermediate handlers. 7. Name/signature/date of party accepting final disposition of debris. M. Contractor is responsible to prevent sediment and non-stormwater run-off, including drill cuttings and solids, from entering any water body or stream. N. All salvaged items to be delivered to SCIP as directed by RPR. Blue Lake Expansion Project – Contract No. 9 02105-5 General Construction May 2012 3.02 CONCRETE DEMOLITION A. Demolition will be limited to mechanical methods and shall be accomplished by pneumatic (hammer) methods combined with line drilling, cutting, wedging, barring, ripping or combination thereof. B. Concrete and masonry demolition shall be to the neat lines shown on the drawings. C. Lines, which will be visible after completion of the project, shall, to the extent practicable, be saw cut. Over break at exposed corners shall be repaired with mortar, grout, or formed concrete to the dimensional neat lines As Shown and at no expense to Owner. Over break shall be repaired in accordance with the Sika Concrete Restoration Systems manual for the applicable case. A copy of the manual shall be maintained on site by Contractor. 3.03 DEMOLITION SEQUENCE A. Contractor shall coordinate demolition/construction activities with RPR. B. Demolition sequence shall conform to the project schedule, drawings, and Contractor's approved work plan. 3.04 INTAKE AREA DEMOLITION AND SALVAGE A. Existing intake gate hoist house – Salvage Items: 1. Stainless steel wire rope, two sections of approx 3/4” dia rope. Unspool rope from gate hoist and cut end of rope near the existing intake at elevation 320’ or lower. Salvage as two individual rope sections. Spool or coil and deliver to the Owner at the SCIP. B. Existing intake gate hoist house – Demolition: 1. Demolish and dispose of: the building’s steel access door; steel doors at wire rope entry to the building; engine-driven gate hoist; hydraulic pressure unit for bypass gate operator; and the asphalt-tar paper roofing materials. 2. Detergent wash the inside of the building floor and walls to remove oil and gasoline residue. Hot water pressure wash after detergent wash of these surfaces. 3. Note that the building structure may be left in place. Note that the entire roof slab may be demolished and discarded, in lieu of stripping off the roofing material. 4. Demolish and discard the two hydraulic oil hoses running from the hoist house to the intake structure. Use methods that do not allow the release of hydraulic oil into the lake. Remove the hoses to a point no higher than elevation 244’ (the top of the intake structure). Cap the hoses at or below elevation 222’ (top of the intake trashrack) using corrosion resistant fittings attached to the hose or hydraulic cylinder or corrosion resistant crimp-type hose sleeves, if the hoses are crimped to seal them. Note that these hoses run in an HDPE pipe sleeve from the hoist house to the intake. This HDPE pipe sleeve may be left in place and may be cut as needed for demolition of the hoses. 3.05 DAM AREA DEMOLITION AND SALVAGE Blue Lake Expansion Project – Contract No. 9 02105-6 General Construction May 2012 A. Dam area – Salvage Items: 1. None. 2. Note that the sluice gate hydraulic pressure unit at the crest of the existing dam is to be temporarily relocated during construction, modified, installed at the crest of the dam extension, and then tested. Requirements for this work are specified elsewhere in these specifications. Refer to Section 13460. B. Dam area – Demolition: 1. Demolish the existing parapet walls, metal guardrails; spillway training walls (partial demolition); concrete blocks at abutments; and dam access ladder from the right abutment to the dam crest, all As Shown. 2. Note that all concrete surfaces on the existing dam onto which new concrete will be placed, shall be excavated a nominal depth of 3 inches to provide an adequate bonding surface. All such surfaces shall be high pressure (10,000 psi) water blasted prior to placement of new concrete. Protect all adjacent areas of the dam crest from damage during excavation. 3. Concrete demolition work shall be carried out in a manner that prevents broken and cut concrete from entering the lake. Structures and equipment below the dam crest shall be protected from falling demolition debris. These structures and equipment include as a minimum: the Howell Bunger access ladder; the Howell Bunger valve house, valve access walkway, guardrails, and discharge hood: the sluice gate trashrack on the upstream face of the dam (in the lake at el. 233); piezometer piping and conduit/wire in the plunge pool area. 3.06 FISH VALVE UNIT DEMOLITION AND SALVAGE A. Fish Valve Unit – Salvage Items: 1. Fish Valve Unit turbine-generator, consisting of: inlet valve, turbine; draft tube elbow; turbine auxiliary equipment mounted to the turbine; generator; PMG; Generator termination cubicle and grounding resister; oil cooling system; Flow indicators; and Gate Positioner. 2. Note that the existing turbine draft tube cone which is partially embedded in the floor of the FVU building may be demolished and disposed. 3. Embedded conduits that can be incorporated into the Work. B. Fish Valve Unit – Demolition: 1. FVU foundation concrete and embedded metalwork as required to allow installation of the new FVU equipment. 2. FVU building wall and floor concrete as required for installation of new FVU draft tube. 3. Metalwork covers, guards, electrical conduit, wiring, piping and miscellaneous items that must be removed for installation of the new equipment, or which become un-needed with the new equipment. Blue Lake Expansion Project – Contract No. 9 02105-7 General Construction May 2012 4. Wall mounted exhaust fan, motor, vents, louvers and all embedded metalwork as required for installation of new FVU fan equipment provided by Contractor. 3.07 POWERHOUSE AREA DEMOLITION AND SALVAGE A. Powerhouse Area – Salvage Items: 1. Existing 96-inch to 84-inch reducing pipe section and approximately 140 ft of 11/16-inch wall, 84-inch dia penstock, from the existing 96-inch diameter flange to the upstream flange of the 84-inch diameter butterfly valve, As Shown and refer to Reference Documents. Salvage these pipe sections and deliver to the Owner for storage at the recycle center located next to the Blue Lake power house. Note that these sections are connected with sleeve couplings, with a maximum section length of 40 ft. 2. Three 84-inch diameter sleeve type pipe couplings on the existing penstock. 3. Seven 4160V – 69kV transformers in the switchyard, including bushings and oil. 4. Note: The existing FVU and Dam feeder transformer 4160/12470 will be replaced with a 1500Kva 12470/12470 transformer called ‘T4’. This work will be done by Owner. B. Powerhouse Area – Demolition: . 1. Remove existing 4160v switchyard bus foundations, structures, bus duct, conduits and cables. 2. Conduits to be removed As Shown. All conduit and cable removal to be co- ordinated with Owner before removal. 3. Penstock saddles and saddle foundations as needed for construction of new penstock system. 4. Transformer foundation and oil containment structures, As Shown. 5. Existing powerhouse tailrace walls and footings, as required for construction of the new powerhouse. 6. Remove existing metal garage adjacent to old powerhouse. 3.08 EXISTING POWERHOUSE SEPTIC DRAIN FIELD AND PIPING A. Establish new or temporary sewer service system prior to disconnection/interruption of existing service. Interruption of sewer service shall not exceed 24 hours without approval of the RPR. New or temporary service shall be in place and functional prior to demolition of the drain field. B. Demolition of septic field sewer rock, soil cover, subsoils, drain field pipes, standpipes, insulation, and other septic contaminated loose soils. 1. Complete as much demolition of the septic drain field as necessary for construction of the Project and providing a safe work area during construction. 2. Piping and related materials Blue Lake Expansion Project – Contract No. 9 02105-8 General Construction May 2012 a) Pump clean all septic liquid and sludge material and dispose in accordance with Owner requirements. Use wash down water for cleaning while collecting waste liquids. b) Disinfect pipe and related materials by applying hydrated lime (raise to pH 12 for at least one hour) or 5% sanitizing chlorine solution. c) Dispose of disinfected materials in accordance with Owner solid waste requirements. 3. Soils a) Apply hydrated lime to layer of soil. b) Excavate layer with lime such that soil and lime mixture attain a pH of 12 for at least 1 hour. Contractor is responsible for pH testing and shall perform and report tests as requested by Owner or Engineer. c) Dispose of treated soil in accordance in Owner requirements for biodsolids monofill and Section 02316. C. Demolition of septic contaminated bedrock. 1. Apply hydrated lime to exposed rock. 2. Cover with clean backfill. If concrete is to be poured directly on the bedrock, remove lime from rock before placing any forms, rebar, anchors, or concrete after a minimum contact time of 1 hour at pH 12. D. Existing Septic System Design Drawings: Refer to Reference Documents. 3.09 Water Transmission Main A. Remove existing water transmission main between tie-ins at the locations As Shown or as needed to complete the Work. B. Excavate only enough material to expose the transmission main for cutting and installation of blind flanges and restraint at each end prior to removal of the remainder of the transmission main. Under no circumstances shall excavation extend close enough to disturb thrust blocks. Notify RPR of any thrust block disturbance. C. Prior to cutting of existing water transmission main verify, with the Owner, that valves are closed, that main is isolated, that main is pressure relieved, and verify that leakage is not occurring past valves. D. Remove, handle, and salvage useable sections of the water transmission main pipe, fittings, and other components individually and without causing damage to the materials. Polyethylene wrap, gaskets and bolts shall be disposed in accordance with Section 01800. Salvaged sections of pipe and materials not used in the construction of the Project shall be cleaned and transported for storage at SCIP. E. Remove the 4 inch waterline between the water transmission main and the powerhouse. 3.10 Water Treatment Plant (WTP) Blue Lake Expansion Project – Contract No. 9 02105-9 General Construction May 2012 A. Remove and salvage water treatment plant supply fittings, valves and pipe as necessary to connect new water supply. Relocate tee inside WTP as required to install butterfly valve, fittings, and new PRV for the supply line from the new penstock. Salvaged materials not reused in the construction of the Project shall be cleaned and transported for storage at site designated by the RPR. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02230-1 General Construction May 2012 SECTION 02230 CLEARING AND GRUBBING PART 1 GENERAL 1.01 WORK INCLUDED A. Perform all clearing and grubbing required for construction of project features. 1.02 RELATED SECTIONS A. Section 02315: Rock Excavation and Scaling B. Section 02316: Unclassified Excavation C. Section 02370: Erosion, Sediment and Pollution Control Measures D. Section 02630: Site Drainage PART 2 PRODUCTS Not Used. PART 3 EXECUTION 3.01 GENERAL A. Contractor shall minimize clearing and grubbing activities to land areas required to perform construction. Clearing beyond the specified limits for Contractor’s convenience shall only be performed with the approval of RPR. B. Erosion and sediment control measures must be constructed prior to beginning any land disturbances and in accordance with the approved Erosion and Sediment Control Plan. See Section 02370 for installation methods. C. All vegetation cleared or grubbed for construction will become property of the contractor. D. Burnable cleared and grubbed material may be burned on site in consultation with RPR. Attend fires at all times. Contractor is responsible for obtaining all required local and state permits for brush burning. Comply with all permits and notify RPR and Sitka Fire Department before and after burning. E. All, grubbed stumps, non-salvageable trees and shrubs, and non-burnable woody debris shall be hauled for disposal at the Green Lake Road Spoils Disposal Area. Area is a borrow area on the uphill side at mile 2.3 of the Green Lake Road. Refer to Owner ESCP in the Reference Documents. F. Timber suitable for firewood must be removed from site by Contractor prior to substantial completion. Blue Lake Expansion Project – Contract No. 9 02230-2 General Construction May 2012 G. All locations used for burning shall be restored in accordance with Section 02370 prior to substantial completion. 3.02 CLEARING A. Clearing shall consist of cutting, removal and disposal of all trees, brush, fallen timber, debris, and other perishable materials from areas specified, on the surface of the ground and in the beds of watercourses. B. All material shall be cut to within 6-inches of the surface of the ground. 3.03 GRUBBING A. Following clearing, the entire area shall be grubbed to remove all stumps, large roots and buried logs or debris. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02240-1 General Construction May 2012 SECTION 02240 DEWATERING AND WATER CONTROL PART 1 GENERAL 1.01 WORK INCLUDES A. The Work of this Section consists of the removal of surface water and groundwater as necessary to perform the Work, including all underground work and any excavations where groundwater is encountered. It shall include, but not be limited to: 1. Designing, providing and maintaining all necessary temporary water containment facilities, channels and diversions. 2. Designing, providing and operating all piping, pumps and other facilities and equipment required for dewatering and water control. 3. Designing, furnishing, installing and operating all water retention and settling basins, in conjunction with the Erosion and Sediment Control Plan. (ESCP). 4. Removing all temporary works and dewatering and water control equipment upon completion of the construction activities. B. All Work shall be designed and performed in accordance with the Contractor’s site specific Erosion and Sediment Control Plan (ESCP) and Stormwater Pollution Prevention Plan (SPPP) and Spill Prevention, Control and Countermeasures Plan (SPCC). Refer to Section 02370. C. The work shall be scheduled and constructed to maintain uninterrupted operation of the existing project facilities. 1.02 RELATED WORK A. Section 01012: Hydrology and Hydraulics B. Section 01014: Closure of Existing Intake C. Section 01800: Environmental Conditions and Controls D. Section 02315: Rock Excavation and Scaling E. Section 02316: Unclassified Excavation F. Section 02370: Erosion and Sediment Control Measures G. Section 02400: Rock Tunneling H. Section 03300: Cast-in-Place Concrete 1.03 REFERENCE STANDARDS Blue Lake Expansion Project – Contract No. 9 02240-2 General Construction May 2012 A. Alaska Department of Environmental Conservation, Storm Water Guide, June 2009 B. Environmental Protection Agency, Clean Water Act, Section 402: National Pollutant Discharge Elimination System. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Contractor shall prepare a Dewatering and Water Control Plan as part of the Work Plan (see Section 01200). The plan shall include any planned diversion of surface water, dewatering of work areas including tunnel and subsurface work areas, and borrow and spoil areas. 1. The plan must be approved prior to commencing with any construction activity for which water control is required. 2. Estimated Blue Lake water levels during the Work are described in Section 01012, for use in Contractor’s cofferdam design at the intake. Flows with occurrence frequencies at the powerhouse area, for use in the Contractor’s cofferdam design are available in Section 01012. a) It is anticipated that work at the intake structure and in the intake tunnel will be confined to periods when lake levels are below EL. 330.0, see section 01012. Contractor should schedule construction activities during periods when the lake levels are expected to be below this elevation. 3. The Dewatering and Water Control Plan shall reference the Emergency Action Plan (EAP), refer to Section 01450, and shall describe in detail the action to be taken with respect to the evacuation of workers and equipment from Work areas whenever overtopping or failure of any control of water system is imminent. PART 2 PRODUCTS 2.01 GENERAL A. Furnish all materials, equipment and appurtenances required for installing and removing water control facilities. B. Contractor shall supply sufficient standby pumping and auxiliary equipment to preclude any interruption of pumping operations during periods of breakdown or maintenance. 2.02 COFFERDAMS A. Cofferdam materials shall be suitable for the intended use, satisfy the requirements of the design, and shall meet the requirements and conditions of the applicable water quality regulations. PART 3 EXECUTION 3.01 GENERAL Blue Lake Expansion Project – Contract No. 9 02240-3 General Construction May 2012 A. Contractor shall carry out all water control activities and associated discharges and diversions in compliance with all applicable Federal, State and local water body discharge and pollution control regulations. B. In the event of Contractor’s non-compliance with environmental regulations in the performance of the Work, Contractor shall take immediate corrective actions to re- establish compliance. 3.02 COFFERDAMS A. All cofferdams shall be constructed in accordance with methods suitable for this type of construction. B. Temporary cofferdam construction shall not result in unacceptable damage, defacement, discoloration, etc, to permanent works. Should this occur, Contractor shall make necessary repairs at no additional cost to Owner. C. Where cofferdams are constructed parallel to the flow, adequate measures should be taken, such as placing gabions or rock fill appropriately sized to withstand high velocity flows at the toe of the cofferdam, to prevent undermining. D. Maintain the temporary cofferdam(s) for the periods when protection of the construction or permanent works is required. Maintenance shall include all work necessary to provide the cofferdam in a serviceable condition, capable of sustaining all the design loads with the required factors of safety, and to maintain the construction area in a dewatered state. Maintenance shall include, but not be limited to: 1. Repair of erosion 2. Repair of leaks 3. Repair of impact and flood damage 4. Removal of trash 5. Removal of silt and sediment accumulation upstream E. All temporary cofferdams shall be completely removed and the materials disposed of off-site in accordance with federal, state and local regulations. 3.03 DIVERTING SURFACE FLOW A. Contractor shall install, maintain and operate all channels, flumes, sumps and other temporary diversion and protective works required to divert stream flow and other surface water through or around the construction work areas. B. Surface water control shall be continuous during the period that damage to the construction work could occur. C. The diversion outlet shall be into the same drainageway that the water would have reached before being diverted. Except, water may not be discharged into Blue Lake reservoir from any surface areas affected by the Work. All drainage towards the reservoir from areas disturbed by the Work shall be collected and pumped to ESCP facilities away from the reservoir. Blue Lake Expansion Project – Contract No. 9 02240-4 General Construction May 2012 3.04 DEWATERING SURFACE CONSTRUCTION AREAS A. Foundations, cutoff trenches and all other sections of the construction site shall be dewatered and kept free of standing water and muddy conditions as required for proper execution of the Work. B. Contractor shall furnish, install, operate and maintain all drains, sumps, pumps, casings, well points and all other equipment required to properly dewater the site. Dewatering systems that cause a loss of soil fines from the foundation areas will not be permitted. 3.05 DEWATERING TUNNEL AND SUBSURFACE WORK AREAS A. All tunnel and subsurface work areas shall be dewatered and kept free of standing water and groundwater seepage and leakage from the existing intake gates and the new intake gates as required for the proper execution of the work. B. Dewatering flows from the intake tunnel, existing intake, and new intake shall be collected and pumped to ESCP facilities away from the reservoir. C. Contractor shall furnish, install, operate and maintain the required dewatering system. 3.06 DEWATERING BORROW AND SPOIL AREAS A. Contractor shall maintain all borrow and spoil areas free of surface water or otherwise provide for timely removal of surface and subsurface water that accumulates. 3.07 EROSION AND POLLUTION CONTROL A. All water control activities shall be implemented in accordance with the SWPP and permitting requirements. The work shall be accomplished so that erosion and the transport of sediment and other pollutants are minimized. 3.08 REMOVAL OF TEMPORARY WATER CONTROL WORKS A. When the installed temporary works are no longer required, Contractor shall remove and return the work area(s) to a condition similar to that which existed before construction unless otherwise specified. B. All disturbed areas shall be graded for positive drainage and restored in accordance with Section 02370. C. Contractor shall exercise extreme care during the removal activities to minimize the loss of soil, sediment and debris that may have been trapped during construction. D. Pipes, casings, pumps and any other material or equipment used to dewater the work areas shall be removed from the site as well as any temporary wells. The wells shall be filled to ground level with clean gravel and plugged. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02290-1 General Construction May 2012 SECTION 02290 GEOTECHNICAL INSTRUMENTATION AND MONITORING PART 1 GENERAL 1.01 WORK INCLUDED A. Work includes but is not limited to, furnishing all equipment and materials and performing all labor for slope instrumentation and monitoring of rock excavation activities in the left abutment of the arch dam, or elsewhere, if deemed necessary, by the Owner, during detailed design and construction. The monitoring instrumentation may include, but is not limited to: 1. Borehole extensometers. 2. Borehole pressuremeters. 3. Piezometers. 4. Pressure relief well pipe drains. B. The Work covered by this section shall also include design, selection, supply and installation of long term monitoring systems. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 02020: Survey Control C. Section 02405: Drilling D. Section 02440: Pressure Relief Wells 1.03 REFERENCE STANDARDS A. ASTM D1785: Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120 B. ASTM D2281: Standard Specification for Poly(Vinyl Chloride) (PVC) Pressure- Rated Pipe (SDR Series) 1.04 SUBMITTALS A. Submit under the provisions of Section 01300 for review. 1. At least 30 days prior to the commencement of the installation of instruments, Contractor shall submit to RPR for review, a ‘Geotechnical Instrumentation Plan’. The plan shall include complete installation details and operating and maintenance data instructions for the instruments. Blue Lake Expansion Project – Contract No. 9 02290-2 General Construction May 2012 2. Provide an Operating Instructions for the installed instrumentation to the RPR. This section shall include a general description of each system including all components, diagrams and location plans for each system, a recommended maintenance program and a recommended frequency of monitoring. 1.05 GENERAL A. Turn over instrumentation in good operating condition to Owner. B. Upon final completion of the Work, it is Owner’s intent to continue to use the monitoring devices during the operation of the project. Therefore, the instrumentation shall be rugged and reliable and be installed in accordance with the manufacturer’s instructions to operate for its expected life span. 1.06 INSTALLATION AND READING OF INSTRUMENTATION A. The installation of instruments shall be undertaken by a specialist subcontractor unless Contractor has personnel who are suitably experienced to undertake the Work. B. Provide all the necessary supervision and equipment for the installation and reading of the instruments at the locations As Shown or where directed by RPR. C. Allow sufficient time to read instruments and witness or participate in the taking of the readings upon installation to verify instrumentation is working properly. The procedures for installation of instruments shall be agreed with RPR prior to any work being undertaken. D. Locate air, water, electrical supplies and other utilities to be clear of the instrumentation. E. All instrumentation stations shall be clearly marked with an identifying reference number. F. Protect all instruments and connections from damage and displacement during progress of work, and shall install markers and barricades as required. Provide steel covers firmly fixed to the rock surface to protect all instrument heads from damage. Damage to, or displacement of, instruments and connections shall be repaired immediately to satisfaction of Contractor. PART 2 PRODUCTS 2.01 EXTENSOMETERS A. A borehole extensometer shall consist of several steel rods in protective plastic sleeves with groutable anchors, reference head and protective cap. The steel rods shall be recoverable for inspection and repair. The reference head shall be designed to allow reading with a depth micrometer to 0.5-mm resolution. The protective sleeve shall be made of polyvinyl chloride (PVC) pipe meeting the requirements of ASTM D1785 for Schedules 40 and 80 and D2241. The extensometers shall be Geokon Model A-3 or equivalent. 2.02 BOREHOLE PRESSUREMETERS Blue Lake Expansion Project – Contract No. 9 02290-3 General Construction May 2012 A. The encapsulated borehole pressure cell shall be an RST BPC0001, manufactured by RST Instruments Ltd., 200-2050 Hartley Ave., Coquitlam, BC V3K 6W5, http://www.rstinstruments.com/, or equivalent. 2.03 PIEZOMETERS A. Piezometers shall be RST VW 2100 2 MPa vibrating wire piezometers, manufactured by RST Instruments Ltd., or equivalent and shall be installed in the location and depths As Shown in accordance with the supplier’s recommendations. 1. Provide backfill materials as recommended by Supplier. 2. Provide a secure fibreglass enclosure as manufactured by piezometer Supplier. 2.04 CONCRETE A. All concrete shall be Mix C in accordance with Section 03300. PART 3 EXECUTION 3.01 EXTENSOMETERS A. Extensometers in the excavation faces, as directed by RPR shall be installed not later than 7 days after completion of excavation and installation of support. The holes for installation shall be thoroughly washed prior to insertion of the extensometer bundle. B. Reading frequency shall be every 3 days by RPR. 3.02 BOREHOLE PRESSUREMETERS A. Encapsulated borehole pressure cells shall be installed as directed by RPR in the exploratory drill holes. B. Reading frequency shall be every 3 days by RPR. 3.03 PIEZOMETERS A. Backfill piezometers using the fully grouted method as recommended by the Supplier. B. Connect the cables to the multi-channel datalogger and install a secure fiberglass enclosure for the data logger around each borehole. C. Piezometer readings shall be recorded using a datalogger installed as directed by RPR and be recorded daily by RPR. 3.04 PRESSURE RELIEF WELL PIPE DRAINS A. The frequency of reading for the pipe drains shall be every 3 days by RPR. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02310-1 General Construction May 2012 SECTION 02310 BACKFILL PART 1 GENERAL 1.01 WORK INCLUDED A. Perform all placing and compacting of backfill materials As Shown. Also provide any geotextile fabric necessary for backfill. B. Backfilling shall include: 1. Backfill for structures 2. Backfill trench excavations 3. Backfill for the penstock 4. Backfill behind retaining walls 5. Backfill for roads/parking areas C. Contractor shall provide the services of a soil testing laboratory. Contractor shall coordinate lab and field testing to accommodate his construction schedule. 1.02 RELATED WORK A. Section 01300: Submittals B. Section 02240: Dewatering and Water Control C. Section 02315: Rock Excavation and Scaling D. Section 02316: Unclassified Excavation E. Section 02370: Erosion, Sediment and Pollution Control Measures F. Section 02510: Water Distribution G. Section 02530: Sanitary Sewerage H. Section 02620: Subdrainage System I. Section 02630: Site Drainage J. Section 02700: Gravel Surface, Base and Subbase Courses K. Section 02950: Site Restoration L. Section 03300: Cast-In-Place Concrete Blue Lake Expansion Project – Contract No. 9 02310-2 General Construction May 2012 M. Section 13100: Penstock Installation 1.03 REFERENCE STANDARDS A. AASHTO M 288: Standard Specification for Geotextile Specification for Highway Applications B. Alaska DOT & PF Standard Specifications for Highway Construction, 2004 C. ASTM C 136: Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates D. ASTM C 535: Standard Test Method for Resistance to Degradation of Large Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine E. ASTM D 4253: Standard Test Methods for Maximum Index Density and Unit Weight of Soils Using a Vibratory Table F. City and Borough of Sitka, Alaska Standard Specifications for Streets-Parks- Utilities-Drainage, 2002, http://www.cityofsitka.com/government/departments/publicworks/index.html G. OSHA Regulations Part 1910: Occupational Safety and Health Standards H. WAQTC FOP for AASHTO T 180: Moisture Density Relations of Soils: Using a 4.54-kg (10-lb) Rammer and 457-mm (18-in) Drop I. WAQTC FOP for AASHTO T 310: In-Place Density and Moisture Content of Soil and Soil-Aggregate by Nuclear Test Methods (Shallow Depth) 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Prior to placement of any backfill, Contractor shall submit test reports indicating conformance with the grading requirements specified below. C. At the time of delivery, a batch ticket shall be supplied to RPR indicating the material type, material source, date of delivery, and tons delivered. PART 2 PRODUCTS 2.01 MATERIALS A. All backfill and fill materials shall be void of any frozen material, brush, roots, stumps, sod, or other organic or unsuitable materials. The suitability of all materials for use in construction will be determined by RPR. Contractor shall continuously maintain the fill materials in a satisfactory manner until the final completion and acceptance of all of the Work. B. Backfill material shall be sound, granular material conforming to the following gradation requirements, and shall be well graded within the specified limits. 1. Bedding Material C-1 – This material may be used as backfill for all site drainage features and structures. Aggregate shall be crushed stone or crushed gravel and Blue Lake Expansion Project – Contract No. 9 02310-3 General Construction May 2012 consist of sound, tough, durable pebbles or rock fragments of uniform quality. The material shall conform to CBS Standard Specification Section 20.11 and have the following gradation: Sieve Size Percent Passing by Weight 1-1/2 inch 100 1 inch 70-100 3/4 inch 60-90 3/8 inch 45-75 No. 4 30-60 No. 8 22-52 No. 40 8-30 No. 200 0-6 2. Bedding Material D-1 – This material shall be used as backfill for all water and sewer mains, penstock and structures. Aggregate shall be crushed stone or crushed gravel and consist of sound, tough, durable pebbles or rock fragments of uniform quality. The material shall conform to CBS Standard Specification Section 20.11 and have the following gradation: Sieve Size Percent Passing by Weight 1 inch 100 3/4 inch 70-100 3/8 inch 50-80 No. 4 35-65 No. 8 20-50 No. 40 8-30 No. 200 0-6 3. Filter Material – This material shall be used as backfill along any drainage piping or other areas where the material must be free draining. Material shall be washed and contain no fines. The material shall be either naturally occurring or crushed gravel and conform to CBS Section 20.11 and have the following gradation requirements: Sieve Size Percent Passing by Weight 2 inch 100 1 ½ inch 95-100 3/4 inch 0-20 3/8 inch 0-5 4. Rock Fill – The materials for any compacted rock fill shall be sound, durable, unrippable rock. Compacted rock fill material shall be quarry run sizes generally between 12 inches maximum dimension and ¾ inch minimum size. 5. Native Backfill – Materials created through excavation and trenching operations. The material may not be used for any structural backfill purposes or within the load influence of a designated vehicular surface. Material must be approved by RPR for backfill. 6. Riprap – The material shall conform to Alaska DOT & PF Standard Specifications, Section 611. Riprap should be hard, angular, evenly graded stones. Do not use rounded or stones on slopes greater than 2H:1V. Only use Blue Lake Expansion Project – Contract No. 9 02310-4 General Construction May 2012 stones with breadth and thickness at least ¼ of its length. Riprap shall have the following gradations with percents by total weight: a) Class I: 0-100% weighing up to 25 lbs (Approx. 8 inch dia.) 0-10% weighing more than 50 lbs (Approx. 10 inch dia.) b) Class II: 0-15% weighing up to 25 lbs (Approx. 8 inch dia.) 50-100% weighing 200 lbs or more (Approx. 16 inch dia.) 0-10% weighing more than 400 lbs (Approx. 20 inch dia.) c) Class III: 0-15% weighing up to 25 lbs (Approx. 8 inch dia.) 50-100% weighing 700 lbs or more (Approx. 24 inch dia.) 0-10% weighing more than 1400 lbs (Approx. 31 inch dia.) d) Class IV: 0-15% weighing up to 400 lbs (Approx. 20 inch dia.) 50-100% weighing 2000 lbs or more (Approx. 35 inch dia.) 0-10% weighing more than 5400 lbs (Approx. 48 inch dia.) C. Geotextile Fabric: The geotextile fabrics used for separation of backfill materials, subsurface drainage and riprap may be either woven or nonwoven and conform to AASHTO M 288. The geotextile fabrics shall meet the following physical and mechanical properties: Geotextile Property Material Separation Subsurface Drainage Riprap Tensile Strength, lbs 180 90 200 Elongation, %30 N/A 15-70 Burst Strength, psi 400 125 320 Trapezoidal Tear, lbs.70 25 50 Puncture Strength, lbs 70 25 80 Permittivity, Sec-1 0.05 0.08 0.08 UV Degredation, %70 70 70 Apparent Opening Size #30 to 70 #70 min #30 min PART 3 EXECUTION 3.01 SURFACE PREPARATION A. After completion of clearing, grubbing, and excavation as required, the area shall be prepared for backfill. Loose soil and topsoil shall be removed. Prior to installation of backfill, soil areas shall be proof rolled and soft areas removed. Where backfill is to be placed on rock, the rock surface shall be free from all soft, loose, or disintegrated material greater than 3 inches in thickness. B. Contractor shall obtain approval of prepared surfaces RPR prior to placement of backfill and fill. C. Contractor to notify RPR of any questionable foundations for review prior to initiating backfill operations. Any subsurface material deemed unsuitable for foundations by RPR shall be removed and backfilled with the approved bedding material. Blue Lake Expansion Project – Contract No. 9 02310-5 General Construction May 2012 3.02 PLACING AND COMPACTION A. Backfill and fill shall be placed and compacted to the lines and grades As Shown. B. No backfill or fill materials shall be placed on any portion of the foundations or against or upon any structure until such portions and structures have been approved by RPR. Backfilling near newly placed concrete structures shall also be in accordance with Section 03300. Contractor shall repair any damage to an approved foundation or structure surface prior to placement of backfill or fill materials. C. All backfill and fill materials shall be placed in the dry. D. No backfill or fill materials shall be placed on frozen ground. E. Material shall be placed and compacted in continuous, approximately horizontal layers up to the following maximum thicknesses: 1. Bedding Material C-1: 12 inches 2. Bedding Material D-1: 12 inches 3. Filter Material: 12 inches 4. Rock Fill: 18 inches 5. Native Backfill: 12 inches 6. Riprap: N/A F. Compaction shall be done with not less than a 10-ton (drum weight) smooth steel drum vibrating roller or other compaction equipment suitable to RPR. Weight per linear foot of drum shall exceed 4,000 pounds. G. Each layer of the material shall be compacted by four consecutive passes of the roller. The roller shall travel at a maximum velocity of 3 ft per second. A pass of the roller shall be defined as one direct vertical application of compaction effort over all areas of the lift surface. H. Portions of the fill, which, in the opinion of RPR, cannot be compacted adequately with rollers because of inaccessibility or the possibility of damage to structures, shall be placed in layers not thicker than 6 inches and compacted with a vibrating plate or vibrating drum compactor weighing not less than 200 lbs. Each layer shall be compacted by four consecutive passes minimum of the compactor. Vibration frequency should be no less than 1,600 cycles per minute. The type of tamper and its method of operation shall be subject to acceptance by Engineer. 1. Care shall be taken to avoid contacting penstock or any other backfilled feature with vibratory equipment. Any damaged structure shall be repaired by Contractor at no expense to Owner, subject to acceptance of repair by RPR. If structure cannot be adequately repaired by determination of RPR, it shall be replaced. Blue Lake Expansion Project – Contract No. 9 02310-6 General Construction May 2012 I. Any compaction to be performed in confined spaces shall be performed in accordance with OSHA Regulations Part 1910: Occupational Safety and Health Standards, and shall be part of Contractor’s Site Specific Health and Safety Plan. J. The backfill surfaces between lifts shall be kept free from unsuitable materials. K. Construction traffic shall be planned to ensure an even distribution of traffic over the backfill surface. L. Sampling of aggregates shall be done in accordance with ASTM C 136. M. The testing of moisture content of materials shall be done in accordance with WAQTC FOP for AASHTO T 180. Materials shall be within +/- 2% of optimum moisture content. N. The in-place density testing of materials shall be done in accordance with WAQTC FOP for AASHTO T 310. O. Material shall be compacted to the following maximum density: 1. Bedding Material C-1: 95% 2. Bedding Material D-1: 95% 3. Filter Material: N/A 4. Rock Fill: N/A 5. Native Backfill: 90% 6. Riprap: N/A P. Riprap shall be placed to its full course in one operation. It shall be placed to the grade, length and width As Shown, with a minimum thickness 1.5 times the maximum stone size. 1. Where riprap is to be placed on soil, a geotextile layer shall be installed prior to riprap placement. 2. Contractor shall place riprap in a well graded mass to minimize segregation and voids. Fill unacceptable voids with smaller stones. 3.03 Geotextile Fabric Installation A. The placement surface shall be smoothed prior to installation and free of holes or ruts. The surface shall also contain no stumps, roots, boulders or other sharps objects which may cause punctures. B. Unroll fabric directly onto the prepared surface. Overlap adjacent sections of fabric a minimum of 3 feet. C. Backfill materials may be dumped directly onto the fabric surface provided that the drop height is less than three feet and does not puncture the fabric. Backfill materials may also be carefully pushed and spread by machinery. Take precautions to maintain geotextile fabric overlaps and continuity while performing backfill activities. Spread backfill material in the direction of fabric overlaps. Blue Lake Expansion Project – Contract No. 9 02310-7 General Construction May 2012 D. Do not operate machinery on unprotected geotextile fabric. Maintain a minimum depth of 1 foot between machinery and fabric. E. In the event of a fabric puncture or tear, clean backfill materials from the fabric. Overlay the torn area with fabric a minimum overlap of 3 feet on all sides. 3.04 PLACING BACKFILL IN WATER A. Backfilling may not be performed in water without the approval of RPR and ECM. Where it is not practical to dewater an area prior to backfilling, the backfill shall be dumped in a continuous layer to 1 ft above the water level and compacted. Backfilling above the water level shall be as specified herein. Contractor may elect to use controlled, low-strength material (CLSM) for structural backfill. However, it must contain an anti-washout additive and include appropriate sediment controls during placement. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02315-1 General Construction May 2012 SECTION 02315 ROCK EXCAVATION AND SCALING PART 1 GENERAL 1.01 WORK INCLUDED A. Perform all Work required for the excavation, scaling, disposal and cleaning of rock surfaces As Shown and specified herein. B. Foundation preparation for new concrete structures, installation of rock support, blast monitoring and pre-blast survey are included in this section. C. Rock excavation shall be performed within the limits of the Vibration and Noise Management Plan. 1.02 WORK NOT INCLUDED A. The Work covered by this Section does not include the removal of existing loose (removable by hand or with hand tools such as chisel and hammer) rock rubble, shotcrete, or masonry in connection with the demolition of structures as covered in Section 02105 or removal of unclassified excavation (soils) as covered in Section 02316. 1.03 RELATED SECTIONS A. Section 01300: Submittals B. Section 02105: Demolition C. Section 02230: Clearing and Grubbing D. Section 02240: Dewatering and Water Control E. Section 02316: Unclassified Excavation F. Section 02370: Erosion, Sediment and Pollution Control Measures G. Section 02400: Rock Tunneling H. Section 02410: Rock Bolts I. Section 02411: Rock Anchors J. Section 02413: Grouted Dowels K. Section 03300: Cast-In-Place Concrete 1.04 REFERENCE STANDARDS A. ASTM D1785: Polyvinylchloride Plastic Pipe, Schedule 40, 80, and 120 Blue Lake Expansion Project – Contract No. 9 02315-2 General Construction May 2012 B. United States Army Corps of Engineers EM-1110-2-3800: “Systematic Drilling and Blasting for Surface Excavations”. C. International Society of Explosives Engineers (ISEE): “Field Practice Guidelines for Blasting Seismographs”, Copyright 1999. 1.05 SUBMITTALS A. Submit under the provisions of Section 01300 for review, an overall Rock Excavation Plan of proposed methods and sequence for open-cut excavation for review by RPR or as part of the Work Plan. Details of the plan shall meet all the requirements as outlined under these Specifications. The plan shall include proposed equipment and crews; rock spoil removal and disposal strategy; typical depths of blast holes; the typical type, strength, amount, and distribution of explosives to be used per hole, per delay and per blast; the normal sequence and pattern of delays, controlled perimeter blasting procedures; the description and purpose of any special methods to be adopted by Contractor; copies of licensed blaster’s certificate and safety and warning procedures; at least three original copies of the company safety plan and a site specific hazard analysis plan; any certificates of special training including blasting certificates, high angle rescue certificates and scaling course certificates; and monitoring plan including types of instruments, proposed location for monitoring and method of reporting monitoring results. If the plan fails to meet the requirements of these Specifications, a new plan, in whole or in part, shall be submitted by Contractor. The Rock Excavation Plan may be combined with the Rock Tunneling Plan as described in Section 02400. B. The Rock Excavation Plan shall also include all Contractor proposed excavation support materials, such as: 1. Shotcrete information. 2. Wire mesh information. 3. All rock support accessories information. 4. Certified mill lists for steel, material lot and heat numbers. 5. Note: Rock bolt submittal requirements are covered in Section 02410. C. If, in a specific area, a plan which has been previously adopted does not produce rock surface conditions in accordance with the requirements of these Specifications, Contractor shall submit a revised plan before continuing excavation in adjacent areas. D. Maintain accurate records of all rock scaling. Make available to RPR copies of all rock scaling records. Include any unusual occurrence, but not limited to, rockfalls, unstable or soft ground and inflows of water. E. Revisions to plans: If, in a specific area, a plan which has been previously adopted does not produce rock surface conditions in accordance with the requirements of these specifications, Contractor shall submit a revised plan before continuing scaling in adjacent areas. Blue Lake Expansion Project – Contract No. 9 02315-3 General Construction May 2012 F. As construction progresses, Contractor shall re-inspect as often as necessary to verify the adequacy of his construction methods for prevention of damage. If any changes are necessary, this shall be formally submitted to RPR in writing. 1.06 DEFINITIONS A. “Rock” shall mean sound material of hardness and texture such that it cannot be readily loosened or removed by backhoe, clamshell, or hand shoveling. This definition shall not include frozen material. B. "Rock excavation" shall mean the removal of all rock which requires drilling, barring, wedging or ripping for removal; and the removal of boulders, pieces of detached rock, and buried shotcrete two cubic yards or more in volume, each piece. C. “Line drilling” shall mean the drilling of a row of drill holes along the excavation limit spaced no more than three times the hole diameter or 6 inches on centers, whichever is greater. It is suggested that Contractor line drill 3-inch diameter holes; however, it remains Contractor’s responsibility to successfully line drill and split the rock based on his experience and equipment. D. “Scaling” shall mean removal of loose, detached rock, which naturally occurs or results from mechanical rock excavation, to prevent unsafe conditions. Such rock removal is generally accomplished by the use of hand tools to provide a sound, finished rock surface. E. “Smooth blasting” shall mean a controlled blasting technique where the neat line holes are detonated after the bulk has been blasted and removed. F. “Pre-splitting” shall mean the formation of cracks along the final excavation faces by firing a single row of holes prior to the initiation of the rest of the holes of the blast pattern. G. A “round” shall mean a single cycle of drilling, loading and blasting to excavate rock, including scaling, mucking and moving equipment in and out. H. “Overbreak” shall mean the volume of rock removed beyond the neat lines for the excavation As Shown. I. “Peak particle velocity”: The greatest of the three peak velocity components measured at any point, with the three components being measured in the vertical and mutually perpendicular horizontal directions. 1.07 ROCK EXCAVATION AND SCALING RECORDS A. In addition to other records, Contractor shall maintain accurate records of all rock excavation and blasting operations performed under this Contract. 1. As-built details of the location and elevation of blast, the drilling pattern, number, locations and sizes of drill holes and the type and amount of explosives used in each round or lift, the type, location and firing pattern of detonators and the time of each blast. 2. Any unusual occurrence including, but not limited to, rockfalls, unstable or soft ground and inflows of water. Blue Lake Expansion Project – Contract No. 9 02315-4 General Construction May 2012 3. Contractor shall make available to Owner copies of all rock excavation and blasting records as requested. 1.08 SAFETY A. Safety within the excavation is the responsibility of Contractor. B. Maintain haul roads and access roads in stable and safe conditions. C. Provide warning to site personnel and public of blasting. 1.09 PRE-BLAST SURVEY A. Prior to the start of construction, conduct a Pre-blast Survey. The purpose of the Pre-blast Survey is to obtain sufficient evidence of structure condition to verify the adequacy of methods for prevention of damage and for use in defense against possible claims for damage. B. The pre-blast survey shall be made by qualified specialists approved by RPR and retained for this purpose by Contractor to observe the condition of existing structures and facilities in the vicinity of the work. The survey shall include inspections of all structures and facilities located entirely or partially within 500 ft of areas to be blasted. The pre-blast survey shall include diagrams, sketches, photographs, videos of all walls, partitions, floors and ceilings showing existing cracks, or damage and other data as applicable to locate and define the amount and extent of existing structural deficiencies. The pre-blast survey shall be signed by those who witnessed and/or took part in the inspections. All existing structural deficiencies, major or minor, shall be shown. C. Prepare and deliver to RPR prior to the start of construction two (2) bound copies of the Pre-blast Survey containing all field notes taken, sketches, and diagrams prepared, photographs obtained, video tapes taken, descriptions and reports, all signed and witnessed by those taking part in the inspection. Thereafter, as construction progresses, re-inspect as often as necessary to verify the adequacy of construction methods for prevention of damage. Data obtained from each re- survey shall be promptly delivered to RPR. D. Nothing contained herein shall relieve Contractor of responsibility for claims arising from his construction operations. Failure to inspect any structure, whether or not required by these Contract Documents, or inadequacy of the inspections, shall not relieve Contractor of his responsibility. 1.10 PERMITS A. Obtain all necessary permits to perform the blasting. PART 2 PRODUCTS 2.01 GENERAL A. Furnish all products necessary for the completion of the Work covered by this Section. B. Use of non-explosive (chemical) demolition agent such as Bristar or approved equal may be considered for some of the excavation activities. Blue Lake Expansion Project – Contract No. 9 02315-5 General Construction May 2012 2.02 DRAIN HOLES A. Pipe sleeves for drain holes, as required to stabilize the holes, shall conform to ASTM D1785, Schedule 40 PVC Pipe. PART 3 EXECUTION 3.01 EXCAVATION METHODS A. Secure the services of a qualified blasting consultant with at least 10 years experience in blasting close to sensitive structures. The specialist shall plan and assist in the execution of the Rock Excavation Plan. B. Rock excavation shall be accomplished by blasting, line drilling, cutting, wedging, barring, hammering, mechanical ripping, or non-explosive (chemical) demolition agent, or a combination thereof. Contractor shall select and be responsible for methods and procedures to be used, except as hereinafter provided. C. Perform drilling in accordance with Section 02405. D. Contractor shall do all excavation work in accordance with good modern practice and according to local, state and federal regulation, using methods and techniques that will minimize overbreak beyond the limits shown on the drawings, and that will preserve the rock beyond these limits in the soundest possible condition. Particular care shall be taken to avoid damage to existing structures which are to remain. Any excavation beyond what is shown on the drawings or repair of damage to materials that are to remain shall be at Contractor’s expense. Damage shall mean any structural defect, crack, deformation, or other change to the structure or slope caused by the blasting. E. Scaling: 1. Rock scaling will be required on all or part of the exposed rock face to allow subsequent placement of concrete or reinforced shotcrete or provide smooth lining for flow conveyance for otherwise untreated surfaces that will be exposed to flow. 2. It is anticipated that most of the scaling will be accomplished using only hand tools, scaling bars, and pry bars. Contractor may be required to provide supplementary compressed air power tools such as pavement breakers, jack hammers and rock splitters complete with power supply and necessary hoses. F. Contractor shall be responsible for the stability and safety of all his excavations until final acceptance, and shall do all remedial work required for the duration of the Contract to ensure that all excavated rock surfaces are maintained in a stable and safe condition. G. Install rock bolts under provisions of Section 02410 immediately following excavation and prior to further excavation or commencement of other construction activities adjacent to the rock face. 3.02 DRAIN HOLES A. Drill drain holes in accordance with Section 02405. Blue Lake Expansion Project – Contract No. 9 02315-6 General Construction May 2012 B. As rock excavation progresses, install all drain holes required, As Shown. In surface excavation, the height between the bottom of the excavation and the lowest row of drain holes shall not exceed 8 ft at any time during excavation. C. All water emanating from the drain holes shall be directed to sumps, pipe headers, flumes, monitoring weirs, or other collector systems and the water subsequently removed from the excavation area. D. Where required to ensure the stability of the hole, supply and install in the drain holes slotted liners manufactured from rigid Schedule 40 PVC pipe, or acceptable equivalent. E. Continuously protect and maintain the drain in working order. Drain holes which become inoperative due to improper installation or from being plugged with debris shall be re-drilled and washed or replaced. 3.03 INSPECTION OF EXCAVATED ROCK SURFACES A. Plan and schedule excavation so that inspection and geologic mapping of the rock faces that may be made by RPR for each 20 ft of depth excavated. For convenience and ease of installation of rock support, Contractor may limit his depth of excavation of any intermediate stages of excavation to less than 20 ft. Contractor shall clean rock surfaces exposed during excavation to permit a thorough inspection and assessment of the condition of the rock by RPR. Excavation shall not proceed until the inspection has been completed and the required rock bolts installed. B. Cleaning of rock surfaces for inspection shall consist of the removal of all organic material, soil, demolition debris, and loose rock from the exposed rock surface. Cleaning may be done with high pressure air jets, water jets, brooms or by any other method acceptable to RPR. C. All standing water shall be removed by Contractor from the area to be inspected to permit proper examination of the rock. D. Contractor shall provide suitable means of access for inspection of the excavated and scaled areas by RPR. 3.04 EXCAVATION LIMITS A. Rock excavation will be based on the neat lines As Shown. No payment will be made for rock excavation beyond these neat lines. Any rock projecting inside the neat lines shall be removed. Care shall be taken in removing this under excavated rock to avoid disturbance of the rock mass which might cause subsequent over excavation. B. Contractor shall survey all excavated surfaces. Cross-sections shall be surveyed at intervals as approved by RPR averaging 10 ft on center to suit the degree of irregularity of the surface and geometry of neat lines. Contractor shall graphically plot rock profiles against neat lines to determine compliance with the specifications. The spacing of survey points along any section shall be selected to ensure the surveyed profile is representative of the actual rock profile. Additional points shall be surveyed as necessary to locate extreme surface undulation and sharp changes in grade. Blue Lake Expansion Project – Contract No. 9 02315-7 General Construction May 2012 C. Over excavated rock faces against which concrete or shotcrete is to be placed shall be backfilled with concrete or shotcrete to the neat lines. No additional payment shall be made for this concrete or shotcrete. The cost shall be deemed to be included in the excavation and shotcrete rates. D. Over excavated faces against which concrete or shotcrete is not to be placed may be required to be backfilled with concrete or shotcrete if overbreak exceeds 2 ft in depth. Grouted dowels may be required to secure the concrete or shotcrete to rock on steep faces. Backfill concrete or shotcrete shall be placed to within 2 ft of the neat line. RPR shall determine the need for backfill concrete or shotcrete based on the stability requirements of the rock face and the effect of the overbreak on hydraulic flow. No additional payment shall be made for backfill concrete or shotcrete or grouted dowels. The cost shall be deemed to be included in the rates for rock excavation. 3.05 CONTROLLED BLASTING A. Use controlled blasting on all surfaces excavated by the best methods of blasting. Controlled blasting techniques may include presplitting smooth blasting and line drilling as agreed upon with the RPR. 3.06 BLASTING PROCEDURES A. Drilling and Blasting: 1. All blasting and use of explosives shall be in strict compliance with the latest federal and state regulations. 2. Perform blasting in a manner such that limits for PPV and air overpressure are not exceeded at all site structures. 3. Prepare Blast Reports for each blast. These reports shall include the location, depth and area of the blast; diameter, depth, pattern and inclination of blast holes; type, strength, amount, column load, and distribution of explosives per hole and per delay; sequence and pattern of delays; and description and purpose of any special methods to be used. As excavation proceeds, Contractor shall adjust his techniques as necessary to maintain acceptable excavation results and minimize overbreak. 4. Plan at least 24 hours in advance before placement of any explosives for blasting. 5. Protect all sensitive structure areas from fly rock by using blasting mats which are in good condition or other suitable measures. 6. Initiation of all blasting materials and explosives shall be by non-electric means B. Explosives – Handling and Use: 1. All explosives onsite shall be stored in suitable magazines provided and maintained by Contractor. The magazine shall be appropriate for the types and quantities of explosives to be used. The magazine shall be constructed, fitted out, grounded, and made secure in compliance with all federal and state regulations. Blue Lake Expansion Project – Contract No. 9 02315-8 General Construction May 2012 2. Keep fully detailed records giving the types and quantities of explosives delivered, on hand, and used, including Supplier’s batch numbers. Similar records of detonators by types and delays shall also be maintained. These records shall be available for inspection and shall be maintained at Contractor’s site office. 3. Transport of explosives and detonators shall be in vehicles suitably grounded and protected from lightning strikes and electrical storm phenomena, all in accordance with applicable regulations. 4. No explosives shall be handled, transported, or in any way made use of during any period of electrical storm, lightning, or other electrical phenomena. 5. A blaster designated by Contractor and experienced in controlled blasting techniques shall be present during, and in direct control of, all explosives handling, loading, and blasting operations. 6. Take every precaution to prevent premature explosions and misfires. Under no circumstances are lighting or power cables to be used for fitting. 7. An adequate warning system shall be provided to ensure that all persons are at a safe distance before a blast is detonated. Blasting signal signs shall conform to 29 CFR 1926.909 (OSHA) and shall be posted at each access to the work site. 8. Should a misfire occur, Contractor shall warn all persons affected and no persons other than the designated blaster and supervisor shall enter the area until the charge has exploded or been made safe. Only when Contractor’s designated blaster and his supervisor are satisfied that danger no longer exists will the workers be allowed back into the area. C. Blast Monitoring: 1. Monitor each blast by means of three-component particle velocity measuring equipment to determine particle velocities generated by the blast. 2. The blast monitoring equipment shall be capable of measuring and recording the displacement, velocity, and frequency in three vertically perpendicular directions: vertical, radial, and perpendicular to the vibration source. The blast monitoring equipment shall have variable trigger level settings, digital peak velocity memory, and shall be capable of performing Fourier transforms on the data. 3. Blast monitoring equipment shall be of a type that provides a readout that can be fully evaluated on site. Recording on magnetic tape that requires special equipment for interpretation is unacceptable. 4. Blast monitoring instruments shall have been calibrated within the previous six months to an acceptable standard. 5. The blast monitoring equipment shall have a flat velocity frequency response with a minimum broad band channel of 6 Hz to 150 Hz with a tolerance equation better than +10 percent. 6. Install and operate blast monitoring equipment in accordance with the Field Practice Guidelines for Blasting Seismographs as set forth by the International Blue Lake Expansion Project – Contract No. 9 02315-9 General Construction May 2012 Society of Explosives Engineers and in accordance with this specification. The more stringent shall apply. 7. Maintain an adequate supply of printing paper for data output. 8. Provide monitoring equipment to monitor vibration velocities at a minimum of three locations. Install at least two monitoring locations, spaced at least 30 ft apart, and adjacent to the base of the left abutment Blue Lake Dam, nearest the specific blast. Contractor shall supply all recording equipment sensors, cables, accessories, printing data reduction equipment, and skilled operators. 9. The locations for blast monitoring velocity measurements will be selected by the Contractor and RPR after the pre-blast survey. The locations will be based on distance from the blast, the condition of the structure, and the importance and risk associated with the structure. Locations may be changed during construction. Monitoring locations include, but are not limited to, the drainage tunnel, intake tunnel, penstock, powerhouse, Water Treatment Plant, Blue Lake Dam, and existing structures. 10. Provide power supply for monitoring equipment. If the equipment is battery powered, maintain at least one spare fully charged battery for each monitoring unit. 11. Provide protection for blast monitoring equipment left unattended against damage, unauthorized movement of the sensors, theft and vandalism. 12. Prepare Blasting Record for each blast. The record shall include date, time, location, and elevation of the blast; the depth, spacing, burden, number, and diameter of holes; delay pattern; powder factor and maximum quantity of explosive per delay; distance to nearest structure; and seismograph locations and copies of seismograph reading records. 13. Continuously monitor for stray electrical currents utilizing device(s) designed for detecting both stray ground electrical potential and currents and atmospheric electric potential over ground. Monitoring devices shall be OSHA or MSHA approved, and shall be specifically designed for the specified monitoring use. 14. Adequately identify in writing to RPR all potential EMF and RF hazards to his operation, and eliminate or guard against such hazards in accordance with OSHA Standards and IME “Safety Guide for the Protection of Radio Frequency Radiation Hazards in the Use of Electric Blasting Caps”. D. Limiting Particle Velocities: 1. Blasting shall be done in a manner such that adjacent existing structures, associated foundations and project concrete structures are not damaged. Contractor remains responsible for damage to existing structures. Do not exceed the following particle velocities. Location or Structure Maximum Particle Size Velocity (in/sec) Existing Blue Lake Dam 5.0 Powerhouse 1.0 Blue Lake Expansion Project – Contract No. 9 02315-10 General Construction May 2012 Water Treatment Plant 2.0 Intake and Gate Structures 2.0 Other Structures 2.0 Tunnels, Existing and New Excavations 2.0 Locations along Penstock 1.0 Adjacent framed structures at point closest to blast 2.0 Adjacent massive concrete structures and concrete more than 7 days old 5.0 Concrete greater than 24 hours old but less than 7 days old 2.0 For concrete less than 24 hours old Blasting not allowed 3.07 DISPOSAL A. Contractor shall be responsible of the coordination of excavation, stockpiling, reuse of the material in the Work, and disposal of surplus materials. B. Unless otherwise directed by RPR, excess excavated rock materials shall be disposed of As Shown and in accordance with Owner ESCP (refer to Reference Documents) and in accordance with local, state and federal law. Care shall be taken to prevent refuse and rock debris from falling into the adjacent water bodies. Any debris or refuse which falls into the water bodies shall be removed promptly. C. Excavated materials shall be removed and disposed of as the Work progresses. Debris shall not be allowed to accumulate in the Work area. D. See Section 02105 (“Chain-of-Custody” letter) for proper handling of waste materials. E. Contractor may use excavated rock for his temporary works. The rock used for any temporary work shall be removed upon completion. 3.08 ROCK FOUNDATION PREPARATION FOR NEW CONCRETE AND SHOTCRETE A. Rock surfaces against which concrete or shotcrete is to be placed shall be clean, solid, and free from oil, standing or running water, mud, coatings, debris, and loose, semi-detached, or unsound fragments. B. Rock surfaces shall be prepared before placement of forms, reinforcing steel, concrete or shotcrete. C. Plan and schedule foundation preparation so that an inspection of the rock surface may be made by RPR. This inspection of rock surface will be after completion of foundation preparation and at least two days prior to placement of forms, reinforcing steel, concrete or shotcrete. D. The methods employed for the rock surface preparation shall include the use of high-velocity air-water jets, wet sand blasting, stiff wire brooms, picks or other methods. Rock surfaces shall then be washed to remove all loose material. All Blue Lake Expansion Project – Contract No. 9 02315-11 General Construction May 2012 pools of water shall be removed from depressions to ensure proper bonding of the fresh concrete or shotcrete to the rock surface. E. Where water flows from or over rock surfaces against which concrete or shotcrete is to be placed, the water shall be excluded from the area by caulking or diversion pipes, or other means, and in such a manner that the concrete or shotcrete will be unaffected by the action of the water through erosion or percolation by hydrostatic pressure. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02316-1 General Construction May 2012 SECTION 02316 UNCLASSIFIED EXCAVATION PART 1 GENERAL 1.01 WORK INCLUDED A. Perform all excavation and disposal of unclassified material As Shown. Unclassified Excavation shall mean all excavation other than rock excavation as defined in Section 02315 or demolition as covered in Section 02105. 1.02 RELATED SECTIONS A. Section 02105: Demolition and Salvage B. Section 02230: Clearing and Grubbing C. Section 02310: Backfill D. Section 02315: Rock Excavation and Scaling E. Section 02370: Erosion and Sediment Control Measures F. Section 03300: Cast-in-Place Concrete PART 2 PRODUCTS Not Used. PART 3 EXECUTION 3.01 EXCAVATION A. Erosion and sediment control measures shall be constructed prior to beginning any land disturbances and in accordance with the approved Erosion and Sediment Control Plan (ESCP). These measures and devices shall not be removed until the disturbed areas are stabilized. All devices shall be properly maintained and kept in optimum operating condition for the duration of construction. B. Any unsuitable material found at the design grade shall be removed as directed by RPR, and replaced with concrete or compacted Bedding Material D-1 (See Section 02310) as directed by RPR. The excavation shall be dewatered and kept dry until completion of concrete placement and acceptance by RPR. C. Excavation carried out below design grade and beyond neat excavation lines as a result of Contractor’s operations shall be backfilled to required grade with fill concrete or structural backfill material and compacted as specified in Section 02310 at no cost to Owner. Blue Lake Expansion Project – Contract No. 9 02316-2 General Construction May 2012 D. RPR will make spot checks of excavated materials and of materials reported environmentally suspicious by Contractor’s excavation foreman. 3.02 DISPOSAL A. Uncontaminated, unclassified excavation material suitable for backfill shall be used in the Work As Shown. Contractor shall be responsible for testing materials he intends to reuse for backfill, including tests for gradation, Atterberg limits, moisture content and moisture-density relationship. Contractor shall be responsible for stockpiling all materials suitable for backfill in accordance with the approved Erosion and Sediment Control Plan. B. All reusable stripped topsoil shall be stockpiled for re-use in site restoration activities (Section 02370) and protected in accordance with the approved ESCP. C. Contractor may use uncontaminated, unclassified excavation material for his temporary works provided that this does not result in a shortage of material for the permanent works and the material used in the temporary works is removed on completion. D. A “Chain-of-Custody” letter shall be provided for all excavated materials hauled off the project site. See Section 02105, “Chain-of-Custody” letter for proper handling of waste materials. 3.03 NOTIFICATION A. Contractor shall immediately cease work and notify RPR if buried material is encountered which appears to include chemicals, petroleum products, or unidentifiable wastes. 3.04 MAINTENANCE OF SLOPES A. Contractor shall maintain excavated slopes in a safe and stable condition at all times, according to OSHA requirements, until final acceptance of the Work. Heavy construction equipment shall not be permitted within 20 ft from the top of the excavated slope unless either slopes are specifically stabilized for heavy equipment (Contractor to submit plan) or otherwise noted on the drawings. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02370-1 General Construction May 2012 SECTION 02370 EROSION, SEDIMENT AND POLLUTION CONTROL MEASURES PART 1 GENERAL 1.01 WORK INCLUDED A. Contractor shall design a site-specific Erosion and Sediment Control Plan (ESCP), Stormwater Pollution Prevention Plan (SPPP) and a Spill Prevention, Control and Countermeasures Plan (SPCC). Provide all erosion, sediment and pollution control measures included in the plans and regularly maintain during construction. Remove all control measures following construction and restore disturbed areas. Sediments to be controlled shall include but not be limited to, soil, demolition products, mortar, drilling cuttings, grouts (waste and injected), concrete, cement and other construction products and debris. B. The erosion and sediment control measures, also referred to as Best Management Practices (BMPs), shall be installed as specified in the Contractor’s site specific Erosion and Sediment Control Plan (ESCP). C. All erosion, sediment and pollution control work is to be done in conformance with all federal, state and local permits and regulations. D. All erosion/sediment control work is to be done in conformance with Owner’s ESCP plan approved with the FERC licence Amendment Application. 1.02 RELATED WORK A. Section 01012: Hydrology and Hydraulics B. Section 01200: Project Administration C. Section 01300: Submittals D. Section 01800: Environmental Conditions and Controls E. Section 02105: Demolition and Salvage F. Section 02230: Clearing and Grubbing G. Section 02240: Dewatering and Water Control H. Section 02310: Backfill I. Section 02315: Rock Excavation and Scaling J. Section 02316: Unclassified Excavation K. Section 02400: Rock Tunnelling L. Section 02405: Drilling Blue Lake Expansion Project – Contract No. 9 02370-2 General Construction May 2012 M. Section 02430: Grouting N. Section 02630: Site Drainage O. Section 02700: Gravel, Base and Subbase Courses P. Section 02950: Site Restoration Q. Section 03300: Cast-in-Place Concrete 1.03 REFERENCE STANDARDS A. AASHTO M 288: Standard Specification for Geotextile Specification for Highway Applications B. Alaska Department of Environmental Conservation, Storm Water Guide, June, 2009 C. Alaska DOT&PF Highway Drainage Manual, 2001 D. City and Borough of Sitka, Alaska, Standard Specifications for Street-Drainage- Utilities-Parks, 2002 http://www.cityofsitka.com/government/departments/publicworks/index.html E. US Forest Service Handbook FSH 2509.22, Soil and Water Conservation Handbook, October 31, 1996 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Contractor shall submit with the Work Plan (see Section 01200) a site-specific ESCP, SPPP, and SPCC. Provide these documents as stand-alone attachments to the Work Plan. Note: As part of the FERC license Amendment Application, Owner has obtained approval for resource protection and monitoring plans (see Section 01800). Contractor’s site specific plans shall use Owner’s approved plans as guideline for developing more detailed plans, including soil erosion and sedimentation controls measures specific to Contractor’s Work Plan. 1. Include in each plan schedules, methods and materials designed for the Best Management Practices (BMPs). 2. ESCP shall utilize soil erosion and sedimentation measures described in the US Forest Service Handbook FSH 2509.22, Soil and Water Conservation Handbook, and Alaska DOT&PF Highway Drainage Manual. Maintain field copies of the US Forest Service Handbook FSH 2509.22 and the Alaska DOT & PF Highway Drainage Manual. The ESCP shall also include: a) Detailed information on the generic erosion and sediment control measures, procedures and equipment to be used during trench excavation and backfilling, including dewatering and sediment settling methodologies. b) Drawings describing the proposed methods and detailing the location and type of erosion control measures. Blue Lake Expansion Project – Contract No. 9 02370-3 General Construction May 2012 c) An inventory list of supplies needed to respond to unanticipated sediment discharges including, but not limited to, silt fence, diking materials, and stakes. 3. SPCC shall address the project specific information outlined below: a) Site Information: Identify general site information useful in construction planning, recognizing potential sources of spills including Contractor’s and owner-furnished equipment, and identifying personnel responsible for managing and implementing the plan. b) Project Site Description: Identify staging, storage, maintenance, and refueling areas and their relationship to drainage pathways, waterways, and other sensitive areas. Specifically address: i. Contractor’s equipment maintenance, refueling, and washout/cleaning activities. ii. Any hazardous materials that will be used for the project and procedures for inventory, storage, handling and monitoring. c) Spill Prevention and Containment: Identify spill prevention and containment methods to be used at each of the locations identified above. d) Spill Response: Outline spill response procedures including notification procedures, assessment of the hazard, securing spill response and personal protective equipment, containing and eliminating the spill source, and mitigation, removal and disposal of the material. e) Standby, On-Site, Material and Equipment: Provide an inventory list of materials and equipment that will be maintained on site to carry out the preventative and responsive measures for the items listed. The inventory list shall also include items that will be maintained on hand in order to respond to accidental discharges of other deleterious substances, including, but not limited to, oil absorbent booms, spill pads, absorbent materials, and brooms. f) Reporting: List all federal, state and local agency phone numbers the Contractor must notify in the event of a spill. g) Program Management: Identify site security measures, inspection procedures and personnel training procedures as they relate to spill prevention, containment, response, management and cleanup. h) Pre-existing Contamination: If pre-existing contamination in the project area is described elsewhere in the plans or specifications, the SPCC plan shall indicate measures the Contractor will take to conduct work without allowing release or further spreading of the materials. Contractor shall document pre-existing levels of contaminates. 4. No work shall begin until the ESCP, SPPP and SPCC have been approved by appropriate federal, state or local agencies, and RPR. 5. If conditions change during construction, Contractor shall revise the plan and resubmit to RPR and ECM for review and approval. Blue Lake Expansion Project – Contract No. 9 02370-4 General Construction May 2012 PART 2 PRODUCTS 2.01 General A. All erosion and sediment control measures shall utilize materials that conform to Alaska DOT & PF Highway Drainage Manual – Chapter 16 Erosion and Sediment Control. 2.02 MATERIALS A. Seed and Fertilizer: The seed and fertilizer mix shall conform to the USFS FSH 2509.22 and consists of the following mix and application rates. Kind of Seed Live Seed (lbs/acre) Boreal Red Fescue 10 Annual Ryegrass 10 Arctared Fescue 5 Total 25 1. If either Boreal Red Fescue or Arctared Fescue is unavailable, Fawn Tall Fescue may be substituted. If Fawn Tall Fescue is unavailable, then the amounts of the available two may be adjusted to total 100%. 2. Seed mixture shall not contain more than 0.01% other seed, whether identified or not. 3. Fertilizer shall be applied at a rate of 200 pounds of 10-20-10 (Nitrogen- Phosphorus-Potassium) fertilizer plus 100 pounds urea per acre in all applications. B. Erosion Matting: Erosion control matting may be either jute mesh, nylon matting or excelsior blanket and conform to the material requirements of CBS Standard Specification Section 75.03 - Soil Stabilization. 1. Contractor may use either staples or wood stakes for securing erosion matting. C. Silt Fence Fabric: 1. Silt fence fabric shall be a pervious sheet of propylene, nylon, polyester or ethylene yarn and shall be certified by the manufacturer or supplier as conforming to the following requirements and are suitable for the intended application. For controlling coarse sands, hardened concrete debris, and larger particles, fabric with maximum sieve size US #20 may be used. For controlling fines smaller than US #30 such as silts and cement fines, use fabric with maximum opening size US Sieve #70. Fabric requirements for coarse and fine particles shall conform to the following: a) Coarse Particles Physical Property Requirement Filter Efficiency 75% (min.) Maximum Opening Size U.S. Sieve #20 Blue Lake Expansion Project – Contract No. 9 02370-5 General Construction May 2012 Tensile Strength at Extra Strength – 20% (max.) Elongation* 50 lbs/lin. In. (min.) Standard Strength – 30 lbs/lin. In (min.) Flow Rate 0.3 gal/sq ft/min (min.) b) Fine Particles Physical Property Requirement Tensile Strength 375/250 lbs Puncture Strength 145 lbs Equivalent Opening Size U.S. Sieve No. 70 Permeability 0.1 cm/sec 2. Silt fence fabric shall contain ultraviolet ray inhibitors and stabilizers to provide a minimum of six months of expected usable construction life at a temperature range of 0 degrees F to 120 degrees F. 3. Silt Fence Posts: Posts for silt fences may be either wood or steel. Posts shall have a maximum overall height of 36 inches. Note a minimum of 18 inches shall be driven into the ground. D. Straw Bale: Straw bales (bales) may only be used if they are certified to be weed free. Bales should be bound with wire or string. Bales may be secured with either 2 in x 2 in x 36 in wood stakes or 36 in long No. 4 rebar. E. Rock Check Dams: Shall be constructed with clean, hard, angular (e.g. crushed, shot) rock graded to expected flows. Note: Maximum design velocity is 6 ft/sec. F. Sediment Trap: Sediment traps shall be sized by Contractor based on the drainage area coming from disturbed areas in accordance with Alaska DOT & PF, Highway Drainage Manual requirements. 1. Drainage area shall be less than 1 acre. 2. Storage Volume: 35 cubic yards per acre of disturbed ground 3. Wet Storage Area Depth: minimum 2 ft to 3 ft, maximum 4 ft G. Sediment Basin: Sediment basins shall be sized by Contractor based on the drainage area coming from disturbed areas in accordance with Alaska DOT & PF, Highway Drainage Manual requirements. 1. Storage Volume: 134 cubic yards per acre 2. Wet Storage Area Depth: minimum 2 ft to 3 ft, maximum 4 ft H. Inlet Protection: Contractor shall protect storm drain inlets using materials and methods shown in the Alaska DOT & PF, Highway Drainage. These methods include: Blue Lake Expansion Project – Contract No. 9 02370-6 General Construction May 2012 1. Filter Fabric Fence: Fence and stakes are the same as Silt Fence. Washed gravel ¾ in to 1 ¾ in diameter with less than 5 % fines. 2. Block and Gravel Filter: wire mesh with ½ in openings, silt fence, concrete blocks 4 – 12 in wide, 12 - 24 in high, washed gravel ¾ - 4 in diameter, and wood stud 2 in by 4 in for curb inlets. 3. Gravel and Wire Mesh Filter: wire mesh with ½ in openings, silt fence, washed gravel ¾ - 4 in diameter I. Riprap: Riprap shall be in accordance with Section 02310. J. Fuel Storage and Refueling Area: The proposed system shall provide for total containment of anticipated maximum fuel levels. 1. The containment system at a minimum shall include and impervious PVC type liner with a suitable earth berm and earth cover and earthen containment berm. 2. The containment berm shall have a reinforced raised entrance ramp. 3. The fuel storage and containment berm area should be protected from precipitation, which could prematurely cause an overtopping of the containment berm. 4. Provide absorbent material at the refuelling site in quantities suitable for spill cleanup. PART 3 EXECUTION 3.01 GENERAL A. All erosion and sediment control measures shall be installed and maintained in accordance with the Alaska DOT & PF Highway Drainage Manual – Chapter 16 Erosion and Sediment Control. B. In the event of any spill or discharge of sediment, Contractor shall immediately notify the RPR and ECM and implement measures of ESCP, SPPP and SPCC. C. Contractor shall make every effort to minimize erosion from clearing and grubbing, excavation and backfilling operations, including, but not limited to, the following: 1. Construction of temporary berms, dikes, and diversion ditches to divert runoff of rainwater in an approved manner, at the conclusion of each day's activities. Runoff, as defined in this specification, is that portion of the precipitation on a drainage area resulting from the 10-year, 24-hour rainfall event, which is discharged from that area via surface drainage. 2. Use of extreme caution to limit disturbances of natural areas to the absolute minimum required. 3. Sequence clearing and grubbing, excavation and backfilling operations to maintain natural traps for eroded material and any other measures effective in minimizing erosion and limiting sediment discharge. Blue Lake Expansion Project – Contract No. 9 02370-7 General Construction May 2012 4. Excavation from any source shall not be deposited in or near rivers, streams, or impoundments nor otherwise located to be susceptible to erosion due to high water, flooding, or rainwater runoff. 5. Perform shaping of the top of earthwork in a manner to permit and facilitate the runoff of rainwater. Drainage ditches and/or intercept dikes shall be provided along the top of all excavated slopes and along the inside edge of all berms. The protective measures at the top of slopes shall be constructed before excavation. 6. Provide temporary slope drains to accommodate the runoff of rainwater. These drains shall be located as needed at no greater than 500-foot intervals. D. All erosion, sediment and pollution control measures must be installed prior to beginning any land disturbances. These measures and devices cannot be removed until the disturbed areas are stabilized. All devices must be properly maintained and kept in optimum operating condition for the duration of construction. Additional measures shall be implemented as necessary to ensure that sediment from Contractor’s activity does not enter adjacent water bodies and is controlled so that it may be collected and disposed of off-site in accordance with Federal, state, and local regulations. E. Runoff from any land disturbing activity shall not be directly discharged or have the potential to be discharged off site, onto roadways, or into storm drains or into a watercourse. Accumulated sediment in a properly designed silt fence or trap shall be removed and disposed when 60% of the storage capacity of the structure/fence is filled with sediment. F. Temporary sediment trapping devices, such as silt fences, shall be removed within 30 calendar days following establishment of permanent stabilization. G. Riprap: Placing of riprap shall be performed in accordance with requirements of Section 02310. H. All points of construction ingress and egress shall be protected to prevent the deposition of materials onto roadways and paved areas either by installing and maintaining a stabilized construction entrance, or by washing all vehicle wheels in a safe disposal area. All materials deposited onto roadways and paved areas shall be removed immediately. 3.02 SEED AND FERTILIZER A. All sites shall be stabilized and seeded with erosion control measures, such as straw mulch, jute mesh, or excelsior within five days of final grading. If construction is suspended, or sections completed, areas shall be seeded immediately and stabilized with appropriate erosion control measures. Maintenance shall be performed as necessary to ensure continued stabilization. B. Areas that are completed either before or after the seeding season specified, and all areas that will be left exposed for more than five days, including all excavated and stockpiled materials, shall be temporarily mulched with hay (straw) and anchored with Terratac or other approved binder. The application rate for temporary mulching shall be two tons of mulch per acre and application of mulch anchorage/binder at rates recommended by the manufacturer, unless otherwise noted. Blue Lake Expansion Project – Contract No. 9 02370-8 General Construction May 2012 C. Seeding Season: Seeding is in this region is generally considered to be most successful if completed by mid-June, to ensure that ground cover is established before heavy fall rains and frost. If seeding cannot be performed prior to September 15, or appears unsuccessful by that time, other erosion control measures must be applied to disturbed areas near surface waters before heavy fall rains and frost. 3.03 EROSION MATTING A. Install erosion matting within 24 hours of seeding. B. Installation procedures shall conform to CBS Standard Specification Section 75.03 – Soil Stabilization. 3.04 SILT FENCE A. The silt fence shall be continuous if possible or otherwise successive layers shall be overlapped by 3 ft with the overlap going from upstream to downstream. B. Silt fence shall be installed as recommended by manufacturer and as recommended by the Alaska DOT & PF Highway Drainage Manual. It should be anchored securely to prevent movement by driven stakes to a minimum depth of 18 inches. Maximum spacing of stakes is 6 ft. All stakes must be placed on the downhill side of the silt fence. C. Fabric shall be maintained or replaced as needed to maintain integrity of the sediment barrier. Filter barriers shall be removed at the completion of the contract. Restore disturbed areas caused by removal of silt fence. D. Sediment and debris collected within the sediment barriers shall be disposed of off- site in accordance with Federal, state, and local regulations. 3.05 STRAW BALE A. Do not install bales on any rock or hard surfaces where the barrier cannot be uniformly secured. B. Install bales such that the maximum flow path to them is 150 ft. C. Bales should be placed in a single row, parallel to the contour. Excavate a trench a minimum or 4 inches deep before setting the straw bale. D. Bales should be anchored with at least two stakes driven a minimum of 12 inches into the ground. E. Fill any gaps between bales with wedged straw. F. Remove and replace straw bales when straw begins to deteriorate or within 3 months of installation whichever comes first. 3.06 ROCK CHECK DAM INSTALLATION A. The maximum dam height shall be 2 ft or one half the channel depth. The difference between the center and banks should be no more than 6 inches. The structures slopes should be 2H:1V. Blue Lake Expansion Project – Contract No. 9 02370-9 General Construction May 2012 B. Check dams shall be spacing in the channel such that the top of a check dam is level with the toe of the upstream check dam. The maximum spacing of check dams based on channel gradient is as follows: Channel Gradient (%)Check Dam Spacing (ft) 2 100 3 67 4 50 5 40 6 33 C. Contractor shall periodically repair check dam voids and bank undercuts. Clean up any migrated rock. D. After a disturbed area has been stabilized, Contractor shall discuss with the RPR if a rock check dam shall be removed or remain as a permanent feature. Disposal of materials shall be in accordance with Section 01800. 3.07 SEDIMENT BASINS AND TRAPS A. Install in accordance with guidelines from the Alaska DOT & PF Highway Drainage Manual and the approved Contractor design. B. Contractor shall remove sediment when the feature has become more than 50 % full or earlier. C. After a disturbed area has been stabilized, Contractor shall discuss with the RPR if a sediment basin or trap shall be removed or remain as a permanent feature. Disposal of materials shall be in accordance with Section1800. 3.08 INLET PROTECTION A. Install in accordance with guidelines from the Alaska DOT & PF Highway Drainage Manual and the approved Contractor design. B. Contractor shall not punch holes in filter fabric to permit faster draining. C. Contractor shall remove any sediment from the manhole and catch basin sumps as a result of Contractors work activities. 3.09 RIPRAP A. Riprap shall be installed as channel, outlet and slope protection and in accordance with Section 02310. 3.10 TERRACING A. Surface roughening and terracing is a form of slope protection and is the process of creating horizontal grooves, furrows, depressions, steps or terraces running parallel to the slope contour over the entire face of a slope. This measure is intended to support the re-vegetation of seeded slopes by reducing runoff velocity and increasing infiltration. Various methods are described below: 1. Tracking: Run tracked machinery up and down slopes to leave horizontal depressions in the soil. Typically performed on sandy soils. Blue Lake Expansion Project – Contract No. 9 02370-10 General Construction May 2012 2. Groove Cutting: The process of cutting serrations along the contour using a blade. 3. Contour Furrows: The process of cutting serrations along the contour using disks, tillers, or teeth of a bucket. 4. Stair Step Grading: The process of cutting steps along the contour using heavy machinery. This method is typically utilized on slopes greater than 3H:1V and have soils soft enough to be bulldozed. 5. Gradient Terracing: The construction of earth embankments or ridge and channels along the face of a slope to intercept surface runoff and convey it to a stable outlet. This method is typically used on long, steep slopes where water erosion is a problem. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02400-1 General Construction May 2012 SECTION 02400 ROCK TUNNELING, SHAFT EXCAVATION AND SUPPORT PART 1 GENERAL 1.01 WORK INCLUDED A. Perform all excavation, loosening, removing, scaling and disposing of rock materials as required for the construction of the tunnels and shafts including all special trimming and shaping of surfaces to the lines, grades, and dimensions As Shown. Also provide all necessary temporary supports, handling of underground water, lighting, and ventilation. B. Provide all rock support including steel sets, wire mesh and drain holes As Shown and at the direction of RPR. Note: Rock bolts and shotcrete are covered under Sections 02405 and 03370 respectively. C. The tunnel and shafts shall be located and oriented As Shown. No variations in location, length, orientation or grade will be permitted without prior written acceptance of Owner. Excavation shall be carried out to the lines and grades As Shown. D. Provide access for RPR and Engineer. 1.02 INTENT OF SPECIFICATION A. It is the intent of this specification to outline acceptable methods of rock tunnelling and shaft excavation. Contractor shall be responsible for the design of the excavation means and methods, temporary ground support, site safety, and other construction issues. B. Utilize the Technical Memorandum No. 7, Geotechnical Findings Report, when planning the Work. Refer to Reference Documents. 1.03 RELATED SECTIONS A. Section 01300: Submittals B. Section 02105: Demolition C. Section 02020: Survey Control D. Section 02240: Dewatering and Water Control E. Section 02315: Rock Excavation and Scaling F. Section 02405: Drilling G. Section 02410: Rock Bolts H. Section 03370: Shotcrete Blue Lake Expansion Project – Contract No. 9 02400-2 General Construction May 2012 1.04 REFERENCE STANDARDS A. ASTM A36: Standard Specification for Carbon Structural Steel B. ASTM A185: Welded steel wire fabric, plain, for concrete reinforcement. C. ASTM D1785: Polyvinylchloride Plastic Pipe, Schedule 40, 80, and 120 D. Occupational Safety and Health Administration Standards (OSHA). E. Mining Safety and Health Administration Standards (MSHA). F. ASCE Geotechnical Baseline Reports for Underground Construction. 1.05 SUBMITTALS A. Submit under provisions of Section 01300 for review, an overall Rock Tunnelling and Shaft Excavation Plan of proposed methods and sequence for rock tunnelling and shaft excavation for review by Owner as part of the Work Plan. Details of the plan shall meet all the requirements as outlined under these Specifications. The plan shall include proposed equipment and crews; equipment for movement of personnel and materials in the shaft; rock spoil removal and disposal strategy; typical depths of blast holes; the typical type, strength, amount, and distribution of explosives to be used per hole, per delay and per blast; the normal sequence and pattern of delays, controlled perimeter blasting procedures; the description and purpose of any special methods to be adopted by Contractor; survey procedures to control line and grade; copies of licensed blaster’s certificate and safety and warning procedures; an explosives handling and storage plan; at least three original copies of the company safety plan; a site specific hazard analysis plan; a ventilation plan and design; and blast monitoring plan including types of instruments, proposed location for monitoring and method of reporting monitoring results. If the Rock Tunnelling and Shaft Excavation plan fails to meet the requirements of these Specifications, a new plan, in whole or in part, shall be submitted by Contractor. The Rock Tunnelling and Shaft Excavation Plan may be combined with the Rock Excavation Plan. B. The Rock Tunnelling and Shaft Excavation plan shall also include all necessary information to completely describe the rock support system, such as: 1. Steel set shop and installation drawings. 2. Shotcrete information. 3. Wire mesh information. 4. All rock support accessories information. 5. Certified mill lists for steel, material lot and heat numbers. 6. Note: Rock bolt submittal requirements are covered in Section 02410. C. If, in a specific area, a plan which has been previously adopted does not produce rock surface conditions in accordance with the requirements of these Specifications, Contractor shall submit a revised plan before continuing tunnelling. Blue Lake Expansion Project – Contract No. 9 02400-3 General Construction May 2012 D. As construction progresses, Contractor shall re-inspect as often as necessary to verify the adequacy of his construction methods for prevention of damage. If any changes are necessary, this shall be formally submitted to RPR in writing. 1.06 DEFINITIONS A. “Unavoidable Overbreak” – over-excavation due to the processes of drilling and blasting. B. “Geological Overbreak” - over-excavation beyond the drill and blast tunnel profile; occurs due to the presence of adversely oriented rock fractures regardless of drilling and blasting practice 1.07 SAFETY OF WORK A. Contractor shall inspect and report in writing to RPR regularly, but not less frequently than once each shift, on the condition of the excavated tunnel and shaft works under his jurisdiction and immediately remove or support any rock which Contractor or RPR may deem unsound or disintegrated or in any way unsafe. The report shall be submitted daily in writing on a form accepted by RPR. B. Notwithstanding the provisions of this Specification, Contractor shall perform all remedial work required in excavations throughout the duration of the Contract to ensure that all excavated rock surfaces are maintained in a safe and stable condition at no additional cost to Owner. C. By all means Contractor shall enforce all necessary measures and take all necessary precautions to avoid harm or threat to the tunnel and shaft excavation crews. Under no circumstances the excavation works will proceed when Contractor or RPR deem any rock conditions unsound or disintegrated or in any way unsafe, until an agreement between Owner and Contractor is reached to safely continue with the works. 1.08 TUNNELING RECORDS A. Maintain accurate records of all tunnelling work performed under the Contract and provide RPR daily with two copies of records relating to the previous day’s work. RPR will receive and sign such records for information purposes only. B. The following data (as a minimum) shall be recorded in the Daily Reports: 1. Start and end of shift, tunnel heading station or shaft elevation 2. Drilling pattern including number, locations, sizes, and length of holes. 3. Air quality measurement data. 4. Presence of water, flow measurement (s), groundwater inflow locations and measurements. 5. Feeler holes and stationing. 6. Survey records of excavations, including offset from design. 7. Type and amount of explosives for each round and the type, locations and firing pattern of detonators. Blue Lake Expansion Project – Contract No. 9 02400-4 General Construction May 2012 8. Number, length, location and type of rock bolts and steel sets installed. 9. Areal extent and thickness of shotcrete applied. 10. Number and classification of men and plant engaged on each tunnelling, excavation, preparation and support operation. 11. Elapsed time for moving and setting up, drilling, loading, blasting, ventilation, mucking, scaling, preparation for and installation of supports, excavation, standby, testing periods, and downtime. 12. Injuries to workers. 13. Ground behavior and any unsafe conditions. C. During the progress of the tunnelling and shaft construction work, establish measuring points (i.e. chainage, tunnel work points, shaft depths) and make measurements to facilitate: monitoring the behavior and stability of the tunnel and shaft excavations; geological mapping; and other technical investigations, including monitoring of underground water flow and pressure, where applicable, as may be pertinent to the Work. Such activities may require short interruptions and minor interferences with routine construction operations and shall be documented in the daily report. PART 2 PRODUCTS 2.01 ROCK BOLTS A. Rock bolts shall be in accordance with the applicable requirements of Section 02410. 2.02 STEEL SETS A. Steel ribs shall be fabricated from AISC A36, steel sections conforming to the dimensions As Shown on the drawings or determined by design. B. Steel sets shall include all hardware for bolted connections, foot blocks, collar pipes and tie rods to provide a complete installation. 2.03 WIRE MESH A. Welded wire mesh shall be 4 inch by 4 inch, W1.4 wire size welded steel wire fabric conforming to the requirements of ASTM A 185 or acceptable equivalent and shall also be used in areas where mesh reinforced shotcrete is required. 2.04 DRAIN HOLES A. Pipe sleeves for drain holes, as required to stabilize the holes, shall conform to ASTM D1785, Schedule 40 PVC Pipe. PART 3 EXECUTION Blue Lake Expansion Project – Contract No. 9 02400-5 General Construction May 2012 3.01 EXCAVATION METHODS A. General: The tunnels and shafts shall be excavated in accordance with the applicable sections of this Specification. Contractor is expected to employ drill and blast techniques for rock tunnel excavation depending upon actual rock conditions. B. Carry out excavation for tunnel with the utmost care and with the strictest precautions to prevent ground movement, subsidence, and damage to any adjacent properties. Every effort shall be made to excavate the tunnels and shafts in accordance with the typical sections As Shown, excavations for tunnels and shafts shall be properly supported with rock bolts, timber, mesh, shotcrete, rock bolts as detailed in Section 02410 of this Specification. Where excavation is discontinued for more than 48 hours, any exposed ground shall be supported as necessary. C. Scaling of the excavated rock faces shall be performed in accordance with the applicable requirements of Section 02315. D. Where rock is badly disturbed, such as ground immediately in the vicinity of a fault, proceed with extra caution and support the disturbed ground. E. Explosives: Blasting and blast monitoring shall be performed in accordance with the applicable requirements of Section 02315. Drilling and blasting shall be performed carefully and skillfully to minimize the shattering or loosening of material outside the required excavation limits. F. Securing of Portal Faces: Prior to commencement of the tunnel excavation, inspect the rock faces above and around the open cut. The rock faces shall be scaled and where and when necessary, rock bolts, chainlink or wire mesh fabric, and shotcrete shall be installed to give positive protection to the workers. 3.02 INSPECTION OF EXCAVATED ROCK SURFACES A. Plan and schedule excavation so that inspection and geologic mapping of the rock faces that may be made by RPR for each 20 ft of depth excavated. For convenience and ease of installation of rock support, Contractor may limit his depth of excavation of any intermediate stages of excavation to less than 20 ft. Contractor shall clean rock surfaces exposed during excavation to permit a thorough inspection and assessment of the condition of the rock by RPR. Excavation shall not proceed until the inspection has been completed and the required rock bolts installed. B. Cleaning of rock surfaces for inspection shall consist of the removal of all organic material, soil, demolition debris, and loose rock from the exposed rock surface. Cleaning may be done with high pressure air jets, water jets, brooms or by any other method acceptable to RPR. C. All standing water shall be removed by Contractor from the area to be inspected to permit proper examination of the rock. D. Contractor shall provide suitable means of access for inspection of the excavated and scaled areas by RPR. 3.03 DESIGN FOR TEMPORARY SUPPORT Blue Lake Expansion Project – Contract No. 9 02400-6 General Construction May 2012 A. Develop rock material design properties for the design of the underground excavations and its supports as required to ensure worker safety. Base these parameters on Owner-provided in-situ testing, laboratory tests and other standard methods and include engineering properties, water levels, permeability of soil and rock strata in the tunnel zone, and other data necessary for the design. B. Design calculations for the temporary tunnel support system shall include design stresses in the rock and temporary supports, and include control of water during excavation. 3.04 STEEL SETS A. Prefabricated steel ribs shall be installed in underground rock excavations in locations As Shown on the drawings and where rock conditions require such support. B. Steel ribs shall be blocked with hardwood blocks at no more than 3-ft spacing at the locations As Shown. C. Steel set support accessories shall include, but shall not be limited to, collar braces, tie rod spreaders, liner plates, lagging, cribbing, blocking wedges, foot blocks, sills and invert struts which are fabricated from steel plates or sections or other steel products. D. Wire mesh, lagging, and cribbing shall be installed as necessary to secure the rock and fully engage each steel set to support rock loads. E. Lagging shall be steel or concrete members which span between ribs and which transfer loading from the rock being supported to the ribs. F. All steel and concrete support accessories shall be solidly blocked and braced against the excavated rock surfaces and such blocking and bracing shall be checked regularly and, if necessary, adjusted to maintain the support in a secure condition. G. Have available at all times a sufficient supply of steel sets to accommodate rate of tunnel advancement, but in any event not less than that required to support two rounds of excavation. 3.05 EXCAVATION LIMITS A. Excavation shall be to a profile at the minimum limits as described below: 1. Minimum Limit: The minimum limit shall be defined by the neat lines As Shown on the drawings. Any soil, boulder or rock projecting inside the neat lines shall be removed. Care shall be taken in removing any under excavation to avoid disturbance of the material to remain. Over excavation outside the minimum limit of 1 ft beyond the neat line shall be filled using shotcrete and/or Class 3 support As Shown at no cost to Owner. B. Transport and dispose of spoil materials shall be As Shown and in accordance with Owner ESCP, refer to Reference Documents. 3.06 DRILLING FEELER HOLE Blue Lake Expansion Project – Contract No. 9 02400-7 General Construction May 2012 A. In order to investigate the rock condition and presence of groundwater in advance of tunnel excavation, continuously drill a feeler hole at the heading with a minimum overlap of 15 feet. B. The feeler hole shall be drilled to depths up to 150 ft ahead of the excavation, and may be oriented either horizontally or inclined. The hole diameter shall not be less than 2 inch, and should be as large as Contractor needs to classify the rock. C. Contractor shall be prepared to grout feeler hole if groundwater inflows do not diminish to less than 50 gpm in 24 hours. 3.07 DRAIN HOLES A. Drain holes shall be drilled for the purpose of relieving groundwater pressure or for the draining of groundwater from work adjacent to tunnel excavation. Drain holes shall have maximum depths As Shown on the drawings. B. The minimum size of percussion-drilled holes shall be 2 inches diameter. C. Percussion holes shall be continuously flushed with water during drilling. D. The use of grease, rod dope, drilling mud or other lubricants on drill rods or in the holes will not be permitted. E. Determine the schedule and sequence for drilling drain holes. In general, no drain holes shall be drilled less than 24 hours after all grouting has been completed in the same area of the Work. F. Immediately after each drain hole has been drilled, flush out the hole by injecting water and air at the bottom of the hole until clear water appears and thereafter for a period of five minutes. G. Control of Water for sections of the tunnel that are below the water table or where water is present, is required. Determine the method that corresponds with excavation method and site conditions. Lowering the water table by pumping, drain or other means shall consider the effect of settlement and a lower water table on surrounding aspects of the project, all in accordance with environmental requirements. H. Where required to ensure the stability of the hole, supply and install in the pressure relief holes slotted liners manufactured from rigid Schedule 40 PVC pipe, or acceptable equivalent. 3.08 WIRE MESH AND ANCHORS A. Wire mesh shall be securely fastened to the rock face by the bearing plates of the rock bolts installed as specified herein. If the wire mesh is placed after rock bolts are installed, a second nut and plate shall be installed to anchor the wire mesh to the work face. Sheets of wire mesh shall be overlapped a minimum of two squares (8 inches) B. Wire mesh shall be anchored by means of wire mesh anchors in areas where it cannot be attached to rock bolts. Wire mesh anchors shall be used to secure the edges of wire mesh tight to the rock surface, to provide anchorage at overlaps and to provide intermediate support between rock bolts. The anchors shall also be used to ensure that the mesh closely follows the irregular rock surface. Blue Lake Expansion Project – Contract No. 9 02400-8 General Construction May 2012 C. Wire mesh anchors shall be minimum 18-in long split set rock bolts or equivalent. D. Wire mesh to be concreted or shotcreted shall be fitted with spacers, 1-in in height, placed between the rock and the mesh to ensure full encapsulation of the mesh by the concrete or shotcrete. 3.09 VENTILATION A. Ventilation must constantly supply fresh air to the work face and provide an adequate amount of air, remove smoke, dust and fumes from the heading, and remove the exhaust fumes of diesel engines. Ventilation and air quality shall comply with OSHA, MSHA and local regulations. 3.10 LIGHTING A. Provide lighting of the tunnel in accordance with all applicable regulations but not less than the light provided by a string of 100 watt lamps mounted along the crown or on one wall of the tunnel at 10 ft intervals at least 3 ft from the floor. The working face shall be provided with additional lighting to ensure safe working conditions satisfactory to the RPR. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02405-1 General Construction May 2012 SECTION 02405 DRILLING PART 1 GENERAL 1.01 WORK INCLUDED A. Perform all drilling required for rock excavation, rock tunnelling, rock anchors, rock bolts and drain holes, rock dowels, exploratory holes, investigation boreholes, pressure relief wells, micropile holes, and any other miscellaneous holes As Shown. Refer to Section 02430 for drilling requirements for grout holes and Section 02400 for tunnel drain holes. B. Drilling shall be performed with the limits of the Noise and Vibration Management Plan. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 02315: Rock Excavation and Scaling C. Section 02370: Erosion, Sediment and Pollution Control Measures D. Section 02400: Rock Tunnelling E. Section 02410: Rock Bolts F. Section 02411: Rock Anchors G. Section 02413: Grouted Dowels H. Section 02430: Grouting I. Section 02435: Water Pressure Testing J. Section 02440: Pressure Relief Wells K. Section 02465: Micropiles 1.03 REFERENCE STANDARDS Not used. 1.04 SUBMITTALS A. Submit under the provisions of Section 01300 for review, an exploratory drilling and borehole documentation plan as part of the Work Plan. 1.05 DEFINITIONS Blue Lake Expansion Project – Contract No. 9 02405-2 General Construction May 2012 A. “Exploratory Cored Holes” – boreholes drilled by means of the rotary drilling method and a diamond coring bit to obtain bedrock cores. These holes are drilled upward from within the drainage tunnel. B. “Exploratory Holes” – boreholes drilled using percussion or air rotary methods from which bedrock cores are not produced. These holes are drilled upward from within the drainage tunnel. C. “Micropile Holes” - boreholes drilled using rotary drilling methods and used for the installation of micropiles as per the applicable requirements of Section 02465. D. “Piezometer Holes” boreholes drilled using a percussion or air rotary drill for the installation of piezometers as per the applicable requirements of Section 02290. E. “Pressure Relief Well Holes” – boreholes drilled using rotary drilling and diamond coring methods and used for the installation of pressure relief wells as per the applicable requirements of Section 02440. F. “Rock Anchor Holes” – boreholes drilled using percussion or air rotary methods and used for the installation of rock anchors as per the applicable requirements of Section 02411. G. “Rock Bolt and Drain Holes” – boreholes drilled using percussion or air rotary methods and used for the installation of rock bolts and drain holes as per the applicable requirements of Section 02410. 1.06 GENERAL REQUIREMENTS A. Contractor shall implement adequate measures in accordance with Section 02370 to prevent drill cuttings and solids from entering the any watercourse, including the dewatered reach of Sawmill Creek and the plunge pool and reservoir. B. Contractor is responsible to control dust during drilling operations to and control allowable dust limits according to said regulations and to prevent fouling of respirator and air monitoring equipment. PART 2 PRODUCTS 2.01 BOREHOLE DOCUMENTATION EQUIPMENT A. The borehole camera shall be an OBI 40 Slimhole Optical Televiewer, or equal. PART 3 EXECUTION 3.01 DRILLING EQUIPMENT B. All drilling equipment shall be of a type and capacity and in mechanical condition suitable for performing the Work satisfactorily. C. Drilling for rock bolts, rock anchors, or grouted dowels, exploratory, and piezometer holes may be by percussion or rotary methods. If necessary to penetrate rubble or steel pipes and reinforcing, rotary core drilling shall be used at no additional cost to Owner. Blue Lake Expansion Project – Contract No. 9 02405-3 General Construction May 2012 D. Drilling for exploratory cored boreholes shall be by rotary methods using a minimum HQ-sized diamond bit. E. Drilling for pressure relief well holes shall be by rotary methods using a minimum HQ-sized diamond bit. F. Drilling for micropiles shall be by rotary methods using a minimum 10-inch boring bit. 3.02 DRILLING FOR ROCK ANCHORS, ROCK BOLTS, ROCK DOWELS AND DRAIN HOLES A. RPR will witness drilling for rock anchors, rock bolts, rock dowels, and drain holes as determined by the RPR. B. Holes shall be drilled to depths, orientations and inclinations at locations As Shown, or as required by RPR. C. The collars of all holes will be marked at the required locations by Contractor and verified by RPR. Contractor shall provide access to the face for this purpose. D. Holes which are drilled out of place or alignment shall be replaced as required by RPR at no additional cost to Owner. E. Percussion type drilling equipment, satisfactory to RPR, may be used for drilling holes. If, because of position or rock condition, a hole cannot be drilled with a percussion drill, a rotary drill with a diamond bit shall be used. No extra payment will be made for rotary drilling. F. The excessive use of grease, rod dope, or other lubricant on the drill rods will not be permitted. Driller shall wipe excess from outside of joint. G. The hole diameter for each bolt, anchor, or dowel shall be the minimum as governed by anchor or bolt diameter and hole depth. Hole diameter shall be uniform for the entire length of the hole. Telescoping of holes will be permitted only on the certified written recommendation of the resin and bolt Suppliers. H. The hole diameter for each drain hole shall be As Shown. I. Extend the holes depth beyond the required anchor depth to meet Supplier’s requirements. J. Upon completion of drilling of a hole, the hole shall be flushed and cleaned of all drill cuttings, debris, and sludge by inserting a rigid tube in the back end of the hole and blowing air or an air-water mixture through the tube as it is slowly withdrawn. 3.03 DRILLING FOR PRESSURE RELIEF WELL HOLES A. RPR will witness drilling of the pressure relief well holes. B. Contractor shall provide skilled drill crews, experienced in drilling, sampling, and testing procedures. Contractor shall also provide personnel to maintain and repair the drilling equipment under the direction of the drill foreman, who will supervise and coordinate the drilling and moving of drilling equipment. Blue Lake Expansion Project – Contract No. 9 02405-4 General Construction May 2012 C. The drill shall be advanced through the bedrock and overburden using the rotary drilling method for all pressure relief well holes using a minimum HQ-size coring diamond drill bit. The minimum starter casing shall be H-sized. A triple-tube core barrel, minimum HQ-3 size, shall be used. At the collar, the borehole orientation shall be within 1 degree of the azimuth and inclination specified by Engineer. D. The rotary diamond drill rig shall be capable of drilling vertical and inclined drill holes into bedrock to a depth of 100 ft beyond the hole collar. E. Contractor shall provide core orientations on the cored boreholes using the borehole camera. F. The rotary diamond drill rig shall have a water supply pump with an adequate supply of water hose and all necessary pipes, fittings, valves, gauges, meters and tools to permit the pump to be used for water pressure testing. This water pump shall be capable of pumping water up to a maximum distance of 300 ft. G. Contractor shall provide two sets of 5-ft long HQ-3-sized split tubes, as well as at least one 5-ft long HQ-sized core barrel. The split tubes shall be in good condition. H. Contractor shall provide plastic or wooden blocks to mark the end of each drill run and a sufficient quantity of 5 ft long wooden core boxes and lids to store the bedrock cores. I. Contractor shall provide, on Site, at all times, a set of casing jacking equipment which, in the opinion of the Engineer, is of adequate capacity and design to remove stuck casing and drill rods. 3.04 DRILLING FOR EXPLORATORY CORED HOLES A. Engineer will witness drilling of the exploratory cored boreholes. B. Contractor shall provide skilled drill crews, experienced in drilling, sampling, and testing procedures. Contractor shall also provide personnel to maintain and repair the drilling equipment under the direction of the drill foreman, who will supervise and coordinate the drilling and moving of drilling equipment. C. The drill shall be advanced through the bedrock and overburden using the rotary drilling method, for all cored boreholes using a minimum HQ-size coring diamond drill bit. The minimum starter casing shall be H-sized. A triple-tube core barrel, minimum HQ-3 size, shall be used. At the collar, the borehole orientation shall be within 1 degree of the azimuth and inclination specified by Engineer. D. The rotary diamond drill rig shall be capable of drilling vertical and inclined drill holes upward into bedrock to a depth of 50 ft beyond the hole collar. E. The rotary diamond drill rig shall be capable of drilling within the confined spaces of the tunnel As Shown. F. Contractor shall provide core orientations on the cored boreholes using an OBI 40 Slimhole Optical Televiewer, or Equivalent. G. The rotary diamond drill rig shall have a water supply pump with an adequate supply of water hose and all necessary pipes, fittings, valves, gauges, meters and tools to permit the pump to be used for water pressure testing. This water pump shall be capable of pumping water up to a maximum distance of 300 ft. Blue Lake Expansion Project – Contract No. 9 02405-5 General Construction May 2012 H. Contractor shall provide two sets of 5-ft long HQ-3-sized split tubes as well as a 5-ft long core barrel. The split tubes shall be in good condition. I. Contractor shall provide plastic or wooden blocks to mark the end of each drill run and a sufficient quantity of 5 ft long wooden core boxes and lids to store the bedrock cores. J. Contractor shall provide, on Site, at all times, a set of casing jacking equipment which, in the opinion of the Engineer, is of adequate capacity and design to remove stuck casing and drill rods. 3.05 DRILLING FOR EXPLORATORY HOLES A. Engineer will witness drilling of the exploratory holes. B. The exploratory holes shall be drilled using either a percussion or air rotary drill capable of drilling 160 linear ft at an angle of 90 degrees from horizontal, upwards from inside the tunnel. No drilling muds or additives shall be used. C. The rotary diamond drill rig shall be capable of drilling within the confined spaces of the tunnel As Shown. D. The exploratory holes shall have minimum diameter of 3 in. E. Upon completion of each exploratory hole, the hole shall be flushed and cleaned of all drill cuttings, debris, and sludge by inserting a rigid tube in the back end of the hole and blowing air or an air-water mixture through the tube as it is slowly withdrawn. F. After the holes have been flushed, water pressure testing, as described in Section 02435, shall be undertaken in each borehole as directed by Engineer. G. Drill the exploratory drill holes in the locations and to the target elevations As Shown or as specified herein. H. Upon completion of water testing, Contractor shall insert a borehole camera into each hole drilled, as directed by Engineer, to record any major discontinuities and sections of weaker or more highly fractured rock in the first 30 feet of the hole. Contractor shall provide the digital imagery obtained from each borehole to Owner. 3.06 DRILLING FOR PIEZOMETER HOLES A. Engineer will witness drilling of the piezometer holes, which is expected to occur at the same time as the grouting of the B. The piezometer holes shall be drilled using either a percussion or air rotary drill capable of drilling 300 linear ft at an angle of 60 degrees from horizontal. C. The piezometer holes shall have minimum diameter of 3 in. D. Upon completion of each piezometer hole, the hole shall be flushed and cleaned of all drill cuttings, debris, and sludge by inserting a rigid tube in the back end of the hole and blowing air or an air-water mixture through the tube as it is slowly withdrawn. Blue Lake Expansion Project – Contract No. 9 02405-6 General Construction May 2012 E. After the holes have been flushed, water pressure testing, as described in Section 02435, shall be undertaken in each borehole as directed by Engineer. F. Drill the exploratory drill holes in the locations and to the target elevations As Shown or as specified herein. 3.07 DRILLING FOR MICROPILE HOLES A. Engineer will witness drilling of the micropile holes. B. Contractor shall provide skilled drill crews, experienced in drilling, sampling, and testing procedures. Contractor shall also provide personnel to maintain and repair the drilling equipment under the direction of the drill foreman, who will supervise and coordinate the drilling and moving of drilling equipment. C. The drill shall be advanced through overburden and bedrock using the rotary drilling method, for all micropile holes using a minimum 10-inch drill bit. At the collar, the borehole orientation shall be within 1 degree of the azimuth and inclination specified by Engineer. D. The rotary drill rig shall be capable of drilling vertical and inclined drill holes into bedrock to a depth of 100 ft beyond the hole collar. E. The rotary drill rig shall have a water supply pump with an adequate supply of water hose and all necessary pipes, fittings, valves, gauges, meters and tools to permit the pump to be used for water pressure testing. This water pump shall be capable of pumping water up to a maximum distance of 300 ft. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02410-1 General Construction May 2012 SECTION 02410 ROCK BOLTS PART 1 GENERAL 1.01 WORK INCLUDED A. Provide all rock bolts required for rock support of surface and underground excavations As Shown. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 02315: Rock Excavation and Scaling C. Section 02400: Rock Tunnelling, Shaft Excavation and Support D. Section 02405: Drilling E. Section 02411: Rock Anchors 1.03 REFERENCE STANDARDS A. ASTM A615M: Standard Specification for Deformed and Plain Billet - Steel Bars for Concrete Reinforcement. B. AWS D1.4: Structural Welding Code - Reinforcing Steel. C. PTI: Post Tensioning Institute Manual 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review: 1. Rock bolt, resin and accessories product data, installation information, including Suppliers’ names. 2. Signed mill certificate from the Supplier warranting the strength of each lot of rock bolt(s) prior to shipment to site. This certificate shall include at minimum the following information: a. Shape, size, grade and specification description. b. Material composition of the rock bolt. c. Minimum cross-sectional area of the threaded portion of the bar. d. Minimum cross-sectional area of the unthreaded portion of the bar. e. Yield strength of the bar. f. Ultimate tensile strength of the bar. Blue Lake Expansion Project – Contract No. 9 02410-2 General Construction May 2012 g. Percent elongation of the bar at yield and ultimate strength. 3. Specifications and Supplier’s product data sheets showing name of material, Supplier, graph of unconfined compressive strength development versus time, gel time, viscosity, shelf life, storage and handling requirements for the epoxy resin cartridge and/or grout to be used. 4. Hydraulic Jack Calibration Certificates: See requirements from Section 02411. 5. An alternate installation work plan if it does not follow that described in Section 3.02. 1.05 DEFINITIONS A. “Rock Bolts” – 1-inch diameter tensioned solid steel bars defined in Section 2.01. B. "Pattern Bolts" - rock bolts (same as above) installed on a regular pattern As Shown or as set out in the field after inspection of an excavated face or profile. C. "Spot Bolts" - rock bolts (same as above) installed in areas not covered by pattern bolts, as set out in the field or by Contractor as required for safety of the Work. D. “Rock Anchors” – are defined in Section 02411. PART 2 PRODUCTS 2.01 ROCK BOLTS A. Rock bolts shall be 1-inch diameter, grade 75 (ASTM A615.95) galvanized Dywidag (Threadbar) unless noted otherwise. B. The length of the installed rock bolt shall be As Shown on the drawings (unless directed otherwise by RPR). The supplied rock bolt shall be of sufficient length to provide a final rock bolt of the length specified. C. Rock bolts shall be provided with a galvanized flat washer, a nut and galvanized steel flat or bevelled bearing plates As Shown. The plate shall be Grade A36. The bevelled washers or plate shall be provided as required so that the nut is normal to the axis of the rock bolt. D. Resin shall meet the following criteria at minimum: 1. Shall be mixed and cured to meet minimum unconfined compressive strength per Supplier’s recommendations. 2. Encased in a plastic film that provides optimum resistance to moisture, and is easily ruptured to enable complete mixing during installation. 3. Suitable thixotropic and viscous properties to permit adequate mixing of the resin components by rotation of the rock bolt bar and to contain the resin within the drill hole. 4. Easily identifiable gel time and as recommended by the resin Supplier. Blue Lake Expansion Project – Contract No. 9 02410-3 General Construction May 2012 5. Reach 80% of its ultimate strength within a time interval equal to five times the gel time and non-shrink after the gel time. 6. Unaffected by mild acids or mild alkalis. 7. Cartridges should come from a new box which is labelled with the resin expiry date. E. If anchor grout will be used in place of the slow set resin, a Supplier’s product sheet must be submitted approved by RPR in accordance with the provisions of Section 01300. F. Mortar Pads shall be used where required to provide a flat tension surface. The pad shall be made from quick setting Portland cement or RPR approved alternate product. G. If an alternate reinforcement system is proposed, it is required that all rock bolts shall be from a proprietary system with a well proven record of use under similar long-term conditions. Contractor shall provide the proposed name(s) of rock bolt suppliers to RPR for approval. H. Contractor shall provide a hydraulic jack suitable for tensioning of the specified rock bolts to their design lock off load. I. Contractor shall provide a calibrated torque wrench to tension the rock bolts installed in the tunnel to their design lock-off load. PART 3 EXECUTION 3.01 GENERAL A. The rock reinforcement and support requirements for surface rock excavations are As Shown or as determined by field conditions. These systems will be designed to accommodate conditions anticipated as likely to occur and shall be installed following a full evaluation of actual conditions by Contractor as specified in Section 02315. B. Rock support shall be installed prior to the excavation of the next lift or round. In surface rock excavations, removal of the next lift or adjacent rock in the same lift shall be performed such that there is no more than 10 ft vertical distance of unsupported rock face exposed. C. Contractor will evaluate rock support requirements as excavation proceeds. Modifications may be required based on changes in rock conditions. Contractor shall make his evaluation with respect to safety aspects of the Work. 3.02 ROCK BOLTS A. The diameter of the holes shall be in accordance with the resin cartridge Supplier's recommendations and shall be such that the ultimate strength of the steel can be developed without failure of the resin. B. Extend rock bolt hole depths beyond required anchorage depth to meet Supplier’s requirements. Blue Lake Expansion Project – Contract No. 9 02410-4 General Construction May 2012 C. The installation of rock bolts shall be performed by personnel experienced in this type of work and special care shall be taken to ensure thorough and complete encapsulation of the full length of the embedded portion. D. The locations of the collars and inclinations of all RPR-approved rock bolt holes will be marked on the excavated rock face by RPR. Contractor shall provide access to the face for this purpose as soon as possible after the completion of scaling in the adjacent area, at each bench level. E. Grout full RPR-rejected holes at no additional cost to Owner. Notify RPR if holes are drilled out of place or alignment. F. In order to provide an acceptable bearing surface, RPR may require that the rock surface around the drilled holes be chipped smooth or be covered with a smooth quick-set mortar pad prior to tensioning of the rock bolt. G. Immediately prior to the installation of the rock bolt, the hole shall be flushed with air until the hole is cleaned of all cuttings, debris, ice and water. H. Contractor shall take measures to seal fractures and voids in drill holes to prevent epoxy or grout loss. If required the hole shall be water tested, grouted and re-drilled and re-tested at no additional cost to Owner. I. Accurate records shall be kept of rock bolt installation, including verification that the bolts have been tensioned to the specified lock-off load. Contractor shall provide to RPR two original copies, on a daily basis, of the records of the installation performed the previous day. J. Rock bolts shall be installed in accordance with the following procedures: 1. After the hole is cleaned, a sufficient number of fast-setting resin cartridges to achieve the required anchorage, shall be inserted in the hole and tamped to the bottom of the hole. The remainder of the hole shall then be filled with sufficient slow-setting resin cartridges (or approved anchor grout) to a level that will completely encapsulate the rock bolt. 2. The resin cartridges shall be stored at temperatures not below 50°F or above 122°F. Rock bolts shall be warmed, as required, to a minimum of 50°F, before installation. If anchor grout is proposed to be used in place of epoxy for the free- stressing length the application and mixing method for the grout shall be included in the rock support installation plan by the Contractor. 3. The bolt shall be pushed and spun through the cartridges at a minimum speed of 100 r/min for a minimum of one minute. 4. Setting time of the fast-setting resin cartridges shall be between two and four minutes, and the setting time of the slow setting cartridges shall be between 15 and 30 minutes. 5. Mount bearing plate and secure bearing plate with anchor nut. Wedge washers or quick set mortar pad are required when anchor plate is not perpendicular to bolt. All threads on the bolt and the spherical nut shall be free of rust and burrs. An approved grease or wax mastic shall be used between the spherical nut and the bearing plate and on the bolt threads. Blue Lake Expansion Project – Contract No. 9 02410-5 General Construction May 2012 6. The rock bolts installed in the tunnel portal face and the excavated rock slopes shall be tensioned to a sufficient initial load to result in the final specified lock-off load (47,000 lbs) after 10-minutes of testing. Contractor shall determine the appropriate starting load on the hydraulic jack to achieve this result without failing the specified testing criteria in Section 3.04. 7. The rock bolts installed in the underground excavations shall tensioned using a calibrated torque wrench to the specified lock-off load (5,000 lbs) in accordance with the procedure provided in Section 3.03. 8. Any bolt that will not carry the required tension load without yield of the bolt or anchorage slip will be rejected and a new bolt shall be installed in a new hole in the immediate vicinity of the rejected bolt, as directed by RPR at no additional cost to Owner. Yield of the bolt or anchorage slip shall mean outward movement of the bolt which occurs and continues: a. Without increase in the load; or b. With a decrease in the load. 9. Bolts shall be tensioned when the fast-setting resin cartridges have set and before setting of the slow-setting cartridges is complete. After the bolt has been tensioned, the tension shall not be relaxed before the slow-setting resin has hardened. Any deviation from this procedure shall only be done with the RPR approval. 10. If it is found that any bolt will not take the required tension without anchorage slip, another bolt shall be installed in a new hole drilled in the immediate vicinity of the unsatisfactory bolt at no additional cost to Owner. K. Any defects in the galvanized plates or bevelled washers coated not galvanized shall be coated before installation with an approved protective coating compound. Any defects in the coating shall be adequately recoated after installation. The outer ends of the rock bolts, nuts and washers shall also be coated after installation and tensioning. The remaining portions of all rock bolts shall be clean and free of all deleterious materials, including dirt, paint and grease. 3.03 TENSIONING OF ROCKBOLTS INSTALLED IN TUNNELS OR SHAFTS A. Do not blast within 30 ft of a resin-anchored and encapsulated bolt for at least three hours after installation and tensioning. B. Inspect the rock bolts after blasting. Any bolt within 50 ft of a blasting operation which shows signs of loosening shall be torque or tension tested within four hours after each blast and re-tensioned, if necessary, to a load 10 percent greater than the bolt working capacity. 3.04 ROCK BOLT TESTING – TUNNEL PORTALS AND ROCK SLOPES A. All rock bolts installed at the tunnel portal face and in the rock slope shall be tested in accordance with the following procedure: 1. The rock bolt shall be test tensioned and locked off following set-up (or curing) of the bond zone and before set-up of the free stressing length. Prior to testing, the bond zone grout and/or resin shall meet the strength specified by the anchor Blue Lake Expansion Project – Contract No. 9 02410-6 General Construction May 2012 Supplier. The following procedure applies to 1-inch diameter, grade 75 (ASTM A615.95) galvanized Dywidag. 2. Rock bolts shall be test-tensioned to an initial load of 53,400 pounds (70% of ultimate strength). The test load should be held for at least 10 minutes. The load should be recorded at 0, 5 and 10 minutes. 3. The rock bolt shall be locked-off to the design working load of after testing. 4. During the test a load loss of greater than 10% of the initial load applied shall be indicative of anchorage failure. Creep movement at the head of the bolt shall not exceed 1/16-inch during the test. A replacement rock bolt shall be installed at the Contractor's expense where these criteria are not met. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02411-1 General Construction May 2012 SECTION 02411 ROCK ANCHORS PART 1 GENERAL 1.01 WORK INCLUDED A. Perform all labor for the embedment grouting, installation, tensioning and testing of single bar, post-tensioned, rock anchors. Rock anchor installation locations include dam abutments, penstock anchor blocks, powerhouse structure and reservoir debris boom, As Shown. Rock anchor installation requirements vary from feature to feature. Specific requirements are As Shown with “anchors” and “rock anchors” having different installation details. Anchors are installated through concrete structures into rock. Rock anchors are installated directly in rock and bear on rock. B. Drilling, water pressure testing and consolidation grouting of holes for rock anchors will be covered by other sections. Rock bolts are covered by other sections. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 02315: Rock Excavation and Scaling C. Section 02405: Drilling D. Section 02410: Rock Bolts E. Section 02430: Grouting F. Section 02435: Water Pressure Testing 1.03 REFERENCE STANDARDS A. ACI 318: Building Code Requirements for Reinforced Concrete B. ASTM A36: Structural Steel C. ASTM A722: Uncoated High Strength Steel Bar for Prestressing Concrete D. ASTM C109: Compressive Strength of Hydraulic Cement Mortars E. ASTM C150: Portland Cement F. PTI: Post-Tensioning Institute Manual 1.04 SUBMITTALS A. Submit under the provisions of Section 01300 for review: 1. Hydraulic Jack Calibration Information: Provide a calibration curve (gage pressure versus transfer load) for the hydraulic jack(s) to be used during the tensioning operations. Provide hydraulic jack(s) identification number, cylinder cross sectional area and calibration curve seven days prior to start of the Blue Lake Expansion Project – Contract No. 9 02411-2 General Construction May 2012 testing program. Provide current calibration information based on hydraulic jack testing performed within six weeks of the time the jack is planned to be put in service. The calibration testing shall be performed by a certified independent testing lab. 2. Rock Anchor Grout Mix Design: Provide the rock anchor grout mix design including all admixture and water-cement proportions. Include a letter from the rock anchor manufacturer certifying the mix meets the design requirements of the rock anchors including strength and rate of strength gain. 3. Rock Anchor Test Forms: Provide copies of proposed forms for use in recording proof and performance testing, together with acceptance criteria 30 days prior to the start of tensioning operations. 4. Rock Anchor Shop Drawings: Provide submittal of the anchor system described in this Section. If an alternative system is proposed, as specified in Item 1.06, Contractor shall provide submittal of the alternative anchor system. 5. Rock Anchor Test Results: Submit the results from all rock anchor testing within 24 hours of the conclusion of each day when anchors are being tested. 6. Rock Anchor Grout Test Data: Provide unconfined compressive test results for rock anchor grout test cubes. 1.05 ROCK ANCHOR INSTALLATION RECORDS A. Maintain current rock anchor installation records on approved test forms. B. Contractor shall submit results of grout cube testing and for embedment grout prior to tensioning. 1.06 ALTERNATIVE ANCHOR SYSTEMS A. Contractor may propose an alternative system of anchors to be approved by Engineer. Alternative systems may include a bar supplied by a Supplier other than specified. Complete details of the proposed system must be submitted under the provisions of Section 01300 for review. If the capacity, length, spacing or corrosion resistance of the alternative system is different from that As Shown, Contractor shall provide with the submittal, design calculations for the proposed system together with a stress analysis of the stress distribution of anchor loads and design calculations and drawings of any changes required to be made to the structures as a result of the proposed alternative system. The submittal shall also include details of tensioning and testing of the proposed alternative anchor system. PART 2 PRODUCTS 2.01 ROCK ANCHORS A. Rock Anchors: Dwyidag Threadbar Grade 150 (ASTM A722) rock anchors manufactured by Dwyidag Systems International., or approved equal. B. Provide rock anchors size and strength As Shown and specified. Blue Lake Expansion Project – Contract No. 9 02411-3 General Construction May 2012 C. Rock Anchor Storage and Handling: Observe the Rock Anchor supplier‘s requirements for storage, handling, and temporary support of high tensile prestressing bars (rock anchors). 2.02 NUTS, WASHERS AND BEARING PLATES A. Nuts and washers and bearing plates: Conform to anchor Supplier's recommendations. Anchor bearing plates shall be steel plates conforming to the Supplier’s recommendations to the size As Shown and shall be suitably drilled to accommodate necessary tubes for grouting and venting. 2.03 COUPLERS A. Rock Anchor Bar Couplers: Provide Dwyidag couplers in accordance with ASTM A722, exceeding the requirements of ACI 318. 2.04 ANCHOR EMBEDMENT GROUT A. Rock anchors shall be embedded in cement grout. Rock anchor embedment grout shall be Portland Cement Type 2 mixed in proportions recommended by anchor Supplier to achieve minimum compressive strength (modified ASTM 109) 1 day - 1,500 psi, 3 day – 3,500 psi and 7 day – 5,500 psi. Provide additives as recommended by anchor supplier and approved by the RPR. 2.05 CORROSION INHIBITOR A. Provide corrosion inhibitor grease or mastic for filling the annular space between the bar and the protective cap in accordance with PTI-Post Tensioning Manual, Chapter 4, Section 6.3.3. 2.06 PROTECTIVE CAP A. Provide protective plastic cap to cover the nuts and washers and seat uniformly on bearing plate. The cap shall be filled with corrosion inhibitor. The cap shall be secured in place by a retaining nut. Gaskets shall be installed between bearing plate and cap, and between cap and retaining nut, to prevent leakage of corrosion inhibitor. The gasket material shall be compatible with corrosion inhibitor. 2.07 BAR CENTRALIZERS A. Provide bar centralizers in accordance with bar Supplier’s recommendations. 2.08 STORAGE AND HANDLING A. Contractor shall be aware of the sensitivity of high tensile prestressing bars to mistreatment, particularly where the application of heat and cold are concerned. Under no circumstances shall such material be welded or tack welded, nor shall hot slag be allowed to fall on the material from adjacent welding operations. The tensioning of material which has been contaminated in this fashion can be extremely hazardous. B. Take special care to prevent damage to the outer sleeve of the anchor. Cutting, storage, and handling of prestressing materials and rock anchors shall be in accordance with Supplier's recommendations. Blue Lake Expansion Project – Contract No. 9 02411-4 General Construction May 2012 C. Contractor responsible for replacement of damaged materials at no expense to Owner. PART 3 EXECUTION 3.01 EQUIPMENT FOR TESTING AND TENSIONING ROCK ANCHORS A. Contractor shall provide, maintain in good working condition, and have available on site during anchor testing and tensioning, all the equipment and spare parts necessary for testing and tensioning single bar rock anchors. This equipment shall consist of center hole hydraulic jack(s), and means for attaching the jack to the end of the anchor, hydraulic pump(s), strain measuring device(s), and all other necessary accessories. The hydraulic jack(s) shall be capable of tensioning all anchors to 80 percent of the guaranteed ultimate tensile strength of the anchors within the rated pressure capacity of the pumping units. The strength of the couplers, extension bars and the connection between the anchor and the jack shall be no less than that of the anchor. The jack shall have sufficient travel to allow for the maximum elongation of the anchor during testing without having to be reset. Contractor shall provide RPR a test calibration certificate for the jack as specified in Item 1.05. Strain shall be measured with plunge type dial indicator(s) with sufficient travel to allow for measuring maximum elongation of the anchor during performance and proof testing without having to be reset and shall be accurate to 0.001 inch. B. Contractor shall provide all equipment for installation, tensioning and testing gate bearing anchors in accordance with the drawings and as specified herein. 3.02 INSPECTION OF FOUNDATIONS A. Contractor shall arrange his operation and shall cooperate with RPR so that RPR may inspect concrete integrity and rock foundation surfaces as soon as is reasonable to confirm actual rock anchor lengths and arrangements. 3.03 INSTALLATION OF SINGLE BAR ROCK ANCHORS A. Rock anchors shall be installed As Shown and in accordance with PTI except as otherwise specified herein. B. The general sequence of work for installation of rock anchors shall be as follows: 1. Drill holes for rock anchors in accordance with Section 02405. 2. Perform water pressure testing in accordance with Section 02435. If rock anchor hole passes water pressure test proceed with testing of anchor (Step 5). If rock anchor hole does not pass water pressure test perform consolidation grouting (Step 3), re-drill hole (Step 4) and re-perform water pressure test. Repeat these operations until hole passes water pressure test. 3. Perform consolidation grouting As Shown in accordance with Section 02430. 4. Re-drill hole in accordance with Section 02405 when consolidation grout has achieved an unconfined compressive strength of at least 1,000 psi. The consolidation grout strength shall be determined by testing 2-in. cubes in accordance with ASTM C-109 on the first three anchor holes and every other tenth hole thereafter. Blue Lake Expansion Project – Contract No. 9 02411-5 General Construction May 2012 5. Test anchors in accordance with PTI except as otherwise specified herein. C. Qualifications of Personnel for Rock Anchor Installation: The rock anchors shall be installed by personnel experienced in installation of such devices. Contractor shall provide the services of the Supplier's representative or Contractor's approved qualified personnel that is certified by Supplier on site full time for the first five days of rock anchor installation to supervise installation and the first three days of tensioning to provide advice on tensioning procedures. Contractor shall abide by the recommendations of the anchor Supplier's representative. Contractor shall maintain rock anchor temperature above 40ºF for 48 hours prior to installation. D. Rock Anchor Hole Cleaning: Immediately prior to the installation of a rock anchor, the hole shall be flushed and cleaned of all drill cuttings, debris, and sludge. Cleaning shall be done by inserting a rigid tube to the bottom of the hole and blowing an air-water mixture through the tube as it is slowly withdrawn. This operation shall be done twice, and delivered air pressure shall be not less than 80 psi nor more than 120 psi during the operation. E. Inspection of Rock Anchors: Immediately prior to installation of rock anchors, inspect rock anchors for any damage. F. At the time of installation, rock anchors shall be clean and free of all deleterious materials, including dirt, rust, grease, oil, and paint. Bare steel portions of the anchors may have surface rust as allowed by ACI 318. G. Two Stage Rock Anchor Grouting 1. Facilitate inspection of rock in vicinity of each rock anchor to select foundation type, Type 1 or 2, required to transfer anchor load to rock. 2. Install anchor in hole with grout supply pipes for bond zone and stressing length, grout return pipe for bond zone, packer to allow first stage grouting of the bond length and anchor bearing foundation including steel bearing plate. 3. Grout bond length. Assure that anchor embedment grout fully encapsulates the bond length of the anchor by running anchor embedment grout through bond zone grout supply pipe until fluid grout with no air bubbles, discoloration or dilution is observed discharging from the bond zone grout return pipe. Obtain grout test cubes for strength testing. 4. Allow anchor embedment grout encapsulating bond length of rock anchor to cure until test cubes achieve 3,000 psi compressive strength. 5. Test anchor following PTI procedures described below and lock off. 6. Grout stressing length using grout supply pipe. Observe anchor embedment grout flowing through the grout return or hole in the bearing plate is the same as the grout being pumped into the grout supply pipe. 7. Apply corrosion inhibitor to head of anchor and install protective plastic cap over anchor head. 8. If temperatures are at or fall below the required installation temperatures, Contractor shall provide necessary means of warming the necessary materials and conditions to the appropriate temperature at no cost or expense to Owner. Blue Lake Expansion Project – Contract No. 9 02411-6 General Construction May 2012 9. Embedment grout strength shall be tested for all anchors subjected to performance testing. Testing shall be performed on 2-inch cubes in accordance with ASTM C-109. Three cubes each shall be tested after curing 3, 7, and 28 days. Complete test results shall be submitted to Engineer. H. Rock Anchor Curing after Installation: Do not disturb rock anchors for seven days after they have been grouted or until an anchor embedment grout strength of 4,000 psi achieved whichever is takes longer. If the anchors are disturbed and the bond between anchor and grout or between rock and grout is in any way adversely affected, then install a replacement anchor in a new hole adjacent to the disturbed anchor without any cost or expense to Owner. 3.04 TESTING ROCK ANCHORS A. Facilitate observation and inspection of rock anchor testing by the RPR. B. Testing of Multiple Rock Anchors: Test and stress multiple rock anchors in an order proposed by Contractor and acceptable to RPR. Perform lift-off tests in the same order as initial stressing. C. Rock Anchor Test Sequence: 1. Performance Test: Conduct performance tests to a maximum load of 80 percent of guaranteed ultimate tensile strength on the first three anchors and every tenth anchor thereafter. 2. Proof Test: Conduct proof tests to a maximum load of 80 percent of guaranteed ultimate tensile strength on the remaining anchors not scheduled for performance testing. 3. Creep Test: Perform creep tests as required by results of performance and proof tests. 4. Immediately after performance, proof and creep tests, reduce anchor load to 70 percent of guaranteed ultimate tensile strength, the nut shall be tightened and the jack load shall be reduced to zero so as to fully transfer the jack load to the anchor, nut and bearing plate. 5. Perform initial lift off check immediately after transferring jack load to anchor. If initial lift off load is less than 95 percent of the lock off load, then re-tension the anchor to the lock off load, re-tighten the nut, fully transfer load to anchor and perform lift check again. 6. Perform lift off tests on anchors as directed by RPR. Lift off tests shall be performed between 24 hours and 7 days after final lock off. D. Documentation of Rock Anchor Testing: Record all data during performance, proof, creep and lift off testing on data sheets approved by RPR. Use individual data sheets for the performance and the proof test. Confirm that approved data sheets have space to record the following: Project name, Contractor, name and company of individuals performing and witnessing the test, date of test, test begin time, temperature, structure being anchored, anchor data, performance, proof, creep and lift off test data. Anchor data shall include: Anchor ID number, Supplier, ASTM steel grade, guaranteed ultimate tensile strength, cross-section area, bond length, stressing length and jack length. Performance and proof test data shall include: Blue Lake Expansion Project – Contract No. 9 02411-7 General Construction May 2012 test loads as recommended by PTI (in gage pressure and kips), dial indicator readings for each load, total movement, residual movement (for performance test only) and time at final lock off. Creep test data shall include: dial readings for time intervals as recommended by PTI and shall be included on the performance and proof test data forms. Lift off test data shall include: date and time of lift off test and the lift off reading in gage pressure and kips. Modify data sheets if they have insufficient space for recording rock anchor test data. E. Sign completed rock anchor test data sheets immediately after testing and submit to RPR. F. Acceptance of rock anchors will be by RPR, based on the testing results and in accordance with the PTI. G. Replace all anchors not meeting the acceptance criteria, overstressed, or otherwise damaged in any way without any cost or expense to Owner. H. Safety during Rock Anchor Tensioning: Take all necessary safety precautions during tensioning. In particular, keep he "line of fire" clear in the event of anchor failure. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02413-1 General Construction May 2012 SECTION 02413 GROUTED DOWELS PART 1 GENERAL 1.01 WORK INCLUDED A. Provide all grouted dowels for concrete placement As Shown. 1.02 RELATED SECTION A. Section 01300: Submittals B. Section 02315: Rock Excavation and Scaling C. Section 02405: Drilling D. Section 03200: Concrete Reinforcement E. Section 03300: Cast-In-Place Concrete F. Section 03600: Structural Nonshrink Grout 1.03 REFERENCE STANDARDS A. ACI 315: Details and Detailing of Concrete Reinforcing B. ACI 318: Building Code Requirements for Reinforced Concrete C. ASTM A615: Deformed and Plain Billet-Steel Bars for Concrete Reinforcement D. PTI: Post Tensioning Manual 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review: B. Shop Drawings: Prepare and submit shop drawings for grouted dowels including bending and reinforcing bars. The shop drawings shall contain dowel steel schedules with the quantity, shape and size, weight per foot and total weights, bending details, and mark numbers. The shop drawings shall also show concrete outlines and construction joint locations of lifts, lift station numbers and elevations. Shop Drawings shall be drawn to scale and include adequate notes, symbols, and abbreviations. 1. Dowels shall be identified by mark number and indicated on Shop Drawings. C. Test Reports: Certified test reports for dowels showing that the steel complies with the applicable specifications shall be submitted to RPR by Contractor. Reports and delivery tickets shall be furnished for each steel shipment and shall be identified with specific lots prior to use of the steel in the Work. Blue Lake Expansion Project – Contract No. 9 02413-2 General Construction May 2012 PART 2 PRODUCTS 2.01 DOWELS A. Unless otherwise noted on the drawings, dowels shall be deformed bars conforming to ASTM A615, Grade 60. Dowel sizes and lengths are As Shown. B. Fabrication: 1. Cut and bend dowels in accordance with ACI 315 and ACI 318. 2. Site fabrication of bent dowels is permitted. 3. Bend dowels cold. 4. Dowels with kinks or unnecessary bend shall not be used. 5. Welding of dowels is not permitted. 2.02 ACCESSORIES A. All accessories shall be in accordance with Section 03200. B. Wire Ties: Wire ties shall be 16-gage or heavier black annealed wire. 2.03 GROUT A. Nonshrink grout shall be in accordance with Section 03600. PART 3 EXECUTION 3.01 DELIVERY, STORAGE AND HANDLING A. Delivery, storage and handling requirements shall be consistent with Section 03200. 3.02 INSPECTION A. Areas where dowels will be placed shall be inspected by RPR for defects that would prohibit their satisfactory installation and performance. Defects, if existing, shall be corrected prior to commencing installation of reinforcing materials. B. After installation of dowels, Contractor shall notify RPR and provide adequate access inspection. Contractor shall not begin concrete placement until receiving approval from RPR of dowel installation. 3.03 PLACEMENT A. General: Install grouted dowels and accessories As Shown and as on approved shop drawings, and in accordance with Section 03200. B. Accurately place dowels and secured in position to prevent displacement during placement of concrete. Blue Lake Expansion Project – Contract No. 9 02413-3 General Construction May 2012 C. Allow a minimum of 24 hours for grout to cure after installation of grouted dowels before disturbance by placing concrete. D. Do not allow welding of grouted dowels. 3.04 HOLES A. General: Contractor shall follow the drilling procedures described in Section 02405. B. Drill grouted dowel holes using rotary percussive method to the exact depths As Shown. Drill hole diameter shall be two times the nominal bar diameter or as otherwise stated on the drawings, but not less than 2 inches. If the holes are drilled deeper than specified, dowels shall be supported in their proper location until the grout has set. Holes shall be free of dirt, mud and any material that would prevent proper anchorage. C. Tolerances for drilled holes shall be as follows: Location Inclination Depth ±2 inches ±5° +6”, -0” D. Drill holes for horizontal dowels at least 5 degrees (no minus tolerance allowed) below the horizontal to assist in placement of the embedment grout by limiting grout loss at top of hole. E. On completion of drilling, flush all holes with air until the hole is cleaned of all cuttings, debris, fines, sludge, foreign materials, ice and water. 3.05 DOWEL INSTALLATION A. Perform the installation of grouted dowels with personnel experienced in this type of work and special care shall be taken to ensure thorough and complete grouting of the full length of the embedded portion. B. Take measures to seal fractures and voids in drill holes to prevent epoxy or grout loss. If required the hole shall be water tested, grouted and re-drilled and re-tested at no additional cost to Owner. C. Mix and place grout in accordance with Supplier's recommendations and Section 03600. Holes shall be filled to the top with grout by means of a pipe extending to the bottom of the hole, and then the dowels shall be installed in the holes. D. Wedge dowels with steel wedges so they will not move. E. If temperatures are at or fall below the required installation temperatures, provide necessary means of warming the necessary materials and conditions to the appropriate temperatures at no cost or expense to Owner. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02420-1 General Construction May 2012 SECTION 02420 PRESSURE RELIEF DRAINS (WEEPHOLES) PART 1 GENERAL 1.01 WORK INCLUDED A. Perform all labor for the installation of pressure relief drains in concrete structures. Note that drain holes in excavated rock faces and tunnels are covered in Sections 02315 and 02400 respectively. 1.02 RELATED SECTIONS A. Section 02405: Drilling B. Section 03300: Cast-In-Place Concrete 1.03 REFERENCE STANDARDS A. ASTM D1785: Polyvinylchloride Plastic Pipe, Schedule 40, 80, and 120 1.04 SUBMITTALS Not used. PART 2 PRODUCTS 2.01 MATERIALS A. Pipe, sleeves for pressure relief drains shall conform to ASTM D1785, Schedule 40. PART 3 EXECUTION 3.01 INSTALLATION A. Pressure relief drains shall be installed as located and As Shown and as modified by RPR to suit conditions. B. Pipe sleeves for drains shall be installed As Shown or as determined by design. After concrete placement, drain holes shall be cleaned and/or drilled As Shown. C. After resurfacing concrete has been placed, the weepholes shall be drilled no more than 150 mm (6 in.) past the end of the pipe sleeve and past the existing concrete, and 300 mm (12 in.) into rock. D. Drains which become damaged or clogged during construction shall be repaired or cleaned. Blue Lake Expansion Project – Contract No. 9 02420-2 General Construction May 2012 END OF SECTION Blue Lake Expansion Project – Contract No. 9 02430-1 General Construction May 2012 SECTION 02430 FOUNDATION GROUTING PART 1 GENERAL 1.01 WORK INCLUDED A. Perform all curtain and consolidation grouting for the dam extension and thrust block As Shown. B. Intent of Specification: Engineer will direct the grouting operation. The specified procedures are the basic grouting requirements; however, since all grouting eventualities cannot be predicted, variations in procedures, sequence of grouting and/or grout mixes may be adjusted in the field. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 02370: Erosion Protection C. Section 02405: Drilling D. Section 02411: Rock Anchors E. Section 02435: Water Pressure Testing F. Section 03300: Cast-In-Place Concrete G. Section 03610: Dam Contraction Joint Grouting 1.03 REFERENCE STANDARDS A. ASTM A 53/A 53M-07: Standard Specification for Pipe, Steel, Black and Hot- Dipped, Zinc-Coated, Welded and Seamless B. ASTM A 197/A 197M-00(2006): Standard Specification for Cupola Malleable Iron C. ASTM A 234/A 234M-07: Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service D. ASTM C33: Standard Specification for Concrete Aggregates E. ASTM C94: Standard Specification for Ready Mixed Concrete F. ASTM C109: Standard Test Method for Compressive Strength of Hydraulic Cement Mortars G. ASTM C150: Standard Specification for Portland Cement H. ASTM C 494/C 494M-05a: Standard Specification for Chemical Admixtures for Concrete Blue Lake Expansion Project – Contract No. 9 02430-2 General Construction May 2012 I. ASTM C 1602/C 1602M-06: Standard Specification for Mixing Water Used in the Production of Hydraulic Cement Concrete J. NEMA 250-2008 Enclosures for Electrical Equipment (1000 Volts Maximum ) 1.04 DEFINITIONS A. "Curtain grouting" - Drilling and grouting one or more lines of holes to fill voids within a rock mass to reduce the permeability of a rock mass. B. "Consolidation grouting" - Drilling and grouting of holes to fill voids around the drill hole to increase the structural strength and reduce the permeability of the surrounding material. C. "Contact grouting" - Grouting of holes through embedded sleeves or through concrete to fill voids or shrinkage spaces between concrete and adjacent concrete, masonry or rock. D. “Foundation grouting” – General term used for the combination of curtain and consolidation grouting for foundation treatment. E. "Gage pressure for grouting" - Pressure of grout as measured at the header while grout is being pumped into the hole. F. "Grout take" - The quantity of materials injected in a hole expressed in units of bags of cement (94 lbs). G. "Stage grouting" - Drilling, washing, water-pressure testing, and the grouting of a hole in stages. The grouting of stages may be performed either stage-up or stage- down. H. "Water-cement ratio" - The ratio of the volume of water to the volume of cement. 1.05 EXPERIENCE A. Contractor will employee a grouting crew who is experienced in performing grouting operations and the maintenance of grouting equipment. Contractor shall demonstrate grouting crew’s expertise and experience to RPR for acceptance. The grouting crew’s experience shall meet but not be limited to the following: 1. Grouting Supervisor: Minimum of 5 years of experience in responsible charge of grouting for construction similar in nature to that required by this contract. 2. Other grouting personnel shall have a minimum of 2 years experience in grouting for construction similar in nature to that required by this contract. 3. Maintain sufficient qualified personnel to perform required drilling and grouting work. 1.06 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Foundation Grouting Plan: Contractor shall submit a Grouting Plan for review prior to starting any grouting work. Work shall not begin until plan approval. Include the following information with the plan: Blue Lake Expansion Project – Contract No. 9 02430-3 General Construction May 2012 1. Proposed equipment, methods of access, sequence, materials, schematic layout sketch, procedures, record sheets and completed copy of the check list attached at the end of this section (ref. Attachments A and B). a) The schematic layouts shall be simple line sketches for each phase of grouting identifying the work plan showing the general arrangement of mixer, pump, gages, valves, hoses, connection and all other proposed equipment to be used in grout operations. b) Grout Plant Details: Pump rating curves; mixer and agitator details; photographs of mixing and pumping equipment; power system for grout pump and agitator; and agitator tubs. Note: Utilizing the helical screw grout pump as the agitator will not be allowed. c) Flow Meter/Density Gauge Information: Supplier’s instructions and operations manual. d) Plasticizer: Supplier’s name and specific brand names, product description, instructions, recommended dosage, chloride content, and precautions for its use. Also include the supplier’s recommended proportioning. 2. Hole Numbering: Use hole numbering conventions As Shown so grouting records can easily be related to the plans and the foundation grouting design. 3. Resume: Qualifying experience of individuals responsible for supervising and directing pressure grouting foundation work. Also include experience record of key grouting personnel. 4. ESCP and SPCC measures to keep grout materials and products out of the adjacent water courses. 5. Completed copy of the check list attached at the end of this section (ref. Attachment A). C. Certifications and Test Reports: 1. Cement: Supplier’s certification and test reports for each lot of cement from which shipments are drawn. 2. Certify materials were tested during production or transfer in accordance with specified reference specification. 3. Submittal of certification and test reports shall not relieve Contractor of responsibility for furnishing materials meeting specified requirements. 4. Plasticizer: Manufactured Dates and anticipated shelf life of each shipment of plasticizer. D. Foundation Grouting Records: Maintain grouting records for all grouting operations and submit completed and signed copies for each day’s grouting activities. See attached “Grout Injection Record” for a recommended record log. The minimum requirements for grouting records shall include but not be limited to: 1. Date. Blue Lake Expansion Project – Contract No. 9 02430-4 General Construction May 2012 2. Hole number/location (station). 3. Hole diameter/inclination. 4. Elevation of collar. 5. Final and intermediate hole depths. 6. Height of interval between pressure gage and top of packer. 7. Stage number/stage elevation top. 8. Time of start and completion. 9. For cementitious grout: a) Water-cement ratio (w/c) for each stage. b) Total bags pumped for each w/c. c) Time duration for each w/c pumped gage pressure/actual pressure at regular intervals. 10. Total quantity (bags of cement (94 lb)) used in each hole and set-up. PART 2 PRODUCTS 2.01 CEMENTITIOUS GROUT MATERIALS A. Provide grout mix and mix proportions as directed by the Engineer to suite the particular conditions encountered in the rock. Provide a neat grout mixture of Portland cement and water. B. Mixing water shall be fresh, clean and free from oil, acid, alkali, salts, organic matter, or other deleterious substances. River or lake water may be used upon Engineer's acceptance of certified laboratory analysis performed by Contractor per ASTM C94. C. Contractor shall handle, store, and protect all cement and additives in such a manner that these materials will not be subject to deterioration or contamination. Deteriorated or contaminated materials shall not be used in this work. 2.02 PORTLAND CEMENT A. Portland cement: 1. ASTM C 150, type III. 2. Meet equivalent alkali requirements of ASTM C 150 – Table 2. 3. Meet false-set requirements of ASTM C 150 – Table 4. 2.03 WATER A. ASTM C 1602, including optional requirements of Table 2. Blue Lake Expansion Project – Contract No. 9 02430-5 General Construction May 2012 2.04 PLASTICIZER A. ASTM C 494, type F high range water reducing admixture (HRWRA). Construction Product Rheobuild 1000, as manufactured by BASF or equal. 2.05 CURTAIN GROUT MIX A. Anticipated water-cement ratio of grout mixture will vary from 5:1 to 0.8:1 by volume. Assume, as a basis for bid, a water-cement ratio of 5:1. B. Cement may be furnished in 94 pound bags or 47 pound bags. C. Use plasticizer (HRWRA) in grout mix as directed by the Engineer. D. Batch plasticizer separately in liquid form in dispensers capable of measuring at one time the full quantity of plasticizer required for each batch. E. Measure plasticizer by weighing or by volumetric-admixture dispensers constructed and located so the full batch quantity of plasticizer can be observed in a visual gauge by the plant operator. F. Discharge plasticizer separately into the mixed grout. G. Normal amount of plasticizer used in grout mix varies between 4 and 16 fluid ounces per bag of cement. H. The Engineer reserves the right to adjust the quantities of plasticizer or discontinue its use. Contractor is not entitled to any additional allowances for such adjustments. I. When plasticizer is initially added to grout mix, circulate mix through the circulating line system for 5 minutes minimum prior to down-hole injection. 2.06 GROUT PIPE A. Pipe: ASTM A 53, standard weight, schedule 40, black steel pipe. B. Pipe fittings: ASTM A 197 malleable iron fittings or ASTM A 234 steel fittings. 2.07 GROUT PLANT AND EQUIPMENT A. Use plant and equipment of a type and size approved by the Engineer to mix and place grout. B. Use plant and equipment capable of effective mixing and stirring of grout and grout into grout holes or grout connections in a continuous flow at any pressure up to a maximum of 250 pounds per square inch. C. Use adequate water supply to mixer to achieve required pumping rate. D. Mixing Plant: 1. Cylindrical mixing tank: a) Mounted vertically. Blue Lake Expansion Project – Contract No. 9 02430-6 General Construction May 2012 b) Volume: 17 cubic feet minimum. c) High-speed colloidal type. d) Equipped with high-speed, diffuser-type centrifugal mixing pump operating at 1,500 to 2,000 revolutions per minute during mixing. e) Delivers 300 gallons per minute at 30 pounds per square inch. f) Water meter reading cubic feet to tenths of a cubic foot for controlling amount of mixing water used in the grout. Water meter shall have capability to be reset to zero after each batch is mixed. 2. Return flow from centrifugal mixing pump directed tangentially into the cylindrical tank near the top to create a vortex. 3. Provide a holdover mechanical agitator tank similar in volume to the mixer. 4. Pass grout through a U.S. Standard No. 16 screen as it is discharged from the mixer to the agitator. 5. Make arrangement of screen so the return line of the circulating grout system is also included such that grout returns from the manifold can be passed over the screen. 6. Keep screen clean and free of grout scale and build-up. 7. Make screen readily accessible for cleaning and replacement. 8. The Engineer has right to require the Contractor to make changes in the equipment which the Engineer determines necessary to make equipment perform satisfactorily during grouting operations without additional cost to the Owner. E. Communication Facilities: 1. Use page/party telephone system between grout plant and/or mixing plant and the holes being grouted or hand held radios as listed below. a) GAI-Tronics Model 491-204 – mine phones in weatherproof Lexan cases interconnected with No. 14 AWG, twisted-pair interconnect cable as manufactured by GAI-TRONICS Corp., 455 Lowries Run Road, Pittsburg, PA 15237. Telephone no. 1-888-254-9155; or equal. b) Provide radios for communication purposes between engineer’s staff and the contractor to the Engineer. c) Motorola HT1250 Professional Radio or equal. d) The Contractor shall furnish 4 radios, extra batteries, and 4 chargers to the Engineer for use by the Engineer for the grouting operations. e) Radio frequencies for the contractor’s grouting staff and the Engineer’s staff shall be the same. Separate frequencies for the grouting operations shall be maintained. Blue Lake Expansion Project – Contract No. 9 02430-7 General Construction May 2012 F. Grout Plant: 1. Grout pump: Helical-screw, rotor-type pumps that produce a uniform flow without pulsation. a) Pump minimum capacity of 35 gallons per minute at pressure of 250 pounds per square inch. b) No grout pumps allowed with open-throat design or open throat hoppers. 2. Include standby grout pumps as part of grout plant, capable of being placed in operation with no more than 15-minute notice given by the Engineer. 3. Maintain grouting equipment in a manner satisfactory to the Engineer so it is capable of continuous and efficient performance during any grouting operation. 4. Arrange grouting equipment to provide a supply line and a return line from the grout pump to the grout hole. 5. Provide manifold at collars of grout holes As Shown. Locate manifold in the grout line at the collar of the hole to permit continuous circulation, accurate control and monitoring of grouting pressure, bleeding, and regulation of flow into grout holes. 6. Minimum size of supply lines and manifolds including valves and fittings: 1-inch inside diameter. 7. Use color code system for air, water, and grout lines. G. Pressure Gauges and Pressure Sensors: 1. Pressure gauges as manufactured by Marsh Bellofram, 8019 Ohio River Road, State Rt. 2, Box 305, Newell, WV 28050, Telephone no. 1-800-727-5646, or equal with the following essential characteristics: a) Glycerin filled. b) Plain case. c) Pressure indicated in pounds-per-square-inch (psi). d) 2.5-inch diameter minimum dial-face size. 2. Rating of each pressure gauge not more than three times the pressure rating at which the grout is anticipated to be pumped for the stage being grouted. 3. Gauges accurate to no more than 2 percent error over the full range of gauge. 4. Equip pressure gauges with approved flow through pressure sensor (gauge savers) when pumping grout. 5. Check gauges with attached pressure sensor at least once per shift to accuracy. Blue Lake Expansion Project – Contract No. 9 02430-8 General Construction May 2012 6. Pressure Sensors: Red Valve Co., Inc., Series 42 pressure sensors (gauge savers), as manufactured by Red Valve Company, Inc. 700 N. Bell Ave. Carnegie, PA 15106, Telephone no. 1-412-279-0044, or equal. 7. Mount pressure sensor in the manifold in the flow pattern above the flow-density meter and control valve and ahead of the bleed-off valve As Shown. 8. Immediately replace defective gauges or gauges with broken glass faces. 9. Provide an accurately calibrated, high precision master gauge for periodic of the accuracy of gauges used in the grouting operations. 10. Master gauge: Calibrated and certified by gauge Supplier to be accurate to not more than 1percent error over the full range of gauge. 11. Provide accurate and reliable gauge tester and keep at grout plant at all times. 12. Use valves with permanently attached minimum 6-inch lever handles that clearly show position of the valves. Use only cast iron or steel bodied valves. 13. Calibrate the flow meters at least once a week or when calibration is found to be off. Calibrate the flow meters before continuing grouting operations. 14. Calibration to consist of an adequate water supply, a calibrated container capable of holding 55 gallons of water, and scales to weigh water container. 15. Keep calibration material and equipment onsite throughout the job. 16. Immediately replace defective flow meters. 17. Demonstrate testing and calibration procedures to the Engineer for approval prior to grouting start-up. 18. Use grout hose attachments to flow-density meters with standard manufactured quick disconnect couplers of appropriate sizes so grout hoses can be rapidly disconnected. 19. Clean flow meter plumbing after grouting of stage of a drill hole is completed, or every 8 hours while grouting is in progress, or at times directed by the Engineer: a) Clean flow-density meter by flushing plumbing with clear water until there are no visible signs of grout. b) Use muriatic acid to remove hardened grout and scrub flow meter plumbing with a round, stiff bristle brush of appropriate size until hardened grout is removed as approved by the Engineer. H. Flow-Density Meters 1. Provide flow-density meters of a type approved by the Engineer in grout lines for grout holes. Blue Lake Expansion Project – Contract No. 9 02430-9 General Construction May 2012 2. Flow-Density meters to consist of complete density gauge and density monitoring control system to measure the density of cement grout ranging from 0.8:1 to 5:1 water/cement ratios by volume. 3. Measurement precision: Plus or minus 0.001 g/cc with a calibration accuracy of plus or minus 0.001 g/cc. 4. Flow-Density meter system: a) Mass flow meter mounted in accordance with Supplier’s recommendations. 5. Flow-Density meters: Micro Motion Series T-Series, Coriolis Flow and Density Meters as manufactured by Emerson Process Management, or equal having the following essential characteristics: a) A digital readout and an isolated output that is linear, relative to density, 4- to 20-milliampere signal. b) Factory calibrated so 4-milliampere signal represents zero flow in gallons per minute, and 20-milliampere signal represents 90 gallons per minute. c) Readout in pounds per cubic foot. d) Operated from 110 volt alternating current and control-readout box is remotely located. 6. Install one flow-density meter in supply line for each pump at the location As Shown. 7. Demonstrate testing and calibration procedures to the Engineer for approval before grouting start-up. 8. If the Engineer determines that the flow-density gauge equipment and/or lines are not operating or malfunctioning, repairs shall be made after that particular stage or hole has been completed and before grouting is continued to the next stage or hole. 9. Clean by flushing with muriatic acid until hardened grout is removed from gauge, then flush with clear water until there are no signs of grout, or by other methods approved by the Engineer. 10. Clean gauge at the end of each shift, and during shift as determined by the Engineer. 11. At all times, keep at jobsite at least one calibrated, standard, working flow-density meter, fitted identical to the meters in use for immediate replacement of defective meters. I. Power Supply and Connections: 1. Provide reliable, suitable power supply to density-flow meters. 2. Use cables of proper size and type for outdoor construction environment Blue Lake Expansion Project – Contract No. 9 02430-10 General Construction May 2012 3. Only one splice allowed per line. 4. Splices: Soldered and sealed watertight with heat-shrink tubing. a) Heat-shrink tubing: PVC-Voltrex PVC-105 or equal. 5. Cable connectors and electrical boxes: watertight. 6. Maintain power supplies, cables, connectors, and electrical boxes as recommended by Suppliers. Protect from damage; keep operational during all grouting operations. 7. Failure of Contractor to maintain equipment in working condition will result in suspension of grouting operations until necessary repairs or replacements have been made. J. Grout Supply Pipes and Packers: 1. Furnish grout supply pipes and packers. 2. Have available at all times a sufficient number and variety of packers to accomplish the grouting. 3. Packers to consist of pneumatic tubes attached to the end of the grout supply pipe. 4. Design packers so that they can be expanded and be able to withstand, leakage, water pressure equal to the maximum grout pressures to be used for the entire period of time in which the packer is used. 5. Supply pipe to the packer: Flush coupled, box threaded packer pipe or tubing with a 1-inch minimum inside diameter. 6. Heavy-gauge packer is recommended for use with deep holes and high grouting pressures. 7. Use 3/4-inch minimum inside diameter pipe through packer. 8. Obstructions to inside diameter of the packer or packer pipe caused by the supply airline hookup to the packer will cause the packer to be rejected. 9. Poly pipe for grouting shall not be allowed unless approved by the Engineer. 10. Use of grout reels in place of packer pipe shall not be allowed. PART 3 EXECUTION 3.01 GENERAL REQUIREMENTS A. Foundation Grouting Blue Lake Expansion Project – Contract No. 9 02430-11 General Construction May 2012 1. Drilling and grouting dam foundation from excavated foundation surface and other locations by means of high-pressure curtain grout holes. 2. Grouting faults, joints, shear zones, springs, and other foundation defects as determined by the Engineer. 3. Drilling and grouting consolidation holes as directed by the Engineer. 4. Drilling and grouting at other locations As Shown or directed by the Engineer. 5. Expected required depth of grout holes will vary between twenty feet and a maximum of 150 feet. If grout holes are required to be drilled to a greater depth, payment will be made in accordance with Item 1.23 of Section 01270 and General Conditions Articles 10, 11, and 12. 3.02 GROUT PIPE A. Grout pipe shall be installed in the foundation or concrete As Shown or as directed by the Engineer. B. Grout pipes shall be cleaned of all dirt, oil, and grease before installation. C. The bottom end of grout pipes shall be slightly swelled before installation. D. Grout pipes shall be installed to an accuracy of 1 degree in the vertical direction and 2 degrees in the horizontal direction. E. After grouting all holes shall be backfilled by the tremie method with heavy grout. After backfilling is complete all grout pipes shall be cut off flush with the final excavated rock or concrete surface. 3.03 DRILLING GROUT HOLES A. Use rotary drilling or wet percussion to drill grout holes at spacings, angles, and to depths As Shown. B. Drill each grout hole to its full depth, clean, and grout in stages up from bottom of the hole (stage-up grouting), or down from top of hole (stage-down grouting) as directed by the Engineer. C. All drilling shall be performed through grout pipe installed in the rock foundation or concrete As Shown. D. Percussion-type drills will be permitted for drilling grout holes. Percussion drilling must be performed utilizing wet percussion. The returning drill water must maintain an annulus velocity of 90 feet per minute except for those portions of grout holes which are drilled for setting grout pipe. E. Minimum diameter of each grout hole: Not less than that produced by the commercial standard AX-size drill bit (2 inches in diameter). Maximum size allowable grout hole will be BX-size drill bit (2-1/2 inches in diameter for curtain grout holes only. F. Drill fluid: Clean, clear water, except approved neutral liquid soap may be added to drill water. Blue Lake Expansion Project – Contract No. 9 02430-12 General Construction May 2012 G. Use of “rod dope,” grease, or other lubricants on drill rods or in grout holes shall not be allowed. H. Reverse circulation drilling will not be allowed. I. Use mufflers on rotary air drills. J. Use drilling equipment and techniques to minimize causing a hole to cave or become oversize. K. When drilling of each hole or stage of a hole is complete, flush hole with clean water until hole is free of drill cuttings. L. Temporarily cap or suitably protect hole to prevent it from becoming clogged or obstructed until it is grouted. 1. Any hole that becomes clogged or obstructed due to Contractor’s failure to protect the hole until it is grouted shall be opened by and at expense of Contractor. 2. Do not leave a hole open for more than 48 hours before water testing it or beginning grouting it. 3.04 CASING GROUT HOLES A. Some grout holes drilled through, soft, granular broken material may require casing to complete hole drilling to required depth. B. Case only those portions of holes which are determined to require casing and which are approved by the Engineer. C. Where casing is approved, place the casing in the designated portions of holes to completely support unstable material or to seal water loss zones and to support the drill rods when drilling through the diversion conduits. D. Holes requiring casing may be grouted with a packer set below the bottom of the casing, or by grouting through drill rods or grout pipe extending to the bottom of the hole after removal of casing, or by other methods approved by the Engineer. E. Remove casing placed in ungrouted stages of holes before completing the stages. F. Removed casing shall remain the property of the Contractor. 3.05 HOOKUPS TO GROUT HOLES A. Hook onto each drilled hole, As Shown, or as directed by the Engineer to pressure grout. 3.06 PRESSURE GROUTING A. Force grout under pressure through standard pipe and/or packer pipe into each hole and grout connection using approved grout mix. 3.07 WATER PRESSURE TESTING AND WASHING Blue Lake Expansion Project – Contract No. 9 02430-13 General Construction May 2012 A. Water pressure test and/or wash grout holes before pressure grouting. B. Test each stage with clean water under continuous pressure. C. Perform water pressure testing in accordance with Section 02435. D. If the Engineer determines more extensive washing of grout holes is required, such as washing alternately with water and air under pressure to eject materials from adjacent holes, Contractor will be paid for such washing with water and air in accordance with General Conditions Articles 10, 11, and 12. 3.08 GROUTING PROCEDURES A. Method of grouting: Stage-up or stage-down, as directed by the Engineer. B. Stage-up grouting: 1. Drill each grout hole to its full depth and grout in stages up from the bottom of the hole (stage-up grouting). 2. Attach a packer to the end of the grout supply pipe. 3. Lower the grout supply pipe into hole to the top of bottom stage that is required to be grouted. 4. Water test and grout at required pressure. 5. Leave packer in place until there is no back pressure. Deflate packer and wash grout supply pipe until clear water appears at the collar before withdrawing the grout supply pipe to the next higher stage. 6. After grouting, release pressure on the packer and wash out the grout from the packer pipe. 7. Continue washing until clear water flows from the top of the grout hole. 8. Withdraw grout supply pipe and packer to the top of next higher stage that is required to be grouted. 9. Successively grout hole in stages at specified grouting pressures until the entire hole is completely grouted. C. Stage-down grouting: 1. Where 50 percent or more drill water loss or hole caving occurs during drilling; drill, clean, and grout hole in successive operations by stages down from top of hole (stage-down grouting). 2. Drill hole to a limited depth. 3. Wash out hole. 4. Seat a packer just above the stage to be grouted. Blue Lake Expansion Project – Contract No. 9 02430-14 General Construction May 2012 5. Water test and grout that stage. 6. Clean out grout hole by washing or other means before grout in the hole has set sufficiently to require redrilling. 7. Allow grout surrounding the grout hole to attain its initial set as determined by the Engineer. 8. Drill hole to additional depth. 9. Successively drill and grout the hole at various depths within the stages 10. Washing with less than 3/4-inch, inside-diameter plastic pipe is not acceptable. 11. If plastic hose or tubing is used, make lower end contain a minimum of 5 feet of rigid, 1-inch minimum inside diameter pipe. Cut bottom of rigid pipe on a diagonal to aid penetration and enable washing the hole to the full diameter size. D. Where caving of a grout hole persists and hole does not remain open for grouting, grout through flush-coupled grout pipe or drill rods extending to the bottom of the drilled stage with a stuffing box at the collar of the hole. E. When grouting through pipe, withdraw pipe slowly to prevent loss of pipe. F. Grout each hole in stages located between depths in the hole to best treat the defects in the foundation as determined by the Engineer and in accordance with the following maximum stages: 1. Between 0 and 100 feet grout hole depth: (20 feet). 2. Between 100 and 150 feet of grout hole depth: (30 feet). G. Once grouting of any stage is begun, continue grouting that stage until it is completed or as directed by the Engineer. H. In general, do not allow maximum pressures as measured at the collar of the hole exceed 1-1/2 pounds per square inch per foot of depth greater than any initial back pressure, measured normal from the ground surface to the packer. Except, grout the top stage at a maximum of 30 pounds per square inch greater than any back pressure or as directed by the Engineer. I. Elevation of grout pump to not exceed elevation of collar of hole being grouted by more than (20 feet) to prevent pressure head in the line from exceeding the allowable grouting pressure at the collar of the hole. J. Do not place grout pump more than (200 feet) away from the hole being grouted. K. Temporarily cap grout holes or connections where, during grouting of such holes, is found to flow from adjacent grout holes or grout connections in sufficient quantity to interfere with grouting operations or to cause loss of grout. Blue Lake Expansion Project – Contract No. 9 02430-15 General Construction May 2012 L. Where temporary capping of grout holes is not necessary as determined by the Engineer, leave ungrouted holes open to facilitate escape of air and water as grout is forced into other holes. M. Before grout sets, connect grout pump to adjacent capped holes and to other holes from which grout flow was observed, and complete grouting of all holes at the pressures specified for grouting. N. When grouting is being done with packers, measure the pressure of the grout returning from any adjacent hole by seating a packer in the adjacent hole immediately above where the grout is entering. Keep such pressures below the allowable pressures for that stage of hole. O. If grout is found to flow or leak from bedrock during grouting of any hole, plug or caulk such flows or leaks. P. The contractor shall have sufficient caulking tools and materials on hand at all times, such, hammers, chisels, picks, pry bars, oakum, wooden wedges, and etc. Q. When surface leakage occurs, the Engineer may direct Contractor to wait 24 hours before drilling can be resumed and after the leaking stage has been completed. R. Refusal Criteria: Grouting of any stage of any grout hole or grout connection may be discontinued after that stage or connection takes grout at the following rates and pressures: 1. Less than 1 cubic foot of grout mixture in 20 minutes if pressures of 50 pounds per square inch or less are being used. 2. Less than 1 cubic foot of grout mixture in 15 minutes if pressures between 50 and 100 pounds per square inch are being used. 3. Less than 1 cubic foot of grout mixture in 10 minutes if pressures between 100 and 250 pounds per square inch are being used. S. Grouting of any stage may also be discontinued when less than 2 bags of cement per hour for two consecutive hours are being injected when pumping is continuous. T. Maintain full grouting pressures constantly during grout injections or as directed by the Engineer. U. As a safeguard against foundation displacement, or while leaks are being caulked, the Engineer may require reducing pumping pressure, intermittent pumping, or discontinuing of pumping. V. Where the grout hole or grout connections take a large amount of grout, the Engineer may require that pumping be done intermittently, waiting up to 8 hours between pumping periods to allow grout in the hole to set. Provide additional grouting equipment if necessary to efficiently progress foundation grouting in other locations while “high take” holes are completed. Blue Lake Expansion Project – Contract No. 9 02430-16 General Construction May 2012 W. Maintain pressures after the grouting of the hole or connections is complete by using stopcocks or other suitable valve devices until the grout has set sufficiently so that it will be retained in the hole or connections being grouted. X. Waste grout not injected within 2 hours after mixing. No payment for grout will be made if, as determined by the Engineer, such waste is due to Contractor’s negligence or equipment breakdown. Y. Clean Up 1. Take precautions during drilling and grouting operations to prevent drill cuttings, oil, grout, or other substances from plugging drains or from defacing or damaging any surface of any part of the uncompleted or completed Work. 2. Do not allow any buildup of wasted or leaked grout at any time. Remove any grout, drill cuttings, or other foreign material from drains by washing or other suitable means. 3. During grouting Work provide for adequate disposal of all waste. Remove all waste grout, and empty packaging. Blue Lake Expansion Project – Contract No. 9 02430-17 General Construction May 2012 ATTACHMENT A GROUTING EQUIPMENT CHECK LIST Mixer: Type: Capacity: cu ft Model: Supplier: Grout Pump Type: Capacity: cu ft psi Model: Supplier: Grout Lines Size: inches internal diameter Gages: Number of Number of Range 0 to psi Range 0 to _____ psi Type: Type: Supplier: _________Supplier: _________________ Diameter: inches Diameter: inches Packers: Type: Size: If gas filled, max inflation pressure ________ psi Attachment B - Grout Injection Record Project: Blue Lake Expansion Project – Contract 9 General Construction Contractor :______________________________________ Superintendent:___________________________________ Shift____________________________________________ Date: Hole Diameter (in): Type: Inclination: Elevation of Collar: Height (Top Packer to Pressure Gauge): Stage No./ Top Elev: Bearing: Time Grout Batched Injected From To Elapsed (Min) Gauge Pressure (psi) Mix Cement (lb) Plasticizer (oz) Sand (lb) Volume (gal) Volume (gal) Cement (lb) Acceptance Rate (gal/Min.) Remarks (Always Include Packer Settings) Totals: Sheet ______ of ______ Cement: lb Other: Qty Check: Hole No. Sand: lb Packer Settings: No. Engineer: Plasticizer: oz Complete Contractor: Blue Lake Expansion Project – Contract No. 9 02431-1 General Construction May 2012 SECTION 02431 CONTACT AND TUNNEL LINER GROUTING PART 1 GENERAL 1.01 WORK INCLUDED A. Perform all contact grouting for concrete tunnel plugs as well as the tunnel liner grouting As Shown. Mobilization and demobilization, grout plant and other grouting requirements shall conform to the applicable provisions of Section 02430. B. Perform tunnel liner grouting in stages As Shown. Stages 1 and 2 are to be consolidation grouting using neat cement. Stages 3 and 4 are to be contact grouting using concrete Mix E, and Stage 5 is to be contact grouting using neat cement. Sequencing and curing times are to be As Shown. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 02370: Erosion Protection C. Section 02405: Drilling D. Section 02430: Foundation Grouting E. Section 02435: Water Pressure Testing F. Section 03300: Cast-In-Place Concrete G. Section 13110: Tunnel Steel Liners 1.03 REFERENCE STANDARDS A. ASTM A 53/A 53M-07: Standard Specification for Pipe, Steel, Black and Hot- Dipped, Zinc-Coated, Welded and Seamless B. ASTM A 197/A 197M-00(2006): Standard Specification for Cupola Malleable Iron C. ASTM A 234/A 234M-07: Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service D. ASTM C33: Standard Specification for Concrete Aggregates E. ASTM C39: Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens F. ASTM C94: Standard Specification for Ready Mixed Concrete G. ASTM C109: Standard Test Method for Compressive Strength of Hydraulic Cement Mortars H. ASTM C150: Standard Specification for Portland Cement Blue Lake Expansion Project – Contract No. 9 02431-2 General Construction May 2012 I. ASTM C 494/C 494M-05a: Standard Specification for Chemical Admixtures for Concrete J. ASTM C939: Standard Test Method for Flow of Grout for Preplaced-Aggregate Concrete (Flow Cone Method) K. ASTM C940: Standard Test Method for Expansion and Bleeding of Freshly Mixed Grouts for Preplaced-Aggregate Concrete in the Laboratory L. ASTM C 1602/C 1602M-06: Standard Specification for Mixing Water Used in the Production of Hydraulic Cement Concrete M. NEMA 250-2008 Enclosures for Electrical Equipment (1000 Volts Maximum) 1.04 DEFINITIONS A. "Contact grouting" - Grouting of holes through embedded sleeves or through concrete to fill voids or shrinkage spaces between concrete and adjacent concrete, masonry or rock. B. "Gage pressure for grouting" - Pressure of grout as measured at the header while grout is being pumped into the hole. C. "Grout take" - The quantity of materials injected in a hole expressed in units of bags of cement (94 lbs). D. “Tunnel liner grouting” – Similar to “contact grouting”, tunnel liner grouting is to be performed through threaded ports in the liner As Shown to fill voids between steel tunnel liner and the rock walls of the tunnel, to increase the structural strength. E. "Water-cement ratio" - The ratio of the volume of water to the volume of cement. 1.05 EXPERIENCE A. Contractor shall employee a grouting crew who is experienced in performing grouting operations and the maintenance of grouting equipment. Contractor shall demonstrate grouting crew’s expertise and experience to RPR for acceptance. The grouting crew’s experience shall meet but not be limited to the following: 1. Grouting Supervisor: Minimum of 5 years of experience in responsible charge of grouting for construction similar in nature to that required by this contract. 2. Other grouting personnel shall have a minimum of 2 years experience in grouting for construction similar in nature to that required by this contract. 3. Maintain sufficient qualified personnel to perform required drilling and grouting work. 1.06 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Tunnel Liner Grouting Plan: Contractor shall submit a tunnel liner grouting plan for review prior to starting any grouting work. Note that any equipment or submittal Blue Lake Expansion Project – Contract No. 9 02431-3 General Construction May 2012 data included in Section 02430 that will be used in this section may be referenced in the tunnel liner grouting plan. Include the following information with the plan: 1. Proposed equipment, methods of access, sequence, materials, schematic layout sketch, procedures, record sheets and completed copy of the check list attached at the end of this section (ref. Attachment A). a) The schematic layouts shall be simple line sketches for each phase of grouting identifying the work plan showing the general arrangement of mixer, pump, gages, valves, hoses, connection and all other proposed equipment to be used in grout operations. b) Grout Plant Details: Pump rating curves; mixer and agitator details; photographs of mixing and pumping equipment; power system for grout pump and agitator; and agitator tubs. Note: Utilizing the helical screw grout pump as the agitator will not be allowed. c) Flow Meter/Density Gauge Information: Supplier’s instructions and operations manual. d) Plasticizer: Supplier’s name and specific brand names, product description, instructions, recommended dosage, chloride content, and precautions for its use. Also include the supplier’s recommended proportioning. e) Materials and plan for stabilization of tunnel steel liner to prevent misalignment during grouting. 2. Resume: Qualifying experience of individuals responsible for supervising and directing pressure grouting foundation work. Also include experience record of key grouting personnel. 3. ESCP and SPCC measures to keep grout materials and products out of the adjacent water courses. 4. Completed copy of the check list attached at the end of this section (ref. Attachment A). C. Grout Mix Design: 1. Pre-Construction test program results of all proposed concrete (Mix E) and neat cement grout mixes confirming fluid and set characteristics meet all minimum specified requirements as outlined in Section 2.07, herein. 2. Grout Mix Designs: Mix designs for each grout mix proposed for use. Each mix design shall show the ingredients of the mix and shall include: a) Type, brand, source, and amounts of cement, Pozzolans, admixtures, and other additives. b) Source and amount of water. c) Representative samples of materials for materials testing and mix proportion testing. d) Combined grading of each mix design. Blue Lake Expansion Project – Contract No. 9 02431-4 General Construction May 2012 e) Specific gravity of all materials. f) Results of required tests. D. Certifications and Test Reports: 1. Cement: Supplier’s certification and test reports for each lot of cement from which shipments are drawn. 2. Certify materials were tested during production or transfer in accordance with specified reference specification. 3. Submittal of certification and test reports shall not relieve Contractor of responsibility for furnishing materials meeting specified requirements. 4. Additives: Manufactured Dates and anticipated shelf life of each shipment of additive. E. Grouting Records: Submit a sample grout record form, subject to approval by RPR, prior to construction. Maintain grouting records for all grouting operations and submit completed and signed copies for each day’s grouting activities. Note: RPR will maintain his records independent of Contractor’s records. The minimum requirements for grouting records shall include but not be limited to: 1. Date. 2. Hole number/location (station). 3. Hole diameter/inclination. 4. Elevation of collar. 5. Total depth. 6. Time of start and completion. 7. For neat cement grout (Stages 1, 2 and 5): a) Water-cement ratio (w/c) and mix design for each stage. b) Total bags pumped for each w/c. c) Time duration for each w/c pumped gage pressure/actual pressure at regular intervals. d) Refusal criteria met 8. Tunnel liner grout (Stagers 3 and 4): a) Batch ticket for each truck. b) Volume placed at each stage c) Time duration for each stage. Blue Lake Expansion Project – Contract No. 9 02431-5 General Construction May 2012 PART 2 PRODUCTS AND EQUIPMENT 2.01 CEMENTITIOUS GROUT MATERIALS A. Stage 1, 2 and 5 neat cement grout shall consist of a mixture of Portland cement and water. The mixture shall be designed to suit the particular conditions encountered in the rock. B. Mixing water shall be fresh, clean and free from oil, acid, alkali, salts, organic matter, or other deleterious substances. River or lake water may be used upon RPR's acceptance of certified laboratory analysis performed by Contractor per ASTM C94. C. Contractor shall handle, store, and protect all cement and additives in such a manner that these materials will not be subject to deterioration or contamination. Deteriorated or contaminated materials shall not be used in this work. D. Stage 3 and 4 tunnel liner grout shall be concrete Mix E per section 03300. 2.02 PORTLAND CEMENT A. Portland cement: 1. ASTM C 150, type III. 2. Meet equivalent alkali requirements of ASTM C 150 – Table 2. 3. Meet false-set requirements of ASTM C 150 – Table 4. 2.03 WATER A. Clear, free from injurious amounts of oil, acid, alkali, organic matter, sediment, or other substance harmful to the mixing and curing of grout. Conform to the requirements of ASTM C 1602, including optional requirements of Table 2. 2.04 PLASTICIZER A. Provide same plasticizer as in Section 02430. 2.05 SAND A. Sand for tunnel liner grout shall be per section 03300 for concrete Mix E, including gradation. 2.06 ADDITIVES A. Viscosity modifier (Thixotropic agent): Natural, soluble, high molecular weight biopolymer, such as Whelan Gum or Diutan Gum, as produced by Kelco (a unit of Monsanto Company, San Diego), or approved equal. 1. The biopolymer must enhance the stability of the suspension grouts when added at a ratio of maximum 0.1 percent (by weight of water). 2. The viscosity modifier shall also be used to enhance resistance against pressure filtration and control “run away” grouting operations. Therefore, at low shear rates Blue Lake Expansion Project – Contract No. 9 02431-6 General Construction May 2012 and at rest, the viscosity modifier shall trigger a substantial increase in viscosity and cohesion of the grout, providing the thixotropy required to limit travel length of the grout. At high shear rates, the impact of the viscosity modifier on the grout rheology shall be minimal. The viscosity modifier shall not have adverse affect on the unconfined compressive strength of the cured grout. All viscosity modifiers supplied in powder form must be pre-mixed with water via high shear mixer into a 1% solution and then pre-hydrated for a minimum of 1 hour prior to use in the grout mix. This pre-hydrated solution shall be lump free. 2.07 GROUT MIXES A. Contact grout mix shall be as follows: 1. Neat Cement Grout: Portland cement and water B. Tunnel liner grout shall be as follows: 1. Tunnel Liner Grout (Mix E): Portland cement, sand and water, per section 03300. C. Additives: The admixture content, batching method, and time of introduction to the mix shall be in accordance with the manufacturer’s recommendations for minimum shrinkage and for compliance with these specifications. No calcium chloride or admixture containing chloride from other than impurities from admixture ingredients will be acceptable. D. Grout mix requirements: 1. Provide grout consisting of a mixture of Portland cement, a pozzolanic material, fluidifier, sand and water proportioned and mixed to produce a grout capable of being pumped. Submit mix designs for each type of grout in accordance with Part 1.06.C.2 Grout Mix Design. 2. It is critical that the grout consistency permit the complete filling of the void space behind the liner without segregation of ingredients. 3. Contact grout must have a minimum 7-day compressive strength of 2,800 psi. Compressive strength testing shall be performed in accordance with ASTM C109, with 1 specimen tested at 3-days and 2 specimens tested at 7-days for each 10 cubic yards of grout placed, or for each day of placement, whichever results in more tests. 2.08 GROUT PIPE A. Conform to same materials as in Section 02430. 2.09 GROUT PLANT AND EQUIPMENT A. Conform to same equipment as in Section 02430. B. The Contractor shall provide a “day-box” and any other equipment required to test, store and transport the collected grout samples such that they can be secure until either testing is completed or the samples can be safely transported without impacting results of the tests. Blue Lake Expansion Project – Contract No. 9 02431-7 General Construction May 2012 PART 3 EXECUTION 3.01 GENERAL REQUIREMENTS A. Perform all drilling in accordance with Section 02405. B. Provide stabilization measures, per approved plan, to prevent misalignment of tunnel steel liner during grouting. C. Do not perform grouting until concrete has achieved design strength. See Section 03300. D. Pressure Grouting: Force grout under pressure through standard pipe and/or standard pipe with packer into each hole and grout connection using approved grout mix. E. All pressure grouting operations to be performed in presence of the RPR. Notify the RPR of proposed grouting schedule and give 48-hour notice prior to change of a shift schedule. 3.02 GROUT PIPE A. Grout pipe shall be installed in the foundation or concrete As Shown or as directed by the RPR. B. Grout pipes shall be cleaned of all dirt, oil, and grease before installation. C. Grout pipes shall be installed to an accuracy of 1 degree in the vertical direction and 2 degrees in the horizontal direction. D. After grouting all holes shall be backfilled by the tremie method with heavy grout. After backfilling is complete all grout pipes shall be cut off flush with the final excavated rock or concrete surface. 3.03 GROUTING PROCEDURES A. Perform contact and tunnel liner grouting according to sequences As Shown. B. Perform grout consistency measurements at the time of initial pumping and in accordance with ASTM C939. Blue Lake Expansion Project – Contract No. 9 02431-8 General Construction May 2012 ATTACHMENT A GROUTING EQUIPMENT CHECK LIST Mixer: Type: Capacity: cu ft Model: Supplier: Grout Pump Type: Capacity: cu ft psi Model: Supplier: Grout Lines Size: inches internal diameter Gages: Number of Number of Range 0 to psi Range 0 to _____ psi Type: Type: Supplier: _________Supplier: _________________ Diameter: inches Diameter: inches Packers: Type: Size: If gas filled, max inflation pressure ________ psi END OF SECTION Blue Lake Expansion Project – Contract No. 9 02435-1 General Construction May 2012 SECTION 02435 WATER PRESSURE TESTING PART 1 GENERAL 1.01 WORK INCLUDED A. Perform all water pressure testing for exploratory (cored and percussion) holes, (curtain, consolidation and tunnel plug) grout holes, rock anchor holes and pressure relief wells. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 02405: Drilling C. Section 02411: Rock Anchors D. Section 02430: Foundation Grouting 1.03 REFERENCE STANDARDS A. ASTM D4044: Standard Test Method for (Field Procedure) for Instantaneous Change in Head (Slug) Tests for Determining Hydraulic Properties of Aquifers B. ASTM D6034: Standard Test Method (Analytical Procedure) for Determining the Efficiency of a Production Well in a Confined Aquifer from a Constant Rate Pumping Test C. Post Tensioning Institute (PTI): Recommendations for Prestressed Rock and Soil Anchors 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review, a list of proposed equipment, a water pressure testing schematic and proposed test record sheets. The schematic shall be a simple line sketch showing pumps, gages, valves, hoses, hookups, and all other associated equipment to be used in water pressure testing. An equipment check list is attached at the end of this section. 1.05 WATER PRESSURE TESTING RECORDS A. Submit copies of completed and signed water pressure test records for grout and rock anchor holes to RPR 24 hours after completion of testing. B. Water pressure testing records shall include: project name, Owner, name and signature of tester, date(s) and time(s) of testing; location and I.D. # of hole; hole diameter; type, number and depth of packers for each test; water level in hole at start of test; water meter readings at beginning and end of each increment; gage pressure for each increment; and remarks or observations relating to water Blue Lake Expansion Project – Contract No. 9 02435-2 General Construction May 2012 pressure testing including down time equipment failure etc. that otherwise affect the testing. PART 2 PRODUCTS Not Used. PART 3 EXECUTION 3.01 EQUIPMENT FOR WATER PRESSURE TESTING A. All water pressure testing equipment shall be of a type and capacity and in mechanical condition suitable for performing the Work satisfactorily (see attached water pressure testing equipment checklist). B. Water-pressure testing equipment shall consist of pumps, piping, pressure gages, valves, fittings, seal assemblies (packers), and all other accessories. The pumps furnished shall be of gear, centrifugal, or other approved type, with an output of not less than 50 gpm at 50 psi pressure, and shall be capable of maintaining constant pressures. There shall be a water supply with storage tanks having sufficient capacity for the pumps in addition to two sets of flowmeters and Bourdon gages for calibration and checking purposes. C. The packers or seals shall be of the multiple leather cups, mechanically expanded rubber ring, or pneumatically expanded rubber sleeve type. Packers shall be capable of sealing holes at any specified level to a maximum depth of 100 ft without leakage. These packers shall be capable of being used either singly or in pairs, separated by up to 10 ft of perforated pipe. The diameter of the pipes used for separating the packers and for placing the packers in holes shall be the maximum possible for the size of the hole. The packers shall be capable of withstanding the maximum gage plus existing water column pressure without leakage for a period of 10 minutes. 3.02 WATER PRESSURE TESTING FOR EXPLORATORY HOLES, GROUT HOLES AND PRESSURE RELIEF WELLS A. RPR will witness water pressure testing for grouting. All consolidation grouting holes shall be tested. B. Each hole shall also be thoroughly washed under pressure immediately before pressure testing to remove any accumulation of fines, sludge, or foreign materials. Holes shall be washed out by water injection at the bottom of the hole for five minutes or until the return water is clear. C. Water-pressure testing in sections shall be carried out as required by RPR. D. Each section shall be isolated by means of two packers spaced a distance of 10 ft apart. For each section, back pressure shall be measured at the collar of the hole with the hole full of water. Water pressure shall then be applied to the test section for a minimum period of 10 minutes and the volume of water inflow shall be measured to the nearest half-gallon and recorded. E. The applied pressure at the midpoint of the interval being washed or water pressure tested shall not exceed the grouting pressure or 1 psi per ft of depth being Blue Lake Expansion Project – Contract No. 9 02435-3 General Construction May 2012 tested or 1 psi per ft of rock cover depth as measured along the drain line being tested, whichever is less. This pressure may only be exceed by up to 5 psi if specifically directed by RPR. F. Any water loss shall be measured to an accuracy of one-half gallon or one percent, whichever is less. 3.03 WATER PRESSURE TESTING FOR ROCK ANCHORS A. RPR will witness water pressure testing for rock anchors. All rock anchor holes shall be tested. B. Each hole shall also be thoroughly washed under pressure immediately before pressure testing to remove any accumulation of fines, sludge, or foreign materials. Holes shall be washed out by water injection at the bottom of the hole for five minutes or until the return water is clear. C. Prior to anchor installation, anchor holes shall be water pressure tested and meet the acceptance criteria recommended by PTI. 1. A single packer water pressure test for rock anchor holes shall be performed on the entire depth of hole in rock after drilling or re-drilling and prior to anchor installation. A single packer shall be used to seal the top of the hole. If the water loss exceeds 2.75 gallon over a ten minute period, the hole shall be consolidation grouted, re-drilled and retested. This operation shall be repeated until the hole passes the water pressure test. Consolidation grouting for rock anchors shall be in accordance with Section 02430. 2. The applied pressure shall be measured at the midpoint of the interval being washed or water pressure tested . The grouting pressure shall be 5 psi plus and additional 1 psi per ft of depth being tested, except where specifically directed by RPR. D. Contractor shall have on site a double packer system for water pressure testing holes that experience excessive leakage. Water pressure tests shall be in 10-ft sections. A double-packer system shall be used to isolate the 10-ft long test section. If the water loss exceeds 0.001 gallon per minute per inch diameter per foot of length, the hole shall be consolidation grouted, re-drilled and retested. This operation shall be repeated until the hole passes the water pressure test. Consolidation grouting for rock anchors shall be in accordance with Section 02430. 3.04 BOREHOLE LEAKAGE TEST A. A static-head borehole leakage test may be conducted in lieu of the water pressure test. This test shall be applied as a check on rock anchor hole leakage prior to consolidation grouting of the anchor hole. This test will in no way relieve Contractor's obligation to perform a final watertightness pressure test and meet the acceptance criteria recommended by PTI (See 3.03.C.) on each anchor hole. B. The borehole to be tested will be filled with water and maintained at a constant head. The flow of water into the top of the hole will be regulated to equal the leakage flow out of the borehole column. This rate of flow will be observed and measured for a minimum period of 5 minutes. Blue Lake Expansion Project – Contract No. 9 02435-4 General Construction May 2012 END OF SECTION Blue Lake Expansion Project – Contract No. 9 02435-5 General Construction May 2012 ATTACHMENT A WATER PRESSURE TESTING EQUIPMENT CHECKLIST Project: Name of Contractor Blue Lake Expansion Project – Contract 9 General Construction and/or Subcontractor: _____________________________________ Date: _____________ Gages: Number of Number of Range 0 to psi Range 0 to psi Type: Type: Manufacturer: Manufacturer: Diameter: inches Diameter: inches Water Meter: Type: Size: If gas filled, max. inflation pressure psi Water Pump: Type: Capacity: cu ft psi Model: Manufacturer: Blue Lake Expansion Project – Contract No. 9 02440-1 General Construction May 2012 SECTION 02440 PRESSURE RELIEF WELLS PART 1 GENERAL 1.01 WORK INCLUDED A. Perform all work necessary for drilling, installation and development of six (6) pressure relief wells (PR1 to PR6) in the channel infilling material and/or weathered bedrock in the area immediately downstream of Blue Lake Dam As Shown, or as directed by RPR. 1. The objective in installing the six (6) pressure relief wells is to reduce uplift pressure acting on the gorge infilling material and/or weathered bedrock. In addition, by drilling the six wells, it is expected to provide information regarding the type and permeability of the gorge infilling material and underlying bedrock. B. Drilling and installation of pressure relief well shall be performed according to this technical specification and under the technical direction and supervision of RPR. The subsurface condition is not clear in the vicinity to the proposed well locations. On-site adjustment may be required to suit field condition. This may include, but will not be limited to, the location and orientation of drill holes, the establishment of sequence of drilling, testing procedures, sand pack materials to be used, and well screen location. Adjustments and modifications required by RPR shall be executed by Contractor without cause for delay in the construction program. C. Contractor shall continuously protect and maintain the pressure-relief holes in working order. Pressure relief holes which become inoperative due to improper installation or from being plugged with debris or ice shall be re-drilled or replaced, to the satisfaction of RPR. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 02290: Geotechnical Instrumentation and Monitoring C. Section 02315: Rock Excavation and Scaling D. Section 02405: Drilling E. Section 02413: Grouted Dowels F. Section 02435: Water Pressure Testing G. Section 03100: Formwork H. Section 03200: Concrete Reinforcement I. Section 03300: Cast-In-Place Concrete Blue Lake Expansion Project – Contract No. 9 02440-2 General Construction May 2012 1.03 REFERENCE STANDARDS A. American Water Works Association (AWWA) Standard A100: Water Wells B. API Specification 13A: Petroleum and natural gas industries — Drilling fluids — Specifications and testing C. ASTM C33/C33M: Standard Specification for Concrete Aggregates D. ASTM C150: Standard Specification for Portland Cement E. ASTM C 494/C 494M-05a: Standard Specification for Chemical Admixtures for Concrete F. ASTM C 1602/C 1602M-06: Standard Specification for Mixing Water Used in the Production of Hydraulic Cement Concrete 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review, an overall Pressure Relief Well Plan of proposed methods and sequence for well installation as part of the Work Plan. Details of the plan shall meet all the requirements as outlined under these Specifications. The plan shall include proposed equipment, including availability and time required to mobilize to jobsite; names and resumes of all crewmembers, including sub-contractors; and the description and purpose of any special methods to be adopted by Contractor. B. Submit results of testing and installation to RPR. See requirements of subsection 3.04. PART 2 PRODUCTS 2.01 DRILLING RIG A. The Contractor shall supply a rig capable of drilling PQ (4.83 inch diameter) and HQ (4 inch diameter) sized hole as specified in Section 02405. 2.02 PRESSURE RELIEF WELL MATERIALS A. The Contractor shall supply all equipment and materials necessary to install six pressure relief wells. Well materials shall include the following or equivalent: 1. Prepacked screens to avoid possible bridging/blocking during sand pack installation. Johnson 304SS stainless Muni-Pak of 2”x3” (3.5” O.D and 2” I.D.), with No. 12 screen slot size (0.3 mm) and filter pack 20/40, or equivalent. 2. PQ sized casing for infill retention As Shown. 3. Solid riser pipe with same diameter as the screen. 4. Bentonite 5. Protective top cap and casing As Shown Blue Lake Expansion Project – Contract No. 9 02440-3 General Construction May 2012 2.03 PIEZOMETER A. The Contractor shall supply all equipment and materials necessary to install one (1) piezometer in one of the six wells. The piezometer shall be the same as specified in Section 02290. 2.04 GROUT A. The cement grout mixes As Shown may be considered for backfilling completed or abandoned grout holes. B. Portland cement shall adhere to ASTM C150 standards. C. Sand shall adhere to ASTM C33/C33M standards. D. Bentonite shall adhere to API Specification 13A standards. 2.05 SAND PACK A. The sand pack around the screen shall have a gradation as follows: Sieve Designation Nominal Sieve Opening (mm) Content (%) Percent Finer No. 16 1.18 20% 100 No. 30 0.6 60% 80 No. 50 0.3 20% 20 2.06 WATER PRESSURE TESTS A. The Contractor shall supply all equipment and materials necessary for water pressure testing as described in Section 02435. 2.07 PRESSURE RELIEF WELL PROTECTION CAP A. Provide all reinforcement and concrete in accordance with Sections 03200 and 03300 respectively. Concrete shall be Mix C. B. All drain pipe materials are As Shown. C. Grouted dowels are As Shown and in accordance with Section 02413. PART 3 EXECUTION 3.01 GENERAL – SITE CONDITIONS A. Photographs (see TM-07) show the site in vicinity to the plunge pool. Accessibility to the site shall be confirmed prior to the mobilization. The water level in the plunge pool (note: normal water level is EL. 190 ft) and spill condition shall be Blue Lake Expansion Project – Contract No. 9 02440-4 General Construction May 2012 checked to ensure a workable and safe condition for the drilling and installation of the pressure relief wells. B. The locations of the pressure relief wells are As Shown. C. The proposed well locations may be subjected to adjustment depending on the site condition and setup of drilling rig. D. Should adjustment of a well location be made, the inclination of the well will be then adjusted according to Part 3.02 C. 3.02 GENERAL – DRILLING A. The fill materials in the channel are outlined in the Geotechnical Data Report (GDR), Geotechnical Baseline Report (GBR) and As Shown in the Drawings B. The estimated subsurface condition is provided to serve as an initial guide for the configuration of the inclined wells with necessary in-situ adjustment depending on the finding during drilling and tests. Sampling drilling and packer-tests are recommended to allow RPR to assess subsurface material and permeability. C. The well shall have an intersection with the centre axis of the channel at the targeted elevation As Shown. D. RPR will supervise drilling and log rock core retrieved from boreholes. Contractor shall cooperate and facilitate all logging activities, if required and at no additional cost to Owner. Core extracted from the boreholes shall be stored as specified in Section 02405. E. Packer tests shall be performed under pressure as required by RPR to evaluate the permeability of subsurface material, assisting to identify the lower gorge infilling material and weathered bedrock. F. On-site adjustment of the well configuration may be required depending on the findings during drilling and test results of packer tests, As Shown or as directed by the RPR. 3.03 PRESSURE RELIEF WELL INSTALLATION A. The Contractor shall locate the drilling rig to the site of pressure relief wells, as determined by RPR, and then perform diamond drilling of boreholes for the purpose of installing screen. Bore holes of varying depths may be required, but the length will not generally exceed 100 ft (30 m). The amount of, and the requirement for, exploratory drilling will be determined in the field by RPR. B. All bore drilling shall be performed with rotary drilling equipment as specified in Section 02405. C. The screen shall consist of appropriate lengths of 5-ft long screen. The Contractor shall have sufficient quantities of 5-ft long well screen, in order to complete each pressure relief well. The total length and slot size of the screen shall be determined through consultation between the RPR and the Contractor, but in general the screen length ranges from 30 ft to 50 ft per one pressure relief well. D. The Contractor shall install the prepacked screen in the infillings and weathered rock zone. Upon installation of the screen, the Contractor shall place a bentonite Blue Lake Expansion Project – Contract No. 9 02440-5 General Construction May 2012 seal above the sand pack. Following the placement of the bentonite seal, the annulus between the borehole and riser shall be tremmie-grouted with non- shrinkage cement to seal the pressure relief well. E. For PR1, PR2, and PR3, solid riser shall be installed up to the ground surface to allow monitoring of the outlet flow if required. For PR4, PR5, and PR6, the upmost 10 ft of well shall consist of prepacked screen to allow water flow into adjacent surface material as a frost protection measure in winter. F. Upon completion of the well development, perform the construction of the pressure relief well protection cap. a. Excavate to sound bedrock. b. Install grouted dowels As Shown and in accordance with Section 02413. c. Clean rock surface to the requirements of Section 03300. d. Construct formwork in accordance with Section 03100. e. Install reinforcement in accordance with Section 03200. Properly align and secure reinforcement and drain pipe for concrete placement. f. Place and cure concrete according to Section 03300. G. A pump test may be required following the development of each pressure relief well by RPR. 3.04 FIELD QUALITY CONTROL AND RECORD KEEPING A. Carry out bore hole drilling, tests, and well installation in presence of RPR. B. Performance of relief wells properly installed and developed is determined by pumping tests. The pumping test is used primarily to determine the specific capacity of the well and the amount of material infiltration experienced during pumping. The information from this test is required to evaluate its performance and loss of efficiency with time. 1. Equipment: The equipment required for a pumping test consists of a pump of adequate size to affect a substantial drawdown. 2. Pumping: The well must be pumped to obtain a sufficient drawdown. C. During drilling, packer testing and well installation operations, Contractor shall maintain complete records for each hole and each packer setting. One person shall be dedicated to this task. The records shall document the following: 1. Location of hole 2. Depth (ft) 3. Time (hh:mm) 4. Weight of cement (lb) 5. Weight of sand (lb) Blue Lake Expansion Project – Contract No. 9 02440-6 General Construction May 2012 6. Weight of bentonite (lb) 7. Rates of water absorption (gal/min) at various times in packer tests 8. Pressure (psi) 9. Areas of leakage 10. Testing results 11. Backfilling and re-drilling, if required. D. All records shall be recorded on suitable forms and signed by the Contractor and RPR. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02465-1 General Construction May 2012 SECTION 02465 MICROPILES PART 1 GENERAL 1.01 OVERIEW A. This Section describes requirements of the micropile construction for the plunge pool scour wall. Other elements of the related work includes the reinforced concrete head beam that needs to be partially constructed over a large existing boulder and keyed in to the natural features in the right and left abutment rock. The tops of the micropiles will be embedded in the base of the concrete head beam, which will be constructed with a height extension that spans the narrow gut of the plunge pool. The micropiles are established in rows that span across the width of the gorge rock abutments in the pattern provided As Shown. Behind the wall excavated tunnel rock fill protected by 5 feet of riprap will be placed at a gradual slope to the toe of the dam. The purpose of the wall is to protect the soils and loose rock in the gut of the creek upstream of the plunge pool from high velocity bottom currents and to act as a retaining wall for this material. B. If Contractor elects to construct the plunge pool scour wall prior to the 2013 Reservoir Spill Window (See Section 01012), the Contractor will be responsible for completing all aspects of the plunge pool scour wall prior to the start of the 2013 Reservoir Spill Window; otherwise any damages to the structure will become the responsibility of the Contractor, unless spill occurs prior to the start of the 2013 Reservoir Spill Window. C. Prior to initiating work on the plunge pool scour wall, the Contractor will be responsible to first construct the six pressure relief wells (See Section 02440) that are located upstream of the plunge pool scour wall. Then allow up to 4 weeks for Engineer to perform possible revisions to the plunge pool scour wall prior to initiating the work. As part of performing the plunge pool scour wall Work, the Contractor will need to dewater the plunge pool as required. 1.02 WORK INCLUDED A. Provide all micropiles for the plunge pool scour wall As Shown. The micropile construction will include drilling, and installation of the steel pipe casing, rock bolts and associated hardware, and performing all grouting. B. Contractor will perform micropile construction in direct consultation with RPR. If the geotechnical conditions encountered are different than expected, or if the conditions change as a result of construction activities, the RPR may revise the micropile plan. C. Contractor is responsible for providing a safe ingress, egress for crews and Engineer for micropile construction. Provide safety measures in accordance with Section 01450. 1.03 RELATED WORK A. Section 01012: Hydrology and Hydraulics Blue Lake Expansion Project – Contract No. 9 02465-2 General Construction May 2012 B. Section 01300: Submittals C. Section 01450: Safety D. Section 02240: Dewatering and Water Control E. Section 02310: Backfill F. Section 02370: Erosion, Sediment and Pollution Control Measures G. Section 02405: Drilling H. Section 02410: Rock Bolts I. Section 02430: Foundation Grouting J. Section 02440: Pressure Relief Wells K. Section 03300: Cast-In-Place Concrete 1.04 REFERENCE STANDARDS A. API SPEC 5CT: Specification for Casing and Tubing B. ASTM A 252: Standard Specification for Welded and Seamless Steel Pipe Piles C. AWS D1.1: Structural Welding Code – Steel D. FHWA SA 97 070: Micropile Design and Construction Guidelines 1.05 EXPERIENCE A. Enlist the services of a micropile specialist Subcontractor unless Contractor can demonstrate expertise. Demonstrate Subcontractor's qualifications, expertise and experience to RPR for acceptance. Specialist Subcontractor must be capable of recommending appropriate installation methods and products. 1. Micropile Specialist shall have a minimum of 5 years of experience installing similar micropile systems. 1.06 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Micropile Plan: Contractor shall submit a micropile installation plan as part of the Work Plan. Include the following information with the plan: 1. Proposed equipment, materials, procedures, methods of access, schematic layout sketch of any temporary staging facilities, and schedule for installation. 2. Proposed methods of splicing for the pipe casing and micropile reinforcement. If welding of the pipe casing is proposed, submit the welding procedures as well as welder’s certifications in accordance with AWS D1.1. Blue Lake Expansion Project – Contract No. 9 02465-3 General Construction May 2012 3. Resume: Qualifying experience of individuals responsible for supervising and directing micropile installation. Also include experience record of key micropile personnel. 4. Proposed schedule for installation of micropiles. Include the schedule for the reinforced concrete beam and backfill placement. C. Certifications, Test Reports and Product Data: 1. Micropile Reinforcement: Conform to submittal requirements for rock bolts from Section 02410. 2. Pipe Casing: mill certificate from the Supplier indicating the strength of the casing, prior to shipment to site. The certificate shall include at a minimum: a) Shape, size, grade and specification description. b) Inside and outside diameter and thickness of casing. c) Yield strength of the casing. d) Ultimate tensile strength of the casing. e) Percent elongation of the casing at yield and ultimate strength. 3. Rock Bolt Spacers: Submit Suppliers product data for proposed spacers, including material type, and installation procedures. 4. Grout Materials: Conform to submittal requirements of Section 02430. D. Grouting Records: Conform to submittal requirements of Section 02430. E. Load Test Results: Submit load test results for rock bolts in accordance with Section 02410. PART 2 PRODUCTS 2.01 MATERIALS A. Rock Bolts: Micropile reinforcement shall be the same as rock bolts from Section 02410. B. Pipe casing shall be of the dimensions and grade As Shown, and conform to API Spec 5CT. C. Spacers: Use rock bolt supplier’s spacers. They may be schedule 40 PVC pipe or tube, or steel. 1. Install spacers along rock bolts in accordance with supplier’s instructions and at a spacing of no more than 10 feet. D. Grout: 1. Grout mixes for pressure grouting at the foundation of the micropiles shall conform to the curtain grout materials of Section 02430. Blue Lake Expansion Project – Contract No. 9 02465-4 General Construction May 2012 2. Grout mixes for installation in the pipe casing shall conform to the requirements of Section 03600. 3. Admixtures: No accelerators, expansive admixtures or admixtures containing chlorides are permitted. PART 3 EXECUTION 3.01 GENERAL A. Install appropriate erosion, sediment and pollution control measures in accordance with approved ESCP and SPCC from Section 02370. B. Facilitate inspection by Engineer of foundation conditions after dewatering, initial excavation and exposure of abutment rock. C. The centerline of the micropile reinforcement shall not be more than 0.5 inches from the indicated location. D. Provide all necessary facilities such as catwalks, ladders, and platforms to enable the Engineer to observe the micropile construction. The Contractor shall provide an audio communication and signal system for use during micropile construction. 3.02 INSTALLATION A. Perform all drilling to the sizes, depths and inclinations As Shown, and in accordance with Section 02405. B. Prior to performing any grouting, wash the hole in accordance with Section 02430. E. Install spacers for rock bolts in accordance with supplier’s instructions and at a spacing no greater than 10 feet. C. Perform splicing of rock bolts and pipe casing in accordance with Supplier’s recommendations. If welding is proposed for the casing, follow the requirements of AWS D1.1 and API Spec 5CT. D. Install and load test rock bolts in accordance with Section 02410. E. Perform pressure grouting in accordance with Section 02430. F. Grouting for the pipe casing may be tremmie grouted and shall be in accordance with the procedures of Section 03600. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02510-1 Water Supply Mains May 2012 SECTION 02510 WATER SUPPLY MAINS PART 1 GENERAL 1.01 WORK INCLUDED A. Provide water supply mains associated with the civil utilities for the powerhouse site, including the following components: 1. Water Transmission Main. 2. Potable Water Main. 3. Municipal Raw Water Main. 4. Pumped Emergency Municipal Raw Water Main. 5. Pumped NSRAA Raw Water Main. B. Work covers all materials, equipment, and performing all labor for the installation for water mains, insulated pipe, hydrants, valves, valve boxes, valve chambers, connections, flushing, testing, and disinfection. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 01500: Construction Facilities (provide temporary facilities) C. Section 01600: Material Control D. Section 01700: Contract Closeout E. Section 02105: Demolition and Salvage F. Section 02310: Backfill G. Section 02315: Rock Excavation and Scaling H. Section 02316: Unclassified Excavation I. Section 03300: Cast-in-Place Concrete J. Section 04100: Mortar and Masonry Grout K. Section 15300: Piping Systems L. Section 09900: Painting and Protective Coatings 1.03 REFERENCES Blue Lake Expansion Project – Contract No. 9 02510-2 Water Supply Mains May 2012 A. The most recent revision of the following standards of the American Society for Testing and Materials (ASTM) and the American Water Works Association (AWWA) are hereby made a part of these Specifications: B. ASTM A126 Specification for Gray Iron Castings for Valves, Flanges and Pipe Fittings. C. ASTM B88 or B88M [Metric] Specification for Seamless Copper Water Tubing. D. ASTM D256 Test Methods for D-C Resistance of Plastics and Electrical Insulating Materials. E. ASTM D3035 Specification for Polyethylene (PE) Plastic Pipe (SDR-PR) Based on Controlled Outside Diameter. F. ASTM D3261 Specification for Butt Heat Fusion Polyethylene (PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing G. ASTM D3350 Specification for Polyethylene Plastic Pipe and Fittings Materials. H. AASHTO M45 Sand for Cement Mortar. I. AWWA C104/ANSI A21.4 Cement-Mortar Lining for Ductile-Iron Pipe and Fittings for Water. J. AWWA C110/ANSI A21.10 Ductile-Iron and Gray-Iron Fittings, 3 in. through 48 in., for Water and Other Liquids. K. AWWA C111/ANSI A21.11 Rubber-Gasket Joints for Ductile-Iron and Gray-Iron Pressure Pipe and Fittings. L. AWWA C115/ANSI A21.15 Flanged Ductile-Iron Pipe with Threaded Flanges. M. AWWA C151/ANSI A21.51 Ductile-Iron Pipe, Centrifugally Cast in Metal Molds or Sand- Lined Molds, for Water or Other Liquids. N. AWWA C303 Reinforced Concrete Pressure Pipe, Steel Cylinder Type, Pre-Tensioned, for Water and Other Liquids. O. AWWA C500 Gate Valves for Water and Sewerage Systems. P. ANSI/AWWA C502 Dry-Barrel Fire Hydrants. Q. ANSI/AWWA C504 Rubber-Seated Butterfly Valves. R. ANSI/AWWA C600 Installation of Ductile-Iron Water Mains and their Appurtenances. S. AWWA C651 Disinfecting Water Mains. T. ANSI/AWWA C800 Underground Service Line Valves and Fittings. U. AWWA C901 Standard for Polyethylene (PE) Pressure Pipe and Tubing, 1/2 inch through 3 inch, for Water Service. V. City and Borough of Sitka, Alaska, Standard Specifications for Street-Drainage-Utilities- Parks, 2002 http://www.cityofsitka.com/government/departments/publicworks/index.html Blue Lake Expansion Project – Contract No. 9 02510-3 Water Supply Mains May 2012 W. Uniform Fire Code (UBC) latest edition and local amendments, National Fire Codes, Volume I and Volume II, 1982 Codes and Standards, National Fire Protection Association. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Water Supply Main Plan: Submit materials to be used and a construction schedule. Include method for installation of water main, pipe and appurtenances, materials, product data, thrust block restraint calculations, and HDPE welder certifications. In addition to the construction schedule also submit the proposed pipe flushing and testing schedule, and proposed supply of water date. C. Prior to placement, submit the source of bedding materials and pipe certifications. 1.05 CLOSEOUT SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Provide record drawings, including directions for operating valves, list of equipment required to operate valves, details of pipe material, location of air and vacuum release valves, hydrant details, maintenance and operating instructions in accordance with Section 01700. C. Provide pressure testing records. D. Record drawings and submittals shall conform to ADEC and Owner requirements. The Contractor will furnish the RPR with AutoCAD electronic files (current version), two (2) signed record drawings and survey field notes. 1. Include top of pipe, horizontal location of fittings and type, valves, valve boxes, valve chambers, hydrants abandoned fittings, etc., grade breaks and utility crossings. 1.06 SCHEDULING OF WORK A. Schedule Work to minimize interruptions to existing services. B. Submit schedule of expected interruptions to RPR for approval and adhere to interruption schedule as approved by RPR. C. Provide written notice to the RPR, the Blue Lake Control Center, City Fire Department, and Water Treatment Plant a minimum of 48 hours in advance of interruption in service. It shall be Contractor's responsibility to coordinate "turn-off" and "turn-on" with the City and Borough of Sitka. D. Do not interrupt water service for more than 4 hours on the transmission main and 12 hour on other lines. The time of day for the turn on and turn off period will be determined by the City and Borough of Sitka based on water demand. E. Notify fire department of any planned or accidental interruption of water supply to hydrants. F. Provide "Out of Service" sign on hydrant not in use. G. Advise local police department of anticipated interference with movement of traffic. Blue Lake Expansion Project – Contract No. 9 02510-4 Water Supply Mains May 2012 PART 2 PRODUCTS 2.01 DUCTILE IRON PIPE A. Ductile Iron Pipe shall conform to the requirement of AWWA C-151, with cement mortar lining conforming to the requirements of AWWA C-104. Class 50 or Class 250 Pipe shall be used for all pipe. B. Fittings shall be of a minimum three hundred fifty (350) psi pressure rating, mechanical joint or bell, lined or unlined ductile iron, unless otherwise required by the contract documents. Pipe shall be US Pipe or equal. All fittings shall conform to the requirements of AWWA C-110. Rubber gasket joints for ductile iron pipe and fittings shall conform to the requirements of AWWA C-111. 2.02 JOINT TIE RODS A. Tie back rods and/or tie back rod and shackle assemblies will not be acceptable as restrained joints or restraining system for fittings, valves, piping deflection points. B. Unless otherwise detailed on the plans, pipe joints shall be push-on rubber gasket type conforming to AWWA C111. Where specified on the plans, restrained joint pipe shall be US Pipe TR Flex, EBAA Iron MEGALUG, Romac Industries GripRing, U.S. Pipe Field LOK Gasket System, or approved equal. All restrained joint installation areas shall include joints, fittings, and piping deflection points. C. Flange adapter shall be used to connect to ductile iron pipe. A flange coupling adapter shall be used on the ductile iron pipe. HDPE flange adapters shall be manufactured by the same Supplier as the pipe using the same resin as the pipe. Each flange adapter shall be furnished with a ductile iron convoluted backup ring drilled to match the standard ANSI bolt. D. Contractor shall provide pipe Supplier submittals which include thrust restraint calculations prior to construction. 2.03 HIGH DENSITY POLYETHYLENE PIPE A. High Density Polyethylene (HDPE) pipe shall conform to ASTM D 3550 designation PE 3408. All HDPE water pipe shall have a standard iron pipe size (IPS) outside diameter. The pipe and fitting material shall have a cell classification of 355434C in accordance with ASTM D3350. In addition, the material must exceed 1000 hours when tested in accordance with the Ring Environmental Stress Crack Resistance Test (Radar Ring Test) with fewer than 20 percent failures. Also, the extruded pipe shall have impact strengths greater than 15 Ft#/in. at 32 degrees Fahrenheit when tested in accordance with the ASTM D 256 Charpy Impact Test. The material shall be listed by the N.S.F. for potable water service. In plant blending shall not be allowed. B. The pipe shall be homogeneous throughout and free of visible cracks, holes, foreign inclusions or other injurious defects. It shall be uniform in color, opacity, density and other physical properties. The pipe shall be marked at five (5) foot intervals with a coded number which identifies the Supplier, SDR size, PPI rating, manufacturing standard reference and production code from which data and place of manufacture can be determined. C. Butt fusion of the pipe and fittings shall be performed in accordance with the pipe Supplier's recommendations as to equipment and technique. The fusion operation shall be performed by an individual who has demonstrated the ability to fuse polyethylene pipe in Blue Lake Expansion Project – Contract No. 9 02510-5 Water Supply Mains May 2012 the manner recommended by the pipe supplier. The individual performing the fusing procedure must hold a current certification for fusing HDPE as stated in Title 49.1 DOT Certification. D. All HDPE mainline shall be installed with No. 10 bare copper locate trace wire. 2.04 MATERIAL LIMITATIONS A. HDPE, copper and ductile iron pipe are the only pipe materials allowed on water service connections. Galvanized pipe, asbestos-cement pipe and the use of lead-tipped gaskets shall be prohibited. 2.05 GATE VALVES A. Resilient seat valves as manufactured in accordance with the requirements of AWWA C- 509, Gate Valves for Ordinary Water Works Service. All valves shall be non-rising stem type with an O-ring seal and a two inch (2’’) square operating nut, and shall open counter clockwise. Valves shall have mechanical joint ends or, if approved by the RPR, flanged ends. Gate Valves shall be M & H Style 4067 or equal. 2.06 BUTTERFLY VALVES A. Butterfly valves shall be of the rubber-seated tight-closing type. They shall meet or exceed the performance requirements of AWWA C504 for operational pressures of 150 psi working pressure and 300 psi hydrostatic pressure. B. Mechanical joint valve ends shall be per AWWA C110/ANSI 21.10 and AWWA C111/ANSI 21.11 of the latest revision and "Short-Body" in accordance with the requirements of Table 2 of ANSI/AWWA C504. Accessories (bolts, glands, and gaskets) shall be supplied by the valve Supplier. C. Valves must use full ANSI/AWWA C504 Class 150 B valve shaft diameter and full Class 150 B underground service operator torque rating throughout entire travel to provide capability for operation in emergency service. D. Valve body shall be high strength cast iron ASTM A126 Class B. For valves with the rubber seat mounted on the disc, the mating surface in the body shall be 304 or 316 steel. For valves containing the rubber seat in the body, the method of seat retention shall be in accordance with the requirements of ANSI/AWWA C504-80, except that no retaining fasteners or other hardware shall be permitted in the flow stream. E. Valve operators, unless otherwise required by the Contract Documents, shall be of the traveling nut type, sealed, gasketed, and lubricated for underground service and capable of withstanding on overload input torque of 450 ft/lbs. at full open or closed position without damage to the valve or valve operator. The number of turns to operate the valve shall be a minimum of two (2) turns per inch of valve diameter for ninety (90) degrees of closure travel at a maximum pull of eighty (80) pounds. All valves shall open counter-clockwise and be equipped with two-inch square AWWA operating nut. F. Butterfly valves twenty inches (20") and less: The valve shaft shall be one piece extending full size through valve bearings, disc and shaft seal. In the event that the shaft is turned down to fit connections to the operator, the limits of ANSI/AWWA C504, Sec. 3.3.2 shall be strictly observed. Carbon steel shafts, if used, shall have 304 or 316 stainless steel journals with static seals to isolate the interior of the disc and the shaft from the water. Blue Lake Expansion Project – Contract No. 9 02510-6 Water Supply Mains May 2012 G. Butterfly valves over twenty inches (20"): The valve shaft shall be of two-piece stub shaft type, made of 18-8 Type 304 stainless steel. Valve bearings and shaft seals for valves of all sizes shall meet the requirements of ANSI/AWWA C504 Sec. 3.6 and 3.7 respectively, with the following additional requirements: 1. Sleeve bearings shall have a maximum coefficient of friction of 0.1. 2. For underground service, packing shall be pressure-energized chevron or "O" ring type, not requiring adjustment and suitable for permanent duty. 2.07 VALVE BOXES A. Valve boxes shall be cast iron of sliding, adjustable height type with round or oval bottom hood sections to fit over the top of the valve. The top section shall be recessed to receive a close fitting "eared" lid with the word "water" cast into it. Internal diameter of the smallest section shall not be less than five (5) inches. Minimum thickness of the metal shall not be less than five-sixteenths (5/16) inch. Castings shall be smooth and the workmanship shall be acceptable to the RPR. B. Valve boxes shall be of sufficient length for the pipe cover depth on the profile drawings and in accordance with the Standard Detail, of these Specifications. Valve boxes shall be installed perpendicular to the main and centered over the operating nut. C. Valve boxes shall be supplied with valve operator extension rods such that the maximum depth from the ground surface to the operator nut does not exceed four (4) feet. 2.08 CONNECTIONS A. Variations in depth from the depth indicated in the plans will not be grounds for additional compensation. It shall be Contractor's responsibility to become familiarized with the depth of water mains and other features for the project. B. Connection to existing 42" bulk water main to be made using a Romac STS420 42" x 20" full circle stainless steel tapping sleeve or equal. 2.09 FIRE HYDRANTS A. Fire hydrants shall conform to the requirements of ANSI/AWWA C502 for Dry Barrel Fire Hydrants. Fire hydrants shall be MH 929. B. All fire hydrants shall be supplied with a five and one- fourth (5-1/4) inch main valve opening. C. All single pumper hydrants shall be furnished with a six (6) inch ANSI Class 125 standard mechanical-joint end. D. All connections shall be restrained mechanical-joint unless otherwise indicated in the Contract Documents. E. Single pumper hydrants shall be furnished with two (2) two and one-half (2-1/2) inch hose connections and one (1) four and one-half (4-1/2) inch pumper connection. F. Unless otherwise required by the Contract Documents, all hydrants shall be furnished with a barrel length that will allow a minimum of five (5) feet of cover over hydrant leg. Blue Lake Expansion Project – Contract No. 9 02510-7 Water Supply Mains May 2012 G. The hydrant main valves shall be of the compression type, where water pressure holds the main valve closed permitting easy maintenance or repair of the entire barrel assembly from above the ground without the need of a water shut-off. H. All fire hydrants shall be furnished with a breakaway ground flange and stem coupling which allows both barrel and stem to break clean above ground upon impact from any angle. Traffic flange design must be such that repair and replacement can be accomplished above ground. I. Painting and coating shall be in accordance with AWWA Specifications. After installation, the hydrant section from the traffic flange to the top of the operating nut shall be pressure- washed, primed and painted "Caterpillar Yellow". J. Operating and nozzle nuts shall be pentagon shaped with one and one-half (1-1/2) inch point to flat measurements. K. Hose nozzle threading shall be in conformance with NFPA #194 for National (America) Standard Fire Hose Coupling Screw Threads). L. All working parts shall be bronze or noncorrosive metal in accordance with the requirements of ANSI/AWWA C502. M. All hydrants shall open counter-clockwise. N. All hydrants shall have drain outlets at the base of the barrel with the drain plug left out unless noted otherwise on the plans. 2.10 AUXILIARY GATE VALVES A. All gate valves and valve boxes shall be furnished and installed in accordance with CBS Standard Specification Section 60.03 - Furnish and Install Valves. 2.11 GUARD POSTS A. The contractor shall install guard posts at each hydrant installation in accordance with the Standard Details of these Specifications. If, in the opinion of the RPR, the guard posts are not to be installed, they shall be delivered to the CBS Water and Wastewater Utility storage yard. Measurement and payment for guard posts shall be incidental to the Bid item "Furnish and Install Fire Hydrant Assembly." 2.12 PIPE BEDDING AND SURROUND MATERIAL A. Granular material to conform to Section 02310 Backfill, use Bedding C-1 or D-1. 2.13 BACKFILL MATERIAL A. In accordance with Section 02310 Backfill, use Granular Backfill. 2.14 PIPE DISINFECTION B. Chlorine shall be used for disinfection. Chlorine shall be applied with a calcium hypochlorite and water mixture. Calcium hypochlorite shall be comparable to commercial products known as HTH, Perchloren or Machochlor to ANSI/AWWA B300, ANSI/AWWA B301, or ANSI/AWWA B303. Blue Lake Expansion Project – Contract No. 9 02510-8 Water Supply Mains May 2012 2.15 PREINSULATED PIPE A. Carrier pipe shall be as specified. B. Insulation shall be polyurethane foam either spray applied or injected with one shot into the annular space between carrier pipe and jacket, and shall be bonded to both. Insulation shall be rigid, 90-95% closed cell polyurethane with a 2.0 to 3.0 pounds per cubic foot density and coefficient of thermal conductivity (K-Factor) of 0.16 and shall conform to ASTM C-591. Maximum operating temperature shall not exceed 250°F. C. Jacketing material shall be extruded, black, high density polyethylene (HDPE), having a wall thickness not less than 100 mils for jacket sizes less than or equal to 12”, 125 mils for jacket sizes larger than 12” to 24”, and 150 mils for jacket sizes greater than 24”. D. Joints: To prevent the ingression of water or debris, jacketing joints shall be covered with a split sleeve and sealed with heat shrink tape or, at bends and joints where a sleeve won't fit, wrapped with polyethylene backed, pressure sensitive rubberized bitumen adhesive tape, 30 mils thick. 2.16 CARBON STEEL PIPE AND FITTINGS A. In accordance with Section 15300. B. Protective coating in accordance with Section 09900. PART 3 EXECUTION 3.01 EXCAVATION AND BACKFILL A. Contractor shall be responsible for, and shall bear the expenses incurred, in the event that a water main should be damaged during excavation or backfilling. Contractor shall bear the cost of all material, labor, and other expenses thereof. B. The Contractor shall provide all excavation, bedding, backfill and compaction necessary to install pipe in accordance with Section 02310. C. Trench depth to provide cover over pipe of not less than 5 feet from finished grade or as indicated. Two inches of closed cell rigid insulation may be substituted for each foot of cover less than 5 feet. Minimum pipe cover, with insulation, is 3 feet. a. Pumped Emergency Municipal Raw Water and NSRAA Raw W ater mains minimum burial shall be 1-1/2 feet where Ductile Iron Pipe is used and 3 feet where HDPE pipe is used. Encase in concrete where burial is less than required in traffic areas. Insulation is not required. D. Trench alignment and depth require RPR approval prior to placing bedding material and pipe. 3.02 MATERIALS DELIVERY A. Pipe and appurtenances shall be handled in such a manner as to ensure delivery to the trench in a sound, undamaged condition. Particular care shall be taken not to injure the pipe, pipe coating, or lining. Before installation, the pipe and appurtenances shall be examined by the RPR for defects. Blue Lake Expansion Project – Contract No. 9 02510-9 Water Supply Mains May 2012 B. Rubber gaskets shall be stored in a cool, dark place to prevent damage from the direct rays of the sun. Gasket lubricant shall be NSF approved for domestic water contact. 3.03 INSTALLATION A. Installation shall be in accordance with the requirements of ANSI/AWWA C600. The interior of the pipe and accessories shall be thoroughly cleaned of foreign matter before being lowered into the trench. Do not lay pipe on frozen bedding. B. The pipe shall be kept clean and plugged during laying operation to prevent trench water from entering the pipe. Whenever work is stopped, install a removable watertight bulkhead at open end of last pipe laid to prevent entry of foreign materials. C. Pipe and appurtenances shall be carefully lowered into the trench by means of derrick, ropes, belt slings, or other suitable equipment. Under no circumstances shall any of the pipe or appurtenances be dropped or dumped into the trench. Care shall be taken to avoid abrasion of the pipe coating. Poles used as levers or skids shall be of wood and shall have broad, flat faces to prevent damage to the pipe and coating. Damage to pipe coating must be repaired per Supplier recommendation before installation, or pipe will be rejected. D. The trench bottom shall be graded to provide uniform support for the pipe barrel. Water shall be kept out of the trench by pumping, if necessary, until the jointing and backfilling is completed. When Work is not in progress, open ends of the pipe, fittings, and valves shall be securely plugged so that no trench water, earth or other substances will enter the pipes or fittings. Where any part of the coating or lining is damaged, the pipe will be rejected. At a sufficient distance, prior to encountering a known obstacle or tie into an existing pipe, the Contractor shall expose and verify the exact location of the obstacle or pipe so that proper alignment and/or grade may be determined before the pipe sections are laid in the trench and backfilled. The connections shall be made by using fittings to suit actual conditions. All connections made under pressure shall be witnessed by RPR personnel. E. Pipe ends left for future connections shall be plugged, or capped, and anchored As Shown or as directed by the RPR. The end of the pipe shall be marked by means of a two by four (2x4) extending from the face of the pipe to two feet (2’) above finish grade. The 2x4 marker shall be painted blue and stenciled with the word “Water” in white two-inch (2”) high letters. A 2-foot piece of rebar shall be driven into the ground next to the 2x4. F. Cutting of pipe shall be done in a neat and workmanlike manner without damage to the pipe. G. Concrete thrust blocks and mechanical restraint of the types shown in the CBS Standard Detail 60-2 and shall be installed where the pipeline terminates or changes alignment, utilizing a tee, cross, bend, or similar fitting. Either poured-in-place or pre-cast thrust blocks are acceptable if the minimum base area is sufficient as shown in the Standard Details. Concrete for the thrust blocks shall be Mix D as described in Section 03300. H. If the Contractor elects to use poured-in-place thrust blocks, fitting joints and bolts shall remain accessible for future repairs. Do not backfill over concrete within [24] hours after placing. 3.04 BEDDING AND SURROUND A. Place granular bedding material in uniform layers not exceeding 6 inch compacted thickness. Blue Lake Expansion Project – Contract No. 9 02510-10 Water Supply Mains May 2012 B. Do not place material in frozen condition. C. Shape bed true to grade to provide continuous uniform bearing surface for pipe. D. Shape transverse depressions in bedding as required to suit joints. E. Compaction shall be performed in accordance with Section 02310. F. Fill authorized or unauthorized excavation below design elevation of bottom of specified bedding with Bedding Material. 3.05 ALIGNMENT AND GRADE A. The pipe shall be so laid in the trench that after the line is completed the bottom of the pipe conforms accurately to the grades and alignment As Shown. A maximum two-tenths (2/10) foot deviation from design elevation and alignment will be allowed. The pipe shall be generally straight to visual observation as determined by the RPR. B. Both line and grade shall be checked and recorded in a field book for each piece of pipe and appurtenances laid. The Contractor shall have instruments such as a transit and level for transferring alignment and grades from offset hubs. He also shall have in his employ a licensed surveyor who is qualified to use such instruments and who shall have the responsibility of placing and maintaining such construction guides and grades. The Contractor will furnish to the RPR a copy of the surveyor's notes daily for the newly installed pipe and appurtenances. The practice of placing backfill over a section of pipe to provide a platform for instruments shall be subject to the approval of the RPR. The Contractor shall provide true, correct, and certified record drawings of the survey notes, to the RPR. C. All adjustments to line and grade shall be done by scraping away or filling the earth under the body of the pipe and not by blocking or wedging up. Deflections from a straight line or grade, as required by vertical curves, horizontal curves, or off- sets shall not exceed the Supplier's recommendations. D. If the alignment requires deflection in excess of the above limitations, the Contractor shall furnish special bends to provide angular deflections within the limits allowable. Short-radius curves and closures shall be formed by shorter lengths of pipe, bevels, or fabricated specials. E. Trace wire shall be installed immediately above all HDPE pipes. F. Pipe alignment and installation require approval from RPR prior to constructing thrust blocks and placing backfill. 3.06 JOINTING OF DUCTILE IRON PIPE A. The Contractor has the option of using either mechanical or push-on joints. All joints shall conform to the requirements of ANSI/AWWA C600. B. The Contractor will be required to use mechanical joints on all hydrant leads. The RPR has the option of checking any or all mechanical joints to assure proper torque as specified by the Supplier. Blue Lake Expansion Project – Contract No. 9 02510-11 Water Supply Mains May 2012 C. Whenever flange connections are shown on the Drawings, called for in the Specifications, or required in the Work, the flange and fittings shall conform to the requirements of AWWA C110/ANSI A21.10 for 350 pound pressure ratings. D. Contractor must field demonstrate to the RPR the installation and/or construction of each new restrained joint or restraining system. Contractor shall contact the Water Department a minimum of forty-eight (48) hours prior, excluding non-working days, to coordinate the review of the field demonstration. The RPR shall certify that the restrained joint system is installed in accordance with the Supplier's instructions. If Contractor fails to install the restrained joint system in accordance with Supplier's instructions, in the opinion of the RPR, Contractor shall remove the disapproved system and replace with a new restrained joint system. E. Contractor shall be responsible for access to the field demonstration location and all trench excavation, de-watering and backfill operations prior to, during, and after the restrained joint system is reviewed by the RPR. The cost for coordinating and providing access for review of Contractor's installation and/or construction of the restrained joint system shall be incidental to the bid item under construction. 3.07 THRUST BLOCKS A. Restrain bends, tees, and fittings by concrete thrust blocks as indicated. B. Keep pipe couplings free of concrete. C. Bearing area of thrust blocks to be as indicated. D. Prepare and place concrete in accordance with Section 03300. 3.08 FLUSHING AND TESTING, GENERAL A. Prior to any tests performed, all newly installed water facilities, including fire lines and services, shall be tested by the Contractor in the following sequence: 1. Open-bore flushing. 2. Hydrostatic testing. 3. Disinfection (not required for Raw W ater mains). B. Disinfection will not be allowed until all open bore flush pipes are removed and the water system is sealed. C. The Owner must be present for all testing and flushing. D. A request to supply water for flushing, testing, and disinfecting shall be scheduled in writing with the RPR at least twenty-four (24) hours prior to obtaining CBS supplied water. The request for flushing, testing, and disinfecting will be subject to water availability. In the event of high water demand or low water availability within the CBS Water Department water system, meeting Contractor's schedule may not be possible. E. Contractor shall submit, in writing, for the RPR to review and approve a schedule and procedure for the flushing, pressure testing, chlorination and bacteriological testing of all newly installed pipes. When, in the opinion of the RPR, the testing and flushing schedule and procedure is deficient, inadequate, improper, or conditions are such that the impact to Blue Lake Expansion Project – Contract No. 9 02510-12 Water Supply Mains May 2012 existing water service areas are adversely affected by service interruptions, Contractor will be notified in writing by the RPR. Such notification shall be accompanied by a statement of the corrective action to be taken. Contractor shall adhere to the testing and flushing schedule and comply with such instruction as directed by the RPR. 3.08 FLUSHING A. All newly installed water facilities shall be "Open-Bore" flushed to remove any foreign matter. "Open- Bore" flushing shall be accomplished prior to hydrostatic testing and disinfection at each extremity of the main, including all fire lines, services, stub-outs and dead-ends. The Contractor shall furnish, install and remove all fittings and pipes necessary to perform the flushing, at no additional cost to Owner. Under no circumstances will open- bore flushing through hydrants or reduced outlets be permitted. All flushing water shall be controlled as to not damage neighboring property. B. It will be the Contractor's responsibility to notify the RPR and the CBS Water Department forty-eight (48) hours in advance of any flushing operations. Flushing of newly-constructed mains may be required between the hours of 1:00 a.m. and 6:00 a.m. depending upon the availability of water, as authorized by Owner. Owner will not be responsible for any cost incurred by the Contractor for flushing. 3.09 HYDROSTATIC TESTING A. All mains shall be flushed, pressure tested, and chlorinated by the Contractor after service connections are made. Pressure testing shall include service lines between the main and the curb stop. B. A hydrostatic test will be conducted on all newly constructed water mains, fire hydrant leads, services and stub-outs. This will occur after "Open-Bore" flushing, and will be in the presence of either the CBS or the RPR in accordance with the requirements of ANSI/AWWA C600 unless hereinafter modified. C. The Contractor shall furnish all necessary assistance, equipment, labor, materials, and supplies (except the test pressure gauge) necessary to complete the test to the satisfaction of the RPR. The Contractor shall suitably valve-off or plug the outlet to the existing or previously-tested water main at his expense, prior to making the required hydrostatic test. Prior to testing, all air shall be expelled from the pipe. If permanent air vents are not located at all high points, the Contractor shall, at his expense, install corporation cocks at such points so the air can be expelled as the line is slowly filled with water. D. All main valves, fire hydrant auxiliary valves, fire hydrant main valves, and plugs shall be tested. All intermediate valves within the section being tested will be closed and reopened as directed by the RPR during the actual test. Only static pressure will be allowed on the opposite side of the end valves of the section being tested. E. All hydrostatic testing will be performed through test copper. Use of fire hydrant and service connections for testing will not be allowed. F. The hydrostatic pressure shall be as shown in the table below. The duration of each hydrostatic pressure test shall be two (2) hours. After the required test pressure has been reached, the pumping will be terminated. If the pressure does not drop more than 5 pounds per square inch, that section of line will not be subject to any future hydrostatic test. Water Main Hydrostatic Test Pressure (psi) Blue Lake Expansion Project – Contract No. 9 02510-13 Water Supply Mains May 2012 Water Transmission Main 250 Potable Water Main 160 Pumped Emergency and Penstock Raw Water Mains 250 Pumped NSRAA Raw Water Main 100 G. Cracked or defective pipe, gaskets, mechanical joints, fittings, valves, or hydrants discovered as a consequence of the hydrostatic tests shall be removed and replaced with sound material at the Contractor's expense. The test shall then be repeated until the results are satisfactory. H. For HDPE pipe the initial pressure test shall be at 150 psi. The initial pressure shall be applied and allowed to stand without makeup water for 3 hours to allow the HDPE pipe to stretch. Return test pressure to 150 psi with makeup water after initial 3-hour period. Allow pipe to stand for 2 additional hours during the test period and then measure the amount of water required to return pressure to 150 psi. Allowable makeup water for pipe expansion is as follows: Pipe Diameter (inch) Makeup Water, (gallons/100 feet of pipe) 4 0.25 6 0.6 8 1.0 10 1.3 12 2.3 16 4.0 18 5.1 20 6.3 24 9.0 I. Check for leaks or significant pressure drops. Correct all leaks and significant pressure drops that require more makeup water than allowable and retest pipe. J. The Contractor shall notify the RPR forty-eight (48) hours, (two (2) working days) prior to any test and shall notify the RPR two (2) hours in advance of the scheduled time if the test is to be cancelled. In the event the RPR has not been notified of cancellation and the Contractor is not prepared for the test as scheduled, the Contractor shall reimburse the RPR for all expenses incurred. These will include, but not be limited to, salaries, transportation and administrative costs. 3.10 DISINFECTION A. Disinfection shall be in accordance with ANSI/AWWA C657, latest edition. Blue Lake Expansion Project – Contract No. 9 02510-14 Water Supply Mains May 2012 B. The chlorinating agent shall be applied at the beginning of the section adjacent to the feeder connection, insuring treatment of the entire line including hydrants and services. Water shall be fed slowly into the new line with chlorine applied in amounts to produce a dosage of forty (40) ppm to fifty (50) ppm. Application of the chlorine solution shall continue until the required dosage is evident at all extremities of the newly laid line. C. Calcium hypochloride shall be injected or pumped into the water main. During the chlorination process, all intermediate valves, service lines, fire hydrants, fire lines and accessories shall be operated. Valves shall be manipulated so that the 40-50 ppm chlorine solution in the line being treated will not flow back into the line supplying the water. The superchlorinated solution shall remain in the system for 24-hours, minimum. Hydrostatic testing of a water line containing the chlorine mixture will not be allowed. D. A residual of not less than twenty-five (25) ppm chlorine shall remain in all parts of the water main at the end of the twenty-four (24) hour period, after which this residual shall be flushed from the line and neutralized at its extremities until the replacement water tests are equal chemically to those of the permanent source of supply. After another twenty-four (24) hours, bacteriological samples shall be taken per the CBS Standards. In no instance shall a water main be chlorinated before "Open-Bore" flushing. E. Chlorination Pipe Diameter (inch) Dosage (oz.) per 100 feet 4 0.6 6 1.35 8 2.75 10 4.3 12 6.19 16 11 20 16 24 24 30 36 1. The above table is to be used as a guide for chlorinating mains by the calcium hypochlorite and water mixture method. The given dosage per 100 feet results in a chlorine solution of forty (40) to fifty (50) ppm. 2. This dosage takes into account that Contractors most frequently used granular HTH, which is sixty-five percent (65%) pure. If another chlorinating agent is used, the dosage must be adjusted. Blue Lake Expansion Project – Contract No. 9 02510-15 Water Supply Mains May 2012 F. After the applicable retention period, heavily chlorinated water should not remain in prolonged contact with pipe. In order to prevent damage to the pipe lining or corrosion damage to the pipe itself, the heavily chlorinated water shall be flushed from the main until chlorine measurements show that the concentration in the water leaving the main is no higher than that generally prevailing in the distribution system or is acceptable for domestic use. 3.11 TEST AND AIR VENT COPPER PIPE REMOVAL A. After completion of testing, all test and air vent copper pipe and corporation stops shall be removed at the main and repaired with a Romac SS1 or SS2 repair band, or equal, in the presence of the RPR. 3.12 VALVES AND VALVE BOXES A. The Contractor shall provide all excavation, bedding, backfill and compaction necessary to install valves and valve boxes in accordance with Section 02310. B. Valves or valve boxes shall be installed As Shown. The valve operator shall be placed on the side of the water main away from the center line of the street or easement. On fire line installations a valve shall be placed outside the building so that all fire hydrants will remain in service in the event water service to the building must be shut off for any reason. C. Valves shall have the interiors cleaned of all foreign matter before installation. If the valve is at the end of the line, it shall be plugged prior to backfilling. The valve shall be inspected by the RPR in the open and closed positions to insure that all parts are in working condition. D. Provisions shall be made to restrict the soils from entering the bottom section of the valve box. Wrap burlap inside bottom section and wrap three (3) layers of non-woven geotextile fabric around the outside of the valve and base section of the valve box and secure the fabric at the top and bottom with wire or tape. E. In areas where running sand is encountered, provisions shall be made to restrict the sand from entering the bottom section of the valve box. F. The Contractor shall expose all valve boxes for pre-final and final inspection. 3.13 HYDRANTS A. The Contractor shall provide all excavation, bedding, backfill and compaction necessary to install fire hydrant assembly in accordance with Section 02080. B. The Contractor shall install the hydrant assembly and accordance with the Plans. C. All fire hydrant legs shall be installed level. The fire hydrant barrel shall be installed plumb. Any adjustments to the fire hydrant traffic flange As Shown shall be made by the Contractor at no cost to the CBS. D. Hydrants installed but not available for use shall be covered with burlap and securely tied. E. In lieu of valve box markers for the auxiliary gate valves, the Contractor shall paint in two (2) inch black lettered stencils, the direction and distances to the nearest one-tenth (1/10) foot the distance to the valve box on the face of the fire hydrant directly below the bonnet flange. Blue Lake Expansion Project – Contract No. 9 02510-16 Water Supply Mains May 2012 END OF SECTION Blue Lake Expansion Project – Contract No. 9 02530-1 Sanitary Sewerage May 2012 SECTION 02530 SANITARY SEWERAGE PART 1 GENERAL 1.01 WORK INCLUDED A. Work includes, but is not limited to, furnishing all materials, equipment and performing all labor for the installation of sewage force mains. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 01500: Construction Facilities (provide temporary facilities) C. Section 01600: Material Control D. Section 02105: Demolition Waste Management and Disposal E. Section 02310: Backfill F. Section 02315: Rock Excavation And Scaling G. Section 02316: Unclassified Excavation H. Section 02370: Erosion and Sediment Control Measures I. Section 02510: Water Distribution J. Section 03300: Cast-in-Place Concrete. 1.03 REFERENCES A. The most recent revision of the following standards of the American Society for Testing and Materials (ASTM) and the American Water Works Association (AWWA) are hereby made a part of these Specifications: B. ASTM D3035 Specification for Polyethylene (PE) Plastic Pipe (SDR-PR) Based on Controlled Outside Diameter C. ASTM D3261 Specification for Butt Heat Fusion Polyethylene (PE) Plastic Fittings for Polyethylene (PE) Plastic Pipe and Tubing D. ASTM D3350 Specification for Polyethylene Plastic Pipe and Fittings Materials E. AWWA C901 Standard for Polyethylene (PE) Pressure Pipe and Tubing, 1/2 in. through 3 in., for Water Service F. City and Borough of Sitka, Alaska, Standard Specifications for Street-Drainage-Utilities- Parks, 2002 http://www.cityofsitka.com/government/departments/publicworks/index.html Blue Lake Expansion Project – Contract No. 9 02530-2 Sanitary Sewerage May 2012 G. Uniform Fire Code (UBC) latest edition and local amendments, National Fire Codes, Volume I and Volume II, 1982 Codes and Standards, National Fire Protection Association. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submit specifications and information on piping products to be used. C. Certification to be marked on pipe. D. Sanitary Connection Plan: Submit a work plan for maintaining sewer service at the existing powerhouse during any planned outage that exceeds 12 hours including shop drawings for connections to existing and a schedule. 1.05 CLOSEOUT SUBMITTALS A. Provide record drawings, including locations, depths, directions for operating valves, list of equipment required to operate valves, details of pipe material, valves, maintenance and operating instructions in accordance with Section 01700 - Contract Closeout B. Provide pressure testing records. C. Record drawings and submittals shall conform to ADEC and Owner requirements. The Contractor will furnish the RPR with AutoCAD electronic files (current version), two (2) signed record drawings and survey field notes. 1. Include top of pipe, horizontal location of fittings and type, valves, manholes, etc., grade breaks, and utility crossings. 1.06 SCHEDULING A. Schedule Work to minimize interruptions to existing services. Service interruptions in excess of 12 hours are not allowed without written approval by the RPR. B. Submit schedule of expected interruptions to Owner and RPR. C. Notify Owner, RPR, and building occupants a minimum of 24 hr in advance of interruption in service. PART 2 PRODUCTS 2.01 HIGH DENSITY POLYETHYLENE PIPE A. High Density Polyethylene (HDPE) pipe shall conform to ASTM D 3550 designation PE 3407 or PE 3408. The pipe shall have a minimum pressure rating of 160 pounds per square inch and a Standard Dimension Ratio (SDR) of 11.0. All HDPE water pipe shall have a standard iron pipe size (IPS) outside diameter. The pipe and fitting material shall have a cell classification of 355434C in accordance with ASTM D3350. In addition, the material must exceed 1000 hours when tested in accordance with the Ring Environmental Stress Crack Resistance Test (Radar Ring Test) with fewer than 20 percent failures. Also, Blue Lake Expansion Project – Contract No. 9 02530-3 Sanitary Sewerage May 2012 the extruded pipe shall have impact strengths greater than 15 Ft#/in. at 32 degrees Fahrenheit when tested in accordance with the ASTM D 256 Charpy Impact Test. The material shall be listed by the N.S.F. for potable water service. In plant blending shall not be allowed. B. The pipe shall be homogeneous throughout and free of visible cracks, holes, foreign inclusions or other injurious defects. It shall be uniform in color, opacity, density and other physical properties. The pipe shall be marked at five (5) foot intervals with a coded number which identifies the manufacturer, SDR size, PPI rating, manufacturing standard reference and production code from which data and place of manufacture can be determined. C. Butt fusion welding of the pipe and fittings shall be performed in accordance with the pipe manufacturer's recommendations as to equipment and technique. The fusion operation shall be performed by an individual who has demonstrated the ability to fuse polyethylene pipe in the manner recommended by the pipe supplier. The individual performing the fusing procedure must hold a current certification for fusing HDPE as stated in Title 49.1 DOT Certification. D. All HDPE mainline shall be installed with No. 10 bare copper locate trace wire. 2.02 PIPE BEDDING AND SURROUND MATERIAL A. In accordance with Section 02310 Backfill, use Bedding C-1 or D-1. 2.03 BACKFILL MATERIAL A. In accordance with Section 02310 Backfill, use Granular Backfill. PART 3 EXECUTION 3.01 PREPARATION A. Pipes and fittings to be clean and dry. B. Prior to any outage, obtain RPR approval. C. Perform all necessary demolition in accordance with Section 02105. 3.02 TRENCHING A. Do trenching Work, in accordance with Section 02310. B. Trench alignment and depth require approval from RPR prior to placing bedding material or pipe. 3.03 GRANULAR BEDDING A. Place granular bedding in unfrozen condition. B. Place granular bedding material in uniform layer[s] not exceeding 6 inch compacted thickness to depth as indicated. C. Shape bed true to grade and to provide continuous, uniform bearing surface for pipe. Blue Lake Expansion Project – Contract No. 9 02530-4 Sanitary Sewerage May 2012 D. Shape transverse depressions as required to suit joints. E. Compact each layer full width of bed to at least 95% corrected maximum dry density. F. Fill excavation below design elevation of bottom of specified bedding with compacted bedding material. 3.04 INSTALLATION A. Lay pipes in accordance with manufacturer's recommendations. B. Join pipes in accordance with ANSI/AWWA C901, for HDPE pipe and manufacturer's recommendations. C. Avoid damage to machined ends of pipes in handling and moving pipe. D. Maintain grade and alignment of pipes. E. Trace wire shall be installed immediately above all pipes. F. Support pipe firmly over entire length, except for clearance necessary at couplings. Do not use blocks to support pipe. G. Keep pipe and pipe joints free from foreign material. H. When stoppage of Work occurs, block pipe as directed by RPR to prevent creep during downtime. I. Pipe alignment and installation require approval from RPR prior to placing backfill. 3.05 HYDROSTATIC AND LEAKAGE TESTING OF FORCE MAIN A. Testing of force main to be carried out in presence of Owner or RPR if designated by Owner. B. Contractor may perform hydrostatic testing prior to backfill. Contractor shall be responsible for insuring pipe is properly restrained in order to prevent movement or damage. Strut and brace caps, bends and tees, as necessary to prevent movement when test pressure is applied. C. Expel air from force main, by slowly filling main with water. Install fused fittings to vent air and to be shut when pressure is applied. Blind flange taps after satisfactory completion of test. D. Apply hydrostatic test pressure of 100 psi based on elevation of lowest point in line and corrected to elevation of test gauge for hydrostatic test and 100 psi for leakage test. E. Apply pressure for 1hr for pressure test and 2hr for leakage test. F. Remove defective joints, pipe and fittings and replace with new sound material. G. Define leakage as amount of water supplied from in order to maintain test pressure for 2hr. H. Do not exceed allowable leakage as defined in Section 02510. Blue Lake Expansion Project – Contract No. 9 02530-5 Sanitary Sewerage May 2012 I. Locate and repair defects if leakage is greater than amount specified. J. Repeat test until leakage is within specified allowance for full length of force main. 3.06 PIPE SURROUND A. Place surround material in unfrozen condition. B. Hand place surround material in uniform layers simultaneously on each side of pipe not exceeding 6 inch compacted thickness C. Compact each layer from pipe invert to mid height to the standards of Section 02310. D. Compact each layer from mid height of pipe to underside of backfill to the standards of Section 02310. 3.07 BACKFILL A. Place backfill material in unfrozen condition. B. Place backfill material, above pipe surround in uniform layers not exceeding 12 inch compacted thickness up to grades as indicated. C. Compaction shall be performed in accordance with Section 02310. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02620-1 General Construction May 2012 SECTION 02620 SUBDRAINAGE SYSTEM PART 1 GENERAL 1.01 WORK INCLUDED A. Provide all subdrainage systems at structures As Shown, including the dam extension, thrust block, powerhouse, penstock, surge chamber top portal, and intake gate house. 1.02 WORK RELATED A. Section 01300: Submittals B. Section 02310: Backfill C. Section 02315: Rock Excavation and Scaling D. Section 02316: Unclassified Excavation E. Section 02370: Erosion, Sediment and Pollution Control Measures F. Section 03600: Grout and Mortar Products G. Section 13100: Penstock Installation 1.03 REFERENCE STANDARDS A. ASTM A 412: Standard Specification for Concrete Drain Tile B. ASTM D 3350: Standard Specification for Polyethylene Plastics Pipe and Fittings Materials C. ASTM D 1785: Standard Specification for Poly (Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80, and 120. D. ASTM D 2466: Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe Fittings Schedules 40 E. ASTM F 477: Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe F. ASTM F 2648: Standard Specification for 2 to 60 inch Annular Corrugated Profile Wall Polyethylene (PE) Pipe and Fittings for Land Drainage Applications 1.04 SUBMITTALS A. Submit under provision of Section 01300 for review. Blue Lake Expansion Project – Contract No. 9 02620-2 General Construction May 2012 B. Contractor shall submit product data on the proposed subdrain pipe and appurtenances. PART 2 PRODUCTS 2.01 PIPE MATERIALS A. Subdrain Pipe and Appurtenances: 1. Dam Extension: As Shown 2. Unless noted otherwise, Contractor may use either dual wall high density polyethylene pipe (HDPE) with perforations and in accordance with ASTM F 2648, or PVC Schedule 40 or greater perforated drainage pipe in accordance with ASTM D 1785. a. Any fabric socks over the perforated pipe must be removed prior to installation. b. All fittings must be soil-tight and be in accordance with ASTM F 477 and ASTM D 2466 for HDPE and PVC pipe respectively. c. Pipe caps shall be slip cap style, Schedule 40. B. Subdrainage backfill shall be Filter Material in accordance with Section 02310. C. Refer to section 03600 for cement mortar. PART 3 EXECUTION 3.01 INSTALLATION A. Contractor shall install and joint the pipe and pipe fittings in accordance with Supplier's recommended installation procedures. B. Install subdrainage systems at grades and locations As Shown. The pipe gradients shall allow positive drainage at all locations. C. Install with perforations facing down. D. Contractor shall provide mechanical couplers at all pipe joints and intersections. E. Placement of subdrainage backfill shall be in accordance with Section 02310. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02630-1 General Construction May 2012 SECTION 02630 SITE DRAINAGE PART 1 GENERAL 1.01 WORK INCLUDED A. Provide all surface and subsurface drainage systems and structures, including culverts, piping, fittings and couplings, outlets, trenching, ties to existing systems and backfilling at roads and parking areas As Shown. 1.02 RELATED WORK A. Section 01300: Submittals B. Section 02310: Backfill C. Section 02315: Rock Excavation and Scaling D. Section 02316: Unclassified Excavation E. Section 02370: Erosion, Sediment and Pollution Control Measures F. Section 02700: Gravel, Base and Subbase Courses 1.03 REFERENCE STANDARDS A. ASTM D 3350: Standard Specification for Polyethylene Plastics Pipe and Fittings Materials B. ASTM F 477: Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe C. ASTM F 2648: Standard Specification for 2 to 60 inch Annular Corrugated Profile Wall Polyethylene (PE) Pipe and Fittings for Land Drainage Applications D. City and Borough of Sitka, Alaska, Standard Specifications for Street-Drainage- Utilities-Parks, 2002 http://www.cityofsitka.com/government/departments/publicworks/index.html 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Product data for proposed site drainage system pipe, culverts and appurtenances. C. Upon delivery of materials to the site, Contractor shall submit bill the manufacturers’ certifications for all storm water drainage materials. 1.05 QUALITY ASSURANCE Blue Lake Expansion Project – Contract No. 9 02630-2 General Construction May 2012 A. Contractor will inspect and document the installation of all systems. Buried portions of the Work shall not be backfilled prior to Contractor’s inspection. PART 2 PRODUCTS 2.01 MATERIALS A. All storm sewer piping and appurtenances shall be dual wall high density polyethylene pipe (HDPE) and in accordance with ASTM F 2648. B. All storm drainage system components shall have soil tight joints and connections in accordance with ASTM F 477. C. Backfill for site drainage systems shall be in accordance with Section 02310. D. Riprap for the end treatment at inlets and outlets shall be Class I, in accordance with Section 02310. PART 3 EXECUTION 3.01 INSTALLATION A. Install HDPE pipe, fittings and appurtenances shall be installed in accordance with the manufacturer’s recommendations. B. Excavation and trench excavation shall be in accordance with Sections 02315 and 02316. C. Install backfill in accordance with Section 02310. D. Unless otherwise noted, install an HDPE flared end section at all surface inlets and outlets. Install Class I riprap in accordance with Section 02310 at inlets and outlets in a minimum pattern of 5’ x 5’ at a 1 ft depth. E. All surfaces shall be graded to positively drain to drainage structures. F. All structures shall be set to the grades, elevations and alignments As Shown. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02700-1 General Construction May 2012 SECTION 02700 GRAVEL SURFACE, BASE AND SUBBASE COURSES PART 1 GENERAL 1.01 WORK INCLUDED A. Perform all placing and compacting gravel surface, base and subbase courses for the permanent roads and parking areas As Shown. Roadways within Contractor's construction yard and other roadways constructed by Contractor for his own use or convenience are excluded. 1.02 RELATED WORK A. Section 01300: Submittals B. Section 02230: Clearing and Grubbing C. Section 02240: Dewatering and Water Control D. Section 02310: Backfill E. Section 02315: Rock Excavation and Scaling F. Section 02316: Unclassified Excavation G. Section 02370: Erosion, Sediment and Pollution Control Measures H. Section 02620: Subdrainage System I. Section 02630: Site Drainage J. Section 02845: Guard Rails 1.03 REFERENCE STANDARDS A. Alaska DOT & PF Standard Specifications for Highway Construction, 2004 B. ASTM C 136: Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates C. ASTM D 1557: Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort D. ASTM D 3017: Standard Test Method for Water Content of Soil and Rock in Place by Nuclear Methods (Shallow Depth) E. ASTM D 4253: Standard Test Methods for Maximum Index Density and Unit Weight of Soils Using a Vibratory Table Blue Lake Expansion Project – Contract No. 9 02700-2 General Construction May 2012 F. City and Borough of Sitka, Alaska, Standard Specifications for Street-Drainage- Utilities-Parks, 2002 http://www.cityofsitka.com/government/departments/publicworks/index.html G. WAQTC FOP for AASHTO T 180: Moisture Density Relations of Soils: Using a 4.54-kg (10-lb) Rammer and 457-mm (18-in) Drop H. WAQTC FOP for AASHTO T 310: In-Place Density and Moisture Content of Soil and Soil-Aggregate by Nuclear Test Methods (Shallow Depth) 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Prior to placement of any gravel surfaces, base or subbase materials, Contractor shall submit test reports indicating material conformance with the grading requirements specified below. C. At the time of delivery, a batch ticket shall be supplied to RPR indicating the date of delivery, material type, material source, moisture content, and tons delivered. PART 2 PRODUCTS 2.01 MATERIALS A. All materials shall be void of any frozen material, brush, roots, stumps, sod, or other organic or unsuitable materials. The suitability of all materials for use in construction will be determined by RPR. Contractor shall continuously maintain the fill materials in a satisfactory manner until the final completion and acceptance of all Work. B. Subbase, base and gravel surface materials shall be sound, granular material conforming to the following gradation requirements, and shall be well graded within the specified limits. 1. Subbase – The material shall conform to CBS Standard Specification Section 20.05, Subbase, Grading B and have the following gradation: Sieve Size Percent Passing by Weight 2 inch 100 3/4 inch 70-100 No. 4 30-70 No. 10 20-50 No. 40 10-30 No. 200 0-6 2. Base Course D-1 – Same as Bedding Material D-1, see Section 02310. 3. Base Course C-1 – Same as Bedding Material C-1, see Section 02310. 4. Gravel Surface – Same as base courses. Contractor may elect to use either Base Course C-1 or D-1 for road surfacing. Blue Lake Expansion Project – Contract No. 9 02700-3 General Construction May 2012 5. Substation/Switchyard Surface Course: Substation/switchyard surface course material shall be clean granular material obtained by crushing sound, blasted rock or by processing natural gravels. The surface course material, as placed and compacted, shall contain a well balanced representation of all particle sizes within the size ranges specified and, when tested by means of standard sieves (ASTM C136), shall conform to the following requirements: Sieve Size Percent Passing by Weight 3 inch 100 1½ inch 20 - 45 3/4 inch 0 - 10 3/8 inch 0 - 3 PART 3 EXECUTION 3.01 GENERAL A. Excavation shall conform to Sections 02315 and 02316. B. Any backfill required to bring subgrade up to grade for subbase shall conform to Backfill and Foundation Fill as described in Section 02310. C. Prior to placement of subbase or backfill, soil areas shall be proof rolled and soft areas removed. Where subbase or backfill is to be placed on rock, the rock surface shall be free from all soft, loose, or disintegrated material greater than 3 inches in thickness. D. Contractor shall obtain approval of prepared surfaces RPR prior to placement of subbase and backfill. E. Contractor to notify RPR of any questionable excavation areas for review prior to initiating backfill operations. Any subsurface material deemed unsuitable by RPR shall be removed and backfilled with the approved backfill material. F. During the life of the project all permanent project roads shall be maintained to standards acceptable to RPR. G. Prior to substantial completion and subject to approval by RPR, all project roads shall be restored to the lines, grades, lines, and thickness As Shown. 3.02 PLACEMENT AND COMPACTION A. Subbase, base and gravel surface courses shall be placed and compacted to the lines, grades and thicknesses As Shown. B. All materials shall be placed in the dry. C. No materials shall be placed on frozen ground. D. Contractor shall place the upper course material on the grade in a manner to minimize segregation, using equipment and procedures reviewed by RPR. Contractor shall not perform uncontrolled spreading from piles dumped on the grade. Blue Lake Expansion Project – Contract No. 9 02700-4 General Construction May 2012 E. The maximum compacted layer thickness is 8 inches. F. Compaction requirements for equipment and procedures are the same as Section 02310. G. Sampling of aggregates shall be done in accordance with ASTM D 1557. H. The testing of moisture content of materials shall be done in accordance with WAQTC FOP for AASHTO T 180. Materials shall be within +/- 2% of optimum moisture content. I. The in-place density testing of materials shall be done in accordance with WAQTC FOP for AASHTO T 310. J. Material shall be compacted to the following maximum density: 1. Subbase: 95% 2. Base Course: 95% 3. Gravel Surface: 95% 4. Substation/Switchyard Surface Course: N/A K. Tolerances: Contractor shall place materials so that after compaction the top surface of the course does not extend more than 1 in. above nor more than 1 in. below true grade for the course at any location. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02820-1 General Construction May 2012 SECTION 02820 FENCES AND GATES PART 1 GENERAL 1.01 WORK INCLUDED A. Provide all galvanized steel chain link fencing, including gates, barbed wire, barbed tape (concertina wire), posts, fittings, hardware, anchors, and concrete footings at the left and right dam abutments, adit tunnel, switchyard and at the surge chamber top portal As Shown. 1. Perform all demolition and proper disposal of the existing switchyard fence As Shown. B. Provide all vehicular gates and accessory materials As Shown. 1.02 RELATED WORK A. Section 01300: Submittals B. Section 02105: Demolition and Salvage C. Section 02310: Fill Placement and Grading D. Section 03300: Cast-In-Place Concrete E. Section 05100: Structural Steel F. Section 16450: Grounding 1.03 REFERENCE STANDARDS A. American Society for Testing and Materials (ASTM) Standards: 1. A120 - Specification for Black and Hot-Dipped Zinc-Coated Welded and Seamless Steel Pipe for Ordinary Uses 2. A121 – Standard Specification for Metallic Coated Carbon Steel Barbed Wire 3. A123 - Specification for Zinc (Hot Galvanized) Coatings on Products Fabricated from Rolled, Pressed, and Forged Steel Shapes, Plates, Bars and Strips 4. A153 - Specification for Zinc Coating (Hot Dip) on Iron and Steel Hardware 5. A392 - Specification for Zinc-Coated Steel Chain Link Fence Fabric 6. F1083 – Standard Specification for Pipe, Steel, Hot-Dipped Zinc Coated (Galvanized) Welded, for Fence Structures 7. F1553 – Standard Guide for Specifying Chain Link Fence Blue Lake Expansion Project – Contract No. 9 02820-2 General Construction May 2012 8. F1712 – Standard Specification for Steel Chain-Link Fencing Materials Used for High Security Applications 9. F1910 – Standard Specification for Long Barbed Tape Obstacles 10. F1911 – Standard Practice for Installation of Barbed Tape B. Chain Link Fence Suppliers Institute: 1. “Standards for Galvanized Steel Chain Link Fence Fabric” 2. “Industrial Steel Specifications for Fence Posts, Gates and Accessories” 3. “Standards for Chain Link Fence Installation” 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Fully detailed shop drawings of fences, gates, and hardware, including footings and installation details, and supplier information. 1.05 FIELD MEASUREMENTS A. Contractor shall secure all field measurements required for proper and adequate fabrication and installation of the Work covered by this Section. Exact measurements are Contractor's responsibility. PART 2 PRODUCTS 2.01 CHAIN LINK FENCE MATERIALS A. General: Fencing shall include 11 gauge (minimum) fabric covering, framework, concrete footings, gates, hardware, and all appurtenances and accessories required for a complete installation As Shown. B. Fence: 1. Unless otherwise noted the fence fabric shall be 0.148 inch diameter wire with 2 inch mesh opening. 2. Chain link fence shall be galvanized in accordance with ASTM A392. C. Barbed Wire and Taped: 1. Barbed Wire shall be 12.5 gauge, 0.099 inch diameter strand wire, with 14 gauge, 0.030 inch diameter barbs in accordance with ASTM A121. 2. Barbed tape shall be in accordance with ASTM F1910. D. Posts: Blue Lake Expansion Project – Contract No. 9 02820-3 General Construction May 2012 1. Posts shall be steel pipe, square or rectangular tubing, or H sections in accordance with the following table. Use only one shape throughout for each post type. All tubular members pipe shall conform to ASTM A120 for weight and galvanized coating. Structural shapes shall conform to ASTM A123 for galvanized coating. a. Provide grounding of posts using the materials As Shown and in accordance with Section 16450. 2. End, Corner, and Pull Posts: Nominal Outside Weight (kg/m)Post Type and Shape Diameter or Dimensions (mm) Fabric Heights • Round • Square 73 (2.875 in.) 64 (2.50 in.) 8.6 (5.79 lb/lin ft) 8.48 (5.70 lb/lin ft) 3. Intermediate: Nominal Outside Weight (kg/m)Post Type and Shape Diameter or Dimensions (mm) Fabric Heights • Round • H-Section 60 (2.375 in.) 57 x 49.5 x 3.5 (2.25 in. x 1.95 in. x .14 in.) 5.43 (3.65 lb/lin ft) 6.10 (4.10 lb/lin ft) 4. Gate Posts: Nominal Outside Weight (kg/m)Post Type and Shape Diameter or Dimensions (mm) • Round • Square 102 (4.00 in.) 76.2 (3.00 in.) 13.5 (9.10 lb/lin ft) 13.5 (9.10 lb/lin ft) E. Rails: Top rails for fence and intermediate rails between line posts when required shall be standard weight steel pipe, conforming to ASTM A120, with nominal outside diameter of 42 mm (1.660 in.) and weighing not less than 3.38 kg/m (2.27 lb/lin ft), furnished complete with couplings, fittings and attachment accessories. Top rail shall form continuous brace from end to end of each run of fence. F. Post Bracing Assembly: Horizontal braces shall be standard weight steel pipe, conforming to ASTM A120, with nominal outside diameter of 42 mm (1.660 in.) and weighing not less than 3.38 kg/m (2.27 lb/lin ft). Diagonal truss type braces shall be 10-mm (3/8-in. dia) galvanized steel rods with turnbuckle adjustment. Couplings, fittings, and attachment accessories shall be included as required. Horizontal braces (intermediate rails) shall be provided at all corners, ends of fence, and gate posts. G. Tension Wire, Zinc-Coated Steel: Tension wire for bottom edge support of fence fabric shall be No. 7-gauge steel wire with minimum tensile strength of 552 MPa (80,000 psi) and zinc coating of not less than 0.24 kg/m2 (0.80 oz/ft2). Blue Lake Expansion Project – Contract No. 9 02820-4 General Construction May 2012 H. Post Caps: Post caps shall be standard malleable iron, wrought iron, or pressed steel, galvanized, designed as a weathertight closure cap for tubular posts. Caps to permit passage of top rails shall be provided. I. Stretcher Bars: Stretcher Bars shall be one piece lengths equal to full height of fabric with a minimum cross section of 1.5 mm (3/16 in.) by 20 mm (3/4-in.). One stretcher bar for each gate and end post and two for each corner and pull post shall be provided. J. Stretcher Bar Bands: Bands shall be heavy pressed steel or malleable iron, spaced not over 380 mm (15 in.) on center to secure stretcher bars to end, corner pull, and gate posts. K. Gates: 1. Gates shall be double-leaf swing type As Shown, furnished complete with all hardware and accessories as required. 2. Gate Frames: Frames shall be round or square tubular members (to match posts) in accordance with the following table: Nominal Outside Weight (kg/m)Gate Size Diameter or Dimensions (mm) Fabric Height • Round • Square 48 (1.90 in.) 50 (2.00 in.) 4.04 (2.72 lb/lin ft) 5.4 (3.60 lb/lin ft) 3. Fabrication of Gates: Gate frames shall be assembled by welding or with fittings and rivets for rigid connections. The same fabric as used for the fence shall be used. Fabric shall be installed with stretcher bars at vertical edges, and tie wires at top and bottom edges. Stretcher bars shall be attached to gate frame at not more than 380 mm (15 in.) on center. Hardware shall be attached with rivets or by other means that will provide security against removal or breakage. Additional horizontal and vertical members shall be provided to ensure proper gate operation and for attachment of fabric, hardware, and accessories. Diagonal cross bracing consisting of 20-mm (3/4-in.) diameter, adjustable length truss rods on gates shall be provided where necessary to provide frame rigidity without sag or twist. 4. Gate Hardware: The following hardware and accessories shall be provided for each gate: a) Hinges: Galvanized pressed steel or malleable iron to suit gate size, nonlift off type, offset to permit 180 degree gate opening shall be provided. b) Latch: Forked type or plunger type latch shall be provided to permit operation from either side of gate. Padlock eye shall be provided as integral part of latch. c) Keeper: Keeper shall be provided, which automatically engages the gate leaf and holds it in the open position until it is manually released, for vehicle gates. d) Double Gates: Gate stops shall be provided for double gates, consisting of mushroom type or flush plate with anchors. Stops shall be set in concrete Blue Lake Expansion Project – Contract No. 9 02820-5 General Construction May 2012 to engage the center drop rod or plunger bar. Locking device and padlock eyes shall be provided as an integral part of the latch, requiring one padlock for locking both gate leaves. L. Accessories: All miscellaneous materials and accessories, ties, clips, anchors, and fastenings shall be furnished as required for a complete installation. All items shall be galvanized. 2.02 VEHICULAR GATE MATERIALS A. All materials shall be galvanized in accordance with ASTM A123 and A153. B. All structural steel tubing and hardware shall be in accordance with Section 05100. C. All connection and accessory materials are As Shown. 2.03 FABRICATION A. Chain link fencing shall be fabricated and pre assembled by the supplier in the factory or shop as far as practicable. 2.04 CONCRETE A. Concrete footings shall be furnished and installed for fence posts under this section. Concrete for posts shall be Mix C, in accordance with Section 03300. PART 3 EXECUTION 3.01 CHAIN LINK FENCE INSTALLATION A. Installation of fencing shall be As Shown and in accordance with reviewed shop drawings, and the supplier's detailed installation drawings, instructions, and recommendations. All posts shall be plumb and rigid after installation. Rails shall be straight and tight. Chain link fabric shall be smooth and uniformly stretched tight and straight. Bottom tension wire shall be pulled taut. B. Installation of fencing shall not be started until final grading has been completed. Dimensions of drill holes for post footings and concrete embedment of the posts shall be as required by Contractor. C. Gates shall be installed plumb, level, and secure for full opening without interference. Ground set items shall be installed in concrete for anchorage as recommended by the fence supplier. Hardware shall be adjusted for smooth operation and lubricated. Gates shall operate smoothly and easily without noise or hinge bind. D. Install barbed tape in accordance with ASTM F1911. 3.02 VEHICULAR GATE INSTALLATION A. All posts shall be set plumb. B. Adjust the gate level with the turnbuckle until all connections are aligned and gate may be opened without interference. Blue Lake Expansion Project – Contract No. 9 02820-6 General Construction May 2012 3.03 CONCRETE PLACEMENT A. Concrete shall be provided around posts in a continuous placement and in accordance with Section 03300. Each post shall be checked for vertical and top alignment and held in position during placement and finishing operations. 3.04 SWITCHYARD FENCE DEMOLITION A. Perform demolition of the existing switchyard fence to the extents As Shown. B. Properly dispose of demolished materials in accordance with the requirements of Section 02105. END OF SECTION Blue Lake Expansion Project – Contract No. 9 02845-1 General Construction May 2012 SECTION 02845 VEHICULAR CONCRETE BARRIERS PART 1 GENERAL 1.01 WORK INCLUDED A. Provide all vehicular concrete barriers and all connection and accessory materials at the Filter Plant Access Road As Shown. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 02310: Backfill C. Section 02700: Gravel Surface, Base and Subbase Courses 1.03 REFERENCE STANDARDS A. Alaska DOT&PF – Standard Specifications for Highway Construction 2004 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submit the Supplier’s data and list of materials for the vehicular concrete barriers. Upon delivery to site, submit the Bill of Materials. PART 2 PRODUCTS 2.01 MATERIALS A. All materials shall conform to Alaska DOT & PF Standard Specification Section 614 – Concrete Barrier, as well as Drawing G-46.10 (Sheets 1 and 2) for Precast Concrete “F” Shape Barriers. PART 3 EXECUTION 3.01 INSTALLATION A. The installation of all vehicular concrete barriers shall be in accordance with the standards of the Alaska DOT & PF Standard Specifications Section 614 – Concrete Barrier, as well as Drawing G-46.10 (Sheets 1 and 2) for Precast Concrete “F” Shape Barriers. B. Vehicular Concrete Barriers shall be installed to the lines and grades As Shown. Blue Lake Expansion Project – Contract No. 9 02845-2 General Construction May 2012 C. All road surfacing materials shall be placed in accordance with Section 2700. Do not block scupper areas of barriers with road surfacing materials in order to allow for drainage through barriers. END OF SECTION DIVISION 03 CONCRETE Blue Lake Expansion Project – Contract No. 9 03100-1 General Construction May 2012 SECTION 03100 FORMWORK PART 1 GENERAL 1.01 WORK INCLUDED A. Design all concrete formwork necessary for completion of concrete structures including dam extension As Shown. Provide all concrete forms for the structures As Shown. Perform removal of all formwork in accordance with approved design. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 03200: Concrete Reinforcement C. Section 03254: Concrete Joints, Waterstops and Joint Filler D. Section 03300: Cast-in-Place Concrete 1.03 REFERENCE STANDARDS A. ACI 347: Recommended Practice for Concrete Formwork B. ACI SP-4: Formwork for Concrete C. NIST Product Standard PS 1-95: Construction and Industrial Plywood 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Shop drawings clearly indicating the proposed formwork. Furnish shop drawings for each concrete lift part and include the following: 1. Dimensions. 2. Location of the formwork. 3. Proposed materials. 4. Installation and removal procedures including any temporary bracing. 5. Design calculations with assumed concrete lateral pressures. Calculations must be stamped by a Professional Engineer registered in the state of Alaska. C. Suppliers' literature for plywood, concrete form hardboard, form accessories, prefabricated forms, and form coating. PART 2 PRODUCTS 2.01 DESIGN Blue Lake Expansion Project – Contract No. 9 03100-2 General Construction May 2012 A. Provide professional engineering services for engineering and design of the formwork, as well as its construction, including shoring and support for overhead forms. Contractor's Engineer responsible for design shall be a Professional Engineer licensed in State of Alaska. Drawings shall bear the seal and signature of the responsible engineer. As a minimum, the formwork shall be designed for loads, lateral pressures, and allowable stresses given in Chapter 2, Design, of ACI 347. Forms shall have sufficient strength to withstand the pressure resulting from placement and vibration of the concrete and shall have sufficient rigidity to maintain specified tolerances. B. Engineer and design formwork to allow for access / egress of manpower, equipment and rescue personnel throughout the entire length of the tunnel. 2.02 MATERIALS A. Forms: Fabricate forms with facing materials that produce the specified construction tolerances and surface requirements of Section 03300. B. Finish Designations shall be as follows: 1. Finish F1: This finish designation shall apply to surfaces upon or against which fill material or concrete will be placed, or surfaces that will otherwise be permanently concealed. 2. Finish F2: This finish designation shall apply to all surfaces which are to be permanently exposed except those specified to receive other finishes. Sheathing shall be of tongue-and-groove or shiplap lumber, plywood, tempered concrete-form-grade hardboard conforming to NBS Product Standard PS-1, Exterior Type, Grade B-B Plyform, or steel. Steel lining on wood sheathing will not be permitted. 3. Finish F3: This finish designation shall apply to special exterior surfaces of the wall which are to be permanently exposed. Sheathing shall be composed of new, well-matched tongue-and-groove lumber or new (for first use on site) plywood panels conforming to NIST Product Standard, PS-1, Concrete Form, Class I, Grade B-B Plyform, High-Density Overlay. 4. Finish F4: This finish designation shall apply to the hydraulic surfaces for turbine and tunnel water passages and dam spillway rollways. The sheathing may be of new, well-matched tongue-and-groove lumber, new plywood, tempered concrete-form-grade hardboard, or steel. Wood sheathing for curved or warped surfaces shall be composed of lumber which can be modified to the required shape without splitting or cracking to form a smooth, tight form. C. Form Accessories: Ties and other similar form accessories to be partially or wholly embedded in the concrete shall be of a commercially manufactured type. Non- fabricated wire shall not be used. After the ends or end fasteners of form ties have been removed, the embedded metal portion of ties shall be terminated not less than 1½ inches below any concrete surface, which is to be either exposed to view or exposed to water. Form ties shall be installed so that the ends or end fasteners can be removed without spalling the concrete. D. Form Coating: Form coating shall be a commercial formulation of proven performance and satisfactory to RPR that will not bond with, stain, or adversely affect concrete surfaces and will not impair subsequent treatment of concrete Blue Lake Expansion Project – Contract No. 9 03100-3 General Construction May 2012 surfaces depending upon bond or adhesion or impede the wetting of surfaces to be cured with water. PART 3 EXECUTION 3.01 INSTALLATION A. Provide forms that are mortar tight, properly aligned, and adequately supported to produce concrete surfaces meeting the construction tolerances and surface requirements of Section 03300. Where concrete surfaces are to be permanently exposed to view, joints in form panels shall be arranged with aesthetic considerations. Where forms for continuous surfaces are placed in successive units, care shall be taken to fit the forms over the completed surface to obtain accurate alignment of the surface and to prevent leakage of mortar. Forms shall not be reused if there is any evidence of surface wear and tear or defects which would impair the quality of the surface. All surfaces of forms and embedded materials shall be cleaned of any mortar or grout from previous concreting and of all other foreign material before concrete is placed in them. B. Contractor shall include placing/consolidation access "windows" on 3 ft horizontal centers on radius or other areas inaccessible to internal vibrators. 3.02 CHAMFERING A. All edges, and external corners that are to be permanently exposed to view, shall be chamfered a minimum of 1 inch by chamfer strips placed in the forms unless the drawings specifically state that chamfering is to be omitted or as otherwise specified. 3.03 COATING A. Forms for surfaces to be permanently exposed or coated shall be coated with form oil or a form-release agent before the form or reinforcement is placed in final position. The coating shall be used as recommended in the supplier's instructions, and shall not interfere with the application of waterproofing coatings. Forms for surfaces that are not to be permanently exposed to view may be wet with water immediately before placing concrete, instead of coating except that in cold weather with probable freezing temperatures coating shall be mandatory. Surplus coating on form surfaces and coating on reinforcing steel and construction joints shall be removed before placing concrete. 3.04 REMOVAL A. General: Forms shall not be removed without authorization of RPR and all removal shall be accomplished in a manner which will prevent damage to the concrete. Forms shall not be removed before the expiration of the minimum time indicated below, except as otherwise directed or specifically authorized. When conditions of the work justify the requirement, forms will be required to remain in place for a longer period. B. Excessive stresses in the concrete shall be avoided that might result from swelling forms. Loosen wood forms for wall openings as soon as possible without causing damage to the concrete. Forms for wall openings shall be constructed to facilitate such loosening. Damaged concrete caused by form removal shall be repaired. Blue Lake Expansion Project – Contract No. 9 03100-4 General Construction May 2012 C. Unsupported Concrete: Formwork for walls, columns, sides of beams, gravity structures, and other vertical type forms not supporting the weight of concrete may be removed as soon as the concrete has hardened sufficiently to resist damage from removal operations, but not less than 24 hours after completion of concrete placement. Where forms for columns, walls, and sides of beams also support formwork for slabs or beam soffits, the removal time for the latter shall govern. D. Supported Concrete: Supporting forms and shoring shall not be removed until structural members have acquired sufficient strength to support safely their own weight and any construction load to which concrete may be subjected. END OF SECTION Blue Lake Expansion Project – Contract No. 9 03200-1 General Construction May 2012 SECTION 03200 CONCRETE REINFORCEMENT PART 1 GENERAL 1.01 WORK INCLUDED A. Detail all concrete reinforcement necessary for completion of concrete structures. Provide all concrete reinforcement, including steel bars, welded wire fabric and all accessory materials for concrete structures As Shown. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 02413: Grouted Dowels C. Section 03100: Formwork D. Section 03254: Concrete Joints, Waterstops and Joint Filler E. Section 03300: Cast-in-Place Concrete 1.03 REFERENCE STANDARDS A. ACI 117: Standard Specifications for Tolerances for Concrete Construction and Materials B. ACI 301: Specifications for Structural Concrete for Buildings C. ACI 315: Manual of Standard Practice for Detailing Reinforced Concrete Structures D. ACI 318: Building Code Requirements for Reinforced Concrete and Commentary E. ACI SP 66: Detailing Manual F. ASTM A 497: Standard Specification for Steel Welded Wire Fabric, Deformed, for Concrete Reinforcement G. ASTM A 615: Standard Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement H. ASTM A 706: Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement I. ASTM A 775: Standard Specification for Epoxy-Coated Reinforcing Steel Bars J. ASTM E 8: Tension Testing of Metallic Materials K. AWS D1.4: Structural Welding Code in Reinforcing Steel 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. Blue Lake Expansion Project – Contract No. 9 03200-2 General Construction May 2012 B. Shop Drawings: Prepare shop drawings for reinforcing steel. Include reinforcing steel schedules with the quantity, shape and size, weight per foot and total weights, bending details, mark numbers and splice lengths. Also include concrete outlines and construction joint locations of lifts, lift station numbers and elevations. Shop Drawings shall include adequate dimensions, notes, symbols, and abbreviations. 1. Mechanical Splices: Submit the proposed method and equipment for making mechanical splices including supplier’s literature. C. Test Reports: Certified test reports for reinforcing steel showing that the steel complies with the applicable specifications shall be submitted to RPR by Contractor. Reports and delivery tickets shall be furnished for each steel shipment and shall be identified with specific lots prior to use of the steel in the Work. PART 2 PRODUCTS 2.01 MATERIALS A. Reinforcing Bars: Reinforcing bars shall be deformed bars conforming to ASTM A615, Grade 60. 1. All epoxy coating of reinforcing bars shall conform to ASTM A775. B. Welded Wire Fabric: Welded wire fabric shall conform to ASTM A497. Wire gages, spacing and arrangement of wires shall be As Shown. 2.02 ACCESSORIES A. Bar Supports: 1. Bar supports shall conform to ACI 315. Bar supports for formed surfaces that are to be permanently exposed to view or to be painted shall be plastic- protected wire, stainless steel or precast concrete supports. 2. Precast concrete bar supports shall be wedge-shaped, not larger than 3-1/2 x 3-1/2 inches, of thickness equal to that indicated for concrete cover. If formed surface is to be permanently exposed to view, the precast concrete bar support shall be the same quality, texture and color as the finish surface. B. Wire Ties: Wire ties shall be 16-gage or heavier black annealed wire. PART 3 EXECUTION 3.01 DELIVERY, STORAGE AND HANDLING A. Store reinforcing steel in designated clearly demarcated laydown/storage areas. Provide color coding to identify reinforcing steel by feature. B. Reinforcing steel shall be bundled, identified, and tagged with marking shown on approved Shop Drawings and shall include quantity in each bundle. C. Each bundle shall be limited to one size and grade of material. Blue Lake Expansion Project – Contract No. 9 03200-3 General Construction May 2012 D. Reinforcing bars shall be stored off the ground and protected from the elements and contaminates that adversely affect bond. E. Any damaged epoxy coated reinforcing bar is subject to rejection by RPR. Repair patches of damaged coating shall conform to the requirements of ASTM A775 and the Supplier’s recommendations. Repaired reinforcing bar may only be used with approval by RPR. 3.02 INSTALLATION A. General: Install reinforcing steel and accessories As Shown and as on approved shop drawings. Placement details of reinforcement and accessories not specified or shown on the drawings shall be in accordance with ACI 315 or ACI 318. Reinforcement shall be fabricated to shapes and dimensions shown, installed where indicated within specified tolerances, and adequately supported against displacement during concrete placement. At the time placing of concrete in a lift is begun, all reinforcement shall be free from loose, flaky rust; scale (except tight mill scale); mud; oil; grease; or any other coating that might reduce the bond with the concrete. B. Hooks and Bends: Reinforcing bars may be shop or field bent. All bars shall be bent cold unless otherwise authorized by Engineer. No bars partially embedded in concrete shall be field bent unless indicated on the drawings or otherwise authorized by RPR. All hooks or bends shall be in accordance with ACI 318. Reinforcing bars with kinks or unnecessary bends shall not be used. C. Welding: Welding of reinforcing bars to other reinf orcing bars or to embedded items will be permitted only where indicated on the drawings or as otherwise directed by RPR. Welding shall be performed in accordance with AWS D1.4 using weldable reinforcing steel meeting ASTM A706, except where otherwise specified or indicated on the drawings. D. Placing Tolerances: 1. Spacing of Bars: Bars shall be spaced as indicated on the drawings or as otherwise directed. The spacing between adjacent bars and the distance between layers may not vary from the indicated position by more than one bar diameter nor more than one inch. 2. Concrete Cover: The minimum concrete cover of main reinforcement steel shall be As Shown. The tolerances shall be in accordance with ACI 318. 3. Unless shown otherwise, the typical project cover is 3 inches for formed, exterior exposure, 4 inches for water passages or surfaces exposed to flowing water. E. Splicing: 1. Splices in reinforcement steel shall As Shown or as directed by RPR. Bars may be spliced at alternative or additional locations at no additional cost to Owner, subject to the acceptance of RPR. All splicing shall be in accordance with approved splicing procedures and requirements of ACI 318. 2. Lap Splices: Lap splices shall be used for all bars. Bar laps may be installed in contact and securely tied or may be spaced transversely apart to permit embedment of the entire surface of each bar in concrete, but shall not be Blue Lake Expansion Project – Contract No. 9 03200-4 General Construction May 2012 spaced farther apart than one-fifth the required length of lap or 6 inches. Lengths of laps for bars or welded wire fabric shall conform to the requirements of ACI 318, except when noted otherwise on the drawings. 3. Mechanical Splices: a) A mechanical splice shall be used where part of the projecting length of a partially embedded bar is broken off or becomes damaged and must be cut off, and the length remaining is not sufficient for the required lap splice, or As Shown. b) Mechanical splices shall be an exothermic, threaded coupling, swaged sleeve or other positive connecting type which will develop in tension or compression, as required, 125 percent of specified yield strength of the bar, unless otherwise noted on the drawings. c) Bar ends may be prepared by sawing, shearing, or flame cutting, provided that the ends of sheared bars are reshaped after shearing, and all slag is removed from the ends of flame cut bars by chipping and wire brushing prior to splicing. Surfaces to be enclosed in a splice sleeve or coupling shall be cleaned prior to splicing by wire brushing or other approved method. d) Splices shall be made in accordance with supplier's instructions using supplier's standard jigs, clamps, ignition devices and other required accessories. e) Mechanical tension splices shall be staggered longitudinally a minimum of five feet so that no more than half of the bars are spliced at any one section, unless otherwise noted on the drawings. f) Mechanical splicing operations will be subject to visual examination and tension tests as required by RPR. F. Inspection: 1. Areas where reinforcing bars will be installed shall be inspected for defects that would prohibit their satisfactory installation and performance. Defects, if existing, shall be corrected prior to commencing installation of reinforcing materials. 2. After installation of reinforcement, Contractor shall notify RPR and provide adequate access inspection. Contractor shall not begin concrete placement until receiving approval from RPR of reinforcement installation. END OF SECTION Blue Lake Expansion Project – Contract No. 9 03254-1 General Construction May 2012 SECTION 03254 CONCRETE WATERSTOPS AND JOINT FILLER PART 1 GENERAL 1.01 WORK INCLUDED A. Provide concrete PVC waterstops, Hydrophilic waterstops, concrete joint filler, joint surface sealant, surface joint bond beaker and similar materials. B. Construct concrete expansion, contraction, and construction joints in dam extension, powerhouse, intake, gate chamber, gate house, and other concrete construction as shown. 1.02 DEFINITIONS A. “Expansion Joint”- A joint filled with resilient material to permit concrete dimensional change without damage to the concrete. B. “Contraction Joint”- A space between concrete surfaces be provided to allow for volumetric shrinkage between monolithic units or movement between monolithic units. The surface of the concrete first placed at a contraction joint shall be coated with sealing compound before the concrete on the other side of the joint is placed. Contraction joints may be grouted to provide structural continuity between the monolith units. C. “Construction Joint”- A concrete surface that has reached its final setting and on or against which new concrete is placed. Construction joints not indicated by the design shall be located and constructed as to least impair the strength of the structure. 1.03 RELATED SECTIONS A. Section 01300: Submittals B. Section 03300: Cast-In-Place Concrete C. Section 13100: Penstock and Manifold Installation 1.04 REFERENCE STANDARDS A. American Concrete Institute (ACI): 1. 504: Guide to Joint Sealants for Concrete Structures B. American National Standards Institute (ANSI) Standard: 1. A116.1: Specification for Two Component Elastomeric Sealing Compound for the Building Trade C. American Society for Testing and Materials (ASTM) Standard: Blue Lake Expansion Project – Contract No. 9 03254-2 General Construction May 2012 1. ASTM D 71: Standard Test Method for Relative Density of Solid Pitch and Asphalt (Displacement Method) 2. ASTM D 412: Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers—Tension 3. ASTM D 570: Standard Test Method for Water Absorption of Plastics 4. ASTM D 624: Standard Test Method for Tear Strength of Conventional Vulcanized Rubber and Thermoplastic Elastomers. 5. ASTM D 792: Standard Test Methods for Density and Specific Gravity (Relative Density) of Plastics by Displacement 6. ASTM D 746: Standard Test Method for Brittleness Temperature of Plastics and Elastomers by Impact 7. ASTM D 792: Standard Test Methods for Specific Gravity and Density of Plastics by Displacement 8. ASTM D 1190: Standard Specification for Hot-Poured Elastic Type Concrete Joint Sealer 9. ASTM D 1751: Standard Specification for Preformed Expansion Joint Fillers for Concrete Paving and Structural Construction 10. ASTM D 1752: Standard Specification for Preformed Expansion Joint Fillers for Concrete Paving and Structural Construction (Nonextruding and Resilient Nonbituminous Types) 11. ASTM D 2240: Standard Test Method for Rubber Property—Durometer Hardness 12. ASTM D 6817: Standard Specification for Rigid Cellular Polystyrene Geofoam 1.05 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Show proposed location of waterstop types, locations, and joint details on lift drawings submittals for concrete construction. C. Product Data and Samples: For all proposed waterstop, joint filler and joint sealer, submit supplier’s product data including chemical characteristics, safety information, performance criteria, storage requirements, shelf life, preparation and installation procedures, and all special procedures. Also include product samples as follows: 1. PVC Waterstop: a) Sample of a spliced butt joint and a corner joint of the plastic waterstop, made with splicing equipment and technique to be used in the field. One sample of each type of PVC waterstop. Blue Lake Expansion Project – Contract No. 9 03254-3 General Construction May 2012 b) Sample replicating the PVC waterstop joint shown on Drawing 109-20-011, Section F-F. c) Sample of each PVC waterstop 1 ft in length. 2. Hydrophilic Waterstop: a) Sample of hydrophilic waterstop 1 ft in length. 3. VOLCLAY Waterstop: a) Sample of VOLCLAY waterstop 1 ft in length. 4. Joint Filler, Premolded: a) 6 inch by 6 inch sample of each type of rectangular board type material proposed for the Work. b) Polysulfide Filler: 1 qt sample of polysulfide filler. 5. Polysulfide Sealant: a) 1 qt of polysulfide sealant. 6. Joint Bond Breaker a) 1 qt sample 7. Compressible Material a) 2 foot x 2 foot sample D. Certificates of Compliance: Furnish supplier's certificate warranting compliance of each material with this Specification. The certificate shall identify the material, quantity, batch number, and the date of manufacture. 1.06 QUALITY ASSURANCE A. All waterstop field joints and joint sealant installation shall be subject to continuous inspection by RPR or Engineer. B. All field joints shall be subject to inspection for misalignment, bubbles, inadequate bond, porosity, cracks, offsets, and other defects that would reduce the potential resistance of the material to water pressure at any point. All defective joints shall be replaced, and all faulty material shall be removed from the site and disposed of by Contractor. PART 2 PRODUCTS 2.01 GENERAL A. All materials placed in contact with each other shall be checked for mutual compatibility. 2.02 PVC WATERSTOP Blue Lake Expansion Project – Contract No. 9 03254-4 General Construction May 2012 A. PVC waterstop (WS) material shall be an elastomeric plastic compound with a basic resin of polyvinyl chloride and containing any additional resins, or other materials needed for the material to comply with the requirements specified. B. Provide PVC waterstop fabricated by an extrusion process such that it will be dense, homogenous, and free from holes and other imperfections. The cross section of the waterstop shall be uniform and symmetrical along its entire length. C. “6” WS”: 6 inch PVC Waterstop: Greenstreak Catalog Item 972, (www.greenstreak.com), or equal. D. “WS”: 9 inch PVC Waterstop: Greenstreak Catalog Item 735, (www.greenstreak.com), or equal. E. “12” WS”: 12 inch PVC Waterstop: Greenstreak Catalog Item 714, (www.greenstreak.com), or equal. F. “TW WS”” Tear Web Waterstop: Greenstreak Catalog Item 700, (www.greenstreak.com), or equal. 2.03 HYDROPHILIC WATERSTOP AND HYDROPHILIC PASTE A. Hydrophilic Waterstop: MC-2010MN hydrophilic waterstop as supplied by Adeka Ultra Seal, (www.adeka.com), or equal. B. Hydrophilic Adhesive Paste: Ultra Seal P-201 as supplied by Adeka Ultra Seal, (www.adeka.com), or equal. 2.04 VOLCLAY WATERSTOP A. Volclay Waterstop: Volclay Waterstop – RX as supplied by CETCO Building Materials Group, (www.cetco.com), or equal. 2.05 PREMOLDED JOINT FILLER A. Premolded joint filler shall conform to the following: 1. Bituminous Type ASTM D1751 2. Non-bituminous Type ASTM D1752 B. Polysulfide Filler shall conform to the following: 2.06 POLYSULFIDE SEALANT A. Polysulfide Sealant: Sonolastic Polysulfide Sealant in grey color as supplied by BASF Sonneborn Systems, (www.buildingsystems.basf.com), or equal. 2.07 JOINT BOND BREAKER A. Joint Bond Breaker: Sikasil WS-290 FPS Silicone Sealant as supplied by Sika, (www.usa.sika.com), or equal. 2.08 COMPRESSIBLE MATERIAL FOR DAM EXTENSION Blue Lake Expansion Project – Contract No. 9 03254-5 General Construction May 2012 A. Compressible Material: EPS29 Geofoam, 1-inch thick or As Shown, as supplied by Foam Control (www.geofoam.com), or equal. 2.09 GEOGRIPPER A. Geogripper as manufactured by Foam Control (www.geofoam.com), or equal. 2.10 ADHESHIVE CAULK A. Adhesive Caulk: Polyseamseal Ultra Exterior as manufactured by Henkel Corporation (www.polyseamseal.com), or equal. PART 3 EXECUTION 3.01 INSTALL PVC WATERSTOP A. General: 1. Embed waterstop material in the concrete with equal portions on both sides of the concrete joint, unless indicated otherwise by the design. A complete filling and bond between the concrete and waterstop shall be achieved. 2. Install the longest practicable length, with joints spliced to form a continuous watertight seal, and shall be supported and protected from becoming damaged. Damaged waterstop shall be replaced at Contractor's expense. 3. Store PVC waterstops so as to permit free circulation of air around the material and to protect it from direct rays of the sun. 4. In the event any PVC waterstop is installed in the concrete on one side of a joint and will remain exposed for more than 2 days, suitable precautions shall be taken to shade and protect the exposed material from the direct rays of the sun until the entire waterstop is embedded in concrete. 5. Install according to PVC waterstop supplier’s recommendations. B. Standard PVC Waterstop Splices: 1. Perform plastic waterstop splices by applying a thermostatically controlled electric source of heat in accordance with the supplier's instructions. The heat shall be sufficient to melt but not burn the plastic. Splices shall be checked for watertightness by an approved electrical spark tester. 2. Maintain continuity of the waterstop ribs and tubular center axis, 3. Prefabricate all joints requiring more than two ends to be joined together and all joints that require an angular cut, an alignment change, or the joining of dissimilar waterstop sections prior to placement in the forms allowing not less than 18” long strips of material beyond the joint. Butt welds of similar waterstop sections may be made while the material is in place in the forms. 4. Fabricate splices with tensile strength not less than 60 percent of the tensile strength of the unspliced material. Blue Lake Expansion Project – Contract No. 9 03254-6 General Construction May 2012 5. Perform splices in accordance with the PVC waterstop supplier’s recommendations. 3.02 INSTALL HYDROPHYILIC WATERSTOP A. Method-1: (Attaching waterstop to smooth concrete): 1. Surface of the concrete must be clean, dry and free from any loose debris. 2. Paint both concrete and waterstop with supplier recommended adhesive. Allow adhesive paste to become tacky. Place a nail or screw every 10” to 12" approximately. 3. Place concrete without displacing or disturbing the position of the waterstop. B. Method-2: (Attaching waterstop to rough concrete): 1. Surface of the concrete must be clean and free from any loose debris or standing water. 2. Apply small bead adhesive paste, using enough to fill any void between waterstop and the concrete surface. 3. Firmly press waterstop into the adhesive paste while it is still in the paste state. Place a nail or screw every 10 inch to 12 inch approximately. 4. Use a wet tool or gloved finger to remove any excess adhesive paste. 5. Place concrete without displacing or disturbing the position of the waterstop. C. Install according to supplier’s recommendations. 3.03 INSTALLATING VOLCLAY WATERSTOP 1. Surface of the concrete must be clean, dry and free from any loose debris. Do not install waterstop standing water or on an iced substrate. 2. Paint both concrete and waterstop with manufacturer’s recommended adhesive. Follow manufacturer’s recommended application rates, procedures, curing times, and all other special instructions. 3. On irregular surfaces such as stone, make sure waterstop remains in direct contact with the substrate along the entire installation. 3.04 INSTALLATION OF JOINT FILLER A. Premolded joint filler shall be installed to cover the entire surface at the joints and also to fit around openings. The exposed edges of the material shall be set back from the finished surface of the concrete and held securely in place in the joint by waterproofing cement. The finished joint shall be tight and leak proof. 3.05 INSTALLATION OF POLYSULFIDE SEALANT A. Install in accordance with the supplier’s recommendations. 3.06 INSTALLATION OF JOINT BOND BREAKER Blue Lake Expansion Project – Contract No. 9 03254-7 General Construction May 2012 A. Install in accordance with the supplier’s recommendations. B. Installation locations include dam extension keyway concrete surfaces. 3.07 INSTALLATION OF COMPRESSIBLE MATERIAL A. Install compressible material at the locations As Shown. END OF SECTION Blue Lake Expansion Project – Contract No. 9 03300-1 General Construction May 2012 SECTION 03300 CAST-IN-PLACE CONCRETE PART 1 GENERAL 1.01 WORK INCLUDED A. Provide all concrete necessary for construction of all concrete structures As Shown, including furnishing materials, batching, mixing, transporting, placing, consolidating, finishing, curing and testing of concrete. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 01400: Quality Assurance C. Section 02370: Erosion, Sediment and Pollution Control Measures D. Section 03100: Formwork E. Section 03200: Concrete Reinforcement F. Section 03254: Expansion, Contraction Joints and Waterstops G. Section 03301: Concrete Instrumentation H. Section 03350: Concrete Sealant 1.03 REFERENCE STANDARDS A. American Concrete Institute 1. ACI 117: Standard Specification for Tolerances for Concrete and Construction Materials 2. ACI 207.1R: Guide to Mass Concrete 3. ACI 211.1: Practice for Selecting Proportions for Normal, Heavyweight, and Mass Concrete 4. ACI 211.5R: Guide for Submittal of Concrete Proportions 5. ACI 301: Specifications for Structural Concrete 6. ACI 302.1R: Guide for Concrete Floor and Slab Construction 7. ACI 304R: Guide for Measuring, Mixing, Transporting and Placing Concrete 8. ACI 304.2R: Placing Concrete by Pumping Methods 9. ACI 305R: Hot Weather Concreting 10. ACI 306R: Cold Weather Concreting Blue Lake Expansion Project – Contract No. 9 03300-2 General Construction May 2012 11. ACI 315: Details and Detailing of Concrete Reinforcing 12. ACI 318/318R: Building Code Requirements for Structural Concrete and Commentary 13. ACI 347R: Guide to Formwork for Concrete 14. ACI SP2: Manual of Concrete Inspection B. American Society for Testing and Materials (ASTM) 1. ASTM C31: Standard Practice for Making and Curing Concrete Test Specimens in the Field 2. ASTM C33: Standard Specification for Concrete Aggregates ASTM C39: Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens 3. ASTM C94: Standard Specification for Ready Mix Concrete 4. ASTM C125: Standard Terminology Relating to Concrete and Concrete Aggregates 5. ASTM C136: Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates 6. ASTM C138: Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete 7. ASTM C143: Standard Test Method for Slump of Hydraulic Cement Concrete 8. ASTM C150: Standard Specification for Portland Cement 9. ASTM C171: Standard Specification for Sheet Materials for Curing Concrete 10. ASTM C172: Standard Practice for Sampling Freshly Mixed Concrete 11. ASTM C231: Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method 12. ASTM C260: Standard Specification for Air-Entraining Admixtures for Concrete 13. ASTM C295: Standard Guide for Petrographic Examination of Aggregates for Concrete 14. ASTM C309: Standard Specifications for Liquid Membrane-Forming Compounds for Curing Concrete 15. ASTM C494: Standard Specification for Chemical Admixtures for Concrete 16. ASTM C566: Standard Test Method for Total Evaporable Moisture Content of Aggregate by Drying Blue Lake Expansion Project – Contract No. 9 03300-3 General Construction May 2012 17. ASTM C618: Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete 18. ASTM C881: Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete 19. ASTM C939: Standard Test Method for Flow of Grout for Preplaced-Aggregate Concrete (Flow Cone Method) 20. ASTM C1017: Standard Specification for Chemical Admixtures for Use in Producing Flowing Concrete 21. ASTM C1064: Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement Concrete 22. ASTM C1107: Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink) 23. ASTM C1260: Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method) 24. ASTM C1602: Standard Specification for Mixing Water Used in the Production of Hydraulic Cement Concrete 25. ASTM D75: Standard Practice for Sampling Aggregates 26. ASTM D4791: Standard Test Method for Flat Particles, Elongated Particles, or Flat and Elongated Particles in Coarse Aggregate 27. ASTM E11: Standard Specification for Woven Wire Test Sieve Cloth and Test Sieves 28. ASTM E329: Standard Specification for Agencies Engaged in Construction Inspection, Testing, or Special Inspection C. CPMB: Concrete Plant Mixer Standards (CPMB 100M-00) D. TMMB: Truck Mixer and Agitator Standards (TMMB 100-05) E. United States Bureau of Reclamation (USBR) 1. USBR Guide to Concrete Repair 2. USBR M47: Standard Specification for Repair of Concrete 1.04 DEFINITIONS A. "Cementitious material" as used herein shall include all cementitious materials, including Portland cement, ground granulated blast furnace slag, and pozzolan. B. "Defective Concrete": Concrete not conforming to required lines, details, dimensions, tolerances or specified requirements. Blue Lake Expansion Project – Contract No. 9 03300-4 General Construction May 2012 C. “Design strength” (f’c) is the specified compressive strength of concrete to meet structural design criteria. D. “Layer”: Concrete placement achieved as concrete is delivered into forms in one pass. E. “Lift”: Concrete placement between horizontal construction joints. F. “Mass Concrete”: Concrete to be placed in the dam, thrust block, cut-off wall and other locations As Shown. G. “Placement”: A concrete placement location defined by the lift base elevation and dam block number or designated feature. H. “Structural Concrete”: Concrete to be placed in a structural slab, beam, or foundation As Shown. 1.05 QUALITY ASSURANCE A. Local Aggregate and Mass Concrete Trial Batch Testing Completed by the Engineer 1. Local Aggregate Test Results: See Reference Documents, Technical Memorandum 36, for local aggregate test results. Tests were performed on course and fine aggregates provided by S&S Construction (S&S) in Sitka, AK. S&S’s course aggregate is: 2. Concrete Mix Trial Batch Test Results: See Reference Documents, Technical Memorandum 36, for mass concrete trial batch test results. B. Preconstruction Testing and Acceptance: 1. Perform preconstruction testing of proposed mix designs if utilizing aggregate from sources other than those tested by the Engineer. 2. Acceptance will be based on completed submittals review by the RPR for each mix design. 3. Contractor shall furnish to RPR a Certificate of Compliance for the proposed air-entraining and water-reducing admixtures. 4. Aggregates from Sources Tested by the Owner: No additional testing will be required if proposed aggregates are from the same sources as those tested by the Engineer. If requested by the RPR, facilitate sampling of the specific aggregate sources proposed for additional independent testing. 5. Aggregates from Sources other than those Tested by the Engineer: Take samples from proposed aggregate sources in accordance with ASTM D75. Perform aggregate testing in accordance with ASTM C33 and submit results to RPR. If proposed aggregate sources are found to be reactive they may be retested with proposed cementitious materials in the proportions proposed for the mix with the lowest proportion of cementitious materials. If the proposed aggregate sources are found acceptable, facilitate sampling of the proposed aggregates by the RPR for additional independent testing. Blue Lake Expansion Project – Contract No. 9 03300-5 General Construction May 2012 6. Concrete Strength Test Results: Show proposed mixes meet strength requirements. Provide plots of strength versus time for each of the concrete mixes tested. C. Construction Acceptance Sampling and Testing: 1. Sample aggregates and concrete for testing to determine compliance with this Specification. Provide facilities including an independent, industry qualified, concrete testing laboratory to perform strength tests and labor necessary for handling of representative test samples. Obtain aggregate samples from plant stockpiles or weigh hoppers for acceptance; however, samples may be taken at various stages in the process and handling operations at the discretion of RPR. 2. Facilitate periodic sampling and testing of concrete and concrete components by Owner’s independent, third-party material testing organization. 3. Sample concrete in accordance with ASTM C172. Make and cure specimens in accordance with ASTM C31, and compression test specimens in accordance with ASTM C39. For concrete with a specified strength at 28 days, cast 6 cylinders; 2 shall be tested at 7 days and 2 tested at 28 days and 2 to be held. For concrete with a specified strength at 90 days, cast 8 cylinders; 2 shall be tested at 7 days, 2 tested at 28 days, 2 tested at 90 days, and 2 to be held. In addition to casting specimens, determine slump, air content, temperature and unit weight in accordance with ASTM C143, ASTM C231, ASTM C1064 and ASTM C138, respectively. 4. Sample concrete at the point of truck discharge, except that when it is conveyed from truck to forms by pumping or bucket, it will be sampled at the point of delivery after any water is added. 5. For each concrete placement, samples for the determination of slump, air content and temperature will be taken at the beginning of placement and thereafter at a frequency of at least one sample for each 50 cubic yards or fraction thereof for each placement or when mix or conditions change. 6. Samples for compressive strength test specimens will be taken at a frequency of at least one sample for each 50 cubic yards or fraction thereof for each placement. The frequency of sample testing may be decreased to one sample for each 100 cubic yards at the direction of the RPR. 7. Whenever the measured air content falls outside the specified range, a check test will be made immediately on another portion of the same sample. In the event of a second failure, the batching plant operator shall be notified, and the operator shall take immediate corrective action. Samples will be taken from each succeeding load and tested until the air content falls within the specified range. Concrete for which the air content falls outside the specified range shall not be placed in the forms. 8. Whenever the measured slump exceeds the specified maximum, a check test will be made on another portion of the same sample. In the event of a second failure, the batching plant operator shall be notified, and the operator shall take immediate corrective action. Samples will be taken from each succeeding load and tested until the slump falls below the maximum specified. Concrete for which the slump exceeds the maximum specified shall not be placed in the forms. Blue Lake Expansion Project – Contract No. 9 03300-6 General Construction May 2012 9. All excess or rejected concrete shall be removed from the jobsite and disposed of properly at Contractor’s expense. 1.06 EVALUATION AND ACCEPTANCE A. Concrete: Test results of compressive strength specimens for each class of concrete will be acceptable provided the averages of all sets of three consecutive test results equal or exceed the required specified strength, and no individual test result (average of three cylinders) falls below the specified strength by more than 500 psi. B. Construction Tolerances: Variation in alignment, grade, and dimensions of the structures from the established alignment, grade, and dimensions shown on the drawings shall be within the tolerances given in ACI 117. C. Surface Requirements: The surface requirements for the classes of finish required by Section 03100-2.02 shall be as hereinafter specified. Allowable irregularities are designated "abrupt" or "gradual" for purposes of providing for surface variations. Offsets resulting from displaced, misplaced or mismatched forms, or sheathing, or by loose knots in sheathing, or other similar form defects, or air bubbles shall be considered "abrupt" irregularities. Irregularities resulting from warping, out-of-plane or similar uniform variations from plane, or true curvature, shall be considered "gradual" irregularities. "Gradual" irregularities will be checked for compliance with prescribed limits with a 5-foot template, consisting of a straightedge for plane surfaces and a shaped template for curved or warped surfaces. In measuring irregularities, the straightedge or template may be placed anywhere on the surface in any direction, with the testing edge held parallel to the intended surface. Finish Abrupt, Inches Gradual, Inches Allowable Irregularities F1 1 1 F2 1/4 1/2 F3 1/8 1/4 F4 1/8 1/4 D. Appearance: Surfaces that are to be permanently exposed, if stained or otherwise discolored, shall be cleaned and/or treated by a method that does not harm the concrete and that is acceptable to RPR. 1.07 SUBMITTALS A. General 1. Submit under provisions of Section 01300 for review. B. Concrete Quality Control Plan: Provide a concrete quality control plan giving specific plans for meeting field quality control requirements and sufficient laboratory resources to meet testing requirements. Incorporate the concrete quality control plan with the QCIP. C. Concrete Mix Designs 1. Mix designs for each strength and type of concrete to be used on the project following guidelines in ACI 211.5R. Blue Lake Expansion Project – Contract No. 9 03300-7 General Construction May 2012 2. Mill certifications for proposed Portland cement and pozzolan. 3. Complete list of materials including type; brand; source and amount of cementitious materials, pozzolans, and admixtures; and applicable reference specifications. 4. Additional data regarding concrete aggregates if the source of aggreg ate changes. 5. Evaluate potential for alkali-silica reactions. 6. Written procedure for all admixtures. 7. Any deviations from the supplier’s written procedures shall be submitted to the RPR for approval. Admixtures shall not be added to the concrete with the modified procedures until the RPR has approved them in writing. 8. Unconfined Compression Test Results: Provide concrete compression strength test results from preconstruction testing for each of the proposed mixes. Plot concrete strength versus for each of the proposed mixes. D. Conveying Equipment 1. Include data on conveying equipment and methods of transporting, handling, and depositing the concrete for mass and structural concrete for each project feature. E. Procedures for Placing Concrete 1. Proposed materials, methods and details for placing the concrete (including temperature control, if applicable). 2. Concrete pump, size and material for pipe, and maximum length and height of concrete to be pumped and proposed operating pressures and flow rates. 3. Technical literature for equipment and methods proposed for vibrating and compacting concrete. Submittal shall include a description of the equipment including vibrator, diameter, length, frequency, amplitude, and centrifugal force. F. Mass Concrete Placement Lift Plans for Dam Extension 1. Mass Concrete lift sequence to suit the intended equipment, concrete production capacity, means and methods and meet the requirement of the specifications. 2. Narrative and figures indicating the size and sequencing of the placement to be used for placing mass concrete. Each placement is to be individually numbered and keyed to a lift placing schedule that details the planned time for joint preparation, concrete placement and form removal for each lift. Scheduling is to allow for sufficient concrete strength gain to properly remove and, as necessary, secure forms. 3. Incorporate following criteria in lift placement drawings: a) Placement Height: Proposed heights for each placement. Blue Lake Expansion Project – Contract No. 9 03300-8 General Construction May 2012 b) Placement Width: Width measured parallel to the dam axis is limited to the block width, approximately 40 feet for interior blocks. c) Placement Length: Length upstream to downstream As Shown d) Horizontal Joints: Each joint to be at a constant elevation to the extent practical. e) Locate horizontal joints a minimum of 12 inches above or below horizontal embedded anchors. f) Time between lift placements: Three days, minimum. g) Show embedded items with placement. h) Concrete Production Capacity: Show that the concrete batch plant has sufficient production capacity to place the planned lifts without cold joints. Indicate if retarding admixtures are necessary to cast the lifts shown. i) Placement Plan Figures: Prepare plans, sections, elevations and schedules to fully define the location and geometry of each placement. Clearly indicate joints between different concrete mixes. G. Weather Placing Procedures 1. Include materials and methods to be used when concrete placement will occur at ambient air temperatures below 40 degrees Fahrenheit. Include proposed curing and temperature control methods. 2. Include materials and methods to be used when concrete placement will occur at ambient air temperatures above 90 degrees Fahrenheit. Include proposed curing and temperature control methods. 3. Incorporate following requirement: Temperature control requirements to limit heat of hydration for mass concrete placements take precedence over weather placing procedures unless weather placing procedure require lower concrete temperature at time of placement. H. Concrete Mix Test Reports 1. Include in submittal (for aggregate sources other than ones included in design study appended to Contract Documents): a) Concrete Strength Test Reports b) Alkali Silica Reactivity: Copies of test reports with concrete mix design showing that the mix has been successfully tested to produce concrete with the properties specified, that mitigation measures for alkali silica reactivity, if needed, are effective, and that mix will be suitable for the job conditions. Test reports shall be submitted along with the concrete mix design. Obtain approval before concrete placement. Alkali Silica Reactivity testing will be Blue Lake Expansion Project – Contract No. 9 03300-9 General Construction May 2012 waived it the aggregate sources are demonstrated to be the same as those tested by the Engineer in 2011. c) Pozzolan test reports: Test results in accordance with ASTM C618. Submit test results in accordance with Section 01300. d) Aggregates test results: Provide recent results for selected aggregate including ASTM C1260 -Test for Potential Alkali-silica Reactions and ASTM C295 - Petrographic Analysis. ASTM C33 for aggregate quality. e) Admixtures: Use only air-entraining, water-reducing, set retarding, acceleration and plasticizing admixtures as specified. Air-entraining, water- reducing, set retarding, acceleration and plasticizing admixtures shall be from the same supplier and shall be compatible. I. Finishing, Curing and Concrete Protection Procedures 1. Include finishing and curing procedures to be used on the project. 2. Include descriptions of methods to be used to protect the surface finish until the concrete has hardened. J. Test Reports and Certificates of Compliance: 1. Aggregates: Contractor's proposed aggregate source will be accepted on the basis of certified reports of tests made in accordance with this specification section. 2. Cement: Cement will be accepted on the basis of supplier's certification of compliance, accompanied by mill test reports that materials meet the requirements of the specification under which it is furnished. Certification and mill test reports shall identify the particular lot furnished. No cementitious materials shall be used until further notice of acceptance has been given by RPR. Cement will be subject to check testing from samples obtained at the mill, at transfer points or at the batch plant by Owner. Provide access as required to inspect storage and to sample for check testing. Material not meeting specifications shall not be used. 3. Concrete Mixture Proportions: The proportions of all ingredients and nominal maximum coarse aggregate size that will be used in the manufacture of each quality of concrete shall be stated. Proportions shall indicate weight of cementitious materials, and water and weights of aggregates in a saturated surface-dry condition. The submission shall be accompanied by test reports from a laboratory complying with ASTM E329 attesting that proportions thus selected will produce concrete of the qualities indicated. No substitution shall be made in the materials used in the Work without additional tests to show that the quality of concrete is satisfactory. 4. Certificates of Compliance: Impervious sheet-curing materials shall be certified for compliance with all specification requirements. K. Review of Plant, Equipment and Methods: Blue Lake Expansion Project – Contract No. 9 03300-10 General Construction May 2012 1. Batching Plant: Details and data on concrete plant shall be submitted for review by RPR for conformance with Section 03300-3.01. Include the plant layout and location of aggregate stockpiles. 2. Mixers: The make, type and capacity of concrete mixers proposed for mixing concrete shall be submitted for review by RPR for conformance with Section 03300-3.01. 3. Conveying Equipment: The methods and equipment for transporting, handling, and depositing the concrete shall be submitted for review by RPR for conformance with Section 03300-3.02. 4. Placing: Placing equipment and methods shall be submitted for review by RPR for conformance with Section 03300-3.04. 5. Joint Cleanup: The method and equipment proposed for joint cleanup shall be submitted for review by RPR for conformance with Section 03300-3.05. Method of waste disposal for any method proposed for joint cleanup shall be submitted for approval by RPR. 6. Curing: The curing medium and methods to be used shall be submitted for review by RPR for conformance with Section 03300-3.08. 7. Cold-Weather Requirements: If concrete is proposed to be placed under cold- weather conditions, the materials, methods, and protection proposed to accomplish it shall be in accordance with the requirements of Section 03300- 3.04C and shall be accepted by RPR. 8. Hot-Weather Requirements: If concrete is proposed to be placed under hot- weather conditions, the materials and methods proposed to accomplish it shall be in accordance with the requirements of Section 03300-3.04D and shall be accepted by RPR. L. Lift Drawings: All lift drawings shall be submitted to RPR for review and acceptance. The pertinent lift drawings shall be submitted along with contiguous drawings three weeks or more before placement of the respective lift. The lift drawings shall show all details of the lift including dimensions, elevations, embedded items and finish. M. Furnish “Pre-placement Checkout Form” per ACI SP2 to RPR confirming that forms, reinforcement, embedded items, construction joints are prepared, and downstream chamfers are in place and ready for concrete placement prior to concrete delivery. N. Batch Records: Provide individual batch tickets as well as electronic copies of batch records from the concrete supplier or batch plant for each batch delivered to the site. Batch records shall include the following information: 1. Name of supplier and/or batch plant operation 2. Name of batching plant and location 3. Serial number of ticket 4. Date 5. Truck number and batch number Blue Lake Expansion Project – Contract No. 9 03300-11 General Construction May 2012 6. Specific job designation (Contract number and location) 7. Volume of concrete (cubic yard) 8. Amount of water in aggregate (above or below SSD conditions) at time of delivery 9. Time loaded and amount of water added at plant. Time loaded is the time water comes in contact with cementitious material. 10. Maximum permissible amount of water to be added at the site, if any 11. Allowable slump 12. Allowable air content 13. Type and brand of cementitious materials 14. Weight of cementitious materials 15. Maximum size of aggregates 16. Weights of coarse and fine aggregates, respectively 17. Type and amount of admixtures, including pozzolan 18. Mix design designation 1.08 MATERIALS DELIVERY, STORAGE AND HANDLING A. Transportation of Cementitious Materials: 1. Bulk cementitious materials shall be transported from the mill or intermediate storage to the batching plant in such a way that it is not exposed to moisture. 2. The temperature of the cementitious materials as delivered to storage at the batching plant shall not exceed 150ºF. B. Storage of Cement: Immediately upon receipt at the batching plant, cementitious materials shall be stored in dry, weather tight, and properly ventilated separate structures. All storage facilities shall be subject to acceptance by RPR and shall permit easy access for inspection and identification. Sufficient cementitious materials shall be in storage at all times to permit continuous placement and to complete any lift of concrete started. C. Aggregates: Aggregate stockpiles shall be arranged and used in a manner to avoid excessive segregation, to prevent contamination with other materials or with other sizes of aggregate and provide uniform moisture content. Coarse aggregate shall be stored in separated size groups. Sufficient fine and coarse aggregate shall be maintained at the batching plant at all times to permit continuous placement and completion of any lift of concrete started. D. Admixtures: Maintain sufficient air-entraining admixture, and, if used, water- reducing admixture, at the batching plant at all times to permit continuous placement and completion of any lift of concrete started. Admixtures shall be Blue Lake Expansion Project – Contract No. 9 03300-12 General Construction May 2012 stored, mixed and dispensed in accordance with the supplier's instructions and recommendations. PART 2 PRODUCTS 2.01 MIX DESIGN A. Contractor-Furnished Mix Design 1. Provide mix designs conforming to ACI 211.1, ACI 301, ACI 318 and ACI 304.2R, except as otherwise specified, and to parameters given herein. 2. Mix A: Structural Mass Concrete (1 ½ inch NMSA), used for dam extension including spillway placements, as well as the scour wall. Mix Requirements Minimum 90-day compressive strength, f'c (psi) 5,000 Slump at placement (Inches) 2 to 4 Maximum Water-Cement Ratio (by weight) 0.48 Air Content at placement (percent) 3.5 to 6.5 Cementitious Material Content (lb/cy) 550 Pozzolan shall be used as 25 to 45 percent, by weight, of total cementitious material. 3. Mix B: Normal Structural Concrete (1 ½ inch Aggregate), used for powerhouse, penstock anchor blocks, intake and tunnel. Mix Requirements Minimum 28-day compressive strength, f'c (psi) 4,000 Slump at placement (Inches) Slump for walls and other locations approved by RPR (Inches) 1 to 4 4 to7 Maximum Water-Cement Ratio (by weight) 0.48 Air Content at placement (percent) 4.5 to 7.5 Suggested Minimum Cementitious Material Content (lb/cy) 500 Pozzolan shall be used as 25 to 45 percent, by weight, of total cementitious material. Note: Mix A may be proportioned such that it meets Mix B requirements as well. 4. Mix C: Normal Structural Concrete (3/4 inch Aggregate), used for powerhouse, intake and tunnel. Mix Requirements Minimum 28-day compressive strength, f'c (psi) 4,000 Slump at placement (Inches) Slump for walls and other locations approved by RPR (Inches) 1 to 4 4 to 7 Maximum Water-Cement Ratio (by weight) 0.48 Blue Lake Expansion Project – Contract No. 9 03300-13 General Construction May 2012 Air Content at placement (percent) 4.5 to 7.5 Suggested Minimum Cementitious Material Content (lb/cy) 550 Pozzolan shall be used as 25 to 45 percent, by weight, of total cementitious material. 5. Mix D: Mass Concrete for Thrust Block (1 ½ inch Aggregate), used for thrust block, cut-off wall, and other mass concrete placements other than the dam extension. Mix Requirements Minimum 90-day compressive strength, f'c (psi) 3,000 Slump at placement (Inches) 2 to 4 Maximum Water-Cement Ratio (by weight) 0.5 Air Content at placement (percent) 4.5 to 7.5 Cementitious Material Content (lb/cy) 400 Pozzolan shall be used as 25 to 45 percent, by weight, of total cementitious material. 6. Mix E: Secondary Structural Concrete (3/8 inch Aggregate), used for tunnel liners, gate guides, embedded parts, and slender locations (to 2 inch minimum dimension). Mix Requirements Minimum 90-day compressive strength, f'c (psi) 4,000 Slump at placement (Inches) 1 to 4 Slump at other locations as approved by RPR (Inches) 4 to 7 Maximum Water-Cement Ratio (by weight) 0.48 Air Content at placement (percent) 4.5 to 7.5 Cementitious Material Content (lb/cy) 550 Pozzolan shall be used as 25 to 45 percent, by weight, of total cementitious material. B. Required Average Strength of Mix Design 1. The selected mix design shall produce an average compressive strength exceeding the specified strength by no less than 15 percent based on laboratory trial mixtures. 2.02 MATERIALS FOR CONCRETE A. Cement 1. ASTM C150, Type II low alkali with maximum heat of hydration of 70 calories per gram at 7 days. B. Pozzolan 1. ASTM C618, Class F, except that the maximum allowable loss on ignition shall be 3 percent. Pozzolan shall be from a single source. Blue Lake Expansion Project – Contract No. 9 03300-14 General Construction May 2012 C. Water: 1. Water for mixing and curing shall conform to ASTM C1602. D. Aggregates: 1. Fine Aggregates: ASTM C33 2. Coarse Aggregates: ASTM C33 Class Designation 4S 3. Reactivity of Selected Aggregates a) Aggregates shall conform to ASTM C33, except as modified herein. Furnish coarse aggregates and fine aggregates from single sources. Aggregates shall not contain any substance that may be deleteriously reactive with the alkalis in the cementitious materials unless effective mitigating measures are taken to control reactivity. b) Aggregates shall show expansions less than 0.10 percent at sixteen (16) days when tested in accordance with ASTM C1260 using a cementitious materials with an alkali content above 0.8 percent (expressed as sodium oxide), and shall not possess properties or constituents that are known to have specific unfavorable effects in concrete when tested in accordance with ASTM C295. c) If mitigating measures are used to control reactivity, submit satisfactory test results from ASTM C1260 as modified below. Satisfactory results shall have a measured expansion of no more than 0.08 percent at 16 days. Should the test data indicate an expansion of more than 0.08 percent, the relative proportions of pozzolan shall be increased and the aggregate retested or a new aggregate source with acceptable expansion shall be submitted. d) ASTM C1260 shall be modified to utilize the contractor’s proposed low alkali Portland cementitious materials and pozzolan in combination for the test proportioning. The laboratory shall use the contractor’s proposed percentage of cementitious materials and pozzolan. E. Admixtures 1. Admixtures, if used, shall conform to the following requirements: a) All admixtures shall be provided by the same supplier. b) Air-Entraining admixture shall conform to ASTM C260. 2. Water Reducing – Water reducing admixtures shall conform to ASTM C494, Types A or D. The dosage of water-reducing admixtures shall be in the upper portion of the range recommended by the supplier. 3. Plasticizing admixture – ASTM C1017, Type I or II F. Materials for Curing Concrete Blue Lake Expansion Project – Contract No. 9 03300-15 General Construction May 2012 1. Impervious Sheeting – ASTM C171; waterproof paper, clear or white polyethylene sheeting, or polyethylene-coated burlap. 2. Liquid Membrane-Forming Compound – ASTM C309, resin base with fugitive dye, Type 2, Class B. No liquid membrane is to be used where monolithic behavior is required, such as at the dam horizontal joints. G. Epoxy Resin 1. Epoxy resin for use in repairs shall conform to ASTM C881/C881M, Type III, Grade I or II. H. Miscellaneous Materials 1. Embedded Items: Care shall be taken to determine that all embedded items are as indicated on the drawings or required. Voids in sleeves, inserts, and anchors slots shall be filled temporarily with readily removable materials to prevent the entry of concrete into the voids. 2. Embedded Metals: Miscellaneous metal to be embedded in concrete shall be placed accurately and held in correct position while the concrete is placed. The surfaces of metalwork in contact with or embedded in concrete shall be thoroughly cleaned of all rust, dirt, grease, loose scale, grout, mortar, and other foreign matter. All metalwork shall have proper fit and shall be job measured where necessary. 2.03 CONCRETE MIXTURE PROPORTIONING A. Quality of Mixture: For each portion of the structure, select mixture proportions so that the strength and W/C requirements listed herein are met. B. Nominal Maximum-Size Coarse Aggregate 1. Mix A: Nominal maximum-size coarse aggregate shall be 1 ½ inches and shall consist of a combination of ASTM C33 Size Number 4 and Size Number 67 coarse aggregates. The quantity of Size Number 4 by weight of total coarse aggregate shall not be less than 40 percent. 2. Mix B: Nominal maximum-size coarse aggregate shall be 1 ½ inches and shall consist of a combination of ASTM C33 Size Number 4 and Size Number 67 coarse aggregates. The quantity of Size Number 4 by weight of total coarse aggregate shall not be less than 40 percent. 3. Mix C: Nominal maximum size coarse aggregate shall be ¾ inches and shall consist of ASTM C33 Size Number 67. 4. Mix D: Nominal maximum-size coarse aggregate shall be 1 ½ inches and shall consist of a combination of ASTM C33 Size Number 4 and Size Number 67 coarse aggregates. The quantity of Size Number 4 by weight of total coarse aggregate shall not be less than 40 percent. Blue Lake Expansion Project – Contract No. 9 03300-16 General Construction May 2012 5. Mix E: Nominal maximum-size coarse aggregate shall be 3/8 inches and shall consist of only fine aggregate meeting ASTM C33. 6. Air Content: Air content as delivered to the forms and as determined by ASTM C231 as indicated herein. . 7. Slump: Determine in accordance with ASTM C143/C143M and as indicated herein. . Where placement by pump is used, the slump shall not exceed 7 inches Note: Segregation of aggregates may occur at slumps in excess of 7 inches, continual monitoring is required. 8. Pumping is not permitted for Mix A and Mix D. 9. All concrete shall contain water reducing admixture. 2.04 REPAIR CONCRETE A. For repair of concrete, use materials specified in the repair procedures detailed in the USBR Guide to Concrete Repair. B. The repair concrete shall not have a maximum aggregate size larger than the surrounding concrete. C. The repair concrete strength shall exceed the strength of the surrounding concrete. PART 3 EXECUTION 3.01 DELIVERY, STORAGE, AND HANDLING A. Furnish “Pre-placement Checkout Form” per ACI SP2 to RPR confirming that forms, reinforcement, embedded items, construction joints are prepared, and downstream chamfers are in place and ready for concrete placement prior to concrete delivery. B. Refer to ACI 301 for job site storage of materials. Protect materials from contaminants such as grease, oil, and dirt. Ensure materials can be accurately identified after bundles are broken and tags removed. 3.02 BATCHING, MEASURING, MIXING, AND TRANSPORTING CONCRETE A. General: Conform to the requirements of ACI 301, ACI 302.1R, ACI 304.2R, and ASTM C94 except as modified herein. The batching plant shall be fully automatic and computer controlled. B. Measuring: 1. Make measurements at intervals as specified in paragraphs entitled "Sampling" and "Testing." 2. Concrete Temperature Control for Mass Concrete Placements: Measure temperature rise of mass concrete placements in accordance with the lift plan as reviewed by the RPR. Blue Lake Expansion Project – Contract No. 9 03300-17 General Construction May 2012 C. Mixing: 1. Concrete Temperature Control for Hot-Weather Mass Concrete Placements: Pre-cool concrete to a maximum temperature of 65 degrees Fahrenheit at placement when measured in accordance with ASTM C1064. Provide effective means such as pre-cooling aggregates; refrigerating the mixing water; adding to the mix water chip, crushed, tube, or other forms of ice up to the full amount of the added mixing water; or a combination of these or other approved methods, as necessary to maintain the temperature of the concrete less than the specified maximum placing temperature. 2. Concrete Temperature Control for Cold-Weather Mass Concrete a) Cold-Weather Placing: Concrete shall not be placed without a procedure approved in accordance with subsection 1.07 when the concrete is likely to be subjected to freezing temperatures before the expiration of the curing period. The ambient temperature of the space adjacent to the concrete placement and surfaces to receive concrete shall be maintained at not less than 40°F. The placing temperature of the concrete having a minimum dimension less than 12 inches shall be between 60° and 75°F. The placing temperature of the concrete having a minimum dimension greater than 12 inches shall be between 50° and 65°F. b) Heating of the mixing water or aggregates will be required to regulate the concrete placing temperatures. Materials entering the mixer shall be free from ice, snow, or frozen lumps. Salt, chemicals, or other materials shall not be mixed with the concrete to prevent freezing. Contractor shall be responsible for all costs associated with cold-weather placement. c) Conform to the requirements of ASTM C94 and ACI 301. Machine mix concrete. d) Reduce mixing time and place concrete within 60 minutes if the air temperature is greater than 85 degrees Fahrenheit except as follows: If set retarding admixture is used and slump requirements can be met, limit for placing concrete may remain at 90 minutes. e) Additional water may be added on arrival of the truck at the placement, prior to the start of discharge to adjust the slump within the specified range provided that the maximum water/cementitious materials ratio is not exceeded. Obtain approval of RPR or his representative prior to adding water to truck. The amount of added water shall be recorded. When additional water is added, an additional 30 revolutions of the mixer at mixing speed is required. Concrete test cylinders shall be taken after any additional water is added. Concrete test cylinders taken prior to adding water shall be discarded. f) Add a sufficient quantity of admixture to bring the entrained air content within the specified limits if the entrained air content falls below the specified limit. Dissolve admixtures in the mixing water and mix in the drum to uniformly distribute the admixture throughout the batch. g) Concrete admixtures shall be added to the concrete mix at the time of batching the concrete or in accordance with the supplier’s written procedure and as reviewed by the RPR. Blue Lake Expansion Project – Contract No. 9 03300-18 General Construction May 2012 D. Transporting: 1. Transport concrete from the mixer to the forms as rapidly as practicable. Prevent segregation or loss of ingredients. Clean transporting equipment thoroughly before each batch. Do not use aluminum pipe or chutes. Remove concrete, which has segregated in transporting and dispose of in accordance with the SPCC plan. 2. Contractor shall dispose of material cleaned from transporting equipment in accordance with approved ESCP and SPCC plan from Section 02370. 3.03 WATERSTOPS, INSTALLATION AND SPLICES A. Install in accordance with Section 03254. 3.04 PREPARATION FOR PLACING A. Construction joint treatment and existing concrete surface cleaning shall conform to the following requirements: 1. Preparation: Concrete surfaces to which additional concrete is to be bonded shall be prepared by cleaning with high-pressure water-blasting or other approved method. Resulting surfaces shall be free from all laitance and inferior concrete so that clean, well-bonded coarse aggregate is exposed uniformly throughout the lift surface. The edges of the coarse aggregate shall not be undercut. Above water surfaces shall be washed clean again as the last operation prior to placing the next lift. There shall be no standing water on the surface upon which concrete is placed. Remove silt, debris and fines from submerged joints immediately prior to placing concrete. 2. High-Pressure Water Jet: A stream of water under a pressure of not less than 6,000 psi may be used for cleaning. Its use shall be delayed until the concrete is sufficiently hard so that only the surface skin or mortar is removed and there is no undercutting of coarse aggregate particles. If the water jet is incapable of a satisfactory cleaning, the water pressure shall be increased until the surface is cleaned to the RPR’s satisfaction. Do not green cut with an air-water mixture. 3. Waste Disposal: The method used in disposing of waste water employed in cleaning, washing, and rinsing of concrete surfaces shall be such that the waste water does not stain, discolor or affect exposed surfaces of the structures, or damage the environment of the project area. The method of disposal shall be subject to approval. 3.05 FIELD QUALITY CONTROL A. Employ a Testing Laboratory to perform on-site and off-site concrete testing. Provide access to Work areas and any on-site laboratory facilities for Owner’s laboratory technicians to accomplish testing activities. Provide samples for testing purposes and assist in obtaining samples. The laboratory shall be approved by the RPR and shall meet the requirements of ASTM E329. B. Required Concrete Testing Blue Lake Expansion Project – Contract No. 9 03300-19 General Construction May 2012 1. Fresh concrete sampling per ASTM C 172, except as modified for slump to comply with ASTM C 94. 2. Concrete slump tests per ASTM C 143, air content tests per ASTM C 231, unit weight tests per ASTM C 138 as follows: a) One test at the start of concrete placement and one test for each 50 cubic yards of concrete at point of discharge. b) One test for each set of compressive strength test specimens. 3. Concrete temperature: Tested hourly when air temperature is 40 F and below, and when 80 F and above; and each time a set of compression test specimens is made. 4. Compression Tests: Concrete samples will be cured and tested as follows: a) A minimum of six cylinders per sample of concrete with a specified compressive strength at 28 days and a minimum of eight cylinders per sample of concrete with a specified compressive strength of 90 days shall be made and cured in accordance with ASTM C31. The number of concrete samples to be taken will be the minimum required by any one of the following criteria. I. One sample per each 100 cubic yards of concrete placed. II. One sample for each day of placement. III. One sample for each mix design. b) Samples will be taken randomly. Results will be identified with respect to location. c) Concrete cylinder compression testing for concrete with a specified compressive strength at 28 days shall follow ASTM C 31 for curing and ASTM C 39 for testing. For each sample, the following tests shall be performed: 2 cylinders at 7 days and 2 cylinders at 28 days. A test result shall be the average of 2 cylinder breaks. The 2 other cylinders shall be held. d) Concrete cylinder compression testing for concrete with a specified compressive strength at 90 days shall follow ASTM C 31 for curing and ASTM C 39 for testing. For each sample, the following tests will be performed: 2 cylinders at 7 days, 2 cylinders at 28 days, and 2 cylinders at 90 days. A test result shall be the average of 2 cylinder breaks. The 2 other cylinders shall be held. e) When the strength of field-cured cylinders is less than 85% of companion laboratory-cured cylinders, evaluate current operations and provide corrective procedures for protecting and curing the in-place concrete. f) Content of Lab Reports: The Contractor shall submit lab reports to the Engineer for approval. Reports of compressive strength tests shall contain the project identification name and number, date of concrete placement, name of concrete testing service, concrete type and class, Blue Lake Expansion Project – Contract No. 9 03300-20 General Construction May 2012 location of concrete batch in the structure, design compressive strength at 28 days, concrete mix proportions and materials compressive breaking strength, and type of break for both 7-day tests and 28-day tests. g) Additional Tests. i. The Testing Laboratory may make additional tests of in-place concrete when test results indicate that the specified concrete strengths and other characteristics have not been attained in the structure. ii. The Testing Laboratory may conduct tests to determine adequacy of concrete by cored cylinders complying with ASTM C 42. h) The costs of such tests conducted, and of any other additional testing required when the presence of unacceptable concrete is verified, shall be borne by the Contractor, at no extra cost to the Owner. 3.06 PLACING CONCRETE A. General: Place concrete as soon as practical after approval for placement by RPR. Confirm the placement area to be placed is clean and all dirt, construction debris, organic deposits, water, snow and ice is removed. B. Conveying from Delivery Point to Forms: 1. Buckets: a) Bottom-dump buckets that have a capacity of 2 cubic yards or less shall conform to the following requirements: i. The interior hopper slope shall be not less than 60º from the horizontal, the minimum dimension of the clear gate opening shall be at least 5 times the nominal maximum size aggregate and the area of the gate opening shall be not less than 2 square ft. ii. The maximum dimension shall not be greater than twice the minimum dimension. iii. The bucket-gates shall be grout-tight when closed and may be manually, pneumatically or hydraulically operated. iv. The design of the bucket shall provide means for positive regulation of the amount and rate of discharge of concrete in each dumping position. b) Bottom-dump buckets, which have a capacity exceeding 2 cubic yards, shall conform to the following requirements: i. The area of the clear gate opening or gate throat opening shall be not less than one-third the maximum interior horizontal area, and the interior hopper slope shall be not less than 70º from the horizontal. Blue Lake Expansion Project – Contract No. 9 03300-21 General Construction May 2012 ii. The minimum dimension of the clear gate opening shall be at least five times the nominal maximum size aggregate. iii. The bucket gates shall be essentially grout-tight when closed, shall be of the double clamshell type, and shall be pneumatically or hydraulically operated. iv. The gate opening mechanism shall be designed to close the gates automatically when the control is released or when the air or hydraulic line is broken. v. If gate actuation is dependent on integral air or hydraulic reservoirs, capacity of the reservoirs shall be sufficient to open and close the gates three times without recharging the reservoir. 2. Chutes: When concrete can be placed directly from a truck mixer or agitator, the chutes attached to this equipment may be used. Separate chutes and other similar equipment will not be permitted for conveying concrete except when specifically accepted by RPR. 3. Belt Conveyors: Belt conveyors may be used when accepted by RPR. Such conveyors shall be designed and operated to assure a uniform flow of concrete from the transporting unit to final place of deposit without segregation of ingredients or loss of mortar and shall be provided with positive means for preventing segregation of the concrete at the transfer points and the point of discharge. 4. Pump Placement: Concrete Mixes B and C may be conveyed by positive displacement pump when accepted by RPR. The pumping equipment shall be piston or squeeze pressure type. The pipeline shall be rigid steel pipe or heavy duty flexible hose. Aluminum alloy pipe shall not be used. The inside diameter of the pipe shall be at least three times the nominal maximum size coarse aggregate in the concrete mixture to be pumped. Pumping equipment shall be capable of delivering concrete to forms in a satisfactory manner. The maximum size coarse aggregate will not be reduced to accommodate the pumps. The distance to be pumped shall not exceed limits recommended by the pump supplier. The concrete shall be supplied to the concrete pump continuously. When pumping is completed, concrete remaining in the pipeline shall be ejected without contamination of concrete in place. After each operation, equipment shall be thoroughly cleaned, and flushing water shall be wasted outside the forms. Flushing water shall not be discharged directly into the river. Water shall be discharged to areas specifically designated for this purpose. C. Concrete Placement 1. Concrete delivered to the Work shall conform to ASTM C94. 2. Transporting and placing concrete shall follow standard practices contained in ACI 304. 3. The slump of concrete shall be as indicated herein. Concrete exceeding the maximum slump may be rejected by the RPR. Concrete rejected for excessive Blue Lake Expansion Project – Contract No. 9 03300-22 General Construction May 2012 slump shall be immediately disposed of in accordance with the SPCC plan. Concrete having less than the minimum slump may be adjusted in accordance with paragraph 3.2.C, and can be placed and vibrated as long as placement requirements are met. 4. Perform placement of concrete mixes A and D by bucket, drop chute, or conveyor. Concrete shall be conveyed from a mixer to place of final deposit by methods that will not cause segregation or loss of material. Place concrete mixes B and C by bucket, drop chute, conveyor, pump or combination thereof. Equipment for placing concrete shall be capable of handling the specified mass concrete mixture at the specified slump without modification of the mixture. 5. Concrete placement shall be in or close to its final position; segregation due to re-handling or flowing shall be avoided. 6. Perform placement of concrete in horizontal layers, not to exceed 20 inches thickness, in a continuous operation until each section or panel is complete. Each layer shall be thoroughly vibrated before placing the succeeding layer. Top surface shall be generally level during placement. 7. Maximum Lift Height: As Shown for dam extension. As submitted and approved for other features. 8. Maximum layer thickness: Individual layers shall not exceed approximately 18 to 20 inches in depth unless otherwise indicated on the plans. Layer heights shall be limited in height so that successive layers will be placed quickly enough that vibrators will penetrate lower layer(s) to effectively mix and bond layers within the lifts before initial set. Lift heights and layouts shown on the plans are advisory and may be altered subject to approval of the RPR. Utilize a method of placement that includes confirmation, by continuous inspection, of concrete set as the placement progresses. Identify maximum height of fluid concrete that should be present at any time during a concrete placement to maintain bulkhead and form stability. Adjust concrete mix design and rate of placement to achieve this requirement. 9. Placing of concrete shall be regulated so that the pressure caused by the wet concrete shall not exceed that used in the design of the forms. 10. Concrete shall not be allowed to free fall a distance of more than 5 feet, and shall not be deposited as a large quantity at any point. For consolidation of concrete it is necessary to vibrate throughout and along the formwork. Forms shall be designed for the added pressure. 11. Concrete on Rock Foundations or Existing Concrete Surfaces: Surfaces upon which concrete is to be placed shall be clean, free from oil, standing or running water, ice, mud, algae, drummy rock (or concrete), coatings, debris, and loose, semi-detached or unsound fragments. Faults or seams shall be cleaned to a depth satisfactory to Engineer and to firm rock/concrete on the sides. Immediately before concrete is placed, all rock/concrete surfaces shall be cleaned thoroughly by the use of air-water jets, wet sandblasting, high-pressure water jet or other approved methods. Blue Lake Expansion Project – Contract No. 9 03300-23 General Construction May 2012 12. All rock/concrete surfaces shall be kept continuously wet for at least 24 hours and allowed to surface dry immediately prior to placing concrete thereon. The first layer of concrete to be placed on a rock foundation shall be thoroughly worked into all irregularities in the surface. 13. Concrete shall be thoroughly worked around reinforcement and embedded items and into corners of forms and existing concrete by effective vibration. Vibrators shall penetrate each layer and into the top of the underlying layer. In placing concrete through reinforcement, care shall be taken that no segregation of the coarse aggregate occurs. 14. Contractor shall note that the two principal indicators of well consolidated concrete are: a) Embedment of large aggregates which requires general batch levelling, blending of the branch perimeter with concrete previously placed, a thin-film of mortar on the top surface, and cementitious materials paste showing at the perimeter of the concrete and forms. b) General cessation in escape of large entrapped air bubbles at the top surface. Time of vibration required depends upon the thickness of the layer. 15. Securely anchor embedded items and restrain them from floatation or movement during placement of concrete. Concrete shall be placed at a rate to prohibit movement of embedded parts. 16. Concrete shall not be placed into or under water. Flowing water shall be diverted away or controlled in a manner approved by the RPR. D. Vibration for Concrete: 1. Conform to the requirements of ACI 301. Furnish no less than two (2) spare vibrators on the job site whenever concrete is placed. Consolidate concrete with high frequency, immersion, mechanical vibrating equipment supplemented by hand spading and tamping. Operate vibrators with vibratory element submerged in the concrete, with a minimum frequency of not less than 8,000 vibrations per minute when submerged with a head diameter of 2 ½ inches. Concrete shall be consolidated by vibration to the maximum practicable density, so that it is free from pockets of coarse aggregate and confined air, and closes snugly against existing concrete and surfaces of forms and embedded materials. In consolidating each layer, the vibrator shall be operated at regular and closely spaced intervals and in a near vertical position. 2. Contractor shall exercise care to avoid damaging temperature thermocouples during concrete placement and consolidation. E. Cold Weather for Mass Concrete: 1. Conform to the requirements of ACI 306.1. 2. Do not allow fresh concrete temperature to decrease below 40 degrees Fahrenheit. Obtain approval prior to placing concrete when the ambient temperature is below 40 degrees Fahrenheit or when concrete is likely to be Blue Lake Expansion Project – Contract No. 9 03300-24 General Construction May 2012 subjected to freezing temperatures within 24 hours. Have insulating materials and heaters on hand for immediate protection of fresh concrete. 3. Insulate concrete and provide sufficient heat to maintain 40 degrees Fahrenheit minimum ambient air temperature adjacent to both the formwork (except formwork that also is a water retaining bulkhead) and the structure while curing. Limit the rate of concrete surface cooling to five (5) degrees Fahrenheit in any one (1) hour and 20 degrees Fahrenheit per 24 hours after forms or insulation is removed. F. Cold Weather for Structural Concrete: 1. Conform to the requirements of ACI 306.1. 2. Do not allow fresh concrete temperature to decrease below 50 degrees Fahrenheit. Obtain approval prior to placing concrete when the ambient temperature is below 40 degrees Fahrenheit or when concrete is likely to be subjected to freezing temperatures within 24 hours. Have insulating materials and heaters on hand for immediate protection of fresh concrete. 3. Insulate concrete and provide sufficient heat to maintain 50 degrees Fahrenheit minimum ambient air temperature adjacent to both the formwork (except formwork that also is a water retaining bulkhead) and the structure while curing. Limit the rate of concrete surface cooling to five (5) degrees Fahrenheit in any one (1) hour and 20 degrees Fahrenheit per 24 hours after forms or insulation is removed. 4. Use no frozen materials or materials containing ice in concrete. 5. Do not use salt or other chemicals to prevent freezing. G. Hot Weather: 1. Conform to the requirements of ACI 305R. Cool ingredients before mixing or use other suitable means to control concrete temperature and prevent rapid drying of newly placed concrete. Shade the fresh concrete as soon as possible after placing. Start curing when the surface of the fresh concrete is sufficiently hard to permit curing without damage. 2. Steel forms and reinforcement shall be cooled prior to concrete placement when steel temperatures are greater than 120 degrees Fahrenheit. 3. Prior to placing concrete have ready water hoses, pipes, spraying equipment, and water hauling equipment, where job site is remote to water source, to maintain a moist concrete surface throughout the curing period. Provide burlap cover or other suitable, permeable material with fog spray or continuous wetting of the concrete for mass concrete or when weather conditions prevent the use of either liquid membrane curing compound or impervious sheets. For vertical surfaces, protect forms from direct sunlight and add water to top of structure once concrete is set. 3.07 SURFACE FINISHES Blue Lake Expansion Project – Contract No. 9 03300-25 General Construction May 2012 A. See Section 03100 – Formwork. B. General: Finishes shall be in accordance with ACI 301 unless otherwise noted. C. Formed Surfaces: Provide chamfers and “V” groves at corners and construction joints As Shown. D. Non-formed surfaces (flatwork): broomed finish as shown. 3.08 FINISHING UNFORMED SURFACES A. See Section 03100 – Formwork. B. General: The ambient temperature of spaces adjacent to surfaces being finished shall be not less than 50°F. All unformed surfaces that are not to be covered by additional concrete or backfill shall be finished to the elevations shown on the drawings. Surfaces to receive additional concrete or backfill shall be brought to the elevations shown on the drawings and left true and regular. Exterior surfaces shall be sloped for drainage unless otherwise shown on the drawing or as directed. Joints shall be carefully made with a jointing tool. The finished surfaces shall be protected from stains or abrasions. Surfaces or edges likely to be damaged during the construction period shall be protected from damage. Tolerance for a screeded finish shall be true planes within 1/4-inch in 2 ft as determined by a 2-ft straightedge placed anywhere on the slab in any direction. Tolerance for a floated finish shall be true planes within 1/4-inch in 10 ft as determined by a 10-ft straightedge placed anywhere on the slab in any direction. Tolerance for a troweled finish shall be true planes within 1/8-inch in 10 ft as determined by 10-ft straightedge placed anywhere on the slab in any direction. C. Finish U1 - Float Finish: All unformed surfaces of concrete that are not to be covered by additional concrete or backfill shall have a float finish unless a steel- trowel finish is specified. Surfaces shall be screeded and darbied or bullfloated to bring the surface to the required finish level with no coarse aggregate visible. No cementitious materials or water shall be added to the surface during the finishing operation. The concrete, while still green but sufficiently hardened to bear a man's weight without deep imprint, shall be floated to a true and even plane. Floating may be performed by use of hand- or power-driven equipment. Hand floats shall be of aluminum or magnesium. D. Finish U2 - Trowel Finish: A steel trowel finish shall be applied to various surfaces as indicated on the drawings. Concrete surfaces shall be finished with a float finish and after surface moisture has disappeared. The surface shall be steel-troweled to a smooth, even, dense finish free from blemishes including trowel marks. E. Finish U3 - Broom Finish: A broom finish shall be applied to various exterior unformed surfaces as indicated on the drawings. Concrete surfaces shall be finished to the requirements of Finish U2 and then prior to hardening of the surface shall be brushed with bristle push broom to lightly score the surface to product a uniform non-slip surface. Broom finish for sloped surfaces shall be across the slope to improve surface traction. 3.09 FINISHING FORMED SURFACES Blue Lake Expansion Project – Contract No. 9 03300-26 General Construction May 2012 A. General: Surfaces, unless other type of finish is specified, shall be smooth rubbed and/or grout cleaned except defective surfaces shall be repaired in accordance with Item 3.06. B. Rubbed Finishes: Where smooth rubbed finish is to be applied, the forms shall have been removed and necessary patching completed as soon after placement as possible without jeopardizing the structure. Formed surfaces shall be given a rubbed finish where indicated on the drawings. 1. Smooth Rubbed Finish: Smooth rubbed finish shall be produced on newly hardened concrete no later than the day following form removal. Surfaces shall be wetted and rubbed with carborundum brick or other abrasives until uniform color and texture are produced. No cementitious materials grout shall be used other than the cementitious materials paste drawn from the concrete itself by the rubbing process. 2. Grout Cleaned Finish: No cleaning operations shall be undertaken until all contiguous surfaces to be cleaned are completed and accessible. Cleaning as the Work progresses shall not be permitted. A grout having the consistency of thick paint shall be produced by mixing 1 part Portland cementitious materials and 12 parts fine sand with sufficient water. White Portland cementitious materials shall be substituted for a part of the gray Portland cementitious materials in order to produce a color matching the color of the surrounding concrete, as determined by a trial patch. The surface of the concrete shall be wetted sufficiently to prevent absorption of water from the grout and the grout applied uniformly with brushes or a spray gun. Immediately after the grout is applied, the surface shall be scrubbed vigorously with a cork float or stone to coat the surface and fill all air bubbles and holes. While the grout is still plastic, all excess grout shall be removed by working the surface with a rubber float, sack, or other means. After the surface whitens from drying (about 30 minutes at normal temperatures), it shall be rubbed vigorously with clean burlap. The finish shall be kept damp for at least 36 hours after final rubbing. 3.10 CURING AND PROTECTION A. General: Conform to the requirements of ACI 301 unless otherwise specified. B. Curing: As per ACI 301 begin curing immediately after placement. Protect concrete from premature drying, excessively hot temperatures, and mechanical injury; and maintain minimal moisture loss at a relatively constant temperature for the period necessary for hydration of the cementitious materials and hardening of the concrete. The materials and methods of curing shall be subject to approval by the RPR. Concrete shall be cured for a period not less than 7 consecutive days by impervious sheeting or liquid membrane-forming curing compound to prevent moisture loss, unless covered with fresh concrete. Liquid membrane-forming curing compound is never to be used on construction joints. C. Impervious Sheeting: Wet the entire exposed surface of the concrete thoroughly with a fine spray of water and cover with impervious sheeting throughout the curing period. Lay sheeting directly on the concrete surface and overlap edges 12 inches minimum. Provide sheeting not less than 18 inches wider that the concrete surface to be cured. Secure edges and transverse laps to form closed joints. Repair torn or damaged sheeting or provide new sheeting. Cover or wrap columns, walls, and Blue Lake Expansion Project – Contract No. 9 03300-27 General Construction May 2012 other vertical structural elements from the top down with impervious sheeting; overlap and continuously tape sheeting joints; and introduce sufficient water to soak the entire surface prior to completely enclosing. Sheeting and sheeting supports must withstand local weather conditions. D. Liquid Membrane-Forming Curing Compound: Seal or cover joint openings prior to application of curing compound. Prevent curing compound from entering the joint. Apply in accordance with the recommendations of the supplier immediately after any water sheen, which may develop after finishing has disappeared from the concrete surface. Provide and maintain compound on the concrete surface throughout the curing period. E. Application: Unless the supplier recommends otherwise, apply compound immediately after the surface loses its water sheen and has a dull appearance, on formed surfaces only. Mechanically agitate curing compound thoroughly during use. Use reviewed power-spraying equipment to uniformly apply two coats of compound in a continuous operation. The total coverage for the two coats shall be 200 square feet maximum per gallon of undiluted compound unless otherwise recommended by the supplier’s written instructions. F. The compound shall form a uniform, continuous, coherent film that will not check, crack, or peel. Immediately apply an additional coat of compound to areas where the film is defective. Re-spray concrete surfaces subjected to rainfall within three (3) hours after the curing compound application. G. Protection of Treated Surfaces: Prohibit pedestrian traffic and other sources of abrasion for at least 72 hours after compound application. Maintain continuity of the coating for the entire curing period and immediately repair any damage. H. Cold-Weather Curing and Protection: When the daily outdoor low temperature is less than 32 degrees Fahrenheit, the temperature of the concrete shall be maintained above 40 degrees Fahrenheit for mass concrete, above 50 degrees Fahrenheit for structural concrete, by heating, insulation or both, for the first seven (7) days after placing. In addition, during the period of protection removal, the air temperature adjacent to the concrete surfaces shall be controlled so that concrete near the surface will not be subjected to a temperature differential of more than 35 degrees Fahrenheit as determined by observation of ambient and concrete temperatures indicated by thermocouples furnished by the Contractor as required and installed adjacent to the concrete surface and 2 inches inside the surface of the concrete. The installation of the thermometers shall be made by the Contractor such locations as may be directed. 3.11 PREPARATION OF AREA FOR CONCRETE REPAIR A. Prepare the area according to the procedures detailed in the USBR Guide to Concrete Repair, USBR M47, and as approved by the RPR 3.12 IMPLEMENTATION OF CONCRETE REPAIR A. Implement minor repairs in accordance with USBR Guide to Concrete Repair and as approved by the RPR. The repair concrete must be as strong as the surrounding concrete. Blue Lake Expansion Project – Contract No. 9 03300-28 General Construction May 2012 B. Implement extensive or severe repairs in accordance with RPR approved procedures to achieve a complete repair that is as strong as the surrounding concrete and meets the structural design performance requirements. Stop work and notify RPR if unexpected conditions are encountered during the repair process that may effect structural stability and/or long term structural performance. 3.13 CONSTRUCTION TOLERANCES A. Except as specified otherwise, a plus tolerance increases and a minus tolerance decreases the dimension to which it applies. A tolerance without sign means plus or minus. Where only one sign is specified, there is no limit in the other direction. Tolerances are not cumulative. The most restrictive tolerance will control. 1. Level and grade tolerance measurements of slabs shall be made as soon as possible after finishing. When forms or shoring are used, the measurements shall be made prior to removal. 2. Construction tolerances shall meet the requirements of ACI 117. END OF SECTION Blue Lake Expansion Project – Contract No. 9 03301-1 General Construction May 2012 SECTION 03301 CONCRETE INSTRUMENTATION PART 1 GENERAL 1.01 WORK INCLUDED A. Provide all Thermocouples, Crackmeters and Jointmeters for the dam extension. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 01400: Quality Assurance C. Section 02020: Survey Control D. Section 03300: Cast-in-Place Concrete E. Section 03600: Structural Grout F. Section 05500: Miscellaneous Steel 1.03 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Thermocouples Installation Plan: 1. Provide plan to support and protect thermocouples (temperature loggers) and wiring in each lift. Locate thermocouples As Shown in specified placements. Route wiring to provide measurements electronically at a central location as agreed upon with the RPR. C. Crack Meters Installation Plan: 1. Provide plan for support and protection of crack meters and wiring to the face of the dam on vertical contraction joints. Route wiring to provide measurements electronically at a central location as agreed upon with the RPR. D. Joint Meters Installation Plan: 1. Provide plan for support and protection of joint meters and wiring during concrete placement. Route wiring to provide measurements electronically at a central location as agreed upon with the RPR. PART 2 PRODUCTS 2.01 THERMOCOUPLES A. Furnish Engius IntelliRock II System for monitoring concrete temperatures including temperature loggers with cable leads attached. Blue Lake Expansion Project – Contract No. 9 03301-2 General Construction May 2012 B. Provide IntelliRock II thermocouples with all necessary attachment hardware. 2.02 CRACKMETERS A. Provide Geokon 4420 Series Crackmeters with attachment hardware and conductors. B. Provide support, install, arrange and terminate the leads in a convenient location for reading. Contractor shall also plan and exercise extreme care to protect system(s) during all construction activities, especially concrete placement and consolidation. 2.03 JOINTMETERS A. Provide Geokon 4400 Series Jointmeters with attachment hardware and conductors. B. Provide support, install, arrange and terminate the leads in a convenient location for reading. Contractor shall also plan and exercise extreme care to protect system(s) during all construction activities, especially concrete placement and consolidation. PART 3 EXECUTION 3.01 THERMOCOUPLES A. Install As Shown in coordination with the RPR during dam extension concrete placement. B. Provide support, install, arrange and terminate the leads in a convenient location for reading. Contractor shall also plan and exercise extreme care to protect system(s) during all construction activities, especially concrete placement and consolidation. 3.02 CRACKMETERS A. Install As Shown in coordination with the RPR and Engineer within one day after dam extension concrete lift placements. B. Anchor to dam extension concrete as recommended by Crackmeter Supplier. C. Provide support, install, arrange and terminate the leads in a convenient location for reading. Contractor shall also plan and exercise extreme care to protect system(s) during all construction activities, especially concrete placement and consolidation. 3.03 JOINTMETERS A. Install As Shown in coordination with the RPR and Engineer during dam extension concrete placements. B. Anchor to dam extension concrete as recommended by Jointmeter Supplier. C. Provide support, install, arrange and terminate the leads in a convenient location for reading. Contractor shall also plan and exercise extreme care to protect system(s) during all construction activities, especially concrete placement and consolidation. END OF SECTION Blue Lake Expansion Project – Contract No. 9 03301-1 General Construction May 2012 SECTION 03301 CONCRETE INSTRUMENTATION PART 1 GENERAL 1.01 WORK INCLUDED A. Provide all Thermocouples, Crackmeters and Jointmeters for the dam extension. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 01400: Quality Assurance C. Section 02020: Survey Control D. Section 03300: Cast-in-Place Concrete E. Section 03600: Structural Grout F. Section 05500: Miscellaneous Steel 1.03 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Thermocouples Installation Plan: 1. Provide plan to support and protect thermocouples (temperature loggers) and wiring in each lift. Locate thermocouples As Shown in specified placements. Route wiring to provide measurements electronically at a central location as agreed upon with the RPR. C. Crack Meters Installation Plan: 1. Provide plan for support and protection of crack meters and wiring to the face of the dam on vertical contraction joints. Route wiring to provide measurements electronically at a central location as agreed upon with the RPR. D. Joint Meters Installation Plan: 1. Provide plan for support and protection of joint meters and wiring during concrete placement. Route wiring to provide measurements electronically at a central location as agreed upon with the RPR. PART 2 PRODUCTS 2.01 THERMOCOUPLES A. Furnish Engius IntelliRock II System for monitoring concrete temperatures including temperature loggers with cable leads attached. Blue Lake Expansion Project – Contract No. 9 03301-2 General Construction May 2012 B. Provide IntelliRock II thermocouples with all necessary attachment hardware. 2.02 CRACKMETERS A. Provide Geokon 4420 Series Crackmeters with attachment hardware and conductors. B. Provide support, install, arrange and terminate the leads in a convenient location for reading. Contractor shall also plan and exercise extreme care to protect system(s) during all construction activities, especially concrete placement and consolidation. 2.03 JOINTMETERS A. Provide Geokon 4400 Series Jointmeters with attachment hardware and conductors. B. Provide support, install, arrange and terminate the leads in a convenient location for reading. Contractor shall also plan and exercise extreme care to protect system(s) during all construction activities, especially concrete placement and consolidation. PART 3 EXECUTION 3.01 THERMOCOUPLES A. Install As Shown in coordination with the RPR during dam extension concrete placement. B. Provide support, install, arrange and terminate the leads in a convenient location for reading. Contractor shall also plan and exercise extreme care to protect system(s) during all construction activities, especially concrete placement and consolidation. 3.02 CRACKMETERS A. Install As Shown in coordination with the RPR and Engineer within one day after dam extension concrete lift placements. B. Anchor to dam extension concrete as recommended by Crackmeter Supplier. C. Provide support, install, arrange and terminate the leads in a convenient location for reading. Contractor shall also plan and exercise extreme care to protect system(s) during all construction activities, especially concrete placement and consolidation. 3.03 JOINTMETERS A. Install As Shown in coordination with the RPR and Engineer during dam extension concrete placements. B. Anchor to dam extension concrete as recommended by Jointmeter Supplier. C. Provide support, install, arrange and terminate the leads in a convenient location for reading. Contractor shall also plan and exercise extreme care to protect system(s) during all construction activities, especially concrete placement and consolidation. END OF SECTION Blue Lake Expansion Project – Contract No. 9 03350-1 General Construction May 2012 SECTION 03350 CONCRETE SEALANT PART 1 GENERAL 1.01 WORK INCLUDED A. Perform the application of interior concrete sealant at the powerhouse and gate house floors. Perform the application of exterior concrete sealant at the dam extension crest and spillway. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 03300: Cast-In-Place Concrete 1.03 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submit concrete sealant product data including materials information, performance criteria, storage requirements, preparation and application procedures, application rates, and available colors and finishes, as well as other special data. C. The supplier's recommended installation procedures will become the basis for inspecting and accepting actual installation used for the Work. PART 2 PRODUCTS 2.01 INTERIOR CONCRETE SEALANT A. Concrete Sealant: Kure-N-Seal as manufactured by BASF (formerly manufactured by Sonnenborn), or approved equal. 2.02 EXTERIOR CONCRETE SEALANT A. Concrete Sealant: Xypex Concentrate as manufactured by Xypex Chemical Corporation, or approved equal. PART 3 EXECUTION 3.01 CONCRETE SEALANT A. Apply concrete sealant in accordance with the supplier's recommendation. END OF SECTION Blue Lake Expansion Project – Contract No. 9 03370-1 General Construction May 2012 SECTION 03370 SHOTCRETE PART 1 GENERAL 1.01 WORK INCLUDED A. Provide all shotcrete for temporary or permanent rock support used in combination with welded wire mesh fabric, rock bolts and steel ribs as specified in Section 02400. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 02315: Rock Excavation and Scaling C. Section 02400: Rock Tunnelling D. Section 02410: Rock Bolts 1.03 REFERENCE STANDARDS A. ACI 214: Guide to Evaluation of Strength Test Results of Concrete B. ACI 506: Guide to Shotcrete (ACI 506.1, ACI 506.2, ACI 506.3, and ACI 506.4) C. ASTM A185: Standard Specification for Steel Welded Wire Reinforcement, Plain for Concrete D. ASTM A820: Standard Specification for Steel Fibers for Steel Fiber-Reinforced Concrete E. ASTM C31: Standard Practice for Making and Curing Concrete Test Specimens in the Field F. ASTM C33: Standard Specification for Concrete Aggregates G. ASTM C42: Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete H. ASTM C94: Standard Specification for Ready-Mixed Concrete I. ASTM C109: Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (Using Two-Inch Cube Specimens) J. ASTM C150: Standard Specification for Portland Cement K. ASTM C192: Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory L. ASTM C1018: Standard Test Method for Flexural Toughness and First-Crack Strength of Fiber Reinforced Concrete (Using Beam with Third-Point Loading) Blue Lake Expansion Project – Contract No. 9 03370-2 General Construction May 2012 M. ASTM C1116: Standard Specification for Fiber Reinforced Concrete N. ASTM C1141: Standard Specification for Admixtures for Shotcrete 1.04 DEFINITIONS A. "Shotcrete" is defined as concrete applied from a spray nozzle onto a surface to form a layer of concrete on that surface. B. “Rebound” is defined as the constituents of shotcrete that rebound from the surface during its application. C. “Fiber-reinforced shotcrete” is defined as shotcrete containing discrete fibers of steel, fiberglass or polypropylene. Continuous meshes, woven fabrics, and long rods are not considered to be discrete fiber type reinforcing elements. D. “Stop joints” mean discontinuity in the work, not necessarily related to a construction joint pattern. 1.05 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. “Shotcrete Materials“ Test Reports and Certificates of Compliance: 1. Aggregates: Submit proposed aggregate source location(s), aggregate test reports including gradations, and samples as required by RPR for additional testing 2. Cement: Submit certification and mill test reports identifying the lot proposed for use. Provide cement samples for testing as required by the RPR. Provide access to the RPR for inspection of storage facilities and sampling. Cementitious materials not meeting specifications shall not be used. 3. Admixtures: Submit proposed admixtures. C. Shotcrete Plant and Equipment: Submit proposed “shotcrete plant and equipment” and in accordance with requirements of Part 2.04. D. Shotcrete Mix Design: The proportions of all ingredients and nominal maximum coarse aggregate size that will be used in the manufacture of each quality of shotcrete shall be stated. Proportions shall indicate weight of cement, and water and weights of aggregates in a saturated surface-dry condition. No substitution shall be made in the materials or methods used in the Work without additional tests to demonstrate that the quality of shotcrete is satisfactory (reference 2.02 and 2.03). E. Shotcrete Testing: Contractor shall make available shotcrete compressive strength test results to RPR and Engineer for review. PART 2 PRODUCTS 2.01 MATERIALS Blue Lake Expansion Project – Contract No. 9 03370-3 General Construction May 2012 A. Shotcrete comprising cement, aggregates, water, and approved admixtures shall conform to the requirements of ACI 506 and this section, unless otherwise specified. B. Cement: Portland Cement; Type II, low alkali as specified in ASTM C150. C. Aggregate shall conform to ASTM C33 and consist of clean, hard, tough, durable, uncoated particles of natural sand, crushed rock or a combination of both. D. All admixtures shall conform to ASTM C 1141. No fillers or admixtures shall be used without prior authorization by Engineer. Fillers and admixtures shall contain no water soluble chlorides or materials corrosive to steel nor be subject to other detrimental effects such as cracking, spalling or debonding. Admixtures shall have a proven compatibility with the cement used. E. Steel fibers shall be low carbon, cold drawn steel wire conforming to ASTM A820, Type 1 with an average ultimate strength of 1240 MPa. The steel fibers shall be 1 inch (25 mm) in length and incorporated into the shotcrete at a minimum concentration of 60 kg/m3 (100 lb/cubic yard). Mixing of the steel fiber reinforced shotcrete shall conform to the uniformity standards of ASTM C94 standard specifications for ready mixed concrete. Measuring materials, toughness, workability and testing shall conform to ASTM C1116. Any steel fibers added to the concrete prior to shooting shall be uniformly distributed through the mix with average 5 minutes mixing time. Fiber balling and clumping shall be avoided. F. Where glass fiber reinforced or polypropylene fiber type reinforced shotcrete is preferred to be used, properties of materials shall be submitted to Engineer for approval in advance. G. Air used in the application of shotcrete shall be clean and free of oil. H. Water: Clean and potable and conform to ASTM C94. I. Reinforcement: Galvanized welded wire fabric, 2 x 2 - W0.9 x W0.9; ASTM A185. J. Reinforcement Anchors: Expansion type “Style L Hook Bolt”, with lead sleeve assembly, by Chicago Expansion Bolt Corporation, 1338 West Concord Place, Chicago, Illinois 60622. 1. Size: 1/4 inch diameter by length as required for location of reinforcement. K. Tie Wire: Black annealed wire, gauge as required to securely hold reinforcement in place during placement of shotcrete. 2.02 MIX PROPORTIONS A. The mix proportions of water, cement, and aggregate shall be determined by Contractor. The mix proportions shall be developed in accordance with the recommendations of ACI 506 to obtain specified strengths of 5 MPa (700 psi) minimum at 8 hours and 35 MPa (5,000 psi) minimum at 28 days. The shotcrete shall have an initial setting time of not more than three minutes and a final setting time of not more than 12 minutes. B. Contractor shall conduct test trials specified in 2.03 to test the various mixes proposed. The test trials shall be carried out with the proposed equipment, operators and nozzlemen, and in similar conditions as will be encountered in the Blue Lake Expansion Project – Contract No. 9 03370-4 General Construction May 2012 Work so that representative rebound, aggregate grading and cement contents can be established. C. Mix proportions shall be varied so as to maintain rebound at a minimum. 2.03 TESTS FOR SHOTCRETE QUALITY A. Test Panels for Mix Proportioning: For the purposes of determining mix proportions, a minimum of three test panels of approximately 1 meter (3 ft) square by at least a 100 mm (4 in) thickness shall be prepared for each mix and for each individual shooting position (e.g., vertical, 45 degrees to the horizontal, horizontal overhead).The panel box shall be wetted and shotcrete applied to the area within the box in the manner specified herein using the same mixing and placing equipment to be used for the Work. B. Additional test panels shall be prepared when a change in equipment is proposed, and whenever required if shotcrete is being produced which does not meet specified requirements. C. Test Panels for Production Quality Testing: In addition to the test panels specified in 2.03A and 2.03B, three test panels shall be prepared in accordance with 2.03A for every 50 square meters (60 square yards) of shotcrete in place for routine quality control. D. Furnish all plant, materials and assistance necessary and carry out all work to obtain representative test panels of shotcrete. E. The test panels shall be left undisturbed at the point of placement until initial set and shall then be transported by Contractor to the laboratory in such a manner as to prevent their being damaged in any way. F. Eight 75 mm (3 in) cubes shall be sawn from each test panel. Ends shall be capped in accordance with ASTM C192. Two cubes each shall be tested by Contractor at 8 hours, 7 days, and 28 days after fabricating the test panel. The remaining cubes shall be retained for check testing. In the case of the test panels prepared for mix design or when a change in mix or equipment is proposed, the remaining portions of test panels for each trial mix shall be identified and stored as a reference. In addition to testing the strength of the mix, the test specimens shall be checked for soundness and uniformity of the material and freedom from laminations and sand pockets. G. Statistically analyze cube test results in accordance with the recommendations of ACI 214. Mix design shall be consistent with the average 28-day compressive strength required to limit the probability of tests falling below the specified compressive strength to 1 out of every 5 tests with a coefficient of variation of 15 percent for quality control. The average of any six consecutive tests shall not be less than the specified compressive strength. H. If the tests performed indicate that the shotcrete fails to meet the specified requirements, then Contractor shall propose for Owner and Engineer approval and implement approved remedial measures. 2.04 PLANT REQUIREMENTS Blue Lake Expansion Project – Contract No. 9 03370-5 General Construction May 2012 A. Advise RPR of the Supplier, expected performance, and model designation of the shotcrete machines he proposes to use, as well as for all other equipment required to carry out the shotcrete operations. B. All equipment required to prepare, mix and place shotcrete shall be kept clean and maintained in good operating condition at all times during construction. C. The shotcrete machines shall have a minimum placing capacity adequate to ensure a minimum of delay of excavation and other operations. The equipment shall be such that the rapid-hardening additive can be mixed satisfactorily and immediately before placing. D. The mixing equipment shall be capable of thoroughly mixing the constituent materials. The minimum mixing time of the mixer shall be established from trials. E. The delivery equipment shall be of a design and size which has given good results in similar work and should be capable of discharging the mixed materials into the delivery hose under close control. It shall deliver a continuous stream of uniformly mixed material at the proper velocity to the discharge nozzle. F. Where a dry mix system is adopted, the nozzle shall incorporate manually controlled water injection system which can distribute the water evenly and is capable of ready adjustment. The nozzle shall deliver a conical stream of material of uniform appearance throughout. Non-uniform deliveries shall be rectified by adjustment or the replacement of defective or worn parts. G. The air supply shall have ample capacity to meet the requirements for the size of nozzle and the working conditions. The water supply shall be pressurized sufficiently to overcome the air pressure at the injection point. H. If the shotcrete equipment becomes unsatisfactory, Contractor shall remedy the fault or replace the equipment and remove and replace any defective shotcrete. I. In all areas where excavation is proceeding, Contractor shall ensure that sufficient equipment is available to supply shotcrete at any face, as specified herein. 2.05 PROFICIENCY OF OPERATORS A. Only trained operators will be permitted to apply shotcrete. The operation will be carried out under the supervision of a foreman highly experienced in shotcreting techniques. Contractor’s nozzlemen shall be suitably qualified and experienced in shotcrete application as generally described in ACI 506. B. Prior to the commencement of shotcrete placement, all operators shall carry out trial applications of the various approved mixes in an approved location to demonstrate their proficiency in the application of shotcrete to vertical or inclined panels. Operators shall familiarize themselves with the operation of the plant and the controlled introduction of water at the nozzle where dry mixes are being used. 2.06 BATCHING AND MIXING SHOTCRETE A. Shotcrete materials shall be accurately weigh batched before mixing. Aggregates shall be thoroughly mixed without the addition of water before being deposited in the placing equipment. Cement shall be added not more than 1 hour before application. Mixes which are not applied within 1 hour of adding cement shall be Blue Lake Expansion Project – Contract No. 9 03370-6 General Construction May 2012 removed from the Work and the material disposed of. Rapid-hardening additive shall be accurately proportioned. 2.07 WELDED WIRE FABRIC A. Welded wire fabric As Shown. PART 3 EXECUTION 3.01 APPLICATION OF SHOTCRETE A. Contractor shall examine rock faces following blasting and scaling. On the basis of such examination, Contractor may require immediate shotcrete on surfaces, in which case shotcrete shall be applied within four hours of blasting and before drilling the next round or lift. Rock conditions for which surface treatment may be required include, but are not limited to, places where rock is loosely jointed or disintegrated or where rock surfaces are spalling, or where popping rock exists, or where rock is subject to air or water slaking. B. The concrete or rock surface to which shotcrete is to be applied shall be thoroughly prepared by scaling and by hosing with high pressure jet of clean water and/or well saturated compressed air. All surfaces shall be rendered wet and free from dirt, mud, oil, debris, loose material or any deleterious material immediately prior to shotcrete application. Surfaces shall be kept moist until the application of shotcrete. In areas with decomposed concrete surface or poor rock conditions, it may be necessary to clean out and excavate unsuitable material to at least 300 mm (12 in) in depth, measured normal to the surface, prior to surface treatment with shotcrete or with a combination of welded wire fabric and shotcrete as required by Contractor’s design. C. Shotcrete, other than that ordered to be placed immediately after blasting, shall not be placed in any area until all blasting within 30 m (100 ft) of the area has been completed. D. Shotcrete shall not be applied when shotcrete cannot be placed effectively because of adverse weather conditions, unless adequate cover is provided over the working area until such time as the shotcrete has been cured. E. Where water flows from the concrete or rock surface against which shotcrete is to be placed and that water cannot be sealed off by shotcrete alone, the water shall be excluded from the area by caulking or diverted by pipes, pans, or other acceptable means in such a manner that the shotcrete will be unaffected by the action of the water through percolation, hydrostatic pressure or erosion. F. When shotcrete is applied, the nozzle shall be held at a reasonable distance from the face in such a position that the material flows at right angles to the surface. The flow of the material at the nozzle shall be continuous and the rate of application over any given area shall be uniform. Slugs, sand spots, wet areas, or other defects shall be cut out and corrected as specified herein. G. Develop operating procedures and operations to produce the best quality shotcrete with: 1. Minimum rebound. Blue Lake Expansion Project – Contract No. 9 03370-7 General Construction May 2012 2. No inclusion of rebound in the finished shotcrete. 3. No hollow areas within the shotcrete. 4. A minimum of shrinking cracks. 5. Good adherence of the shotcrete to rock or other surfaces. Such operating procedures shall include minor variations to mixes, if required, and the establishment of acceptable finishes and thicknesses and quantities to be discharged at the nozzle to unit area of rock. Once procedures for the placement of shotcrete are established, subsequent work shall be carried out accordingly. H. When required by design, the thickness of a layer in any area shall be checked by probing or drilling or by any other means immediately after the shotcrete has been placed. I. Shotcrete on vertical or steeply inclined surfaces shall begin at the lowest point, and the shotcrete layer shall be built up in horizontal strips until the entire surface is covered. J. The edges of shotcrete areas against which no further shotcrete is to be placed and shall be formed to clean, regular lines and sloped at 45 degrees to the adjacent surface. K. Where pressure relief holes have been drilled into rock on which shotcrete is to be placed Contractor shall take all necessary precautions to prevent such holes from being plugged. L. During the spraying process, all rebound aggregate lodging in pockets shall be cleaned off the rock immediately in advance of the spraying operation. Rebound that has been cleaned off shall be removed from the work area and disposed of as specified. 3.02 CONSTRUCTION JOINTS A. Construction joints or stop joints shall be provided. Construction joints shall be an unformed joint with a clean, regular edge sloped at 45 degrees to the adjacent shotcrete surface. Before applying material to the adjacent section, the sloped portion shall be thoroughly cleaned and wetted by means of air and water blast. Square construction joints which form a trap for rebound shall not be permitted. B. On the resumption of work, following a significant delay, all loose adhering material shall be removed to expose a solid face of sprayed concrete which is thoroughly cleaned in accordance with the requirement for surface preparation. The initial application of sprayed concrete shall be along the joint face to prevent any build-up of rebound material and cement dust. 3.03 MULTIPLE LAYERS A. Where a layer of shotcrete is to be covered by a succeeding layer, it shall first be allowed to take its initial set. All laitance, loose material and rebound shall be removed. Any laitance which has been allowed to take its final set shall be removed and the surface cleaned with an air-water jet. Blue Lake Expansion Project – Contract No. 9 03370-8 General Construction May 2012 B. Before a succeeding layer of shotcrete is placed, the preceding layer shall be checked for non-adherence to the rock surface or the presence of voids behind the layer of shotcrete. C. Remove all shotcrete which is of unsatisfactory quality or which has been unsatisfactorily placed and cut back to a sound area of rock or shotcrete. Carry out surface preparation as specified herein and reapply shotcrete to that area. 3.04 WELDED WIRE MESH REINFORCEMENT TO SHOTCRETE A. Contractor shall apply shotcrete in order to embed welded wire mesh (as specified in Section 02410) which has been installed on surfaces as specified herein. Contractor shall remove all loose material from the rock surfaces and retighten the welded wire mesh before any shotcrete is applied. B. Reinforcement shall be adequately supported during shotcrete application. At the time application of shotcrete is begun, all reinforcement shall be free from loose, flaky rust; scale; mud; oil; grease; or any other coating that might reduce the bond with the shotcrete. C. Shotcrete placed in order to embed welded wire mesh shall not be considered complete until the shotcrete layer has been built up to the thickness required by Contractor’s design and until the welded wire mesh and supporting bolts are completely covered with shotcrete to a depth of at least 25 mm (1 in). END OF SECTION Blue Lake Expansion Project – Contract No. 9 03480-1 General Construction May 2012 SECTION 03480 PRECAST CONCRETE HOLLOW -CORE SLABS PART 1 GENERAL 1.01 WORK INCLUDED A. Provide precast concrete hollow-core slabs (HC slabs) for the interior floor at El 39.0 and interior roof at El 48.25 of the powerhouse As Shown. Provide the cast-in-place concrete topping course at the floor and the cast-in-place concrete caps at the perimeter of the floor and roof. Provide all rebar, welded studs, and welded wire fabric As Shown for the cast-in-place concrete features. 1. Via Contract No. 7 – Supply of Steel Building, Owner will furnish the pre- engineered steel building (steel building) for the Blue Lake Powerhouse. The Contractor shall be responsible for supply and installation of HC slabs for the interior floors and interior roof that are compatible with the steel building. Refer to reference documents for shop drawings and product data for the steel building. B. Complete installation of the HC slabs is considered to include providing the HC slabs, cast-in-place concrete topping course and caps, as well as the rebar, welded studs, and welded wire fabric. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 03200: Concrete Reinforcement C. Section 03300: Cast-In-Place Concrete D. Section 05100: Structural Steel E. Section 07900: Building Joint Sealers F. Section 09510: Acoustical Panel Ceilings G. Section 13120: Pre-Engineered Building Installation H. Section 16500: Lighting and Receptacles 1.03 REFERENCE STANDARDS A. ACI 318: Building Code Requirements for Reinforced Concrete B. ACI ITG-7-09: Specification Tolerances for Precast Concrete C. ASCE 7-05: Minimum Design Loads for Buildings and Other Structures Blue Lake Expansion Project – Contract No. 9 03480-2 General Construction May 2012 D. ASTM A 36: Standard Specification for Carbon Structural Steel E. ASTM A 185: Standard Specification for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement F. ASTM A 325: Standard Specification for High-Strength Bolts for Structural Steel Joints. G. ASTM A 615: Standard Specification for Deformed and Plain Billet-Steel for Concrete Reinforcement H. ASTM C 33: Standard Specification for Concrete Aggregates I. ASTM C 150: Standard Specification for Portland Cement J. ASTM C 172: Standard Practice for Sampling Freshly Mixed Concrete K. ASTM C 260: Standard Specification for Air Entraining Admixtures for Concrete L. ASTM C 330: Standard Specification for Lightweight Aggregates for Structural Concrete M. ASTM C 332: Standard Specification for Lightweight Aggregates for Insulating Concrete N. ASTM C 494: Standard Specification for Chemical Admixtures for Concrete O. ASTM C 618: Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete P. AWS D1.1: Structural Welding Code Q. IBC: 2006 ICC International Building Code R. PCI: Design Handbook, 7th Edition 1.04 DEFINITIONS A. Precast Concrete Hollow-Core Slabs: Plant cast, non-pre-stressed, precast concrete hollow-core slabs generally referred to in this Section as HC slabs. 1.05 DESIGN REQUIREMENTS A. Safety Factor: Per ACI 318 Building Code Requirements for Reinforced Concrete. B. Maximum Deflection Under Design Loads: 1/360 of the span. C. Design Loads: The HC slabs shall meet the criteria for the IBC (2006) and ASCE 7- 05. 1. Conform to the design requirements of the steel building. Refer to Reference Documents. Blue Lake Expansion Project – Contract No. 9 03480-3 General Construction May 2012 2. The uniform live load for the floor load is 150 psf with a concentrated load of 1,000 lb as specified for “Library Stack Rooms” in ASCE 7-05. 3. The uniform live load for the interior roof is 100 psf. 4. The suspended collateral load for the floor and interior roof is 5 psf. D. Component Connections: Building dynamics are defined as any building movements or deflections caused by the singular or combined effects of wind, seismic, thermal, live, impact and/or concentrated loads, including the kinetic deflections resulting from the dead load of materials, and the live load of personnel and equipment. 1. The design of component connections, fabrication , assembly, and installation shall accommodate inherent building dynamics related to the fabrication, assembly and installation tolerances of related work not included in the Section and the interior work and mechanical equipment, without the loss of, or any detrimental effect to the performance requirements specified. 2. The design shall be verified and coordinated to accommodate such movements, deflections, and tolerances with the work of other sections. Connections and panel joints shall allow for a relative movement between stories of not less than 3/8 inch. 3. Adjustment shall be provided to accommodate misalignment with structure and adjacent panels without permanent distortion or damage to components, wracking of joint connections, breakage of seals, or moisture penetration. E. HC slabs shall be plant cast within the required tolerances of ACI ITG 7-09. F. HC slab height, width and thickness dimensions shall be As Shown. 1.06 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Shop Drawings: Shop drawings shall be submitted to RPR for review and show the following: 1. Complete details and arrangement of reinforcing and connections. 2. Embedded items. 3. Dimensions. 4. Lifting and erection inserts. 5. Locations of attachments for acoustical panel ceilings. See Section 09510. 6. Locations of penetrations for lighting receptacles As Shown. See Section 16500. 7. Proposed deviations from contract drawings. Blue Lake Expansion Project – Contract No. 9 03480-4 General Construction May 2012 C. Design Analyses and Calculations: Provide all design criteria and calculations used in the design of components of the HC slabs, including sizing of reinforcement, lifting devices, ancillary framing members (kickers, struts, braces, etc.) attachments, anchorages to building structure, temporary shoring and bracing stamped by a registered structural engineer in the State of Alaska. D. Erection Drawings: Submit the following for review: 1. Proposed methods for erection. 2. Show details including lifting devices, method of lifting, bracing, shoring, necessary precautions, etc. 3. Show Details all panel connections to the steel superstructure, and adjacent HC slabs. 4. Show unit location by same identification mark placed on precast lintel. 5. Indicate any preparation requirements and assembly sequence. E. HC Slab Mix Design: Submit mix design of concrete including backup mix, if used. Provide a signed statement that admixtures are compatible. State minimum concrete compressive strength of mix design. 1. Product Data: Provide data on sealants, and admixtures. 2. Proposed aggregate and aggregate source. 3. Type of Portland Cement. F. Submit product data for proposed joint sealers including chemical characteristics, performance criteria, storage and handling requirements, and preparation and installation procedures. G. Provide a minimum two 28-day concrete compressive test results for each precast panel. Provide the submittal within 5 days of the respective tests or prior to shipment. PART 2 - PRODUCTS 2.01 HC SLAB CONCRETE A. Portland cement shall be ASTM C 150, Type I; 100 percent gray color. B. Normal weight or lightweight aggregates shall conform to ASTM C33 and C330 respectively. Aggregates shall be selected to meet the design requirements of Paragraph 1.05. C. Admixtures shall conform to ASTM C 260, C 494, and C 618. D. Air entrainment shall conform to UBC Std. 26-9. 2.02 HC SLAB FORMS Blue Lake Expansion Project – Contract No. 9 03480-5 General Construction May 2012 A. Forms shall be supplier's specially fabricated molds of steel, fiberglass, plastic, or other suitable materials for shapes and textures: 1. Release Agent: Supplier's standard but required to be compatible with subsequently applied coatings, sealants, etc. 2.03 HC SLAB EMBEDMENTS, FASTENERS AND ACCESSORY ITEMS A. Cast-in anchors, angles, steel plates, inserts, lifting inserts, and similar items As Shown and as required. Furnish shapes and hardware as required for assembly and erection, including and required embedded materials in the concrete substructure. Conform to referenced ASTM A 36. Hot-dip galvanize connections and embedded items as referenced in ASTM A 124 and A 153. 1. Embedments required for the attachment of HC slabs to the steel superstructure shall have a bolted connection at the HC slab to allow for alignment and levelling adjustment. There shall be no welding to embedded items at the HC slab. The attachment at the steel superstructure may be welded. B. Hot-dip galvanize all steel angles, plates, channels, inserts, lifting inserts and similar iterms that are not entirely embedded in concrete with at least 1" cover. 2.04 HC SLAB LIFTING AND HANDLING DEVICES A. The HC slab system shall also include the design, fabrication, furnishing and delivery of two panel lifting devices of each type and size required to: unload panels for storage; remove from storage; and, erect the slab system. 2.05 HC SLAB FABRICATION A. Supplier’s standard methods to produce a uniform finish without excessive pocking. Mix coloring agent into concrete mix to match the RPR’s approved samples. Excess pocking not allowed. 2.06 HC SLAB CURING A. Supplier’s high pressure steam, steam vapor, or other standard method as required to produce specified minimum compressive strength: 1. Form-cure precast units until 1,500 psi minimum compressive strength has developed before removing form work. 2. Maintain precast units at minimum temperature of 50ºF for at least 20 hours. 3. Cover precast surfaces with polyethylene sheeting at least 20 hours to prevent loss of moisture. 2.07 SOURCE CONTROL A. Conduct tests at plant to confirm products as specified: Blue Lake Expansion Project – Contract No. 9 03480-6 General Construction May 2012 1. Make a minimum of two 28-day compression tests for each HC slab to confirm each slab meets supplier’s specific strength requirements. 2.08 QUANTITIES A. Supplier shall include a minimum 5% overage of all typical connection materials. 2.09 SUPPLIER A. The HC slabs are to be Spancrete as manufactured by Kiecon, Inc., 3551 Wilbur Avenue, Antioch, CA 94509, Ph: 925-754-0624, or approved equal. 2.10 CAST-IN-PLACE CONCRETE A. Concrete shall conform to the requirements of Mix C according to Section 03300. B. Rebar, welded studs, and welded wire fabric shall be of the sizes As Shown and conform to the requirements of Section 03200. PART 3 - EXECUTION 3.01 PRODUCT DELIVERY, STORAGE AND HANDLING A. Prior to delivery, all HC slabs shall be clearly labeled with substantial tags indicating the erection drawing number and other information required for identification. Mark members at each end. All products shall be suitably packaged and adequately braced for shipment. B. Contractor is responsible for delivery of all HC slab materials and will be required to replace slabs damaged during transport and delivery. C. Protect products at all times: 1. The HC slabs shall be supported and protected according to supplier’s recommendations. 2. Do not store or stockpile on site by methods permitting staining of concrete. Place products on sleepers, bunks, or cradles, firmly bedded. DO NOT PLACE ON GROUND. Store in same position as transported with non-staining, resilient supports in same position as when transported. Place with identification and date marks discernible. D. All items shall be protected and handled so that they will not be over-stressed, bent, broken, deformed or otherwise damaged before and during erection. Contractor shall seek to minimize the handling and any repetitive lifting of HC slabs. E. All lifting devices and rigging shall conform to the Occupational Health and Safety Regulations. F. Lifting and handling may be done with lifting devices, inserts, lifting loops, or slings as recommended by HC slab supplier. Blue Lake Expansion Project – Contract No. 9 03480-7 General Construction May 2012 1. Do not mar or damage concrete surfaces. 2. Locate lifting inserts to minimize stresses. 3. Provide strong-backs, bracing frames, and lifting beams where desirable to equalize and distribute pickup forces and control distortions. 4. Do not use bent reinforcing bars for lifting. 3.02 FIELD EXAMINATION A. Prior to beginning installation, Contractor shall verify installation conditions are satisfactory to receive materials of this Section. Verify structure and anchorage inserts within required tolerances for proper erection of precast panels. B. RPR will inspect all HC slabs prior to installation for any damaged materials that would be unfit for installation. 3.03 ERECTION, BRACING, AND SHORING A. General: Brace and shore as required and as recommended by supplier. Set HC slabs straight, level, plumb, and square. B. Fasten HC slabs in place and construct joints between adjacent panels in accordance with supplier recommendations. C. Refer to Section 07900 for sealing at perimeter of HC slabs. 3.04 PATCHING A. Mix and place patching mixture to match color and texture of surrounding and to minimize shrinkage. B. Adhere patch to hardened concrete with bonding agent. 3.05 CLEANING A. After Installation, clean soiled HC slab concrete surfaces with detergent and water, using fiber brush and sponge, and rinse thoroughly with clean water. B. Only use other products recommended by supplier to clean particularly stubborn stains after more conservative methods have been unsuccessful. C. Use extreme care to prevent damage to precast concrete surfaces and to adjacent materials. D. Rinse thoroughly with clean water immediately after using cleaner. Leave system clean and ready to receive sealants. 3.06 CAST-IN-PLACE CONCRETE A. Perform construction of cast-in-place concrete cap and topping course in accordance with applicable provision of Section 03200 and 03300. Blue Lake Expansion Project – Contract No. 9 03480-8 General Construction May 2012 END OF SECTION Blue Lake Expansion Project – Contract No. 9 03600-1 General Construction May 2012 SECTION 03600 GROUT AND MORTAR PRODUCTS PART 1 GENERAL 1.01 WORK INCLUDED A. Provide structural (nonshrink) grout for applications that include grouted dowels, equipment foundations, block outs, construction of building elements and structural base plates As Shown and as specified herein. Note: All references to “dry pack” grout shall be the same as nonshrink grout, including all product and execution requirements as nonshrink grout specified herein. B. Provide second and third stage grouts for the Fish Valve Unit As Shown. C. Note: Foundation grouting is not included in this section. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 02370: Erosion and Sediment Control Measures C. Section 02413: Grouted Dowels D. Section 02431: Contact and Tunnel Liner Grout E. Section 05100: Structural Steel F. Section 13120: Steel Building Installation 1.03 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submit structural grout Supplier’s information to RPR for review. Include Supplier’s mix design, mix design compressive strength, mixing and installation procedures, cure times, grout shelf life and any other data required to demonstrate compliance with this Section. 1.04 REFERENCE STANDARDS A. ASTM C109: Standard Test Method for Compressive Strength of Hydraulic Cement Mortars B. ASTM C150: Standard Specification for Portland Cement C. ASTM C270: Standard Specification for Unit Masonry D. ASTM C494/C 494M-05a: Standard Specification for Chemical Admixtures for Concrete E. ASTM C942: Standard Test Method for Compressive Strength of Grouts for Preplaced-Aggregate Concrete in the Laboratory Blue Lake Expansion Project – Contract No. 9 03600-2 General Construction May 2012 F. ASTM C1107: Standard Specification for Packaged Dry, Hydraulic-Cement Grout (Nonshrink) G. ASTM C1602/C 1602M-06: Standard Specification for Mixing Water Used in the Production of Hydraulic Cement Concrete PART 2 PRODUCTS 2.01 MATERIALS A. Nonshrink Grout: Provide “Five Star” nonshrink grout as manufactured by Five Star Products, Inc., 750 Commerce Drive, Fairfield, CT 06825, or approved equal. Nonshrink grout shall conform to the requirements of ASTM C1107. B. Water for mixing conform to the requirements of ASTM C1602 and shall be clean and free of oil, acids, organic materials, alkalis and other salts. C. Fish Valve Unit second stage epoxy grout shall be Euclid E3-G epoxy grout system for equipment bases. D. Fish Valve Unit third stage epoxy grout shall be Euclid nonshrink grout. E. Cement Mortar: Provide Type S cement mortar in accordance with ASTM C270. Mortar may be a pre-packaged mix. 2.02 MIXES A. Nonshrink grout mixes shall have a minimum 7 day compressive strength of 5,000 psi unless otherwise noted. B. Proportion: Grout and mortars shall be mixed in the proportions and according to the procedures recommended by the Supplier. C. Mixing Equipment General: Grout and mortars shall be mixed in an approved mechanical mixer. PART 3 EXECUTION 3.01 GROUTING A. Surface preparation, mixing, placing and curing of grout shall be in accordance with Supplier's instructions. B. Surfaces to be grouted shall be cleaned of any paint, oil, and any loose material or anything else that would prevent bonding. C. Equipment and Structural Base Plates: Equipment and structural base plates shall be grouted with flowable or dry-pack, nonshrink grout. Perform equipment grouting according to Supplier’s recommendations. D. Apply cement mortar in accordance with Supplier’s instructions. Create continuous mortar tight joints. Blue Lake Expansion Project – Contract No. 9 03600-3 General Construction May 2012 3.02 GROUT TESTING A. Sample and test grout in accordance with ASTM C109. Cast a minimum of two 2” cube specimens out of each batch of grout prepared. B. Report cube compression test and other test results to RPR within 1 day of the time of testing. C. Maintain record of structural grout test results with project feature, sample location, date, time and other relevant information. D. Facilitate grout sampling and testing activities carry out by RPR and Owner’s technicians. E. Coordinate with the RPR to allow periodic access to Contractor’s on site test facilities by RPR and Owner’s technicians for grout and related materials testing. END OF SECTION Blue Lake Expansion Project – Contract No. 9 03610-1 General Construction May 2012 SECTION 03610 DAM CONTRACTION JOINT GROUTING PART 1 GENERAL 1.01 WORK INCLUDED A. Perform all vertical contraction joint grouting in the dam extension As Shown. Mobilization and demobilization, grout plant and other grouting requirements shall conform to the applicable provisions of Section 02430. 1. Prepare a dam extension vertical contraction joint grouting plan for each stage of grouting. Include in work plan. 2. Grout vertical contraction joints in two stages. 3. Build dam extension from keyway to El. 403. 4. Stage 1: Grout seven approximately 60 foot high vertical contraction joints with single grout lifts from keyway to El. 403. 5. Build dam extension, spillway and thrust block from elevation 403 to the crest after the spillway. 6. Stage 2: Grout seven 22 to 25 foot high vertical contraction joints with a single grout lift per joint from El. 403 to crest of spillway or crest of dam. 7. Implement vertical contraction joint grouting as soon as practicable after the dam has been constructed to elevations required for each stage, concrete heat of hydration has dissipated, and the dam concrete has cooled to the desired temperature as determined by RPR. Contraction joint grouting is to be performed during low lake levels, and the timing will be determined jointly between Contractor and RPR. 1.02 RELATED SECTIONS A. Section 02430: Foundation Grouting B. Section 03254: Concrete Joints, Waterstops and Joint Filler C. Section 03300: Cast-in-Place Concrete D. Section 03301: Concrete Instrumentation 1.03 REFERENCED STANDARDS A. ASTM A53: Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc- Coated, Welded and Seamless B. ASTM A197: Standard Specification for Cupola Malleable Iron C. ASTM A653: Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process Blue Lake Expansion Project – Contract No. 9 03610-2 General Construction May 2012 D. ASTM C150: Standard Specification for Portland Cement E. ASTM D1187: Standard Specification for Asphalt-Base Emulsions for Use as Protective Coatings for Metal F. NEMA C80.3: Steel Electrical Metallic Tubing (EMT) 1.04 SUBMITTALS A. Not used. 1.05 DELIVERY, STORAGE, & HANDLING OF MATERIALS A. Cement for grouting contraction joints shall be furnished in waterproof bags which will prevent, for a minimum period of 90 days, hydration of the cement and lumps in the cement due to warehouse set. B. Cement shall be stored and handled to protect it from damage and deterioration. Cement from broken or torn bags, containing lumps, showing any other evidence of partial hydration, or otherwise damaged shall not be used in the construction. PART 2 MATERIALS 2.01 GENERAL A. Materials for grouting shall be as specified in referenced Section 02430, as specified herein, and As Shown. B. Tubing for supply, header, return and vent lines and the tubing for risers shall be galvanized thin wall electrical metallic tubing (EMT) in accordance with the requirements of NEMA C80.3. Couplings for connecting together the lengths of plain-end electrical metallic tubing, and connectors used to join the plain-end electrical metallic tubing to standard pipe fittings shall be galvanized watertight fittings manufactures expressly for electrical metallic tubing. C. Grout outlets shall be As Shown. D. Tees from headers to risers shall be galvanized and fabricated from appropriate sizes of electrical metallic tubing or galvanized standard weight pipe tees adapted as required. E. Pipe nipples shall be standard weight, galvanized pipe in accordance with the requirements of ASTM A53. F. Caps, couplings, and similar fittings shall be malleable iron galvanized fittings in accordance with the requirements of ASTM A197-47 (R76). G. Asphalt emulsion shall by Type A in accordance with the requirements of ASTM D1187-66 (R70). H. Nails, tie wire, temporary supports and other materials not specified herein or on the Contract Drawings shall be as selected by the Contractor, subject to approval. I. Waterstops are specified in Section 03254. Blue Lake Expansion Project – Contract No. 9 03610-3 General Construction May 2012 J. Grout groove cover plates shall be galvanized steel in accordance with the requirements of ASTM A653 of the gage thickness and dimensions As Shown. K. Cement a. Cement for grouting contraction joints shall be Type II Portland Cement in accordance with the requirements of ASTM C 150 and Section 03300. b. Cement for grouting contraction joints shall be free of lumps, unground clinker, tramp metal, and other foreign material and 100% of the finished product, after processing at the cement plant, shall pass a No. 30 USA Standard Sieve and 99.7% shall pass a No. 100 USA Standard Sieve. In addition, the cement for grouting contraction joints shall be screened at the job site through a N. 16 crimped screen which shall be installed by the Contractor between the mixer and agitator in the grout plant. L. Water for grouting contraction joints shall meet the requirements for water for mixing concrete as specified in referenced Section 03300. PART 3 EXECUTION 3.01 INSTALLATION PROCEDURES A. Tubing and Fittings: 1. All tubing and fittings to be embedded in concrete shall be cleaned thoroughly of all dirt, grease, grout, and mortar immediately before being embedded in the concrete. The tubing and fittings shall be carefully assembled and placed and shall be held firmly in position while the concrete is being placed. Care shall be exercised to insure that the two companion members of each grout outlet are maintained in accurate alignment and position with respect to each other, and that each member becomes an integral part of and moves with the first concrete mass to which it is anchored. Methods of attaching the first member of each grouting outlet to the forms and, in turn, the second member to the first, are As Shown. These methods shall be adhered to unless modified by specific instruction of the RPR. 2. Where grout tubing terminates at exposed concrete surfaces, the tubing shall be fitted with a wrapped galvanized nipple to facilitate removal As Shown. Each surface connection shall have a metal tag attached thereto to identify its purpose or use. B. Grout Groove Cover Plates: 1. Before the cover plates are placed, the grout grooves shall be cleaned thoroughly of all concrete, dirt, and other foreign substances. The sections of the cover plates shall be carefully welded together to form complete, continuous diaphragms and the plates shall be securely anchored to the concrete As Shown. At the upper edges of the cover plates, the joints between the cover plate and the concrete shall be covered with asphalt emulsion so as to ensure tight joints As Shown. C. Concrete Placement: Blue Lake Expansion Project – Contract No. 9 03610-4 General Construction May 2012 1. Prior to concrete placement, the RPR and Contractor will inspect all grout piping to ensure that it is properly supported and connections are tight. Do not begin concrete placement without approval from RPR. 2. During the placement of concrete, maintain a continuous flow of air through the grout piping in the concrete pour. Monitor the grout risers during placement to assure that air flow is maintained. If air flow is stopped, immediately halt the concrete placement. a. Should leakage occur into any of these contraction joint grouting systems during concrete placement, the system shall be cleaned out before the cement has taken its initial set by filling the system approximately half -full of water through the supply header of the affected system, admitting air under pressure through the lowest return available, and opening and closing the air valves in such a manner as to produce water hammer in the system. b. Any tubing that becomes clogged or obstructed before final completion of this portion of the construction, due to any cause, shall, if practicable, be cleaned or opened in a manner as approved. 3. Approximately four hours after the completion of concrete placement, thoroughly wash the grout system with water. D. Hookups: 1. Each stage of contraction joint grouting will be accomplished in single lifts. Each contraction joint grouting lift contains its own seals, supply system, and venting system. Hookups to the contraction joint grouting systems in the dam and elsewhere As Shown or as directed by RPR will be required to wash out and test the contraction joints and grouting systems prior to grouting, to grout the contraction joints and, if necessary, to re-hook the systems during or after the grouting operations in order to complete grouting each lift. Methods and procedures for hooking up to contraction joint grouting systems and for washing and testing the contraction joints shall conform to the applicable provisions of reference Section 02430. E. Pressure Grouting: 1. When directed, the contraction joints, As Shown or as directed by RPR, shall be pressure grouted with cement grout. Use grouting pressure as directed by the RPR. All grout for pressure grouting contraction joints shall consist of neat cement mixed with water. Cool water shall be used in the grout mixture to prevent quick-setting of the grout, and water having temperatures above 70 deg. F shall not be used. The program of grouting, the time when each lift of a contraction joint shall be grouted, the grout mixture used, the pressure applied, and all other details of the grouting operations shall be in accordance with these Engineering Specifications and as directed. 2. The grouting of the vertical contraction joints shall be done singularly or in groups, as directed by RPR, and in separate successive lifts beginning at the base of the dam extension and finishing at the top of the dam. The circulating supply and return line shall extend close to the supply pipe for each lift of contraction joint being grouted. Short lengths of high-pressure hose with valves to regulate the grout entry shall be used to connect with the circulating supply line to the supply pipe for grouting each contraction joint system. When more than one joint is being grouted at the same time, the grout shall be supplied in Blue Lake Expansion Project – Contract No. 9 03610-5 General Construction May 2012 rotation by batches or in such quantities as necessary to fill each joint at approximately the same rate and to complete the filling of all joints at the same time. The grouting of each joint lift shall be completed before the grout takes its set in the grouting system, but shall not be grouted so rapidly that the grout will not settle in the joint. In general, the time consumed in completing any lift of a joint shall not be less than 2 hours. 3. The Contractor shall provide all necessary facilities such as catwalks, ladders, and platforms to enable the RPR to observe the grouting operations at each joint, and for quick and convenient passage from joint to joint as required. The contractor shall provide all labor, tools, and material required to assist in setting any dial gages or other devices used to indicate opening or closing of the joints during the grouting operation. The Contractor shall provide an audio communication and signal system for use during the washing, testing, and grouting operations. 4. Before any lift of a joint is grouted, it shall be washed thoroughly with air and water under pressure and shall remain filled with water for a period of 24 hours. Immediately prior to being grouted, the water shall be drained from the joint lifts to be grouted. 5. During the grouting operations, two or more joints, as determined, of adjacent ungrouted joints at the same level, shall be filled with water to the level of the top of the lift being grouted. Valves shall be used to control the flow of water into and from each joint. All accessible leaks discovered prior to grouting and all leaks occurring during the grouting operations shall be caulked or stopped. Joints into which grout has leaked shall be thoroughly washed out by alternately filling them with water and draining them until all grout has been removed, and all headers and outlets for each such joint shall be tested and shall be clean before the joint shall be considered to be thoroughly washed out. 6. The grout shall be pumped into the supply header of the grout system. During the grouting of each lift of joint, the outlet ends of the vent pipes for each lift being grouted shall have a riser pipe about 5 feet in height. Provide a bleeder valve with a gauge and a gauge saver at the top of each riser pipe. The valves shall be left open until the joint lift is filled and then used for bleeding until grout of proper consistency for retention in the joints remains in the risers at the required pressure. The water and thin grout shall be bled from the top of the joint lifts and pressure shall be applied as many times as is determined to be necessary to force all excess water from the grout. After the system ceases to take an appreciable quantity of grout, the required final or residual pressure shall be maintained on the grout in the joint lift until the grout has taken its initial set. The simultaneous application of grout at two or more points in any one system shall be made if determined necessary. 7. After the grouting operations have been completed, the paper-wrapped grout nipples shall be removed from the concrete. All holes left after the removal of the nipples shall be filled immediately and completely with dry pack in accordance with the provisions of referenced Section 03600. END OF SECTION DIVISION 05 METALS Blue Lake Expansion Project – Contract No. 9 05100-1 General Construction May 2012 SECTION 05100 STRUCTURAL STEEL PART 1 GENERAL 1.01 WORK INCLUDED A. Provide all structural steel members and connection materials for all Work areas As Shown. B. Note: The exterior steel superstructure for the powerhouse (Steel Building) is being furnished by the Owner via Contract 7 – Supply of Steel Building (See Section 13120). 1. Contractor is to provide all structural steel for the interior rooms and structural member supports for all interior stairs, ladders, and walkways for the powerhouse As Shown. 1.02 RELATED WORK A. Section 01300: Submittals B. Section 02240: Dewatering and Water Control C. Section 03300: Cast-In-Place Concrete D. Section 03600: Structural Grout E. Section 05500: Miscellaneous Metals F. Section 09900: Painting and Protective Coatings G. Section 13120: Steel Building Installation H. Section 13210: Installation of Owner-Furnished Gates, Guides and Hoists I. Section 13310: Intake Trashrack and Supports J. Section 14600: Powerhouse Bridge Crane Installation 1.03 REFERENCE STANDARDS A. AISC Manual of Steel Construction B. AISC Specification for Structural Steel Buildings: Allowable Stress Design and Plastic Design C. AISC Code of Standard Practice for Steel Buildings and Bridges D. AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts E. AISC Steel Design Guide 23: Constructability of Structural Steel Buildings Blue Lake Expansion Project – Contract No. 9 05100-2 General Construction May 2012 F. AISC Steel Design Guide 24: Hollow Structural Section Connections G. ANSI/ASME B18.22.1: Plain Washers H. ANSI/ASME B46.1: Surface Texture (Surface Roughness, Waviness and Lay) I. ASCE 7-05: Minimum Design Loads for Buildings and Other Structures J. ASTM A6: Standard Specification for General Requirements for Rolled Structural Steel Bars, Plates, Shapes, and Sheet Piling K. ASTM A36: Standard Specification for Carbon Structural Steel L. ASTM A53: Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc- Coated and Seamless M. ASTM A108: Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished N. ASTM A123: Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products O. ASTM A153: Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware P. ASTM A307: Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength Q. ASTM A325: Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength R. ASTM A384: Standard Practice for Safeguarding Against Warpage and Distortion During Hot-Dip Galvanizing of Steel Assemblies S. ASTM A385: Standard Practice for Providing High-Quality Zinc Coatings (Hot Dip) T. ASTM A490: Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile Strength U. ASTM A500: Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes V. ASTM A529: Standard Specification for High-Strength Carbon-Manganese Steel of Structural Quality W. ASTM A563: Standard Specification for Carbon and Alloy Steel Nuts X. ASTM A780: Standard Practice for Repair of Damaged and Uncoated Areas of Hot- Dip Galvanized Coatings Y. ASTM A807: Standard Practice for Installing Corrugated Steel Structural Plate Pipe for Sewers and Other Applications Blue Lake Expansion Project – Contract No. 9 05100-3 General Construction May 2012 Z. ASTM A992 : Standard Specification for Structural Steel Shapes AA. ASTM F436: Standard Specification for Hardened Steel Washers BB. ASTM F1554: Standard Specification for Anchor Bolts, Steel, 36, 55, and 105-ksi Yield Strength CC. AWS D1.1: Structural Welding Code – Steel DD. MIL-P-21035: Paint High Zinc Dust Content, Galvanizing Repair EE. SSPC-SP1: Solvent Cleaning FF. SSPC-SP3: Power Tool Cleaning GG. SSPC-SP6: Commercial Blast Cleaning 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Shop Drawings: Shop drawings for structural and miscellaneous steel fabrications required for installation of embedded and other steel parts, including complete details and schedules for fabrication and assembly of structural steel members, procedures, and diagrams. 1. Include details of members, cuts, connections, cambers, holes and other pertinent data. Indicated welds by standard AWS symbols and show size, length, and type of each weld. Members and connections for any portion of the structure not shown on the contract drawings shall be detailed by the fabricator and indicated on the shop drawings. 2. Provide setting drawings, templates and directions for installation of anchor bolts and other anchorages to be installed. 3. Installation/Erection Plans: Installation and erection plan for fabricated steel parts. Include bracing plans for bracing necessary to stabilize embedded steel parts to achieve required accuracy. 4. Shop drawings must be signed and sealed by a professional engineer in the State of Alaska. Fabrication and erection shall not be started until shop drawings have been accepted by RPR. C. Certificates of Compliance: 1. Certified mill test reports for structural steel and hardware 2. Certification that each shop and field welder is qualified in accordance with the latest AWS D1.1. 1.05 QUALITY ASSURANCE A. Provide workers familiar with modern materials and methods regarding structural and miscellaneous steel and perform Work in a manner that will best incorporate the most modern materials and methods. Workers employed by the Contractor for Blue Lake Expansion Project – Contract No. 9 05100-4 General Construction May 2012 this Section of the Work shall be skilled in performing tasks related to structural and miscellaneous steel. B. Provide at least one experienced labor foreman on the site who will be responsible at all times during installation of fabricated steel, has at least five years of continuous recent experience in their respective trades, has complete knowledge of the approved Work Plan as it relates to fabricated steel parts and structural design details. 1.06 RESPONSIBILITY FOR ERRORS A. Contractor shall be responsible for all errors of detailing, fabrication, and for the correct fitting of the structural members. B. Contractor shall field verify all dimensions prior to issuing shop drawings. 1.07 SHIPMENT, HANDLING AND STORAGE A. Prepare, pack and load materials for shipment in such a manner that sections are protected from damage during transportation to, and temporary storage at the Project Site. B. Match mark fabrications to ensure correct assembly and erection at the site. Protect match marks such that they are not illegible. C. Material shall be stored in such manner and location as will prevent damage and minimize contamination and deterioration. PART 2 PRODUCTS 2.01 GENERAL A. All exposed steel shall be galvanized, unless otherwise specified. 2.02 MATERIALS A. Structural Steel: Structural steel shapes shall conform to ASTM A992 GR 50. Structural steel angles and plates shall conform to ASTM A36. B. Structural Pipe: ASTM A53 Type S, Grade B, unless otherwise specified. C. Hollow Structural Sections: ASTM A500, Grade B, unless otherwise specified. D. High-Strength Bolts: High-strength bolts shall conform to ASTM A325. E. Carbon Steel Bolts: Carbon steel bolts shall conform to ASTM A307, Grade A. F. Anchor Bolts: Anchor bolts shall conform to ASTM F1554, Grade 36. G. Adhesive Anchors: All adhesive anchors shall be Hilti HIT-RE 500-SD adhesive epoxy anchoring systems, unless otherwise noted H. Expansion Anchors: All expansion anchors shall be Hilti Kwik Bolt TZ Expansion Anchors, unless otherwise noted. Provide stainless steel expansion anchors at all wet locations As Shown, and at all outdoor locations unless otherwise noted. Blue Lake Expansion Project – Contract No. 9 05100-5 General Construction May 2012 I. Headed Concrete Anchors: ASTM A108, Grade 1015 or 1020, cold-finished carbon steel with dimensions complying with AISC Specifications. J. Nuts: Heavy hex nuts shall conform to ASTM A563. K. Washers: Hardened washers shall conform to ASTM F436. L. Plain Washers: Plain washers, other than those in contact with high-strength bolt heads and nuts, shall conform to ANSI B18.22.1, Type B. M. Galvanizing Repair Paint: High zinc dust content paint for regalvanizing welds in galvanized steel, complying with the Military Specifications MIL-P-21035 (Ships). N. Welding Electrodes: Welding electrodes shall be in accordance with AWS D1.1 with a minimum tensile strength of 70,000 psi. 2.03 CONNECTIONS A. Welding shall conform to ANSI/AWS D1.1-90. 2.04 HOT-DIP GALVANIZING A. General: Contractor-furnished ferrous metal items shall be galvanized, unless otherwise indicated to be painted. Refer to Section 09900. B. Galvanizing shall be performed in accordance with ASTM A123, ASTM A153 and ASTM A385 . Coating shall be a minimum of 2 ounces per square foot of surface area. C. Precautions shall be taken when galvanizing items to minimize distortion and twisting of members in accordance with ASTM A384. D. Hex-headed connection bolts including nuts and washers for remain-in-place steel form fabrication shall conform to ASTM A325. E. Field welding of galvanized metals shall be repaired in accordance with ASTM A780. The area to be painted shall be thoroughly cleaned and coated in accordance with the Supplier's application instructions. See Section 09900 for painting details. PART 3 EXECUTION 3.01 FABRICATION AND ERECTION A. General: Structural steel work shall be in accordance with the AISC Specification for Structural Steel Buildings and the AISC Code of Standard Practice for Steel Buildings and Bridges. Welding shall be in accordance with AWS Code D1.1. High-strength bolting shall be in accordance with the AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts. B. Connections: 1. In general, shop connections shall be welded and field connections shall be bolted. Blue Lake Expansion Project – Contract No. 9 05100-6 General Construction May 2012 2. All bolted connections for structural framing shall be made using ASTM A325 bolts. Bearing-type connections shall be used As Shown. 3. Welded connections shall be completed in accordance with AWS D1.1. Welds shall be made by welders or welding operators certified for the weld and positions executed to current AWS certification standards. 4. Minimum weld shall be 1/4 inch fillet weld unless otherwise noted. C. Fabrication: 1. Fabrication shall be in accordance with the applicable provisions of the AISC Specification for Structural Joints and with the approved Shop drawings. Fabrication and assembly shall be done in the shop to the greatest extent possible. Compression joints depending on contact bearing shall have a surface roughness not in excess of 500 micro inches as determined by ANSI B46.1 and ends shall be square within the tolerances for milled ends specified in ASTM A6. Structural steel work, except contact surfaces of within two inches of any field weld location, shall be prepared for painting in accordance with the AISC Specification for Structural Joints and primed with paint in accordance with Section 09900. 2. Properly mark and match-mark materials for field assembly. Fabricate for delivery sequence that will expedite erection and minimize field handling of materials. 3. Where finishing is required, complete assembly, including welding of units, before start of finishing operations. Provide finish surfaces of members exposed in final structure free of markings, burrs, and other defects. 4. Provide fabricated steel parts to the tolerances As Shown, or if not specified, to accepted industry standards. 5. Cut, drill, or punch holes perpendicular to metal surfaces. Do not flame-cut holes or enlarge holes by burning. Drill holes in bearing plates. 6. High-strength Bolted Connections: Install high-strength threaded fasteners in accordance with AISC “Specifications for Structural Joints using ASTM A325 or A490 Bolts”. 7. Headed Concrete Anchors: Prepare steel surfaces as recommended by Supplier of anchors. Use automatic end welding of headed stud shear connectors in accordance with Supplier’s printed instructions. D. Hot-Dip Galvanizing: 1. After the item has been fabricated and inspected, weld spatter, burns, and other objectionable irregularities shall be removed or repaired per SSPC-SP3. Oil, grease and dirt shall be removed from the surfaces by the use of suitable solvents and clean wiping materials, per SSPC-SP1. 2. Surfaces to be coated shall, prior to coating, be grit blasted in accordance with the requirements of SSPC-SP6, “Commercial Blast Cleaning” as required prior to hot-dip galvanizing. Blue Lake Expansion Project – Contract No. 9 05100-7 General Construction May 2012 3. Contractor-furnished ferrous metal items shall be galvanized, unless otherwise indicated to be painted. Refer to Section 09900. 4. Galvanizing shall be performed in accordance with ASTM A123, ASTM A153 and ASTM A385. 5. Any damaged coating shall be repaired in accordance with ASTM A780 and in accordance with Section 09900. E. Erection: 1. General: Erection of structural steel shall be in accordance with the applicable provisions of AISC. Accurately place metal fabrications in location, alignment and elevation, plumb, level, true and free of rack, measured from established lines and levels. 2. Confirm all connections fit accurately together to form tight hairline joints. Weld connections which are not to be left as exposed joints, but cannot be shop welded because of shipping size limitations. Grind exposed joints smooth and touch-up shop paint coat. Do not weld, cut or abrade surfaces after completion of hot-dip galvanizing. 3. Field-Welded Connections: Field-welded structural connections shall be completed in accordance with AWS D1.1, and inspected and accepted by RPR before load is applied. 4. Temporary Shoring and Bracing: Provide temporary shoring and bracing members with connections of sufficient strength to bear imposed loads. Remove temporary members and connections when permanent members are in place and final connections are made. Provide temporary guy lines to achieve proper alignment of structures as erection proceeds. 5. Field Assembly: Set structural frames accurately to lines and elevations indicated and in accordance with AISC. Align and adjust various members forming part of complete frame or structure before permanently fastening. Clean bearing surfaces and other surfaces that will be in permanent contact before assembly. Perform necessary adjustments to compensate for discrepancies in elevations and alignment. a) Level and plumb individual members of structures within specified AISC minimum tolerances or As Shown. b) Establish required leveling and plumbing measurements on mean operating temperature of structure. Make allowances for difference between temperature at time of erection and mean temperature at which structure will be when completed and in service. c) Splice members only where indicated and accepted on shop drawings. d) Comply with AISC for bearing, adequacy of temporary connections, alignment and removal of paint on surfaces adjacent to field welds. e) Do not enlarge unfair holes in members by burning or by using drift pins, except in secondary bracing members. Ream holes that must be enlarged to admit bolts. Blue Lake Expansion Project – Contract No. 9 05100-8 General Construction May 2012 6. Anchor Bolts: Provide anchor bolts and other connections required for securing structural steel to foundations and other in-place work. Provide templates and other devices as necessary for presetting bolts and other anchors to accurate locations. 7. Setting Bases and Bearing Plates: Clean concrete bearing surfaces of bond- reducing materials and roughen to improve bond to surfaces. Clean bottom surface of base and bearing plates. a) Set loose and attached base plates and bearing plates for structural members on wedges or other adjusting devices. b) Tighten anchor bolts after supported members have been positioned and plumbed. Do not remove wedges or shims, but if protruding, cut off flush with edge of base or bearing plate prior to packing with grout. c) Pack grout solidly between bearing surfaces and bases or plates to ensure that no voids remain. Finish exposed surfaces, protect installed materials, and allow to cure. d) Refer to Section 03600 for structural nonshrink grout materials. 8. Column base plates for columns and bearing plates for beams, girders, and similar members shall be provided. Base plates and bearing plates shall be provided with full bearing after the supported members have been plumbed and properly positioned. Separate setting plates under column base plates will not be permitted. 9. Correction of Errors: Minor misfits may be corrected by moderate amounts of reaming, chipping or cutting, and the drawing of elements into line through the use of drift pins. Errors which cannot be corrected by these means or which require major changes in member configuration shall be reported immediately to Engineer. Thermal cutting shall not be permitted unless authorized by Engineer. 10. Touch-Up Painting: Immediately after erection, clean field welds, bolted connections and abraded areas of shop paint. Apply paint in accordance with Section 09900. 11. Adhesive Anchors: Perform all drilling, cleaning of hole, anchor and adhesive installation in accordance with Supplier’s instructions. 12. Expansion Anchors: Perform all drilling, cleaning of hole, installation in accordance with Supplier’s instructions. END OF SECTION Blue Lake Expansion Project – Contract No. 9 05500-1 General Construction May 2012 SECTION 05500 MISCELLANEOUS METALS PART 1 GENERAL 1.01 WORK INCLUDED A. Miscellaneous Steel Items: Provide embedded and non-embedded miscellaneous metal items As Shown. These items include gratings, access hatches, ladder assemblies, stair case assemblies, dam extension ladders, dam extension walkway platform, dam extension permanent survey monitoring systems and all accessory materials required for a complete assembly, such as connections, grating, guardrails (handrails, pedestrian), toe boards and post caps. B. Powerhouse Roof Platform: Install the Owner supplied roof platform grating and guardrail system at the pre-engineered steel building (steel building) for the Blue Lake Powerhouse. Reference Contract 7 – Supply of Steel Building documents for shop drawings and product data for these materials. C. Surge Shaft Steel Liner: Provide 20 ft diameter steel liner plate at the surge shaft top portal. D. Surge Shaft Top Portal: Provide raised pattern safety plate at the surge shaft top portal. 1.02 RELATED WORK A. Section 01300: Submittals B. Section 02020: Survey Control C. Section 02400: Rock Tunnelling D. Section 02410: Rock Bolts E. Section 03300: Cast-In-Place Concrete F. Section 05100: Structural Steel G. Section 09900: Painting and Protective Coatings H. Section 13120: Pre-Engineered Building Installation I. Section 13210: Installation of Owner-Furnished Gates, Guides and Hoist J. Section 13310: Intake Trashrack and Supports 1.03 REFERENCE STANDARDS A. AISC Manual of Steel Construction, 13th Edition B. AISC Specification for Structural Steel Buildings: Allowable Stress Design and Plastic Design Blue Lake Expansion Project – Contract No. 9 05500-2 General Construction May 2012 C. AISC Code of Standard Practice for Steel Buildings and Bridges D. AISI American Iron and Steel Institute E. AISI Type 304 Stainless Steel F. ANSI B18.22.1: Plain Washers G. ASTM A 36: Standard Specification for Carbon Structural Steel H. ASTM A 53: Standard Specification for Pipe, Steel, Black and Hot-Dipped Zinc Coated, Welded and Seamless I. ASTM A 123: Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products J. ASTM A 153: Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware K. ASTM A 307: Standard Specification for Carbon Steel Bolts and Studs, 60,000 psi Tensile Strength L. ASTM A 563: Standard Specification for Carbon and Alloy Steel Nuts M. ASTM A 569: Standard Specification for Steel, Carbon (0.15 Maximum, Percent), Hot-Rolled Sheet and Strip, Commercial N. ASTM A 780: Standard Practice for Repair for Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings O. ASTM A 786: Standard Specification for Hot-Rolled Carbon, Low-Alloy, High- Strength Low-Alloy, and Alloy Steel Floor Plates P. ASTM A 992: Standard Specification for Structural Steel Shapes Q. AWS D1.1: Structural Welding Code R. AWS A2.0: Standard Weld Symbols S. NAAMM: Metal Bar Grating Manual T. OSHA Regulations Part 1910: Occupational Safety and Health Standards 1.04 DESIGN CRITERIA A. All metal fabrications shall be designed in accordance with OSHA Part 1910. B. Maximum shop assembly shall be provided for all material. C. Shop connections shall be welded connections. Field connections shall be assembled in accordance with the AISC Specification for Structural Joints using bolts. Bolts shall be ASTM A307 heavy hexagon structural bolts furnished with heavy semi-finished hexagon nuts of dimensions conforming to ANSI B18.2.1 and B18.2.2, with one hardened washer per bolt. Bolts and accessories for all connections shall be provided by the Contractor. Blue Lake Expansion Project – Contract No. 9 05500-3 General Construction May 2012 D. Personnel Grating: Shall be provided for walkways and platforms at the dam, intake gate house, and powerhouse As Shown, including the intermediate support beams, grating frame, and anchorages. 1. The maximum deflection allowed for personnel grating is 1/4 inches for a uniform load of 100 psf unless otherwise noted. 2. Grating bearing bars shall run perpendicular to direction of foot traffic. E. Gate House Grating: Shall be provided at the gate house As Shown, including the intermediate support beams, grating frame, and anchorages. 1. The maximum deflection allowed for personnel grating is 1/4 inches for uniform loads As Shown. 2. Grating bearing bars shall run perpendicular to direction of foot traffic. F. Turbine Generator Pit Grating: Shall be provided at the powerhouse As Shown, including the intermediate support beams, grating frame, and anchorages. 1. The maximum deflection allowed for grating is 1/4 inches for uniform load As Shown. 2. Grating bearing bars shall run perpendicular to direction of vehicular and foot traffic. G. Gate House Access Hatches: Provide floor and roof access hatches at the gate house As Shown, including all connection and accessory materials. 1. The maximum deflection allowed for the cover plate is 1/4 inches for uniform load As Shown. 2. Lifting lugs shall be designed to permit a balanced, level load when removing the cover plate using standard hooks, chains and machinery. H. Powerhouse Removable Floor Cover Plate: Shall be provided at the powerhouse As Shown, including cover plate, plate frame, and lifting lugs for removal of cover plate. 1. The maximum deflection allowed for grating is 1/4 inches for uniform load As Shown. 2. Lifting lugs shall be designed to permit a balanced, level load when removing the cover plate using standard hooks, chains and machinery. I. Guardrail (Handrail) System: Shall be provided for platforms As Shown. Standard railing shall consist of a top rail, intermediate rail, posts and toeboards. 1. Design for a 200 lb. concentrated load on any point of the rail and post, or 50 lbs/ft uniform load along either the top or bottom rail. 2. All rail and posts shall be standard steel pipe of 1-1/2 inches nominal diameter with posts spaced not more than 6 feet on centers, unless noted otherwise. 3. The nominal vertical height of the upper surface of the top rail to the surface of the platform shall be 42 inches. Blue Lake Expansion Project – Contract No. 9 05500-4 General Construction May 2012 4. Toeboards are required at all exterior railings. Toeboards shall have a nominal vertical height of 4 inches, a maximum clearance above floor level of 1/4 inch, and no openings of greater than 1 inch. 5. Removable guardrail systems at the powerhouse shall include base plate mounts, pins and hardware. Each post shall have a minimum of two pin connections. J. Ladders: 1. Shall be designed for a minimum single concentrated live load of 300 lb. The live loads imposed by persons occupying the ladder shall be considered to be concentrated at such points as will cause the maximum stress in the structural member being considered. 2. The distance between rungs, cleats, and steps shall not exceed 12 inches and shall be uniform throughout the length of the ladder. 3. Bar rungs shall have a minimum diameter of 3/4 inch and a minimum clear length of 16 inches. K. Stairs: Shall be provided at locations As Shown. Staircases shall consist of a rises, stair treads, nosings, standard railings, and landings. 1. The stairways shall be designed to carry a load of five times the normal live load or a moving concentrated load of 1,000 pounds, whichever is greater. 2. The minimum stairway width is 22 inches. 3. All treads shall have a slip resistant nosing. 4. Stairway rise/trend dimensions shall be in accordance with Table D-1 of OSHA Part 1910.24(e). 5. Standard railings shall be provided on all open sides and be designed to the same standards as above in part 1.04.E. Closed staircases shall have a handrail on at least one side in accordance with OSHA Part 1910.24(h). L. Surge Chamber Top Portal Steel Liner Plate: Coordinate with structural steel support design such that connection patterns align. The installation design should be coordinated with the steel erection and concrete placement. 1.05 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Shop Drawings: Shop drawings showing all details necessary for miscellaneous metal items and include the following: 1. All dimensions, sizes, material finishes, clearances, and tolerances. 2. Bills of material. 3. Complete details of all connections, bolted and welded. Bolt layouts and sizes and weld sizes and symbols per AWS A2.0. Blue Lake Expansion Project – Contract No. 9 05500-5 General Construction May 2012 4. Installation instructions and details. 5. Storage and handling requirements and recommendations. C. Certificates of Compliance: Certificates of Compliance shall be furnished for all metal fabrications, for bolts, and for welder qualification. Certified copies of mill test reports shall be furnished for all assemblies. Certification that each welder is qualified in accordance with AWS D1.1 shall be provided. 1.06 RESPONSIBILITY FOR ERRORS A. Contractor shall be responsible for all errors of detailing, fabrication, and for the correct fitting of members and pieces. B. Contractor to field verify all dimensions prior to issuing shop drawings. PART 2 PRODUCTS 2.01 GENERAL A. All exposed and embedded miscellaneous ferrous metals shall be hot-dipped galvanized in accordance with ASTM 123, unless otherwise noted. B. All grating shall have a serrated surface unless otherwise noted. C. Provide stainless steel materials at locations As Shown. 2.02 MATERIALS A. Structural Steel: Conform to ASTM A992, GR 50. B. Steel Plate, Angles and Threaded Rods: Conform to ASTM A36. C. High Strength Bolts: Conform to ASTM A325. D. Carbon Steel Bolts: Conform to ASTM A307. E. Nuts: Conform to ASTM A563. F. Hardened Washers: Conform to ASTM F436. G. Plain Washers: Plain washers shall conform to ANSI B18.22.1, Type B. H. Headed Concrete Anchors: ASTM A108, Grade 1015 or 1020, cold-finished carbon steel with dimensions complying with AISC Specifications. I. Adhesive Anchors: Refer to requirements of Section 05100. J. Expansion Anchors: Refer to requirements of Section 05100. K. Welding Electrodes: Welding electrodes shall be in accordance with AWS D1.1 with a minimum tensile strength of 70,000 psi. Blue Lake Expansion Project – Contract No. 9 05500-6 General Construction May 2012 L. Dam Extension Walkway Platform: Hot dip galvanized ASTM A36 plates, shapes, pipes, and bars with ASTM A325 high strength bolts. M. Dam Extension Permanent Survey Monitoring Embedded Steel: AISI Type 304 stainless steel unless noted otherwise. N. Personnel Grating: W-19-4, welded 1-1/4 inch x 3/16 inch bearing bar, unless noted otherwise O. Turbine Generator Pit Grating: As Shown. P. Surge Chamber Top Portal Grating: As Shown. Q. Gate House Access Hatches: As Shown. R. Turbine Generator Pit Removable Cover: As Shown. S. Guardrail (Handrail) System: 1. Guardrail pipes shall be smooth and straight. Bent pipe required by design shall not show kinks nor shall the pipe be flattened. Intersections of horizontal and vertical members shall be joined by coping or mitering and by welding. 2. Guardrail pipe shall be of welded construction. Welding procedure and performance qualification shall be in accordance with AWS B2/1. 3. Guardrail surfaces shall be free from burrs or other roughness and all welds shall be neatly finished and ground where necessary. 4. Corners of rails shall be smoothly curved, not mitered, with a 2 inch minimum and a 4 inch maximum radius. 5. Guardrails shall be fabricated with rails and posts shop welded into the maximum practicable shipping sections, to minimize field welding. Field splices shall have interior sleeves and shall be located in the rails and not at the posts. 6. Unless otherwise shown on the Drawings, vertical guardrail posts shall be capped with 1/4 inch plate. 7. Guardrail gripping surface shall be continuous without interruption by newel posts or other. T. Ladders: 1. Ladder assembly shall be of welded construction. Welding procedure and performance qualification shall be in accordance with AWS B2/1. 2. Ladder surfaces shall be free from burrs or other roughness and all welds shall be neatly finished and ground where necessary. 3. Center-mounted Saf-T-Climb fall protection systems, as manufactured by Honeywell, shall be provided at locations As Shown. Fall protection system shall include top and bottom end stops, rung clamps, guide rail with rail connector, fall arrester, and accessory materials. Blue Lake Expansion Project – Contract No. 9 05500-7 General Construction May 2012 a. Review Owner’s existing Saf-T-Climb system at the dam and order materials for new system such that Owner’s safety gear may be used interchangeably between the systems. Review systems with Owner prior to order. U. Stairs: Stair treads shall be serrated steel, pressure locked treads with a non-slip nosing. V. Surge Shaft Top Portal Steel Liner Plate: Liner plate shall be Contech 2-Flange Liner Plate as manufactured by Contech, Inc. or approved equal. W. Raised Pattern Safety Plate: 4 way safety plate conforming to ASTM A786 as manufactured by Ryerson, or approved equal. PART 3 EXECUTION 3.01 FABRICATION A. Fabrication and assembly shall be done in the shop to the greatest extent possible. B. All permanently exposed items shall be galvanized unless otherwise noted in accordance with Section 09900: Painting and Protective Coatings. C. Galvanizing shall conform to ASTM A53, ASTM A123, or ASTM A153 as applicable. Any damaged coating shall be repaired in accordance with ASTM A780. D. Surge Chamber Top Portal Steel Liner Plate: Tap all holes in shop prior to galvanizing of plate sections. 3.02 STORAGE AND HANDLING A. Material shall be stored in accordance with Supplier’s recommendations and in such manner and location as will minimize and prevent damage, and minimize contamination and deterioration. 3.03 INSTALLATION A. Installation of miscellaneous metal items shall be in accordance with Supplier’s shop drawings and recommendations, applicable provisions of the AISC Specification and the NAAMM Metal Bar Grating Manual, and OSHA Regulations where applicable. B. All hot dip galvanizing requiring fasteners in field shall be shop drilled prior to galvanizing. C. All guides and embedded frames shall be installed As Shown. Refer to Section 13210 for installation of fixed wheel gate and bulkhead gate. Refer to Section 13310 for installation of the intake trashrack. END OF SECTION DIVISION 06 WOOD AND PLASTICS Blue Lake Expansion Project – Contract No. 9 06066-1 General Construction May 2012 SECTION 06066 DECORATIVE PLASTIC LAMINATE PART 1 GENERAL 1.01 WORK INCLUDED A. Provide all cabinets, countertops, and toilet partitions in the Powerhouse As Shown: 1. Fixed modular laminate clad medium density fiberboard (MDF) cabinets and components. 2. Countertops. 3. Floor Mounted Toilet Partitions. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 05100: Structural Steel. C. Section 09653: Resilient Base and Accessories. D. Section 10800: Toilet, Bath, and Laundry Accessories. 1.03 REFERENCE STANDARDS A. ANSI/NEMA LD 3-2005. B. ASTM A 167: C. ANSI A 208.2-2009: Medium Density Fiberboard. D. ANSI A 208.1: Particleboard, Mat-Formed Wood. E. ASTM D 1037: Standard Test Methods for Evaluating Properties of Wood-Base Fiber and Particle Panel Materials. F. ASTM E 84: Standard Test Method for Surface Burning Characteristics of Building Materials. G. ASTM E 1333: Standard Test Method for Determining Formaldehyde Concentrations in Air and Emission Rates from Wood Products Using a Large Chamber. H. NEMA LD 3: High Pressure Decorative Laminates I. Builders Hardware Manufacturers Association (BHMA): A156.9 Cabinet Hardware. Blue Lake Expansion Project – Contract No. 9 06066-2 General Construction May 2012 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data for materials, fabrication, and installation, including: 1. Plastic laminate. 2. Medium Density Fiberboard (MDF). 3. Adhesive used for plastic laminate application. 4. Cabinet hardware. 5. Installation methods and materials. C. Sample Board with color selections of all architectural finish materials. D. Material Safety Data Sheets: 1. Plastic Laminate. 2. MDF. 3. Adhesive used for plastic laminate application. E. Shop Drawings: Submit two sets of dimensioned plans, elevations, assembly methods, and joint details with a description of materials and finishes, general construction, hardware, means of attachment including required blocking and anchorage, and installation procedures. 1.05 QUALITY ASSURANCE A. Use adequate numbers of skilled workmen who are thoroughly trained and have a minimum of 5 years experience in providing manufactured casework systems for similar types of projects, produce evidence of financial stability, bonding capacity, and adequate facilities and personnel required to perform the Work of this Section. 1.06 PRODUCT HANDLING A. Use all means necessary to protect the materials of this Section before, during, and after installation and to protect the Work and materials of all other trades. B. In the event of damage, Contractor shall immediately make all repairs and replacements necessary to the acceptance of Owner and at no additional cost to Owner. C. Do not deliver casework until HVAC system is operating and until interior concrete work and other wet operations are complete. D. Maintain environmental conditions (temperature, humidity, and ventilation) within limits recommended by Supplier for optimum results. Do not install products under environmental conditions outside Supplier's absolute limits. Supplier’s storage and handling instruction shall be reviewed and maintained. Blue Lake Expansion Project – Contract No. 9 06066-3 General Construction May 2012 E. Field Measurements: Take field measurements prior to component fabrication to ensure proper fitting of Work. PART 2 PRODUCTS 2.01 SUPPLIERS A. Acceptable Suppliers Include: 1. Plastic Laminate: Formica Corporation or Wilsonart International. 2. Cabinets: Kewaunee Scientific Corporation. 3. Toilet Partitions: Ampco Products, LLC. 4. Approved equal. 2.02 MATERIALS A. Countertops: NEMA LD 3, High pressure decorative laminate HGS, 0.048 inch (1.22 mm) minimum. 1. Core Material: Product Standard: ANSI A208.1-2009, grade M-2-MR10 moisture resistant particleboard. 2. Color: to be selected from Supplier’s standard range of colors. B. Cabinets: NEMA LD 3, High pressure decorative laminate HGS, 0.048 inch (1.22 mm) minimum. 1. Core Material: Medium Density Fireboard Core, ANSI A208.2-2009 grade 130 specifications. a) Certification: CPA certified to meet EPP including the following: i. 100 percent recycled/recovered wood content. ii. ANSI A208.2-2009 Table 1 formaldehyde emission requirements. 2. Color: to be selected from Supplier’s standard range of colors. 3. Cabinet Liner: NEMA LD 3, Type CLS, 0.020 inch (0.5 mm) minimum. a) Color: to be selected from Supplier’s standard range of colors. 4. Backing Sheet: Comply with QSI. C. Toilet Partitions: Doors, Panels, and Pilasters: NEMA LD 3, one-piece high pressure plastic laminate surface, Grade GP 50. 1. Core Material: 45 pcf (720 kg/c m) density particleboard core, bonded with polyvinyl acetate adhesive. 2. Color: To be selected from Supplier's standard range of colors. Blue Lake Expansion Project – Contract No. 9 06066-4 General Construction May 2012 3. Edges: Laminate, applied before face laminate and bonded with thermo-setting resin glue under continuous heat and pressure. 4. Thickness with Particleboard Core: Doors and panels 7/8 inch (22 mm); pilasters 1-1/4 inches (32 mm). D. Installation Materials 1. Furring, Blocking, Anchor Strips: materials recommended by Supplier. 2.03 ACCESSORY MATERIALS A. Adhesive for Bonding Plastic Laminate: Unpigmented contact cement. B. Support Members: 1. Countertop Support Brackets: Epoxy powder coated, 11 gage steel with integral cleat-mount opening and wire management opening. 2. Undercounter Support Frames: Epoxy powder coated. 3. Toilet Partition Pilaster Shoes and Caps: 20 gage (0.9 mm) thick ASTM A 167, Type 304 stainless steel; not less than 3 inches (76 mm) high; Number 4 satin (brushed) finish. 4. Anchorages and Fasteners for Floor Mounted Toilet Partitions: Galvanized steel anchorage devices with threaded rod, lock washers, and leveling adjustment nuts at pilasters to permit structural connection at floor; pilaster shoe to conceal supports and leveling mechanism. 2.04 CABINET HARDWARE A. Hinges: Semi-concealed Hinges for Overlay Doors: BHMA A156.9, B01521. B. Pulls: Stainless steel, bent wire type, 4 inches (100 mm) long, 5/16 inch (8 mm) diameter. C. Adjustable shelf supports for hole drilled in cabinet. D. Drawer Slides: 1. Bottom edge mounted drawer slides: BHMA A156.9, B05012. E. Exposed Hardware Finish: Satin chrome plated: BHMA A156.18, Code 626. 2.05 TOILET PARTITION HARDWARE A. Brackets: Type 304 stainless steel with Number 4 satin finish hardware. B. Hinges: Heavy duty cast, surface mounted stainless steel, Type 304 with Number 4 finish; three per door. C. Top and Center Hinge: Opposing nylon gravity-acting cam allowing door to be set in various positions. Fully adjustable. Blue Lake Expansion Project – Contract No. 9 06066-5 General Construction May 2012 D. Bottom Hinge: Free swinging. E. Latch and Keeper: Type 304 cast stainless steel with Number 4 finish; slide latch with combination stop and emergency release feature. F. Coat Hook: Type 304 cast stainless steel with Number 4 finish; combination hook and bumper on inswinging doors. G. Door Pull: Type 304 cast stainless steel with Number 4 finish. H. Exposed Fasteners: Chrome plated brass. 2.06 FABRICATION A. All casework panel components must be precisely cut to size and squareness to ensure strict dimensional quality and structural integrity in the final fabricated product. B. Plastic Laminate-Clad Cabinets: 1. QSI Construction Type: Reveal overlay on face frame. C. Plastic Laminate Countertops: 1. Edges, Including Applied Backsplash: 3mm PVC, exposed edges and corners machine profiled to 3mm (1/8”) radius. Edges are machine applied with water based low Volatile Organic Compound (VOC), non-toxic, PVA adhesive. 2. All countertop joints must be dry fit at the factory to check for consistency in color from one panel to the other and overall finished panel thickness, resulting in a high quality product easy to install. PART 3 EXECUTION 3.01 INSPECTION A. Examine the areas and conditions under which Work of this Section shall be installed and correct conditions detrimental to the proper and timely completion of the Work. B. Examine surfaces adjacent to which casework will be installed. C. Commencement of work by Contractor is acceptance of support conditions. 3.02 PREPARATION A. Clean surfaces thoroughly prior to installation. B. Condition casework to occupancy level environmental conditions for minimum 72 hours prior to installation. C. Verify location of required cutouts and obtain templates for cutouts. Blue Lake Expansion Project – Contract No. 9 06066-6 General Construction May 2012 D. Prepare surfaces using the methods recommended by the Supplier for achieving the best results for the substrate under the project conditions. 3.03 INSTALLATION A. Install in accordance with Supplier’s written installation instructions. B. Erect, plumb, level, true and straight with no distortions. Shim as required. Where laminate clad casework abuts other finished work, scribe and cut to accurate fit. C. Floor Mounted Toilet Partitions: 1. Set stile units with anchorages having not less than 2 inches (51 mm) penetration into structural floor, unless otherwise recommended by Supplier. 2. Hang doors and adjust so tops of doors are level with tops of stiles when doors are in closed position. 3. Secure toilet partition panels to walls and to door stiles with not less than two brackets attached near top and bottom of panel, all brackets to be aligned horizontally. D. Adjust and lubricate hardware for proper operation. E. Repair minor damage per Supplier’s recommendations. 3.04 CLEANING A. Clean all surfaces in accordance with Supplier’s instructions. 3.05 PROTECTION A. Provide temporary protection to the work of this section from damage by other construction operations. END OF SECTION Blue Lake Expansion Project – Contract No. 9 06100-1 General Construction May 2012 SECTION 06100 ROUGH CARPENTRY PART 1 GENERAL 1.01 WORK INCLUDED A. Provide rough carpentry As Shown: 1. Wood furring, grounds, nailers, and blocking at Gate House roofing system. 2. Plywood sheathing at Powerhouse lavatory roof. 3. Pressure treated wood for staff gages at dam. 4. Pressure treated wood for Powerhouse afterbay stoplogs. 5. Pressure treated wood for Intake Tunnel rock traps. 6. Fasteners and metal framing anchors. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 07510: Gatehouse Membrane Roofing System. 1.03 REFERENCE STANDARDS A. AFPA: Manual for Wood Frame Construction. B. ANSI/NFoPA NDS: National Design Specification for Wood Construction. C. ASME B18.6.1: Wood Screws. D. ASTM A153: Zinc Coating (Hot Dip) on Iron and Steel Hardware. E. ASTM A307: Carbon Steel Bolts and Studs. F. ASTM A563: Carbon and Alloy Steel Nuts. G. ASTM A653: Steel Sheet, Zinc-Coated or Zinc-Iron Alloy-Coated by the Hot-Dip Process. H. ASTM D245: Establishing Structural Grades and related Allowable Properties for Visually Graded Lumber. I. ASTM F1667: Driven Fasteners: Nails, Spikes and Staples. J. AWPA C1: All Timber Products Preservative Treatment by Pressure Process. K. AWPA C2: Lumber, Pressure Treated. Blue Lake Expansion Project – Contract No. 9 06100-2 General Construction May 2012 L. AWPB: American Wood Preservers Bureau: Standard specifications. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Material Certificates: Provide at least 30 days prior to fabrication for dimension lumber specified to comply with minimum allowable unit stresses. Indicate species and grade selected for each use. C. Product Data: Provide at least 30 days prior to fabrication for each distinct product specified. Include literature for timber waterproofing sealer. 1.05 DELIVERY, STORAGE, AND HANDLING A. Deliver wood products bundled or crated to provide adequate protection during transit and job storage, with required grade marks clearly identifiable. Inspect wood products for damage upon delivery. Remove and replace damaged materials. B. Keep materials under cover and dry. Protect from weather and contact with damp or wet surfaces. Stack lumber, plywood, and other panels. Provide for air circulation within and around stacks, and under temporary coverings. 1. For lumber and plywood pressure treated with waterborne chemicals, place spacers between each bundle to provide air circulation. C. Protect sheet materials during handling to prevent breaking of corners and damage to surfaces. PART 2 PRODUCTS 2.01 MATERIALS A. Pressure Treated Lumber and Plywood: Treat with waterborne preservatives in accordance with AWPA Standard Specifications; the treated product shall bear the AWPB quality designation LP-2 for aboveground applications, or AWPB quality designation LP-22 for ground contact applications and submerged service. B. Basic allowable stresses (design values) for lumber, as determined by ASTM D245, as follows: TYPE OF STRESS MINIMUM DESIGN VALUE (unless otherwise noted) Bending, Fb 5.5 MPa (800 psi) Tension parallel to grain, Ft 3.4 MPa (500 psi) Shear parallel to grain, Fv 0.6 MPa (85 psi) Compression perpendicular to grain, Fc1 3.4 MPa (500 psi) Compression parallel to grain, Fc 8,300 MPa (1,200,000 psi) min. Blue Lake Expansion Project – Contract No. 9 06100-3 General Construction May 2012 Modulus of Elasticity, E 11,700 MPa (1,700,000 psi) max. C. Lumber and timber shall be straight, sound, and free from warping, knots, shakes, and all other defects. D. Consult with RPR on lumber source prior to construction. 2.02 DIMENSION LUMBER A. General: Provide dimension lumber of any locally available species and grades indicated for applicable use category listed in table below. Lumber shall comply with ALSC National Grading Rule (NGR) provisions of inspection agency applicable to species. PRODUCT (Nominal Dimension) GRADE USE Light Framing 2 to 4 inches thick 2 to 4 inches wide Construction Standard Utility Where high-strength values are not required, such as wall framing, plates, sills, cripples, and blocking. Structural Joists and Planks 2 to 4 inches thick 5 inches and wider Select Structural No. 1 No. 2 No. 3 Intended to fit engineering applications for lumber nominal 5 inches and wider, such as joists, rafters, headers, beams, trusses, and general framing. B. Moisture Content: 19 percent maximum for lumber items not specified to receive wood preservative treatment. 2.03 MISCELLANEOUS LUMBER A. General: Provide lumber for support or attachment of other construction, including rooftop equipment curbs and support bases, cant strips, bucks, nailers, blocking, furring, grounds, stripping, and similar members. B. Fabricate miscellaneous lumber from dimension lumber of sizes indicated, and into shapes As Shown. 2.04 PLYWOOD SHEATHING A. General: Provide APA performance rated panels complying with requirements indicated for grade designation, span rating, exposure durability classification, and edge detail, where applicable. 1. Provide panel clips for edge support as recommended by panel Supplier, or where required by IBC. 2. Provide panels of thickness meeting requirements specified, but not less than thickness indicated. 3. Exposure Durability Classification: Exposure 1. Blue Lake Expansion Project – Contract No. 9 06100-4 General Construction May 2012 4. Span Rating: As required to suit joist spacing indicated. 2.05 FASTENERS A. General: Provide fasteners of size and type indicated, that comply with requirements specified. 1. Where rough carpentry work is exposed to weather, in ground contact, or in areas of high relative humidity, provide fasteners with hot-dip, zinc-coating per ASTM A153. B. Nails, Wire, Brads, and Staples: ASTM F1667. C. Wood Screws: ASME B18.6.1. D. Bolts: Steel bolts complying with ASTM A307, Grade A with ASTM A563 hex nuts and, where indicated, flat washers. 2.06 METAL FRAMING ANCHORS A. General: Provide galvanized steel framing anchors of structural capacity, type, and size indicated, with allowable design loads as published by supplier, that meet or exceed those indicated. B. Galvanized Steel Sheet: Hot-dip, zinc-coated steel sheet complying with ASTM A653, G60 coating designation; structural, commercial, or lock-forming quality, as standard with supplier for type of anchor indicated. PART 3 EXECUTION 3.01 INSTALLATION A. Items cut after pressure treatment shall be brush coated on the cut faces with chemical used for treatment. B. Fasteners shall be installed into accurately located drilled holes as required to achieve the assembly dimensions and tolerances As Shown. C. Warped, twisted, cracked wood or material with defects that impair the quality of rough carpentry shall be discarded at the discretion of the RPR. D. Set rough carpentry to required levels and lines, with members plumb, true to line, cut, and fitted. E. Fit rough carpentry to other construction; scribe and cope as required for accurate fit. Correlate location of furring, nailers, blocking, grounds, and similar supports to allow attachment of other construction. F. Securely attach rough carpentry work to substrate by anchoring and fastening as indicated, complying with IBC Table 2304.9.1 Fastening Schedule. G. Demonstrate proper installation of afterbay stoplogs by installing stoplogs across the afterbay wier. Remove and deliver stoplogs to the owner following trial installation. Blue Lake Expansion Project – Contract No. 9 06100-5 General Construction May 2012 END OF SECTION Blue Lake Expansion Project – Contract No. 9 06200-1 General Construction May 2012 SECTION 06200 MILLWORK PART 1 GENERAL 1.01 WORK INCLUDED A. Provide interior trim, jambs and millwork in the powerhouse As Shown. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 06100: Rough Carpentry. C. Section 08111: Steel Doors. D. Section 08520: Windows. E. Section 09290: Gypsum Board. F. Section 09900: Painting and Protective Coatings. 1.03 REFERENCE STANDARDS A. Woodwork Institute – Manual of Millwork, Standards of the Architectural Millwork Industry. B. ASTM E 84: Standard Test Method for Surface Burning Characteristics of Building Materials. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data for materials, fabrication, and installation. C. Finish Samples: Submit two samples. Include on sample board with color selections of all architectural finish materials. 1.05 QUALITY ASSURANCE A. Supplier to have 5 years experience and adequate facilities and personnel required to perform the Work of this Section. B. Performance shall be in accordance with Manual of Millwork. 1.06 PRODUCT HANDLING A. Use all means necessary to protect the materials of this Section before, during, and after installation and to protect the Work and materials of all other trades. Blue Lake Expansion Project – Contract No. 9 06200-2 General Construction May 2012 B. In the event of damage, Contractor shall immediately make all repairs and replacements necessary to the acceptance of RPR and at no additional cost to Owner. C. Maintain environmental conditions (temperature, humidity, and ventilation) within limits recommended by Supplier for optimum results. Do not install products under environmental conditions outside Supplier's absolute limits. Supplier’s storage and handling instruction shall be reviewed and maintained. PART 2 PRODUCTS 2.01 MATERIALS A. 3/4 inch clear hemlock. PART 3 EXECUTION 3.01 INSPECTION A. Examine the areas and conditions under which Work of this Section will be installed and correct conditions detrimental to the proper and timely completion of the Work. B. Examine surfaces adjacent to which millwork will be installed. C. Commencement of work by installer is acceptance of support conditions. 3.02 PREPARATION A. Clean surfaces thoroughly prior to installation. B. Condition millwork to occupancy level environmental conditions for minimum 72 hours prior to installation. C. Prepare surfaces using the methods recommended by the Supplier for achieving the best results for the substrate under the project conditions. 3.03 INSTALLATION A. Install in accordance with Manual of Millwork, Economy Grade. B. All work shall be secured in place, square, plumb and level. C. All work abutting other components shall be properly scribed. D. Method of attachment, including type, size, frequency, and/or spacing of fasteners shall comply with Manual of Millwork recommendations. 3.04 FINISH A. Paint all millwork as specified in Section 09900. Blue Lake Expansion Project – Contract No. 9 06200-3 General Construction May 2012 3.05 CLEANING A. Clean all surfaces in accordance with Supplier’s instructions. 3.06 PROTECTION A. Provide temporary protection to the Work of this Section from damage by other construction operations. END OF SECTION DIVISION 07 THERMAL AND MOISTURE PROTECTION Blue Lake Expansion Project – Contract No. 9 07100-1 General Construction May 2012 SECTION 07100 DAMPPROOFING AND WATERPROOFING PART 1 GENERAL 1.01 WORK INCLUDED A. Provide below grade foundation wall filter fabric and drainage sheet and waterproof membrane at the powerhouse As Shown. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 02310: Fill Placement and Grading. C. Section 02315: Rock Excavation. D. Section 02316: Unclassified Excavation. E. Section 02620: Subdrainage System. F. Section 03300: Cast-In-Place Concrete. G. Section 07212: Board Insulation. 1.03 REFERENCE STANDARDS A. AATC 127: Water Resistance, Hydrostatic Pressure Test, 1998. B. ASTM C 1311: Standard Specification for Solvent Release Sealants, 2002. C. ASTM D 1621: Standard Test Method for Compressive Properties of Rigid Cellular Plastics, 2004a. D. ASTM D 4491: Standard Test Methods for Water permeability of Geotextiles by Permittivity; 1999a (Reapproved 2004). E. ASTM D 4716: Test Method for Determining the (In-plane) Flow Rate per Unit Width and Hydraulic Transmissivity of a Geosynthetic Using a Constant Head; 2004. F. ASTM D 4833: Standard Test Method for Index Puncture Resistance of Geotextiles, Geomembranes, and Related Products; 2000. G. ASTM E 96/E 96M: Standard Test Methods for Water Vapor Transmission of Materials, 2005. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. Blue Lake Expansion Project – Contract No. 9 07100-2 General Construction May 2012 B. Product Data: Provide for each product to be used, including preparation instructions, recommendations and installation methods. C. Test Reports: Showing compliance with specified requirements. D. Storage, Handling, and Installation Instructions. E. Executed Warranty. 1.05 QUALITY ASSURANCE A. Use adequate numbers of skilled workers who are thoroughly trained and have a minimum of 5 years experience in performing the Work of this Section. 1.06 PRODUCT HANDLING A. Deliver products to Project Site in original packaging with labels intact. B. Store products in manner acceptable to Suppliers. C. When products must be stored for extended periods, keep out of direct sunlight. D. Store and dispose of solvent-based materials, and materials used with solvent- based materials, in accordance with requirements of local authorities having jurisdiction. 1.07 WARRANTY A. 20 year Product Warranty. PART 2 PRODUCTS 2.01 MATERIALS A. Foundation Wall Filter Fabric and Core Board Drainage Sheet: High density polyethylene sheet, dimpled throughout field of sheet, with flat flanges on manufactured edges: 1. Basis-of-Design Product: Cosella-Dorken DELTA DRAIN. 2. Working Temperature Range: Minus 22 degrees F to 176 degrees F. 3. Dimpled Thickness: 5/16 inch (8 mm). 4. Compressive Strength: ASTM D 1621: Approximately 5200 psf. 5. UV Stability: 30 days maximum UV exposure; cover as soon as possible. 6. Sheet Width: As required to result in as few seams as possible. B. Self-Adhering Waterproofing Membrane: 40 mil (1 mm) rubberized asphalt self- adhering membrane: 1. Basis-of-Design Product: Cosella-Dorken DELTA-THENE 40. Blue Lake Expansion Project – Contract No. 9 07100-3 General Construction May 2012 2. Thickness: 1.5 mm min. 3. Sheet Width: As required to result in as few seams as possible. C. Accessories as recommended by product Supplier’s installation instructions, including, primer, fasteners, flashing, and sealant. PART 3 EXECUTION 3.01 INSPECTION A. Verify that substrates are sound enough to retain fasteners and suitable for bonding of sealant. B. Verify that there are no active leaks within the area to be waterproofed. C. Verify that subdrainage system has been properly installed. D. Verify that finish grade elevations are clearly marked. E. Do not begin installation until substrates have been properly prepared. F. If substrate preparation is the responsibility of another trade, notify RPR of unsatisfactory preparation before proceeding. 3.02 PREPARATION A. Prior to installation of drainage sheet, clean surfaces “broom clean”. B. Prior to installation of membrane: 1. All surfaces must be sound, dry, clean and free of oil, grease, dirt, frost or other contaminants. New concrete should be cured for a minimum of 7 days and must be dry before membrane is applied. 2. Apply primer for self-adhered membrane as recommended by Supplier. C. Prepare surfaces using the methods recommended by the Supplier for achieving the best result for the substrate under the project conditions. 1. Remove projections larger than 1/4 inch (6 mm); remove sharp edges. 2. Patch cracks and holes so that they provide suitable substrate as recommended by membrane Supplier. D. Mark installation locations on walls prior to starting installation. 3.03 INSTALLATION A. Install in accordance with Supplier’s written installation instructions. Blue Lake Expansion Project – Contract No. 9 07100-4 General Construction May 2012 B. Do not install when: 1. Ambient temperature is below minus 22 degrees F. 2. Concrete has been cured for less than 3 days. 3. Standing water is present. C. Waterproofing Membrane Installation: 1. Apply waterproofing membrane to prepared substrate in lengths of 6 feet or less. 2. Provide 3 inch laps at both sides and ends. Position for alignment and remove protective film. Press firmly into place. Promptly roll all laps with a counter top roller to effect seal. If more than one length is required on a vertical surface, apply in a shingle fashion. 3. Terminate membrane using termination mastic or termination bar, reglet or counter flashing as indicated. Refer to manufacturers standard details. 4. All laps within 12 inches of a 90 degrees change in plane are to be sealed with termination sealant. D. Board Insulation Installation: Apply over waterproofing membrane per supplier’s recommendations, reference Section 07212: Board Insulation. E. Drainage Sheet Installation: Start at lowest point and work to top, running length of sheets horizontally and overlapping upper sheets in shingle fashion at least 4 inches (100 mm); lap vertical joints at least 6 inches (150 mm). 1. Install sheets without gaps, wrinkles, creases, or tears. 2. Align and interlock overlapping layers. 3. Secure to substrate at edges and in the field of the sheet using fasteners and methods recommended by sheet Supplier; stagger fasteners in alternate rows. 4. Flash and seal top edges, around openings and penetrations, and other locations recommended by Supplier, in manner recommended by Supplier. 5. Install with protruding dimples on side facing substrate. 6. Unless otherwise indicated, fasten dimpled sheets using specified fasteners with dimpled washers interlocked with sheet at not more than 12 inches (305 mm) on center. 7. At top, install with flat edge secured with continuous termination bar, covered by flashing strip. Fasten at not more than 8 inches (200 mm) on center. 8. At all joints, apply continuous bead of sealant between layers and fasten through both layers with specified fasteners with dimpled washers. Blue Lake Expansion Project – Contract No. 9 07100-5 General Construction May 2012 9. At vertical joints, overlap sheets at least 6 inches (150 mm) and interlock dimples, making full contact with sealant. 10. At horizontal joints, apply continuous sealant bead between wall and top flange of lower sheet and fasten lower sheet along top edge; overlap upper sheet over flat flange of lower sheet and fasten through both sheets at lower edge of upper sheet. 11. At interruptions and penetrations, apply continuous bead of sealant between sheet and substrate, fasten sheet around entire opening at not more than 8 inches (100 mm) on center and cover cut edge with flashing strip sealed to wall and fastened at not more than 8 inches (100 mm) on center. 12. At inside and outside corners, install sheet as close to substrate as possible without breaking and fasten along both sides entire length of corner, not closer than 5 inches (125 mm) to corner. 13. At bottom of walls, extend a single sheet from wall over footing and subdrainage pipe. F. Repairs to Dimpled Sheet: Apply patch made of same material interlocked, with continuous sealant bead around tear or penetration. G. Repairs to Filter Fabric: Tape matching material over damaged area. H. After installation of reinforcing bars, inspect drainage sheet and repair damaged sheet and fabric. 3.04 PROTECTION A. Do not leave installed membrane exposed to sunlight for more than 30 days after installation; to cover, complete backfill operation or cover with protection board. B. Prior to backfilling, inspect drainage sheet for tears and other damage and repair. C. Take care when backfilling to avoid damage to drainage sheet; replace materials damaged during backfilling. D. Protect installed products until completion of Project. E. Touch-up, repair or replace damaged products before Substantial Completion. END OF SECTION Blue Lake Expansion Project – Contract No. 9 07212-1 General Construction May 2012 SECTION 07212 BOARD INSULATION PART 1 GENERAL 1.01 WORK INCLUDED A. Provide board insulation As Shown: 1. Protection board over foundation dampproofing at Powerhouse. 2. Rigid thermal insulation at Gate House roof. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 07100: Dampproofing and Waterproofing. C. Section 07213: Batt Insulation. D. Section 07510: Membrane Roofing. 1.03 REFERENCE STANDARDS A. ASTM C 578: Preformed, Cellular Polystyrene Thermal Insulation. B. ASTM C 1289-11: Faced Rigid Cellular Polyisocyanurate Thermal Insulation Board. C. Federal Specification HH-1-524C: Insulation Board, Thermal (Polystyrene). 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Provide data on product characteristics, performance characteristics and limitations. C. Supplier's Installation Instructions: Indicate special environmental conditions required for installation, installation techniques and fastening hardware and materials. D. Supplier’s Certificate: Certify that products meet or exceed specified requirements. 1.05 PRODUCT HANDLING A. Use all means necessary to protect the materials before, during and after installation and to protect the Work and materials of all other trades. Blue Lake Expansion Project – Contract No. 9 07212-2 General Construction May 2012 B. Materials shall be delivered to the Site, and stored in a safe, dry place with all labels intact and legible at time of installation. C. In the event of damage, Contractor’s shall immediately make all repairs and replacements necessary to the acceptance of RPR and at no additional cost to Owner. PART 2 PRODUCTS 2.01 MATERIALS A. General: The insulation materials used in the Work shall be produced by suppliers regularly engaged in manufacture of similar items and with a history of successful production acceptable to RPR. B. Protection Board: Fan-fold 2-inch thick extruded polystyrene foam laminated to high impact capsheets on both sides, compliant with ASTM C 578. C. Rigid Insulation: Faced rigid cellular polyisocyanturate thermal insulation board, compliant with ASTM C 1289-11. D. All other materials not specifically described, but required for complete and proper installation of the Work of this Section, shall be selected, supplied and installed by Contractor. PART 3 EXECUTION 3.01 EXECUTION A. Inspection: Examine the areas and conditions under which Work of this Section will be installed and correct conditions detrimental to proper and timely completion of the Work. B. General Installation: Installation of insulating materials, including fasteners, shall be in strict accordance with the Supplier’s recommendations and As Shown. C. Protection Board Installation: 1. Install over the waterproofing membrane to prevent damage from materials used in backfilling. 2. Apply protection board adhesive in 1 inch wide strips spaced at 16 inches on center. Immediately embed protection board and press into adhesive to ensure full contact. 3. Do not backfill until adhesive has cure dried. Do not use excessive levels of adhesive. END OF SECTION Blue Lake Expansion Project – Contract No. 9 07213-1 General Construction May 2012 SECTION 07213 BATT INSULATION PART 1 GENERAL 1.01 WORK INCLUDED A. Provide fibreglass batt insulation for filling perimeter interior stud wall cavities to meet thermal insulation requirements and for filling interior acoustical partition cavities to meet sound insulation requirements at powerhouse As Shown. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 05100: Structural Steel. C. Section 09290: Gypsum Board. 1.03 REFERENCE STANDARDS A. ASTM C 655: Mineral Fiber Blanket Thermal Insulation for Light Frame Construction and Manufactured Housing. B. ASTM E 84: Test Method for Surface Burning Characteristics of Building Materials. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Provide data on product characteristics, supplier, performance ratings, limitations, preparation recommendations, storage and handling recommendations, and installation methods. PART 2 PRODUCTS 2.01 SUPPLIERS A. Certain Teed Corporation. B. Mitzell Bros. Co. C. Knauf Fiber Glass. D. Approved Equal. 2.02 MATERIALS A. Batt Insulation: ASTM C 665; preformed glass fiber conforming to the following: 1. Thermal Resistance: As Shown. Blue Lake Expansion Project – Contract No. 9 07213-2 General Construction May 2012 2. Batt Size: To suit joist spacing. 3. Facing: To suit joist spacing. 4. Flame/Smoke Properties: In accordance with ASTM E84. B. Tape: Polyethylene self-adhering type, 0.05 m wide. PART 3 EXECUTION 3.01 EXAMINATION A. Do not begin installation until substrates have been properly prepared. B. Verify that all exterior and interior wall, partition, and floor/ceiling assembly construction has been completed to the point where the insulation may correctly be installed. C. Verify that mechanical and electrical services in ceilings, walls and floors have been installed and tested and, if appropriate, verify that adjacent materials are dry and ready to receive insulation. D. If substrate preparation is the responsibility of another installer, notify RPR of unsatisfactory preparation before proceeding. 3.02 PREPARATION A. Clean surfaces thoroughly prior to installation. B. Prepare surfaces using the methods recommended by the Supplier for achieving the best result for the substrate under the project conditions. 3.03 INSTALLATION A. Install in accordance with Supplier's instructions. B. Install in exterior spaces without gaps or voids. Do not compress insulation. C. Trim insulation neatly to fit spaces. Insulate miscellaneous gaps and voids. D. Fit insulation tight in spaces and tight to exterior side of mechanical and electrical services within plane of insulation. E. Install insulation with vapor barrier installed facing the warm side for thermal insulation. Vapor barrier not required for acoustical insulation. Seal or tape joints as required. 3.04 PROTECTION A. Protect installed products until completion of project. B. Touch-up, repair or replace damaged products before Substantial Completion. Blue Lake Expansion Project – Contract No. 9 07213-3 General Construction May 2012 END OF SECTION Blue Lake Expansion Project – Contract No. 9 07510-1 General Construction May 2012 SECTION 07510 MEMBRANE ROOFING PART 1 GENERAL 1.01 WORK INCLUDED A. Provide membrane roofing at the gate house As Shown: 1. EPDM membrane roofing. 2. Roofing accessories. 3. Vapor barrier. 4. Roof access hatch. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 03300: Cast-in-Place Concrete. C. Section 06100: Rough Carpentry. D. Section 07212: Board Insulation. 1.03 REFERENCE STANDARDS A. ASTM D 41: Asphalt Primer Used in Roofing, Dampproofing and Waterproofing. B. ASTM D 312: Asphalt Used in Roofing. C. ASTM D 412: Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers-Tension. D. ASTM D 624: Standard Test Method for Tear Strength of Conventional Vulcanized Rubber and Thermoplastic Elastomers. E. ASTM D 816: Standard Test Methods for Rubber Cements. F. ASTM D 4263: Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method. G. ASTM D 4637: Standard Specification for EPDM Sheet Used In Single-Ply Roof Membrane. H. ASTM E 96: Standard Test Methods for Water Vapor Transmission of Materials. I. UL-700: Standard Test Method for Fire Tests of Roof Coverings. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. Blue Lake Expansion Project – Contract No. 9 07510-2 General Construction May 2012 B. Product Data: Submit for each product to be used, including preparation instructions, storage and handling requirements and recommendations, and installation methods. C. Design Drawings: Submit roof hatch drawings for review and approval, prior to fabrication. D. Warranty: Provide the roof hatch supplier’s warranty, prior to contract closeout. 1.05 QUALITY ASSURANCE A. Use adequate numbers of skilled workers who are thoroughly trained and have a minimum of 5 years experience in performing the Work of this Section. 1.06 PRODUCT HANDLING A. Store products in Supplier’s unopened packaging until ready for installation. B. Maintain environmental conditions per Supplier’s recommendations. C. Supplier to deliver roof hatch unit to the site in two (2) halves due to shipping constraints. Adhere to Supplier’s requirements for proper handling and storage of each section. 1.07 WARRANTY A. EPDM Membrane Roof: 20 year total system warranty. B. Roof Access Hatch: 5 year product warranty. PART 2 PRODUCTS 2.01 SUPPLIERS A. Acceptable Suppliers include: 5. EPDM Membrane Roofing: Carlisle SynTec or approved equal. 6. Roof Access Hatch: The Bilco Company P.O. Box 1203 New Haven, CT 06505 Phone: 203-934-6363 www.bilco.com (Substitutions not accepted) 2.02 MATERIALS A. EPDM Membrane Roofing: Fully adhered waterproof system capable of withstanding uplift requirements with base flashing at all penetrations, plane transitions and terminations and membrane base sheet. 1. Basis-of-Design Product: Sure-Seal Non-Reinforced Adhered Roofing System. Blue Lake Expansion Project – Contract No. 9 07510-3 General Construction May 2012 2. Color: Black. 3. Membrane Thickness: 60 mil nominal. 4. Sheet Size: a) Width: 25 feet wide maximum and as required to result in as few seams as possible. b) Length: As required to result in as few seams as possible. B. Accessories: As recommended by product Supplier’s instructions, including: 1. Metal flashing including drip edge and metal water dam. 2. Cleaners, primers, sealants and bonding adhesive. 3. Fastening components. C. Vapor Barrier: Polyethylene class 1 vapor retarder completely sealed and fully adhered to concrete roof slab: 1. Gauge: 6 mil (0.152 mm). 2. Adhesive: SBS or as recommended by Supplier. 3. Size: Per Supplier and as required to result in as few seams as possible. 4. Seams: Overlap at a minimum of 3” on side laps and 6” on end laps or per Supplier’s recommendations. D. Roof Access Hatch: Bilco D-50T Double Leaf Roof Hatch. 1. Size: 12’-1” x 9’-9”. 2. Material: 11 gauge aluminum (includes cover, cover liner, curb and curb liner) 3. Curb: 12” in height and 2” thick with polyisocyanurate R-12 insulation with 11 gage curb liner on all sides of curb with 4-1/2” curb flange and integral cap flashing. Apply silicone caulk to bottom of curb. 4. Cover: 2” thick thermally enhanced with polyisocyanurate R-12 insulation with a heavy extruded EPDM rubber gasket permanently adhered to cover to assure a continuous seal. 5. Hardware: Stainless Steel. 6. Latches: (2) two-point spring latches (one for each leaf) and (4) heavy duty draw latches (two for each leaf) to secure cover. 7. Hinges: Heavy duty pintle hinges. 8. Lift Assistance: Compression spring operators enclosed in telescopic tubes and automatic hold-open arm with grip handle release. Blue Lake Expansion Project – Contract No. 9 07510-4 General Construction May 2012 9. Locking Device: Provide exterior padlock hasps only. Padlocks to be Owner provided. 10. Finishes: Mill finish aluminum. PART 3 EXECUTION 3.01 INSPECTION A. Verify that substrates are dry, clean and free of foreign matter. B. Verify that there are no active leaks within the areas to be waterproofed. C. Do not begin installation until substrates have been properly prepared. D. If substrate preparation is the responsibility of another trade, notify RPR of unsatisfactory preparation before proceeding. 3.02 PREPARATION A. Clean surfaces thoroughly prior to installation. B. Prepare surfaces using the methods recommended by the Supplier for achieving the best result for the substrate under the project conditions. C. Do not commence work until all other work trades have completed jobs that require them to traverse the roof on foot or with equipment. D. Vapor retarder shall be applied to protect the inside of the structure prior to the roof system installation. 3.03 INSTALLATION A. Install roofing system in accordance with Supplier’s written installation instructions. B. Wall and curb flashing shall be cured EPDM membrane. Continue the deck membrane as wall flashing where practicable. C. Follow Supplier’s typical flashing procedures for wall, curb, and penetration flashing, including metal edging. D. Install roof hatch unit to the concrete roof utilizing both the Contract Drawings and the Supplier’s certified drawings. 3.04 PROTECTION A. When the completion of flashings and terminations is not achieved by the end of the work day, a daily seal must be performed to temporarily close the membrane to prevent water infiltration. Use acceptable membrane seal in accordance with the Supplier’s requirements. B. Protect installed products until completion of Project. Blue Lake Expansion Project – Contract No. 9 07510-5 General Construction May 2012 C. Touch-up, repair or replace damaged products before Substantial Completion. END OF SECTION Blue Lake Expansion Project – Contract No. 9 07900-1 General Construction May 2012 SECTION 07900 BUILDING JOINT SEALERS PART 1 GENERAL 1.01 WORK INCLUDED A. Provide all joint sealers required to create weathertight roof panel and precast wall panel systems at the Powerhouse. Joint sealer systems will be designed by the Steel Building supplier; however, no joint sealant materials will be furnished by the Owner. Refer to reference documents for the required product data. 1. Precast wall panel joint sealers shall include all panel to panel joints, panel to concrete substructure joints, and all panel openings, including electrical boxes, ductwork, doors, louvers and windows. 2. Roof panel joint sealers shall include all panel to panel joints and all roof openings. 3. Joint sealers shall also include an integrated system of flashing structural supports, soffits, and joint sealer at the connection of the roof panels to the precast wall panels. B. Provide all acoustic joint sealers required to create an acoustic seal at the Powerhouse As Shown. C. Provide all joint sealers required to create weathertight system at the Gate House As Shown. D. All joint sealers for cast-in-place concrete shall be in accordance with Section 03254. They are not part of Work included in this Section. E. Joint sealers shall include all necessary sealants and accessories, including primers, cleaners, bond breakers, joint fillers and backing rods, and as required for a weathertight or acoustic joint. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 03300: Cast-In-Place Concrete. C. Section 07510: Membrane Roofing. D. Section 08111: Steel Doors. E. Section 08520: Windows. F. Section 09290: Gypsum Board. G. Section 13120: Pre-Engineered Building. Blue Lake Expansion Project – Contract No. 9 07900-2 General Construction May 2012 1.03 REFERENCE STANDARDS A. ACI 533R: Guide for Precast Concrete Wall Panels. B. ASTM A 36: Standard Specification for Carbon Structural Steel. C. ASTM C 834: Standard Specification for Latex Sealants. D. ASTM C 919: Standard Practice for Use of Sealants in Acoustical Applications. E. ASTM C 920: Standard Specification for Elastomeric Joint Sealers. F. ASTM C 1193: Standard Guide for Use of Joint Sealants. G. ASTM D 1667: Standard Specification for Flexible Cellular Materials – Poly (Vinyl Chloride) Foam (Closed Cell). H. ASTM E 90: Laboratory Measurement of Airborne Sound Transmission Loss of Building Partitions and Elements. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Provide product data including chemical characteristics, performance criteria, storage requirements, shelf life, preparation and installation procedures, available colors, and all special procedures for all joint sealers and accessories. C. For the Powerhouse, use joint sealers specified by the Supplier. Any substitutions will require written approval by Powerhouse Supplier, prior to installation. PART 2 PRODUCTS 2.01 GENERAL A. All joint sealer materials shall be non-staining and match as closely as possibly to the color of the adjacent building materials. B. Accessories: 1. Primer: Non-staining type as recommended by sealant Supplier. 2. Cleaner: Non-corrosive and non-staining type as recommended by sealant Supplier. 3. Joint Filler (Backer Rod): Backer rod shall be closed cell polyethylene or polyurethane foam conforming to ASTM D 1667 and compatible with sealant used and recommended by sealant Supplier. Backer rod shall be cylindrical and oversized a minimum of 30 percent larger than the joint width. Blue Lake Expansion Project – Contract No. 9 07900-3 General Construction May 2012 4. Bond Breaker: Polyethylene or polyurethane with adhesive on one side as recommended by sealant Supplier to suit application. 2.02 POWERHOUSE WALL AND ROOF PANEL JOINT SEALER MATERIALS A. Provide sealer and accessories as recommended in Powerhouse Supplier’s design. Refer to reference documents for the required product data. 2.03 GENERAL PURPOSE EXTERIOR JOINT SEALER MATERIALS A. Provide ASTM C 920, elastomeric, Type S or M, Grade NS, Class 25, Uses M, G, and A. 1. Exterior joints on the Gate House. 2. Other exterior joints for which no other sealant is indicated. 2.04 ACOUSTIC JOINT SEALER MATERIALS A. Provide single-component, non-staining, non-hardening, non-migrating synthetic rubber acoustic sealant meeting ASTM C 834, ASTM C 919 and ASTM E 90: 1. Products: a) Grabber Acoustical Sealant GSC. b) BOSS 824 Acoustical Sound Sealant. c) Approved Equal. PART 3 EXECUTION 3.01 PRODUCT DELIVERY, STORAGE AND HANDLING A. Store joint sealers in accordance with Supplier recommendations in respect to temperature and moisture conditions. 3.02 PREPARATION A. Surface to be caulked must be clean, dry and free of dust. B. Prior to and during installation, maintain control, cleanliness and ambient temperatures during sealant installation according to Supplier recommendations. 3.03 INSTALLATION A. Install all joint sealers according to Supplier recommendations. B. Install all roof panel joint sealers to be a concealed bead in the sheet metal work. END OF SECTION DIVISION 08 DOORS AND WINDOWS Blue Lake Expansion Project – Contract No. 9 08111-1 General Construction May 2012 SECTION 08111 STEEL DOORS PART 1 GENERAL 1.01 WORK INCLUDED A. Provide thermally and acoustically insulated steel doors, door frames, and glazing at Powerhouse and Gate House As Shown. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 01600: Material Control. C. Section 07900: Joint Sealer. D. Section 08710: Door Hardware. E. Section 09900: Painting and Protective Coatings. 1.03 REFERENCE STANDARDS A. ASTM A653: Standard Specification for Steel Sheet, Zinc Coated. B. ASTM A924: Steel Sheet, Metallic-Coated by the Hot-Dip Process. C. ASTM E90-09: Standard Test Method for Laboratory Measurement of Airborne Sound Transmission Loss of Building Partitions and Elements. D. Installation Guide for Doors and Hardware (DHI). E. NFPA 80-07: Standard for Fire Doors and Other Opening Protectives. F. SDI-100: Standard Steel Doors and Frames. G. SDI-105: Recommended Erection Instructions for Steel Frames. H. ULC 752-05: Standard for Bullet Resisting Equipment. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Indicate door configurations and location of cut-outs for hardware reinforcement. C. Sample Board with color selections of all architectural finish materials. D. Shop Drawings: Indicate door elevations, internal reinforcement, closure method, and cut-outs for glazing. Blue Lake Expansion Project – Contract No. 9 08111-2 General Construction May 2012 E. Supplier’s Installation Instructions: Indicate special installation instructions. F. Supplier’s Certificate: Certify that Products meet or exceed specified requirements. 1.05 PERFORMANCE REQUIREMENTS A. Acoustic Doors and Frames: Comply with STC rating requirement As Shown. B. Fire Rated Doors and Frames: Conform to NFPA 80-07; comply with fire resistance rating requirement As Shown. C. Bullet Resistant Security Doors and Frames: Conform to UL 752, Level 4. 1.06 QUALITY ASSURANCE A. Provide steel doors and frames that conform to requirements of SDI-100. B. Supplier: Company specializing in manufacturing the Products specified in this section with minimum three years experience. 1.07 DELIVERY, STORAGE, AND PROTECTION A. Deliver, store, protect and handle Products to Site under provisions of Section 01600. B. Deliver all steel doors in cartons and palletized to provide protection during transit and job storage. C. Inspect doors and frames upon delivery for damage. Minor damage is to be repaired, provided the repair is equal to new work and acceptable to the RPR. D. Store doors and frames at the job site under cover. Place units on wood sills on the floor in a manner that will prevent rust and damage. Avoid the use of non-vented plastic or canvas shelters, which could create a humidity chamber. If the wrapper on the door becomes wet, remove the carton immediately. Provide a 1/4 inch space between stacked doors to promote air circulation. E. Coordinate frame installation with size, location and installation of service utilities. F. Coordinate the Work with door opening construction, door frame, and door hardware installation. G. Sequence Work to ensure wire connections are achieved in an orderly and expeditious manner. PART 2 PRODUCTS 2.01 SUPPLIERS A. Ceco Door Products (substitutions not permitted). Blue Lake Expansion Project – Contract No. 9 08111-3 General Construction May 2012 2.02 HARDWARE LOCATIONS AND GENERAL REINFORCEMENTS A. Locate hardware on doors and frames in accordance with the Supplier’s standard location. B. Hardware reinforcements are to be in accordance with the minimum standard gages as listed in SDI-100. C. Doors shall be mortised, reinforced and function holes provided at the factory in accordance with the hardware schedule and templates provided by the hardware supplier. Through bolt holes, attachment holes, or drilling and tapping for surface hardware, shall be done by others in the field. 2.03 STEEL DOORS A. Sheets are to be made of commercial quality hot dipped zinc coated steel that complies with ASTM A924. B. Vertical edges will join the face sheets by a continuous weld extending the full height of the door. Welds are to be ground, filled to make them invisible and provide a smooth flush surface. C. Hinge reinforcement to be not less than 7 gage (3/16 inch) plate 1-1/4 inch x 9 inch. Approved equal is a 12 gage continuous channel with formed holes drilled and tapped. The Supplier is to provide test information with submittal that this type reinforcement is equal to a 3/16 inch or 7 gage plate reinforcement. D. Reinforce tops and bottoms of all doors with a continuous steel channel not less than 16 gage, extending the full width of the door and welded to the face sheet. Doors with an inverted top channel shall have a steel closure channel screwed or welded in place so the web of the channel is flush with the top of the face sheets of the door. Plastic fillers are not acceptable. E. Exterior Personnel Doors: 1. Door Cores: a) Doors are to be completely filled with a rigid polyurethane core chemically bonded to all interior surfaces with a minimum insulation value of R10. b) Doors to have 20 gage vertical steel stiffeners spanning the full thickness of the interior space between door faces. Stiffeners are spaced not more than 6” apart and attached by spot welds spaced not more than 5” on centers. Spaces between stiffeners are to be filled with fiberglass insulation (Min. density 0.8#/cubic ft.) 2. Acceptable Product: Ceco Door Products: Imperial. F. Interior Acoustical Personnel Doors: 1. Door Cores: Blue Lake Expansion Project – Contract No. 9 08111-4 General Construction May 2012 a) Doors are to be completely filled with sound absorption acoustic core, honeycomb or steel stiffened, with perimeter sound seals, bottom seals, and threshold seals as required to meet acoustic rating requirements As Shown. 2. Acceptable Product: Ceco Door Products: Sound-Tech Xpress. G. Other interior personnel doors (As Shown): 1. Door Cores to be fully filled with a one-piece honeycomb bonded to both faces. 2. Acceptable Product: Ceco Door Products: Regent. H. Bullet resistant security doors: 1. Door Cores to include bullet resistant armor as required to achieve UL 752, Level 4 protection. 2. Acceptable Product: Ceco Door Products: ArmorShield Door and Frame System. 2.04 Steel Frames A. Materials: Exterior and Interior. 1. To be hot dipped galvanized 14 gage steel that complies with ASTM designations A924, G90. 2. All frames, except slip on drywall, are to be assembled so that the face miter seam is “closed and tight”. Weld the face seam and the full web of the frame corner or intersection. Grind and dress the weld area smooth. Apply a zinc rich primer over the grinding area, and finish with a matching prime paint. 3. For acoustical doors, use acoustical frames grouted if required to meet acoustic rating requirements. 4. Acceptable Suppliers: a) Ceco Door Products: SU. B. Fabrication: 1. Provide steel frames for doors, transoms, sidelights, borrowed lites, and other openings to the size and design As Shown. 2. All finished work shall be strong and rigid, neat in appearance, square, true and free of defects. 3. Jamb depths, trim, profile and backbends to be as scheduled and shown on approved shop drawings. 4. When shipping limitations so dictate, frames for large openings are to be fabricated in sections for splicing or splining in the field by Contractor. Blue Lake Expansion Project – Contract No. 9 08111-5 General Construction May 2012 5. Hardware reinforcements are to be in accordance with the minimum standard gages as listed in SDI-100 and as recommended by Supplier. 6. Frames shall be mortised, reinforced, drilled and tapped at the factory for template mortised hardware only, in accordance with approved hardware schedule and template provided by the hardware Supplier. Where surface mounted hardware is to be applied, frames shall have reinforcing plates only; all drilling and tapping to be done in the field by Contractor. 7. Hinge reinforcements to be 7 gage steel. C. Anchors 1. Floor anchors to be provided at each jamb. 2. Anchors for stud partitions to be steel of a suitable design, not less than 18 gage thickness. 3. Dust boxes/mortar guards to be no less than 26 gage. 4. All frames that are to be welded are to have a steel spreader during shipping and handling. Spreader bars are for bracing only and are not be used to size the frame opening. 5. Loose glazing stops are to be of 16 gage galvanized steel, butted at corner joints and secured to the frame with countersunk cadmium or zinc-plated screws. 6. Except on weather-stripped frames, punch the stop for 3 silencers on single door and 2 on double door frames. 2.05 ACCESSORIES A. Glass: As required to meet fire-rating requirements As Shown; factory installed. B. Removal Stops: Rolled steel, channel shape, butted corners; prepared for tamper- proof screws. C. Primer: Zinc chromate type. 2.06 FABRICATION A. Fabricate doors with hardware reinforcement welded in place. 2.07 DOOR AND FRAME FINISH A. Steel Sheet: Galvanized to ASTM A924. B. Primer: Factory finish. C. Paint: Ceco “Colorstyle” factory finish per Section 09900. Blue Lake Expansion Project – Contract No. 9 08111-6 General Construction May 2012 PART 3 EXECUTION 3.01 INSPECTION A. It is the responsibility of the Contractor to confirm all door opening dimensions are accurate. B. Contractor shall repair scratches or disfigurements caused by shipping or handling. Scratches and disfigurements shall be properly cleaned and touched up with a rust inhibitive primer. 3.02 INSTALLATION A. Doors 1. Install doors plumb and in true alignment in a prepared opening and fasten them to achieve the maximum operational effectiveness and appearance. 2. Proper door clearance must be maintained in accordance with SDI-105. 3. Where necessary, only metal hinge shims are acceptable to maintain clearances. 4. Install doors as recommended in “Installation Guide for Doors and Hardware” published by DHI. B. Frames 1. Prior to installation, all frames must be checked for rack, twist and out of square conditions. 2. Place frames prior to enclosing walls and ceilings. Set frames accurately in position, plumbed and braced securely until permanent anchors are set. Remove shipping bar spreader and insert a wood spreader cut to the opening width, notched to clear the stops. 3. When temperature conditions necessitate an additive to be used in the plaster or mortar to prevent freezing, the contractor installing the frames shall coat the inside of the frames, in the field, with a corrosion inhibiting bituminous material. 4. Install frames as recommended in SDI-105. C. Hardware must be applied in accordance with hardware Supplier’s templates and instructions. 3.02 ERECTION TOLERANCES A. Maximum Diagonal Distortion: 1/16 inch measured with straight edge, corner to corner. 3.03 ADJUST AND CLEAN A. Check and re-adjust operating finish hardware items in hollow metal work just prior to final inspection. Leave Work in complete and proper condition. Blue Lake Expansion Project – Contract No. 9 08111-7 General Construction May 2012 B. Immediately after erection, sand smooth any rusted or damaged areas of prime coat and apply to touch-up or compatible air-drying primer. 3.04 SCHEDULES A. After installation, provide Owner with copies of the door schedules when the building is accepted. END OF SECTION Blue Lake Expansion Project – Contract No. 9 08350-1 General Construction May 2012 SECTION 08350 SECTIONAL OVERHEAD DOORS PART 1 GENERAL 1.01 WORK INCLUDED A. Provide insulated overhead sectional doors with operating hardware, supports and controls. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 05100: Structural Steel. C. Section 07900: Building Joint Sealers. D. Section 08710: Door Hardware. 1.03 REFERENCE STANDARDS A. ANSI A216.1: Sectional Overhead Type Door. B. ASTM A653/A653M - Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process. 1.04 SYSTEM DESCRIPTION A. Panels: Insulated flat slats. B. Life Type: Standard lift operating style with track and hardware. C. Operation: Electric Motor. D. Loads: Design and size components to withstand dead and live loads caused by pressure and suction of wind acting normal to plane of wall to a design pressure of 32.5 lb/sq ft at corners and 25 lb/sq ft at walls without exceeding a deflection in accordance with door Supplier’s recommendations. 1.05 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Provide component construction, anchorage method, hardware, and manual operator component data. C. Sample Board with color selections of all architectural finish materials. D. Certificates: Blue Lake Expansion Project – Contract No. 9 08350-2 General Construction May 2012 1. Submit Supplier’s certificate that products meet or exceed specified requirements. 2. Submit installer qualifications. E. Shop Drawings: Provide drawings indicating guide details, head and jamb conditions, clearances, anchorage, accessories, operator mounts and other related information. F. Maintenance Data: Include data for electric motor operator, shaft and gearing, lubrication frequency, spare part sources. G. Warranty: Submit Supplier warranty and ensure forms have been completed in Owner’s name and registered with Supplier. 1.06 QUALITY ASSURANCE A. Perform Work in accordance with ANSI A216.1, Application Type Commercial. Maintain one copy on site. B. Supplier Qualifications: Company specializing in manufacturing the products specified in this Section with minimum five years documented experience. C. Installer: Company specializing in performing the Work of this Section approved by Supplier. 1.07 DELIVERY, STORAGE AND HANDLING A. Comply with Supplier’s ordering instructions and lead time requirements to avoid construction delays. B. Delivery: Deliver materials in Supplier’s original, unopened, undamaged containers with identification labels intact. C. Storage and Protection: Store materials protected from exposure to harmful environmental conditions and at temperature and humidity conditions recommended by the Supplier. 1.08 WARRANTY A. Correct defective Work within a five year period after date of Substantial Completion. B. Provide warranty per Supplier’s recommendations. PART 2 PRODUCTS 2.01 SUPPLIERS A. Raynor: Duracoil Standard, Series IF; sizes and locations As Shown. 2.02 DOOR OPERATORS A. Provide doors designed for electric motor operation. Blue Lake Expansion Project – Contract No. 9 08350-3 General Construction May 2012 1. Drive Orientation: Orient the drive from the left-hand side when facing the reference side of the door (side with counterbalance or hood exposed). B. Supplier Product Designation: Raynor PowerHoist Standard with Contractor style motor starter (Model Series PHO): 1. Type: Jackshaft with manual chain hoist. 2. Motor Horsepower Rating: Continuous 3/4 HP. 3. Electrical Requirements: 115 volt single phase. 4. Duty Cycle: 30 cycles/hour. 5. Control Wiring: Contractor Style Motor starter 24 volt control with provisions for connection of monitoring safety edge for reversing the door. 2.03 CURTAIN A. Material: Interlocking steel slats, 22 gauge (0.030 inch) minimum thickness (20 gauge may be required for larger door per Supplier’s recommendations), roll- formed from commercial quality hot-dipped galvanized (G-90) steel in compliance with ASTM A-653. 1. Slat Type: Insulated Flat Slat with back cover. a) Insulation: Polyisocyanurate with R-value 6.24 and U-value 0.160. b) Back Covers: Galvanized steel, 22 gauge (0.030 inch) minimum thickness. B. Face Mounting: fasten to face of wall on each side of door opening. C. Finish: One finish coat of baked on enamel paint. D. Endlocks: Lateral movement of the slats to be contained by means of powder- coated malleable endlocks fastened with two zinc-plated steel rivets. E. Bottom Bar and Seal: Two roll-formed galvanized steel angles, minimum 1-1/2 inches by 1-1/2 inches by 1/8 inch with single-contact type bottom astragal. Structural angle bottom bar to receive one coat of rust-inhibitive primer. F. Vision Panels: None. G. Curtain Wear Straps: Polyester. 2.04 GUIDES A. Guide Assemblies: To consist of three structural steel angles, minimum 3 inches by 2 inches by 3/16 inch and fitted with removable curtain stops. B. Finish: hot-dip galvanized C. Jamb Construction: Steel jambs with self-tapping fasteners. D. Weather Seal: Guide brush seal. Blue Lake Expansion Project – Contract No. 9 08350-4 General Construction May 2012 2.05 COUNTERBALANCE SYSTEM A. Headplates: 3/16 inch steel plate, attached to wall angle of guide assembly with 1/2 inch diameter class 5 case hardened bolts. Inside of drive bracket fitted with sealed ball bearing. Provide head plates with one coat of rust-inhibitive primer B. Barrel: Minimum 4-1/2 inches outside diameter and 0.120 inch wall thickness structural steel pipe. Deflection of pipe under full load shall not exceed 0.03 inch per foot of span. C. Torsion Spring Counterbalance: Oil-tempered, helical torsion springs, grease packed and mounted on a continuous steel torsion shaft. 2.06 ENCLOSURES A. Round Hood: 24 gauge steel, finish to match curtain. B. Hood Baffle: With EPDM rubber seal to inhibit air infiltration through hood cavity. 2.07 HARDWARE A. Locks: Furnish door system with locking bar, provide interlock switch with cylinder lock. PART 3 EXECUTION 3.01 EXAMINATION A. Verify that wall openings are ready to receive doors, operators, controls and accessories and opening dimensions and tolerances are within specified limits. 3.02 PREPARATION A. Prepare opening to permit correct installation of door unit to perimeter air and vapor barrier seal. 3.03 INSTALLATION A. Install door unit assembly in accordance with shop drawings and Supplier’s instructions. B. Anchor assembly to wall construction and building framing without distortion or stress. C. Securely brace door tracks suspended from structure. Secure tracks to structural members only. D. Fit and align door assembly including hardware. E. Coordinate installation of sealants and backing materials at frame perimeter as specified in Section 07900. Blue Lake Expansion Project – Contract No. 9 08350-5 General Construction May 2012 3.04 ERECTION TOLERANCES A. Maximum Variation from Plumb: 1/16 inch. B. Maximum Variation from Level: 1/16 inch. C. Longitudinal or Diagonal Warp: Plus or minus 1/8 inch from 10 foot straight edge. D. Maintain dimensional tolerances and alignment with adjacent work. 3.05 SUPPLIER’S FIELD SERVICES A. At RPR’s request, provide Supplier’s field service consisting of product installation and use recommendations, and periodic site visits to observe and ensure product installation is done in accordance with Supplier’s recommendations. 3.06 ADJUSTING A. Adjust door assembly to smooth operation and in full contact with weatherstripping. 3.07 CLEANING A. Clean doors, frames and accessories in accordance with Supplier’s instructions. B. Remove temporary coverings and protection of adjacent areas; and remove labels and visible markings. Remove and dispose of construction debris from Project Site. END OF SECTION Blue Lake Expansion Project – Contract No. 9 08520-1 General Construction May 2012 SECTION 08520 WINDOWS PART 1 GENERAL 1.01 WORK INCLUDED A. Provide exterior and interior extruded aluminum windows and glazing As Shown. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 05500: Miscellaneous Metals. C. Section 06200: Millwork. D. Section 07900: Building Joint Sealers. 1.03 REFERENCE STANDARDS A. AAMA 611: Specifications for Anodized Architectural Aluminum. B. AAMA 800: Specifications and Test Methods for Sealants. C. AAMA CW-10: Care and Handling of Architectural Aluminum from Shop to Site. D. ASTM A36: Structural Steel. E. ASTM A386: Zinc Coating (Hot-Dip) on Assembled Steel Products. F. ASTM B209: Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate. G. ASTM B221: Standard Specification for Aluminum and Aluminum Alloy Extruded Bars, Rods, Wire, Profiles and Tubes. H. ASTM E90: Standard Test Method for Laboratory Measurement of Airborne Sound Transmission Loss of Building Partitions and Elements. I. ASTM E283: Rate of Air Leakage through Exterior Windows, Curtain Walls and Doors. J. ASTM E330: Structural Performance of Exterior Windows, Curtain Walls and Doors by Uniform Static Air Pressure Difference. K. ASTM E413: Classification for Rating Sound Insulation. L. ASTM E1332: Standard Classification for Rating Outdoor Indoor Sound Attenuation. Blue Lake Expansion Project – Contract No. 9 08520-2 General Construction May 2012 M. ASTM E 2190: Standard Specification for Insulating Glass Unit Performance and Evaluation. N. Federal Specification TT-P-645: Primer, Paint, Zinc Chromate, Alkyd Type. O. FGMA Glazing Manual: Flat Glass Marketing Association. P. GANA Glazing Manual: Glass Association of North America. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Shop Drawings: Include wall opening and component dimensions; wall opening tolerances required; anchorage and fasteners; color and finishes; affected related Work; and installation requirements. C. Product Data: Provide data on window units. D. Samples: Submit two corner window units with final finish: one interior and one exterior. Include sample color chip on sample board of all architectural finish materials. 1.05 PERFORMANCE A. Window components to provide for expansion and contraction caused by a cycling temperature range of 1700F without causing detrimental effects to components. B. Limit mullion deflection to flexure limit of glass with full recovery of glazing materials. C. Drain water entering joints, condensation occurring in glazing channels, or migrating moisture occurring within system to exterior. D. Air Infiltration: Maximum 0.1 cfm per square foot at 6.24 psf pressure differential when tested in accordance with ASTM E283. E. Structure: Design and size exterior window components to withstand dead and live loads caused by pressure and suction of wind acting normal to plane of wall to a design pressure of 32.5 lb/sq ft at corners and 25 lb/sq ft at walls without exceeding a deflection in accordance with door Supplier’s recommendations and in accordance with ASTM E330. F. Acoustical Tests for Acoustical Interior Windows: 1. Test units in accordance with ASTM E 90 and classified by ASTM E 413 and E 1332. 2. For complete acoustical window assemblies, Sound Transmission Class (STC) will not be less than 50. 1.06 DELIVERY, STORAGE, AND HANDLING A. Materials will be packed, loaded, shipped, unloaded, stored and protected in accordance with AAMA CW-10. Blue Lake Expansion Project – Contract No. 9 08520-3 General Construction May 2012 1.07 WARRANTY A. Provide Supplier’s written warranty against defective materials or workmanship: 1. Product Warranty: 10 years from the date of manufacture. 2. Installation Warranty: 5 years from the date of Substantial Completion. PART 2 PRODUCTS 2.01 MATERIALS A. Aluminum: 1. Extruded aluminum meeting requirements of ASTM B221. 2. Aluminum sheet alloy for anodic finish meeting the requirements of ASTM B209. 2.02 SUPPLIERS A. Supplier: Wausau Window and Wall Systems: 1. Exterior Windows: 4250 Series Fixed Windows. 2. Interior Windows: 2700 Series Fixed Dual Acoustical Windows. 3. Substitutions not permitted. 2.03 FABRICATED COMPONENTS A. Dimensions and units to be determined by design. B. Hardware: Attachment fasteners to be 300 Series stainless steel. C. Sealants: Frame joinery sealants shall be suitable for application specified and as tested and approved by window Supplier. D. Glass: Sealed insulated glass shall be tested and certified in accordance with ASTM E2190. E. Glazing: Glazing method shall be in general accordance with the FGMA Glazing Manual for specified glass type, or as approved by the glass fabricator. F. Glazing Materials: 1. Setting Blocks/Edge Blocking: Provide in sizes and locations recommended by GANA Glazing Manual. Setting blocks used in conjunction with soft-coat low-e glass shall be silicone. 2. Back-bedding tapes, expanded cellular glazing tapes, toe beads, heel beads and cap beads shall meet the requirements of applicable specifications cited in AAMA 800. Blue Lake Expansion Project – Contract No. 9 08520-4 General Construction May 2012 3. At fixed lites, back-bedding tapes, expanded cellular glazing tapes, toe beads, heel beads and cap beads shall meet the requirements of applicable specifications cited in AAMA 800. 4. Glazing gaskets shall be non-shrinking, weather-resistant, and compatible with all materials in contact. G. Steel Components: 1. Concealed steel anchors and reinforcing shall be factory painted after fabrication with rust-inhibitive primer complying with Federal Specification TT-P-645. H. Fasteners: Stainless steel. 2.04 FABRICATION A. Finish, fabricate and shop assemble frame and sash ventilator members into complete windows under the responsibility of one supplier. B. No bolts, screws or fastenings shall bridge the thermal barrier, unless such bridging was also present in thermal test units and thermal models. C. Fabricate to allow for thermal movement of materials when subjected to a temperature differential from -30 °F to +180 °F. D. Fabricate windows allowing for minimum clearances and shim spacing around perimeter of assembly, yet enabling installation. E. Rigidly fit and weld joints and corners. Accurately fit and secure corners tight. Make corner joints flush, hairline, and weatherproof. Seal corner joints with sealant. F. Thermal Break Construction: 1. Exterior Windows: a) Frame and sash members must include a thermal break applied in the Supplier’s facility using concealed low conductance poured-in-place polyurethane. Polyurethane at all members must be poured into pre- finished and mechanically pre-treated cavities. b) After proper curing, remove aluminum bridge section to provide a nominal 1/4 inch separation between exterior and interior metal surfaces. c) Quality assurance records must be maintained and be available as requested. 2. Interior Windows with Acoustic Liners: a) Frames must be continuously joined at the perimeter by an extruded PVC thermal break acoustical liner retained in dovetail grooves. Blue Lake Expansion Project – Contract No. 9 08520-5 General Construction May 2012 b) Thermal separator shall contain a 3/4 inch x 2 1/4 inch open cell, non- vinyl, sound absorbing foam secured by a black anodized perforated aluminum plate. c) The sill of the acoustical liner must be drained without interruption of the window weep system, and be joined at the corners by a stainless steel fasteners placed into integral screw races. d) Factory seal thermal breaks at sill members against water infiltration. G. Weather-stripping: 1. Bulb- or fin-type neoprene, EPDM, dual-durometer PVC, polypropylene, TPE, or other suitable material as tested and approved by the window Supplier. 2. Miter, crowd, stake or join at corners. Provide drainage to exterior as necessary. 3. Weather-stripping shall provide an effective pressure-equalization seal at the interior face of the sash ventilator. H. Prepare components to receive anchor devices. Fabricate anchorage items. I. Provide internal reinforcement in mullions with galvanized steel members to maintain rigidity. 2.05 FINISHES A. Exterior Exposed Aluminum Surfaces: Clear anodize in accordance with AAMA 611. B. Interior Exposed Aluminum Surfaces: Linetec factory finish per Section 09900. C. Concealed Steel Items: Galvanized in accordance with ANSI/ASTM A386 to 0.6 kg/m2 (2.0 oz/sq ft.) D. Apply one coat of bituminous paint to concealed aluminum and steel surfaces in contact with cementitious or dissimilar materials. PART 3 EXECUTION 3.01 INSPECTION A. Verify wall openings and adjoining air and vapor seal materials are ready to receive Work of this Section. B. Beginning of installation means acceptance of existing conditions. 3.02 INSTALLATION A. Install window frames in accordance with Supplier’s instructions. B. Use anchorage devices to securely attach frame to structure. Blue Lake Expansion Project – Contract No. 9 08520-6 General Construction May 2012 C. Align window frame plumb, square and level free of warp or twist for proper weathering and operation D. Pack fibrous insulation in shim spaces at perimeter to maintain continuity of thermal barrier. E. Install perimeter sealant and backing materials in accordance with Section 07900. 3.03 CLEANING A. Remove protective material from prefinished aluminum surfaces. B. Wash down exposed surfaces using a solution of mild detergent in warm water, applied with soft, clean wiping cloths. Take care to remove dirt from corners. Wipe surfaces clean. C. Remove excess sealant by moderate use of mineral spirits or other solvent acceptable to sealant Supplier. END OF SECTION Blue Lake Expansion Project – Contract No. 9 08710-1 General Construction May 2012 SECTION 08710 DOOR HARDWARE PART 1 GENERAL 1.01 WORK INCLUDED A. Provide door hardware, As Shown, including: 1. Hinges, butts and pivots. 2. Locks and latches. 3. Lock cylinders and keying. 4. Fire exit hardware. 5. Stops and bumpers. 6. Door closers. 7. Kick plates. 8. Push and pulls. 9. Filler plates. 10. Thresholds and weatherstrips. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 07900: Building Joint Sealers. C. Section 08111: Steel Doors. D. Section 08350: Manual Sectional Overhead Doors. 1.03 REFERENCE STANDARDS A. BHMA: Builders Hardware Manufacturers Association. B. Door and Hardware Institute. C. IBC: International Building Code. D. UL 10C: Positive Pressure Fire Tests of Door Assemblies. E. UL 305: Panic Hardware. Blue Lake Expansion Project – Contract No. 9 08710-2 General Construction May 2012 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Include Supplier’s technical product data for each item of door hardware with mounting instructions, maintenance of operating parts and finish, and other information necessary to show compliance with requirements. C. Final Hardware Schedule: Coordinate with doors, frames, and related Work to ensure proper size, thickness, hand, function and finish of door hardware. 1. Final hardware schedule content: Based on hardware indicated, organize schedule into hardware sets indicating complete designations of every item required for each door or opening. Include the following information: a) Type; style; function; size and finish of each hardware item. b) Name and supplier of each item. c) Fastenings and other pertinent information. d) Location of each hardware set cross referenced to indications on drawings both on floor plans and in door schedule. e) Explanation of all abbreviations, symbols, and codes contained in schedule. f) Mounting locations for hardware. g) Door and frame sizes and materials. h) Keying information. 2. Submittal Sequence: Submit final schedule at earliest possible date particularly where acceptance of hardware schedule must precede fabrication of other Work that is critical in the Project Construction Schedule. Include with schedule the product data, samples, shop drawings of other Work affected by door hardware, and other information essential to the coordinated review of schedule. D. Samples: Provide one of each type of exposed hardware unit in finish indicated and tagged with full description for coordination with schedule. Submit samples prior to submission of final hardware schedule. 1. Samples will be returned to supplier. Units that are acceptable and remain undamaged through submittal, review and field comparison process may, after final check of operation, be incorporated in the Work, within limitations of keying coordination requirements. a) Templates for doors, frames and other Work specified to be factory prepared for the mounting of door hardware. Check shop drawings of other Work to confirm that adequate provisions are made for locating and installing door hardware to comply with indicated requirements. Blue Lake Expansion Project – Contract No. 9 08710-3 General Construction May 2012 1.05 QUALITY ASSURANCE A. Single Source Responsibility: Unless otherwise specified, all products of a similar nature shall be the product(s) of a single Supplier. 1.06 PRODUCT HANDLING A. Tag each item or package separately with identification related to final hardware schedule, and include basic installation instructions with each item or package. B. Packaging of door hardware is responsibility of Supplier. As material is received, by hardware supplier from various suppliers, sort and repackage in containers clearly marked with appropriate hardware set numbers of approved hardware schedule. Two or more identical sets may be packed in same container. C. Inventory door hardware jointly with representatives of hardware supplier and hardware fitter until each is satisfied that count is correct. D. Deliver individually packaged door hardware items promptly to Project Site. E. Provide secure lock-up for door hardware delivered to the project, but not yet mounted. Control handling and mounting of hardware items that are not immediately replaceable so that completion of the Work will not be delayed by hardware losses before and after completion of Work. 1.07 MAINTENANCE A. Maintenance Tools and Instructions: Furnish a complete set of specialized tools and maintenance instructions needed for Owner’s continued adjustment, maintenance, and removal and replacement of door hardware. PART 2 PRODUCTS 2.01 SCHEDULED HARDWARE A. Requirements for design, grade, function, finish, size and other distinctive qualities of each type of finish hardware by the Supplier, following the City and Borough of Sitka’s past standards. 2.02 SUPPLIER A. Powerhouse Hardware: Best Access Systems: 18401 East Valley Highway Kent, WA 98032 877-433-4370 Contact: Kristy Kovo or Dean Peterson B. Gate House Hardware: 1. Schlage Lock Company 2. Russlin Lock Company Blue Lake Expansion Project – Contract No. 9 08710-4 General Construction May 2012 3. Corbin 4. Yale C. Substitutions not permitted. 2.03 MATERIALS AND FABRICATION A. Supplier’s Name Plate: Do not use Supplier’s products that have Supplier’s name or trade name displayed in a visible location (omit removable name plates) except in conjunction with required fire-rated labels and as acceptable to RPR. B. Base Metals: Produce hardware units of basic metal and forming method indicated, using Supplier’s standard metal alloy, composition, temper, and hardness, but in no case of lesser (commercially recognized) quality than specified for applicable hardware units for finish designations indicated. C. Fasteners: Provide hardware manufactured to conform to published templates, generally prepared for machine screw installation. Do not provide hardware that has been prepared for self-tapping sheet metal screws, except as specifically indicated. D. Furnish Screws for Mounting with Each Hardware Item: Provide Phillips flat-head screws except as otherwise indicated. Finish exposed (exposed under any condition) screws to match hardware finish or, if exposed in surfaces of other Work, match finish of this other Work as closely as possible including prepared for paint surfaces to receive painted finish. E. Provide concealed fasteners for hardware units that are exposed when door is closed except to the extent no standard units of type specified are available with concealed fasteners. Do not use thru-bolts for mounting where bolt head or nut on opposite face is exposed in other Work unless their use is the only means of reinforcing the Work adequately to fasten the hardware securely. Where thru-bolts are used as a means of reinforcing the Work, provide sleeves for each thru-bolt or use hex screw fasteners. 2.04 HINGES, BUTTS AND PIVOTS A. Hinges: Unless otherwise scheduled, hinges shall be of ball bearing type in material, weight and type as hereinafter designated. Furnish two hinges for doors up to and including 5 ft 0 inches in height. Furnish one additional hinge for each additional 2 ft 6 inch height or fraction thereof. For doors up to and including 3 ft 0 inch in width, furnish hinges similar to McKinney TB271 4-4.5 inch by 4.5 inch; for doors over 3 ft 0 inch in width, furnish hinges similar to McKinney T4B3786-4.5 inch by 4.5 inch or per Supplier’s recommendations. B. Hinges for bullet resistant security doors shall be stainless steel or ball bearing 5 inch by 4.5 inch with stainless steel non-removable pins. 2.05 LOCKS AND LATCHES A. Locks shall be heavy duty cylindrical type (Fed. 161 preparation) with forged and/or machined steel, stainless steel, brass or bronze working parts. Latch bolts shall have minimum 9/16 inch throw. Locks shall be provided with external spring cages for additional lever support and through bolts outside of the borehole. Locks shall Blue Lake Expansion Project – Contract No. 9 08710-5 General Construction May 2012 meet all UL requirements. Provide box strikes and curved lips of sufficient length to protect frame and trim: 1. Best 9K series, 15D design. B. Locks for bullet resistant security doors: Mortise lock chassey type with dead bolt. 1. Best 7 pin I-C, #1E74 with cam as required, 1 each mortise cylinder. Cylinder provided by Owner. 2.06 LOCK CYLINDERS AND KEYING A. Metals: Construct lock cylinder parts from brass or bronze, stainless steel or nickel silver. B. Unless otherwise scheduled, locks and cylinders shall be furnished with temporary construction cores. Permanent core will be Owner provided. Owner shall remove temporary cores, replace with permanent cores and return temporary cores to lock Supplier. C. As scheduled, provide interchangeable cores on doors. 2.07 INTERIOR TRIPLE SLIDING DOOR A. Supplier: KN Crowder. 1. Locks: KN Crowder C90-C-90C. 2. Cylinder and manual flush bolt: 1-1/8” mortise (for center door). 3. Track sets: C204, full width of opening; Quantity 3. 4. Mounting brackets: As required. 5. Hangers: C-206-4; quantity 6 (2 per door). 6. Floor track and guides: C202-3; quantity 1. 7. Equal size doors to overlap center door to cover access to manual flush bolt when in locked position. 8. Operation: Lock center door to threshold by manual flush bolt; then close each end door and lock with key into wall strike each side. 2.08 FIRE EXIT HARDWARE A. All exit devices shall be touch bar style, of type, series and function per IBC requirements”. B. All devices to be of a heavy duty, chassis mounted design, with one piece removable covers, metal end caps and all exposed parts of brass, bronze or stainless steel base material. Blue Lake Expansion Project – Contract No. 9 08710-6 General Construction May 2012 C. All devices trims to be thru-bolted to the lock stile case and lever handle design shall match design for locks. 2.09 STOPS AND BUMPERS A. Wherever door or hardware will strike a finished wall or fixed equipment, provide some type of door stop - wall, or floor or overhead type. Wall stops similar to Ives 407 series are preferred. Where wall stops are impractical, provide floor stops similar to Ives 436/438 series or overhead type similar to Sargent 1540 series. Provide roller stops of proper type wherever the swing of two doors conflict. 2.10 DOOR CLOSERS A. Door closers shall be surface mounted with flat, rectangular, minimum projection covers. Closers shall be of cast iron alloy and shall have hydraulically controlled full rack and pinion mechanism. Closing speed, latch speed and back check shall be controlled by separate one piece, captivated valves. Provide arms, brackets, plates, and other accessories as may be necessary to suit individual door conditions. Parallel arm application shall utilize heavy-duty arms. Door closers shall be fully adjustable in spring power size. B. Standard mount closers shall be used wherever possible. Provide parallel arm or inverted amount where required to permit 180 degree swing of doors. Where possible, door closers to be hidden from public view by mounting on the room side of the door. C. All closers shall be provided in accordance with Supplier’s recommendations and shall have a guarantee period of not less than 10 years. 2.11 KICK PLATES A. Kick plates shall be 8 inches high (armor plates shall be 35 inches high) by 2 inch less than nominal door width. Size height to suit conditions at existing doors. B. Plates shall be metal, 0.050 inch thick, anodized aluminum (C28). C. Provide with stainless steel oval undercut head self-tapping screws finished to match plates. 2.12 PUSH AND PULLS A. Pulls shall be similar to Burns 39C x blind fasteners. B. Pull plates shall be similar Burns 39C mounted on 70 series plates modified to 2 inch by 12 inch blind fasteners. Plates shall be cut for cylinder where indicated. Locate pulls on centerline of plate width, unless otherwise required to clear existing concealed hardware. C. Push and pull sets shall be similar to Burns 422 by 26C and 422 by 39C. Provide with back-to-back fasteners at common legs and blind fasteners at free legs. D. Blind head fasteners shall consist of decorative head thru-bolt, requiring spanner wrench application. Blue Lake Expansion Project – Contract No. 9 08710-7 General Construction May 2012 2.13 FILLER PLATES A. Provide filler plates as indicated to suit conditions, existing or new. Filler plates are indicated at door edge - hinge, offset pivot, lock front and strike, and door face (161 cut-out). 2.14 SILENCERS A. Provide door silencers at all interior frames. Provide three for a single opening and two for a double opening. Silencers shall be similar to Glynn-Johnson GJ64 for hollow metal frames. 2.15 THRESHOLDS AND WEATHERSTRIP A. Thresholds (unless otherwise detailed or indicated) shall be as provided at all exterior doors, length as required for width of opening. B. Weatherstrip shall consist of three pieces, one per each jamb and head. Lengths as required for size of opening. Type to be similar to Reese 957C. C. Sweeps shall be similar to Reese 323C, length as required for width of door(s). D. Astragals shall be similar to Reese 961C x 961C, length as required. E. Fasteners: Provide machine screws and expansion shields for all thresholds. Provide self-drilling screws for all other forms of weatherstrip. 2.16 HARDWARE FINISHES A. Provide matching finishes for hardware units at each door or opening, to the greatest extent possible, and as otherwise indicated. Reduce differences in color and texture as much as commercially possible where the base metal or metal forming process is different for individual units of hardware exposed at the same door or opening. In general, match items to the supplier’s standard finish for the latch and lock set (or push-pull units if no latch-lock sets) for color and texture. B. Provide finishes which match those established by BHMA. C. Provide quality of finish, including thickness of plating or coating (if any), composition, hardness, and other qualities complying with Supplier’s standards, but not less than specified for the applicable units by referenced standards. D. Provide protective lacquer coating on all exposed hardware finishes of brass, bronze and aluminum, except as otherwise indicated. E. Finish in general shall be satin chrome (US26D). PART 3 EXECUTION 3.01 MOUNTING A. Mount hardware units at heights indicated in following applicable publications, except as required to comply with governing regulations and except as otherwise directed by RPR. Blue Lake Expansion Project – Contract No. 9 08710-8 General Construction May 2012 1. Recommended Locations for Builders Hardware for Standard Steel Doors and Frames by the Door and Hardware Institute. 2. Door handles, pulls, latches and locks to be located vertically not less than 34 inches and not more than 48 inches above the finish floor per IBC requirements. B. Mount each hardware item in compliance with the Supplier’s instructions and recommendations. Where cutting and fitting is required to mount hardware onto or into surfaces that are later to be painted or finished in another way, coordinate removal, storage and remounting or application of surface protection with finishing Work specified in Section 09900. Do not mount surface-mounted items until finishes have been completed on the substrates involved. C. Set units level, plumb and true to line and location. Adjust and reinforce the attachment substrate as necessary for proper mounting and operation. D. Drill and countersink units that are not factory prepared for anchorage fasteners. Space fasteners and anchors in accordance with industry standards. E. Set thresholds for exterior doors in full bed of butyl-rubber or polyisobutylene mastic sealant complying with requirements specified in Section 07900: Joint Sealers. F. Weatherstripping and Seals: Comply with supplier’s instructions and recommendations to the extent installation requirements are not otherwise indicated. G. Fire Exit Hardware: Listed in accordance with UL 10C and UL 305. 3.02 ADJUSTING, CLEANING AND DEMONSTRATING A. Adjust and check each operating unit of hardware and each door to ensure proper operation or function of every unit. Replace units that cannot be adjusted to operate freely and smoothly or as intended for the application made. 3.03 HARDWARE SCHEDULE A. Provide hardware for each door to comply with requirements of this Section and As Shown. B. Verify all existing conditions and advise RPR of any discrepancies. END OF SECTION DIVISION 09 FINISHES Blue Lake Expansion Project – Contract No. 9 09290-1 General Construction May 2012 SECTION 09290 GYPSUM BOARD PART 1 GENERAL 1.01 WORK INCLUDED A. Provide gypsum board at Powerhouse As Shown. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 05120: Structural Steel. C. Section 05500: Miscellaneous Metals. D. Section 07213: Batt Insulation. E. Section 07900: Building Joint Sealers. F. Section 08111: Steel Doors. G. Section 08520: Windows. H. Section 09650: Resilient Wall Base. I. Section 09772: Decorative Fiberglass Reinforced Wall Panels. J. Section 09990: Painting and Protective Coating. 1.03 REFERENCE STANDARDS A. ASTM C 473: Standard Test Methods for Physical Testing of Gypsum Panel Products. B. ASTM C 840: Application and Finishing of Gypsum Board. C. ASTM C 1178: Standard Specification for Coated Glass Mat Water Resistant Gypsum Backing Panel. D. ASTM C 1396: Gypsum Board. E. ASTM C 1629: Standard Classification for Abuse-Resistant Non-decorated Interior Gypsum Panel Products. F. ASTM D 3273: Standard Test Method for Resistance to Growth of Mold on the Surface of Interior Coatings in an Environmental Chamber. G. ASTM D 4977: Standard Test Method for Granule Adhesion to Mineral Surfaced Roofing by Abrasion. Blue Lake Expansion Project – Contract No. 9 09290-2 General Construction May 2012 H. ASTM D 5420: Standard Test Method for Impact Resistance of Flat, Rigid Plastic Specimen. I. ASTM E 84: Standard Test Method for Surface Burning Characteristics of Building Materials. J. ASTM E 90: Standard Test Method for Laboratory Measurement of Airborne Sound Transmission Loss of Building Partitions and Elements. K. ASTM E 136: Standard Test Method for Behavior of Materials in a Vertical Tube Furnace at 750°C. L. ASTM E 695: Standard Method for Measuring Relative Resistance of Wall, Floor, and Roof Construction to Impact Loading. M. GA-216: Application and Finishing of Gypsum Panel Products. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Provide data on gypsum board products. C. Manufacturer’s Certificate: Certify that products meet or exceed specified requirements. PART 2 PRODUCTS 2.01 HIGH-IMPACT GYPSUM BOARD A. Panel Physical Characteristics 1. Core: Type X, fire resistance rated gypsum core, with additives to enhance mold/mildew resistance, surface indentation resistance and impact resistance, moisture and mold resistant. 2. Surface Paper: Abrasion resistant, 100% recycled content moisture/mold/mildew resistant paper on front, back and long edges. 3. Embedded Fiberglass Mesh. 4. Long Edges: Tapered. 5. Overall thickness: 5/8 inch. 6. Panel complies with requirements of ASTM C 1396, Type X. 7. Surface Abrasion Resistance: 0.126 inch maximum when tested in accordance with ASTM D 4977. 8. Indentation Resistance: 0.150 inch maximum when tested in accordance with ASTM D 5420. Blue Lake Expansion Project – Contract No. 9 09290-3 General Construction May 2012 9. Soft Body Impact: 195 ft-lbf minimum when tested in accordance with ASTM E 695. 10. Hard Body Impact: 100 ft-lbf minimum in accordance with ASTM C 1629. 2.02 MOLD AND MILDEW RESISTANT GYPSUM BOARD A. Panel Physical Characteristics 1. Thickness: 5/8 inch, Type X. a) Core: Mold and moisture resistant gypsum core. b) Surface: Fiberglass Mat; moisture resistant, acrylic coated water barrier on front. 2. Long Edges: Square. 3. Physical Properties: a) Water Absorption: less than 5% when tested in accordance with ASTM C 473. b) Combustibility: Noncombustible when tested in accordance with ASTM E 136. c) Flame spreads/Smoke Developed: 0/0 when tested in accordance with ASTM E 84. d) Mold/Mildew Resistance: 10 when tested in accordance with ASTM D 3273. 4. Panel complies with requirements of ASTM C 1178. 2.03 ACCESSORY PRODUCTS A. Sound Transmission: 1. Acoustical sealant per Section 07900: Building Joint Sealers. 2. 1/2 inch neoprene rubber sheet As Shown. 3. Resilient channel As Shown, size per Supplier’s recommendations. B. Firestopping: 1. Conform to ASTM E 90 Standard Test Method for Laboratory Measurement of Airborne Sound Transmission Loss of Building Partitions and Elements. 2. Products: a) STI SpecSeal SSP Putty Pads. b) BOSS 818 Fire Rated Putty Pads. Blue Lake Expansion Project – Contract No. 9 09290-4 General Construction May 2012 c) Approved Equal. C. Joint Treatment: 1. Tape: a) Paper Tape: 2-1/16 inches wide. b) Paper Tape: 2 inches wide with metal strips laminated along the center crease to form inside and outside corners. c) Fiberglass Tape: Nominal 2 inches wide self adhering tape. d) Alkali-resistant Fiberglass Tape: Nominal 2 inches wide polymer coated alkali-resistant mesh tape. 2. Drying Type Compound: a) Ready Mix vinyl base compound. b) Ready Mix vinyl base compound formulated for enhanced mold and mildew resistance. c) Ready Mix vinyl base compound formulated to reduce airborne dust during sanding. d) Ready Mix vinyl base topping compound for finish coating. e) Ready Mix vinyl base compound for embedding joint tape, corner beads or other accessories. f) Field Mix vinyl base compound. 3. Setting Compound: a) Field mixed hardening compound. b) Field mixed hardening compound for fire resistance rated construction and penetrations. 4. Joint Sealant: Refer to Section 07900: Building Joint Sealers. PART 3 EXECUTION 3.01 HIGH IMPACT GYPSUM BOARD INSTALLATION A. Install in accordance with Supplier’s recommendations. B. Single Layer - 3-5/8 inch metal stud construction: Blue Lake Expansion Project – Contract No. 9 09290-5 General Construction May 2012 1. Apply vertically to each side of metal framing with fasteners 8 inches on center at edges and 12 inches on center in the field of the board. 2. Stagger vertical joint on each side of wall. 3. Tape Joints. C. Unbalanced - metal stud construction: 1. Apply vertically to one side of metal framing using 1 inch Type S screws, 12 inches on center. Apply face layer vertically using 1-5/8 inch Type S screws, 12 inches on center. 2. Opposite side: Apply gypsum board vertically using 1 inch Type S screws, 12 inches on center. 3. Stagger vertical joints 24 inches each layer and opposite sides. 4. Tape first layer prior to hanging the second layer. D. Provide Level 5 Smooth Wall Finish. E. Paint per Section 09900: Painting and Protective Coatings. 3.02 MOLD AND MILDEW RESISTANT GYPYPSUM BOARD INSTALLATION A. General 1. Install in accordance with Supplier’s recommendations, ASTM C840 and GA- 216. 2. Install with acrylic coated water barrier side facing away from the framing, so that finishes shall be applied to the coated side. 3. Caulk or seal penetrations and abutments to dissimilar materials. 4. Install resilient channel horizontally at the bottom and top of the wall, spacing per Supplier’s recommendations. B. Installation for Walls: 1. Install panels horizontal or vertical to supports spaced a maximum of 24 inches on center for 5/8” inch thick panels. 2. Space fasteners 8 inches on center along all support members. Drive fasteners flush with the panel surface, do not countersink. 3. Finish walls with a direct applied finish system, or materials suitable for humid environments. Provide Level 5 finish. 4. Seal transitions and abutments to dissimilar materials with flexible joint sealant per Section 07900: Building Joint Sealers. C. Installation for Ceilings: Blue Lake Expansion Project – Contract No. 9 09290-6 General Construction May 2012 1. Install panels perpendicular to supports spaced a maximum of 24 inches on center for 5/8” inch thick panels. 2. Space fasteners 8 inches on center along all support members. Drive fasteners flush with the panel surface, do not countersink. 3. Finish ceilings with a direct applied finish system, or materials suitable for humid environments. Provide Level 5 finish. D. Tape Joints. E. Paint per Section 09900: Painting and Protective Coatings. END OF SECTION Blue Lake Expansion Project – Contract No. 9 09510-1 General Construction May 2012 SECTION 09510 ACOUSTICAL PANEL CEILINGS PART 1 GENERAL 1.01 WORK INCLUDED A. Provide acoustical panel ceilings at Powerhouse As Shown: 1. Acoustical ceiling panels. 2. Exposed grid suspension system. 3. Wire hangers, fasteners, main runners, cross tees, and wall angle moldings. B. RELATED SECTIONS 1. Section 01300: Submittals. 2. Section 03480: Precast Concrete Hollow-Core Slabs. 3. Section 09290: Gypsum Board. 4. Section15800: Heating and Ventilation Systems. 5. Section 16500: Lighting and Receptacles. 1.02 REFERENCE STANDARDS 1. ASCE 7 Standard – American Society of Civil Engineers, Minimum Design Loads for Buildings and Other Structures. 2. ASTM A 568 Standard Specification for Steel, Sheet, Carbon, Structural, and High-Strength, Low-Alloy, Hot-Rolled and Cold-Rolled, General Requirements. 3. ASTM A 641 Standard Specification for Zinc-Coated (Galvanized) Carbon Steel Wire. 4. ASTM A 653 Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) by the Hot-Dip Process. 5. ASTM A 1008 Standard Specification for Steel, Sheet, Cold Rolled, Carbon, Structural, High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability. 6. ASTM C 423 Sound Absorption and Sound Absorption Coefficients by the Reverberation Room Method. 7. ASTM C 635 Standard Specification for Metal Suspension Systems for Acoustical Tile and Lay-in Panel Ceilings. Blue Lake Expansion Project – Contract No. 9 09510-2 General Construction May 2012 8. ASTM C 636 Recommended Practice for Installation of Metal Ceiling Suspension Systems for Acoustical Tile and Lay-in Panels. 9. ASTM D 3273 Standard Test Method for Resistance to Growth of Mold on the Surface of Interior Coatings in an Environmental Chamber. 10. ASTM E 84 Standard Test Method for Surface Burning Characteristics of Building Materials. 11. ASTM E 119 Standard Test Method for Fire Tests of Building Construction and Material. 12. ASTM E 1111 Standard Test Method for Measuring the Interzone Attenuation of Ceilings Systems. 13. ASTM E 1264 Classification for Acoustical Ceiling Products. 14. ASTM E 1414 Standard Test Method for Airborne Sound Attenuation Between Rooms Sharing a Common Ceiling Plenum. 15. ASTM E 1477 Standard Test Method for Luminous Reflectance Factor of Acoustical Materials by Use of Integrating-Sphere Reflectometers. 16. CISCA Seismic Zones 3 & 4 - Ceilings and Interior Systems Construction Association Guidelines for Seismic Restraint for Direct Hung Suspended Ceiling Assemblies. 17. International Code Council-Evaluation Services - AC 156 Acceptance Criteria for Seismic Qualification Testing of Non-structural Components. 18. International Code Council-Evaluation Services - Evaluation Report, ESR-1308, Fire- and Nonfire-Resistance-Rated Suspended Ceiling Framing Systems. 1.03 SYSTEM DESCRIPTION A. Seismic Loads: Design and size components to withstand seismic loads in accordance with the International Building Code, Section 1621 for Category D, E, and F. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. 1. Product Data: Submit Supplier’s technical data for each type of acoustical ceiling unit and suspension system required. 2. Shop Drawings: Provide layout and details of acoustical ceilings. Show locations of items which are to be coordinated with, or supported by the ceilings. 3. Certifications: Manufacturer’s certifications that system complies with specified requirements: a) For seismic performance: International Code Council Evaluation Report, ESR-1308. Blue Lake Expansion Project – Contract No. 9 09510-3 General Construction May 2012 b) For acoustical performance, each carton of material must carry an approved independent laboratory classification of NRC, CAC, and AC. 1.05 QUALITY ASSURANCE A. Single-Source Responsibility: Provide acoustical panel units and grid components by a single supplier. B. Fire Performance Characteristics: Identify acoustical ceiling components with appropriate markings of applicable testing and inspecting organization. 1. Surface Burning Characteristics: As follows, tested per ASTM E 84 and complying with ASTM E 1264 for Class A products: a) Flame Spread: 25 or less. b) Smoke Developed: 50 or less. 2. Fire Resistance Ratings: As indicated by reference to design designations in UL Fire Resistance Directory, for types of assemblies in which acoustical ceilings function as a fire protective membrane and tested per ASTM E 119. C. Seismic Performance: Provide acoustical ceiling system that has been evaluated by an independent party and found to be compliant with the 2003 International Building Code, Seismic Category D, E, and F: 1. Tested per International Code Council – Evaluation Services – AC 156 Acceptance Criteria for Seismic Qualification Testing of Non-structural Components as evidenced by International Code Council Evaluation Report, ESR-1308. D. Coordination of Work: Coordinate acoustical ceiling work with installers of related work including, but not limited to building insulation, gypsum board, light fixtures, mechanical systems, and electrical systems. 1.06 DELIVERY, STORAGE, AND HANDLING A. Deliver acoustical ceiling units to Project Site in original, unopened packages and store them in a fully enclosed space where they will be protected against damage from moisture, direct sunlight, surface contamination, and other causes. B. Before installing acoustical ceiling units, permit them to reach room temperature and a stabilized moisture content. C. Handle acoustical ceiling units carefully to avoid chipping edges or damaging units. 1.07 PROJECT CONDITIONS A. Space Enclosure: Do not install interior ceilings until space is enclosed and weatherproof; wet work in place is completed and nominally dry; work above ceilings is complete; and ambient conditions of temperature and humidity are continuously maintained at values near those intended for final occupancy. Building areas to receive ceilings shall be free of construction dust and debris. Blue Lake Expansion Project – Contract No. 9 09510-4 General Construction May 2012 1.08 WARRANTY A. Acoustical Panel: Submit a written warranty executed by the Supplier, agreeing to repair or replace acoustical panels that fail within the warranty period. Failures include, but are not limited to: 1. Acoustical Panels: Sagging and warping. 2. Grid System: Rusting and Supplier’s defects. B. Warranty Period: 1. Acoustical panels: Ten (10) years from data of Substantial Completion. Note Space Enclosure requirements. 2. Grid: Ten (10) years from date of substantial completion. C. The Warranty shall not deprive the Owner of other rights the Owner may have under other provisions of the Contract Documents and will be in addition to and run concurrent with other warranties made by the Contractor under the requirements of the Contract Documents. 1.09 MAINTENANCE A. Extra Materials: Deliver extra materials to Owner. Furnish extra materials described below that match products installed packaged with protective covering for storage and identified with appropriate labels. 1. Acoustical Ceiling Units: Furnish quality of full-size units equal to 5.0 percent of amount installed. 2. Exposed Suspension System Components: Furnish quantity of each exposed suspension component equal to 2.0 percent of amount installed. PART 2 PRODUCTS 2.01 SUPPLIERS A. Armstrong World Industries, Inc. B. Approved Equal. 2.02 ACOUSTICAL CEILING UNITS A. Basis of Design: Armstrong Fine Fissured High Acoustics, item 1717: 1. Surface Texture: Medium. 2. Composition: Mineral Fiber. 3. Color: White. Blue Lake Expansion Project – Contract No. 9 09510-5 General Construction May 2012 4. Size: 24 inch x 24 inch x 3/4 inch. 5. Edge Profile: Angled Tegular for interface with Prelude XL 15/16” Exposed Tee Grid System. 6. Noise Reduction Coefficient (NRC): 0.7, complying with ASTM C 423. 7. Ceiling Attenuation Class (CAC): 40, complying with ASTM A 1414. 8. Flame Spread: Class A, complying with ASTM E 1264. 9. Light Reflectance (LR) White Panel: 0.85, complying with ASTM E 1477. 10. Dimensional Stability: HumiGuard Plus. B. Provide spare acoustic ceiling panels equal to 40 square feet of panel surface. 2.03 SUSPENSION SYSTEMS A. Basis of Design: Armstrong Prelude XL 15/16 inch Exposed Tee System. B. Components: Main beams and cross tees in accordance with the International Building Code, Section 1621 for Category D, E and F as described in ESR-1308: 1. Structural Classification: ASTM C 635, Heavy Duty. 2. Color: White, match the actual color of the selected ceiling tile. C. Attachment Devices: In accordance with the International Building Code, Section 1621 for Category D, E, and F. 1. Powder Actuated Fastener. 2. Mechanical Fastener – Seismic Wedge Anchor. D. Wire for Hangers and Ties: In accordance with the International Building Code, Section 1621. E. Wall Moldings: In accordance with the International Building Code, Section 1621 for Category D, E. and F or method as described in ESR-1308. 1. Nominal 15/16 inch x 15/16 inch hemmed, pre-finished angle molding (7809). F. Accessories: 1. BERC2: 2 inch Beam End Retaining Clip, 0.034 inch thick, hot-dipped galvanized cold-rolled steel per ASTM A568 to join main beam or cross tee to wall molding. 2. SJCG: Seismic Joint Clip, 5 inches x 1-1/2 inch, hot-dipped galvanized cold- rolled steel per ASTM A 568 to accommodate a seismic separation joint. Blue Lake Expansion Project – Contract No. 9 09510-6 General Construction May 2012 3. SJMR15: Seismic Joint Clip Main Beam, 1 inch x 4 inches, commercial quality cold rolled hot dipped galvanized steel per ASTM A 568, chemically cleansed. PART 3 EXECUTION 3.01 EXAMINATION A. Do not proceed with installation until all wet work such as concrete, plastering and painting has been completed and thoroughly dried out, unless expressly permitted by Supplier’s printed recommendations. 3.02 PREPARATION A. Measure each ceiling area and establish layout of acoustical units to balance border widths at opposite edges of each ceiling. Avoid use of less than half width units at borders, and comply with architectural ceiling plans. Coordinate panel layout with mechanical and electrical fixtures As Shown. B. Coordination: Furnish layouts for preset inserts, clips, and other ceiling anchors whose installation is specified in other Sections. 1. Furnish concrete inserts and similar devices to other trades for installation well in advance of time needed for coordination of other work. 3.03 INSTALLATON (Category D,E,F) A. Install suspension system and panels in accordance with the International Building Code, Section 1621, except as noted in Section 4.4.3.1 of ESR-1308. B. ESR-1308, Section 4.4.3.1, Alternate Seismic Design Category D,E and F Installation: Under this installation, the runners must be rated heavy-duty and have a minimum simple span uniform load of 16.35 pounds per lineal foot (238 N/m); maximum ceiling weight permitted is 4 pounds per square foot (8.78 kg/m2). 1. The BERC-2 clip is used to secure the main runners and cross runners on two adjacent walls to the structure and the two opposite walls to the perimeter trim, as detailed below. A nominal 7/8-inch (22 mm) wall molding is used in lieu of the 2- inch (51 mm) perimeter supporting closure angle required by Section 9.6.2.6.2.2 (b) of ASCE-7 for Seismic Design Categories D, E and F. Except for the use of the BERC-2 clip and the 7/8-inch (22 mm) wall molding and elimination of spreader bars, installation of the ceiling system must be as prescribed by the applicable code. 2. The BERC-2 clip is attached to the wall molding by sliding the locking lances over the hem of the vertical leg of the wall molding. Clips installed on the walls where the runners are fixed are attached to the runner by a sheet metal screw through the horizontal slot in the clip into the web of the runner. Alternate #2: Fixed attachment may be accomplished by pop-riveting the runner to the wall molding. Blue Lake Expansion Project – Contract No. 9 09510-7 General Construction May 2012 1. Clips installed on the walls where the runners are not fixed to the runner allow the terminal runner end to move 3/4 inch (19.1 mm) in both directions. BERC-2 clips installed in this manner are an acceptable means of preventing runners from spreading in lieu of spacer bars required in CISCA 3-4, which is referenced in ASCE 7, Section 9.6.2.6.2.2, which is referenced in IBC Section 1621. C. Install SJCG Seismic Separation Joint Clip per Supplier’s recommendations, CS- 3815. D. Install SJMR15 Seismic Joint Clip Main Beam per Supplier’s recommendations, CS- 3955. E. For reveal edge panels: Cut and reveal or rabbet edges of ceiling panels at border areas and vertical surfaces. F. Install acoustical panels in coordination with suspended system, with edges resting on flanges of main runner and cross tees. Cut and fit panels neatly against abutting surfaces. Support edges by wall moldings. 3.04 ADJUSTING AND CLEANING A. Replace damaged and broken panels. B. Clean exposed surfaces of acoustical ceilings, including trim, edge moldings, and suspension members. Comply with Supplier’s instructions for cleaning and touch up of minor finish damage. Remove and replace work that cannot be successfully cleaned and repaired to permanently eliminate evidence of damage. END OF SECTION Blue Lake Expansion Project – Contract No. 9 09650-1 General Construction May 2012 SECTION 09650 RESILIENT WALL BASE PART 1 GENERAL 1.01 WORK INCLUDED A. Provide resilient wall base in the powerhouse on gypsum board walls As Shown. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 06066: Decorative Plastic Laminate. C. Section 09290: Gypsum Board. 1.03 REFERENCE STANDARDS A. ASTM E 84: Standard Test Method for Surface Burning Characteristics of Building Materials. B. ASTM F 1861: Standard Specification for Resilient Wall Base. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data for each product to be used, including Supplier’s specification summary sheet for specified products. C. Sample Board with color selections of all architectural finish materials. D. Executed Warranty. 1.05 QUALITY ASSURANCE A. Use adequate numbers of skilled workers who are thoroughly trained and have a minimum of 5 years experience in performing the Work of this Section. B. Obtain resilient wall base and Supplier’s recommended adhesive from a single Supplier. 1.06 PRODUCT HANDLING A. Deliver products to project site in original packaging with labels intact. B. Store materials protected from exposure to harmful weather conditions and acclimated to site conditions at temperature and humidity conditions recommended by Supplier. Blue Lake Expansion Project – Contract No. 9 09650-2 General Construction May 2012 1.07 WARRANTY A. Submit standard warranty document. 1.08 MAINTENANCE A. Deliver extra materials from same production run as products installed. PART 2 PRODUCTS 2.01 SUPPLIERS A. Acceptable Suppliers include: 1. Roppe Corporation. 2. Approved equal. 2.02 MATERIALS A. Complies with ASTM F-1861 Type TS (Thermoset Vulcanized Rubber), Group 1 (Solid). B. Contains 10% natural rubber. C. Thickness: 1/8 inch nominal. D. Color: to be selected from Supplier’s standard range of colors. E. Profile: Standard Toe (Cove Base): 1. Nominal Height: 4”. 2. Length: 120’ coil. 3. Corners: formed by Contractor onsite. F. Provide one spare 120-foot coil of resilient wall base. G. Accessories as recommended by product Supplier’s installation instructions, including adhesive and colored caulk. PART 3 EXECUTION 3.01 INSPECTION A. Verify that substrates are acceptable for installation. B. Do not begin installation until substrates have been properly prepared. C. If substrate preparation is the responsibility of another trade, notify RPR of unsatisfactory preparation before proceeding. Blue Lake Expansion Project – Contract No. 9 09650-3 General Construction May 2012 D. In accordance with Supplier’s installation requirements, visually inspect materials prior to installing. Material with visual defects will not be installed. 3.02 PREPARATION A. Protect adjacent surfaces from damage during product installation. B. Prepare surfaces using the methods recommended by the Supplier; substrate to be smooth, rigid, flat, level, permanently dry, clean, and free of foreign materials, such as paint, dust, grease, oils, solvent, and all other contaminants that may interfere with adhesive bond. 3.03 INSTALLATION A. Install in accordance with Supplier’s written installation instructions. 3.04 FIELD QUALITY CONTROL A. RPR to inspect substrates for suitability for installation, to review procedures during construction, and to review the finished Work. 3.05 PROTECTION A. Protect installed products until completion of Project. B. Touch-up, repair or replace damaged products before Substantial Completion. END OF SECTION Blue Lake Expansion Project – Contract No. 9 09772-1 General Construction May 2012 SECTION 09772 DECORATIVE FIBERGLASS REINFORCED WALL PANELS PART 1 GENERAL 1.01 WORK INCLUDED A. Provide prefinished polyester glass reinforced plastic sheets adhered to unfinished gypsum board in powerhouse As Shown. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 09290: Gypsum Board. 1.03 REFERENCE STANDARDS A. ASTM D 570: Water Absorption. B. ASTM D 638: Tensile Strengths and Tensile Modulus. C. ASTM D 790: Flexural Strengths and Flexural Modulus. D. ASTM D 5319: Standard Specification for Glass-Fiber Reinforced Wall and Ceiling Panels. E. ASTM E 84: Standard Test Method for Surface Burning Characteristics of Building Materials. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: For each product to be used, including preparation instructions and recommendations, storage and handling requirements and recommendations, and installation methods. C. Sample Board with color selections of all architectural finish materials. D. Shop Drawings: Submit elevations of each wall showing location of paneling and trim members with respect to all discontinuities in the wall elevation. E. Supplier’s Material Safety Data Sheets (MSDS): For adhesives and sealants prior to their delivery to the site. F. Product Warranty. 1.05 QUALITY ASSURANCE A. Use adequate numbers of skilled workers who are thoroughly trained and have a minimum of 5 years experience in performing the Work of this Section. Blue Lake Expansion Project – Contract No. 9 09772-2 General Construction May 2012 1.06 PRODUCT HANDLING A. Deliver products to project site in original packaging with labels intact. B. Store panels and trim lying flat, protected from exposure to harmful weather conditions and acclimated to site conditions at temperature and humidity conditions recommended by Supplier. 1.07 WARRANTY A. Submit standard warranty document. PART 2 PRODUCTS 2.01 SUPPLIERS A. Acceptable Suppliers include: 1. Marlite. 2. Approved equal. 2.02 MATERIALS A. Fiberglass reinforced thermosetting polyester resin panel sheets complying with ASTM D 5319. 1. Basis-of-Design Product: Marlite, Standard FRP. 2. Coating: Multi-layer print, primer and finish coats. 3. Dimensions: a) Thickness: 0.090 inch nominal. b) Width: 4'-0” nominal. c) Length: 8’-0” nominal. 4. Tolerance: a) Length and Width: +/-1/8 inch. b) Square: Not to exceed 1/8 inch for 8 foot panels. B. Properties: Resistant to rot, corrosion, staining, denting, peeling, and splintering complying with ASTM D 570, ASTM D 638, and ASTM D 790. C. Back Surface: Smooth; imperfections which do not affect functional properties are not cause for rejection. 1. Color to be selected from Supplier’s standard range of colors. 2. Surface: Smooth. Blue Lake Expansion Project – Contract No. 9 09772-3 General Construction May 2012 D. Provide three spare 4-foot by 8-foot fibreglass wall panels. 2.03 MOLDINGS A. FRP Base Molding for 0.090 inch thick panels. 1. Color to be selected from Supplier’s standard range of colors. B. Extruded PVC Trim Profiles for 0.090 inch thick panels. 1. Color to be selected from Supplier’s standard range of colors. 2. Profiles: a) Inside corner. b) Division. c) Edge. C. Provide 20 linear feet of spare base molding and PVC trim profiles, each type. 2.04 ACCESSORIES A. Adhesive: Water resistant, non-flammable or flexible, solvent based adhesive formulated for fast, easy application. B. Silicone Sealant. PART 3 EXECUTION 3.01 INSPECTION A. Verify that substrates are acceptable for installation. 1. Verify that stud spacing does not exceed 24 inch on-center. B. Do not begin installation until substrates have been properly prepared. C. If substrate preparation is the responsibility of another trade, notify RPR of unsatisfactory preparation before proceeding. D. In accordance with Supplier’s installation requirements, visually inspect materials prior to installing. Material with visual defects will not be installed. 3.02 PREPARATION A. Protect adjacent surfaces from damage during product installation. B. Prepare surfaces using the methods recommended by the Supplier; substrate to be smooth, rigid, flat, level, permanently dry, clean, and free of foreign materials, and all other contaminants that may interfere with adhesive bond; corners to be plumb Blue Lake Expansion Project – Contract No. 9 09772-4 General Construction May 2012 and straight; nails countersunk; and joints and cracks to be filled flush and smooth with the adjoining surface. 3.03 INSTALLATION A. Install in accordance with Supplier’s written installation procedures and sequence. B. Cut sheets to meet supports allowing 1/8 inch clearance for every 8 foot of panel. 1. Cut and drill with carbide tipped saw blades or drill bits, or cut with shears. 2. Pre-drill fastener holes 1/8 inch oversize with high speed drill bit. a) Space at 8 inches maximum on center at perimeter, approximately 1 inch from panel edge. b) Space in field in rows 16 inches on center, with fasteners spaced at 12 inches maximum on center. C. Apply panels to board substrate, above base, vertically oriented with seams plumb and pattern aligned with adjoining panels. 1. Install panels with Supplier's recommended gap for panel field and corner joints. a) Adhesive trowel and application method to conform to adhesive Supplier’s recommendations. b) Drive fasteners for snug fit. Do not over-tighten. D. Apply panel moldings to all panel edges using silicone sealant providing for required clearances. 1. All moldings must provide for a minimum 1/8 inch of panel expansion at joints and edges, to insure proper installation. 2. Apply sealant to all moldings, channels and joints between the system and different materials to assure watertight installation. 3.04 FIELD QUALITY CONTROL A. RPR to inspect substrates for suitability for installation and to review the finished Work. 3.05 CLEANING A. Remove excess sealant from panels and mouldings. B. Refer to Supplier’s specific cleaning recommendations. Do not use abrasive cleaners. Blue Lake Expansion Project – Contract No. 9 09772-5 General Construction May 2012 3.06 PROTECTION A. Protect installed products until completion of Project. B. Touch-up, repair or replace damaged products before Substantial Completion. END OF SECTION Blue Lake Expansion Project – Contract No. 9 09900-1 General Construction May 2012 SECTION 09900 PAINTING AND PROTECTIVE COATINGS PART 1 GENERAL 1.01 WORK INCLUDED A. Provide painting and protective coatings As Shown and specified herein. B. The Work covered by this Section also includes galvanizing of miscellaneous metal parts As Shown and as listed in Table P-2. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 03300: Cast-in-Place Concrete C. Section 05100: Structural Steel D. Section 05500: Miscellaneous Metals E. Section 09290: Gypsum Board F. Section 13100: Penstock Installation G. Section 13110: Penstock Steel Liner H. Section 13310: Intake Trashrack and Supports I. Section 13450: Installation of Bulkhead Gate and Guides J. Section 14600: Powerhouse Bridge Crane Installation K. Section 20100: Turbine and Generator Equipment Installation 1.03 REFERENCE STANDARDS A. Federal Specification - TT-P-00641: Primer Coating, Zinc Dust-Zinc Oxide (for galvanized surfaces). B. SSPC – Society for Protective Coatings: Systems and Specifications, C. AWWA C222: Standard for Polyurethane Coatings for the Interior and Exterior of Steel Water Pipe and Fittings. D. ASTM A123: Standard Specification for Hot-Dip Galvanized Coatings. E. ASTM A385: Standard Practice for Supplying High-Quality Zinc Coatings (hot-dip). F. ASTM A386: Standard Specification for Zinc Coating (hot dip) on Assembled Steel Products. Blue Lake Expansion Project – Contract No. 9 09900-2 General Construction May 2012 G. ASTM A780: Standard Practice for Repair of Hot-Dip Galvanized Coatings. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submit product data, MSDS sheets, and painting procedures for all coating systems. C. Submit a blank quality control checklist which includes fields for: coating system, air temperature, substrate temperature, humidity, number of coats, and mil thickness of each coat. 1.05 QUALITY ASSURANCE A. Products used in the Work of this Section shall be produced by Suppliers regularly engaged in the manufacture of similar items and with a history of successful production acceptable to RPR. B. Contractor shall provide at least one person who shall be present at all times during execution of the Work, who shall be thoroughly familiar with the specified requirements and the materials and methods needed for their execution, and who shall direct all Work performed under this Section. C. Contractor shall provide adequate numbers of workmen skilled in the necessary crafts and properly informed of the methods and materials to be used and all current safety procedures as specified by OSHA. D. Contractor shall undertake the following to ensure acceptable paint coordination: 1. Ensure compatibility of prime coats and finish coats. 2. Review other Sections of this Specification as required, verifying the prime coats used. 3. Provide barrier coats over non-compatible primers, or remove the primer and re-prime as required. 4. Notify RPR in writing of anticipated problems in using the specified coating systems over prime coating supplied under other Sections. 1.06 PRODUCT HANDLING A. Delivery of materials: All materials shall be delivered to the job site in original, new and unopened containers bearing the Supplier's name and label showing the following information: 1. Name or title of material. 2. Federal Specification number, if applicable. 3. Supplier’s stock number. 4. Supplier’s name. 5. Contents by volume for major constituents. Blue Lake Expansion Project – Contract No. 9 09900-3 General Construction May 2012 6. Thinning instructions. 7. Application instructions. B. Contractor shall also include with material delivery, the material safety data sheet (MSDS) applicable to each coating. C. Contractor shall provide proper storage to prevent freezing and damage to and deterioration of paint materials and shall use all means necessary to protect the materials of this Section before, during and after installation and to protect the Work and materials of other trades. D. In the event of damage, Contractor shall immediately make all repairs and replacements necessary for the acceptance of RPR at no additional cost to Owner. 1.07 JOB CONDITIONS A. Weather conditions: Paint shall not be applied in snow, rain, fog or mist; or when the relative humidity exceeds 85 percent; or to damp or wet surfaces unless otherwise permitted by the coating Supplier’s printed instructions as accepted by RPR. Applications may be continued during inclement weather within the temperature limits specified by the coating Supplier during application and drying periods. Contractor shall provide protection for the Work against inclement weather conditions. PART 2 PRODUCTS 2.01 PROTECTIVE COATING SYSTEMS A. All surfaces shall be protected in accordance with the coating systems specified on Tables P-1 and P-2, and in accordance with the coating Supplier's instructions. Where there is a discrepancy between the coating Supplier's instructions and this specification, the former shall govern. The coating materials and systems as specified are intended to establish the minimum quality of the material and system for the environmental conditions imposed. Contractor may utilize a different material or system for which it has preference, provided that a written request detailing the alternative material or system shall be made to RPR and that RPR agrees with such a request in writing. Contractor shall be fully responsible for the preparation and cleaning of all surfaces; the selection and application of all coating materials and systems; the cutting of all coatings; and other items required for satisfactory protective coating of the Work. B. Except where specifically excluded Contractor furnished materials and equipment that have a shop or factory applied coating shall be touch up coated at Site after completion of installation, followed by application a complete new paint coat to provide a uniform surface finish. Surface preparation and cleaning and application of the coating shall be in accordance with the coating Supplier’s recommendations. Contractor shall ensure compatibility of shop or factory coating and site applied coating. C. Only touch up coating will be required for the following Contractor furnished materials and equipment that have a factory applied coating: 1. Materials that are not painted. Blue Lake Expansion Project – Contract No. 9 09900-4 General Construction May 2012 2. Materials and equipment that are buried or submerged during normal operation. 3. Doors and door frames for the powerhouse and gate house, including sectional overhead doors. 4. 24-inch fixed cone valve. 5. Steel lining for the fixed cone valve energy dissipater. D. Owner furnished materials and equipment will have protective coating applied in the shop by the material/equipment supplier, as summarized on Table P-3. Contractor shall touch up coat the material and equipment at the completion of installation. The touch up coating system shall be shall be the same type and from the same coating Supplier as used by the equipment supplier. Owner will provide Contractor with specific details of the coating systems for Owner furnished materials and equipment. Generically equivalent coating from alternate suppliers shall be subject to RPR acceptance. Surface preparation and cleaning and application of the coating shall be in accordance with the coating Supplier’s recommendations. The touch up coating shall match the color of the remainder of the surface to the satisfaction of the RPR. If the color does not match Contractor shall recoat the complete surface. E. Owner furnished penstock and manifold materials have areas adjacent to the joints for site welding that have only a weldable primer applied in the shop. These surfaces shall be coated as specified in Tables P-1 and P-2. F. Any damage to the existing penstock and steel liner sections that will be retained as part of the permanent project shall be repaired by touch up coating with an epoxy coating system acceptable to RPR. Surface preparation and cleaning and application of the coating shall be in accordance with the coating Supplier’s recommendations. 2.02 ENVIRONMENTAL REQUIREMENTS A. All coatings supplied shall comply with the VOC limits specified 40 CFR Part 59, National Volatile Organic Compound Emission Standards for Consumer and Commercial Products. B. Abrasive blasting (if applicable) that utilizes blasting agents that contain radioactive materials shall not be permitted. C. Paint shall not contain lead. 2.03 PAINT MATERIALS A. General: The paint material shall be as specified herein unless otherwise accepted by RPR. Materials not displaying Supplier's identification as a standard best-grade product will not be acceptable. B. Factory Finish: Supplier to provide additional touch-up paint for all factory finished items. C. Durability: Paints of durable and washable quality shall be provided. Paint materials which will withstand normal washing as required to remove pencil marks, Blue Lake Expansion Project – Contract No. 9 09900-5 General Construction May 2012 ink, ordinary soil, and similar materials without showing discoloration, loss of gloss, staining, or other damage shall be used. D. Colors and Glosses: Owner shall select colors to be used in the various types of paint specified and will be the sole judge of acceptability of the various glosses obtained from materials proposed to be used by Contractor. E. Undercoats and Thinners: Undercoat paint shall be produced by the same Supplier as the finish coat. Contractor shall use only the thinners recommended by the paint Supplier, and only to the recommended limits. Insofar as practicable, undercoat, finish coat, and thinner material shall be used as parts of a unified system of paint finish. PART 3 EXECUTION 3.01 PREPARATION A. Surface Conditions 1. Inspection: Prior to commencing the Work of this Section, Contractor shall carefully inspect the installed Work of all other trades and verify that all such Work is complete to the point where this Work may properly commence. He shall verify that painting may be completed in strict accordance with the original design and with the Supplier's recommendations as accepted by RPR. 2. Discrepancies: Contractor shall not proceed in areas of discrepancy until all such discrepancies have been fully resolved. B. Surface Preparation – General 1. Perform all preparation and cleaning procedures in strict accordance with the paint Supplier's recommendations as accepted by RPR. 2. Remove all removable items not scheduled to receive paint finish, or provide surface-applied protection prior to surface preparation and painting operations. 3. After completion of painting in each space or area, reinstall the removed items by using workmen skilled in the necessary trades. 4. Clean each surface to be painted prior to applying paint or surface treatment. 5. Remove oil and grease with clean cloths and cleaning solvents of low toxicity and a flash point in excess of 100°F, prior to the start of mechanical cleaning. 6. Schedule the cleaning and painting so that dust and other contaminants from the cleaning process will not fall onto wet, newly painted surfaces. 7. Fill out a painting quality control checklist (see Part 1.04.C of this Section). C. Surface Preparation – Metals 1. Contractor shall use one or a combination of any of the following methods of surface preparation to achieve the degree of preparation required for the protective coating system involved. The surface preparation for each Blue Lake Expansion Project – Contract No. 9 09900-6 General Construction May 2012 protective coating system shall be considered as a minimum requirement and shall be improved if so dictated by paint Supplier. a) Sandblast Cleaning to "Near White" Metal Surfaces requiring "Near White" metal cleaning shall be sandblasted in accordance with SSPC Specification SP10 with a 2-mil profile. The sand shall be quartz sand, washed, clean, dry and gypsum free. Sea sand shall not be used. Sand shall not be radioactive and shall be tested and documented to provide its content. Heavy deposits of oil or grease shall be removed by solvent prior to blast cleaning. Small quantities of grease or oil may be removed by the blasting process; however, the abrasive shall not be reused if it contains sufficient oil or grease to render it unsuitable for blast-cleaning purposes. Blast-Cleaned surfaces shall be kept under cover in a heated area and shall not be exposed to the weather elements under any circumstances. If rusting has occurred on any sandblast surface prior to application of primer, Contractor shall reblast the surface. b) "Commercial" Sandblast Cleaning Surfaces requiring "Commercial" metal cleaning shall be sandblasted in accordance with SSPC Specification SP 6 with a 2-mil profile. The general requirements specified for blast cleaning in subsection a. above, shall also apply to "Commercial" metal cleaning. c) Power Tool Cleaning When power tool cleaning is specified, surface preparation shall be in accordance with SSPC Specification SP-3 to remove loose rust, mill scale, and other foreign material. As an alternative to power tool cleaning, Contractor may use "Commercial" sandblast cleaning in accordance with SSPC Specification SP 6. d) Final Cleaning For all coating systems and prior to primer application, loose dirt, blasting sand or other foreign material shall be removed from the surface with clean brushes, compressed air or vacuum cleaner. Care shall be taken in the removal of such debris from joints, angles and corners. Grease or oil shall be removed by solvent cleaning. On primed surfaces that have deteriorated, power tool cleaning shall be carried out as in subsection c. above before application of the finish coatings. Under normal conditions prior to final coating, the surfaces shall be solvent cleaned as a required. 2. Paint shall be applied immediately following final cleaning of the surfaces. Under no circumstances shall the elapsed time between commencement of the surface cleaning operation and application of primer or finish coats exceed a period of six hours. D. Materials Preparation – General Blue Lake Expansion Project – Contract No. 9 09900-7 General Construction May 2012 1. Painting materials shall be mixed and prepared in strict accordance with the Supplier's recommendations as accepted by the RPR. 2. Materials not in actual use shall be stored in tightly covered containers. 3. Containers used in storage, mixing and application of paint shall be maintained in a clean condition, free from foreign materials and residue. 4. Stirring: All materials shall be stirred before application to produce a mixture of uniform density, and as required during the application of materials. Do not stir into the material any film which may form on the surface. Remove the film and, if necessary, strain the material before using. 3.02 PAINT APPLICATION – GENERAL A. Following surface preparation, Contractor shall complete all paint application in accordance with the requirements specified herein, together with those recommended by the coating Supplier B. Paint shall be applied under conditions specified by the Supplier. C. If no application conditions are specified by the coating Supplier, paint shall be applied when the humidity, air temperature, and surface temperature encourage evaporation and do not encourage condensation. Surfaces to be coated shall be completely dry and shall be at a minimum temperature of 50°F and at least 5°F above the dew point of the surrounding air. The atmosphere around the surface to be painted shall not contain excessive dust. D. Newly cleaned or painted surfaces shall be protected from moisture, condensation, contamination, and freezing temperatures until the paint is thoroughly cured. Care shall be taken to prevent contamination of surfaces between coats of paint. E. Instructions from the coating Supplier shall be followed in conjunction with the requirements specified herein. Thinners shall not be added to any paint except as recommended by the paint Supplier. Paint thinners, if used, and solvents, shall be compatible with the paint materials being supplied. F. Paint with a pot life specified shall be discarded whenever that life is exceeded and the painting equipment cleaned before starting a new batch. No batch shall be mixed in a quantity greater than is expected to be used within the specified pot life. G. All paint shall be thoroughly mixed before each use, and the pigment shall not be allowed to settle during application. H. For site painting, Contractor shall provide adequate illumination and ventilation during application of the paint. Each coat shall be thoroughly dried and cured before application of succeeding coats. Contractor shall provide all necessary scaffolds, ladders, drape cloths, masking tape, wipers, and other supplies and materials to carry out the Work. Contractor shall provide all necessary mechanical paint mixing equipment. Contractor shall take all precautions necessary to protect personnel and equipment from overspray and noxious fumes and against all fire hazards. Signs shall be posted by Contractor to prevent grinding, welding, smoking, and other unsafe activities from being performed in the painting areas. 3.03 APPLICATION OF PAINT – SPRAY Blue Lake Expansion Project – Contract No. 9 09900-8 General Construction May 2012 A. Spray application shall be performed with airless spray equipment. Spray-painting equipment shall be of ample capacity for the Work and shall at all times be kept clean and in good working order. Spray guns shall be suited to the kind of paint being used and shall be operated with orifices, nozzles, and air pressure suited to the kind of paint and its consistency. Paint pots shall be equipped with means of controlling air or liquid pressure on the pot independently of the pressure at the gun. B. Air lines shall be equipped with water traps for positive removal of condensed moisture. 3.04 APPLICATION OF PAINT – BRUSH A. Brush application of prime coats shall be avoided except as otherwise specified and/or recommended by the paint Supplier. Brush application of any subsequent coats shall not be applied unless previous coat is accepted by RPR. Paint materials shall be applied in flowing coats; each coat shall be of uniform coverage, and well brushed out leaving no defects. B. On all surfaces which are inaccessible for brushes and where spraying cannot be employed, the paint shall be applied by sheepskin daubers specifically constructed for the purpose. 3.05 APPLICATION OF PAINT – ROLLER A. Roller application of coating systems shall be avoided wherever possible, except as recommended by the paint Supplier. Should the use of rollers become essential, the coating material so applied shall be in uniform and even coats, without defects. The second coat shall be applied at right angles to the first coat. Interior angles and other areas inaccessible to rollers shall be coated by brush and sheepskin daubers. 3.06 SURFACES NOT TO BE PAINTED A. The following surfaces shall not be painted: 1. Corrosion-resistant steel surfaces (i.e., stainless, anodized aluminum, and chromium plate) unless shown otherwise. 2. Faying surfaces on connections designed for high strength bolts; however, if primer is of the zinc-rich type, faying surfaces shall be prime coated. 3. Surfaces within 2 inches of field welds, prior to welding. 4. Areas of embedded parts which will be in contact with concrete, except As Shown (these surfaces shall be cleaned of all rust and scale). 5. Metal surfaces of anodized aluminum, stainless steel, chromium plate, copper, bronze, powder coating, and similar finish materials will not require painting under this Section except as may be specified herein. 6. Labels or equipment identification, performance rating, name, or nomenclature plates. 7. Machine finished or similar surfaces; however, such surfaces shall be protected with a corrosion preventive compound. Blue Lake Expansion Project – Contract No. 9 09900-9 General Construction May 2012 3.07 CURING SCHEDULE A. Curing schedules as recommended by the coating Supplier for each coating system shall be followed. Surface temperatures shall be used in determining curing schedules. Allow sufficient curing time between coats. B. Accelerated curing may be employed, but only as recommended by the paint Supplier and whenever surface temperatures are such that proper curing cannot be accomplished within a reasonable time. Accelerated curing shall have the prior written agreement of Owner. C. Oil-base and oleo-resinous, solvent-type paints shall be considered dry for recoating when the paint feels firm, does not deform or feel sticky under moderate pressure of the thumb, and the application of another coat of paint does not cause lifting or loss of adhesion of the undercoat. 3.08 FILM THICKNESS A. For minimum requirements, unless otherwise specified herein or by the Supplier, prime coats shall be 1.5 to 2 mils thick when dry, and intermediate and finish coats of paint shall have a dry film thickness of at least 1.5 mils per coat. No portion of the paint film shall be less than the specified film thickness. Film thicknesses shall not be so great that either the appearance, curing, or service life of the paint will be detrimentally affected. B. The wet film thickness shall be checked at the time the paint is being applied and the dry film thickness then calculated using the volatile matter content of the paint. After all coats are applied, the dry film thickness shall be checked using magnetic gages in accordance with SSPC-PA2-73T. 3.09 PAINT INSPECTION A. Protective coating systems shall not be applied until the painting quality control checklist (See Part 1.04.C of this Section) has been approved by RPR. B. The Contractor shall inspect all painted surfaces. The standard of inspection will be in accordance with the SSPC Manual, Volumes 1 and 2. The Contractor may employ an electrically operated holiday detector in the inspection of coated surfaces. C. Each coat, when dried, shall be inspected and accepted by RPR before application of succeeding coats, otherwise no credit will be given for the coat. As a result, Contractor may be required to recoat the surface at no additional cost to Owner. D. The coated surface will be evaluated to determine uniformity, continuity, and soundness, and will be rejected if any of the following defects are apparent to RPR: 1. Runs, sags, holidays, mudcracking, peeling, flaking or shadowing caused by inefficient application methods. 2. Evidence of poor coverage at plate, lap joints, crevices, pockets, corners, and re-entrant angles. 3. Damage to coating because of handling before the paint is sufficiently dry, or any other contributory cause. Blue Lake Expansion Project – Contract No. 9 09900-10 General Construction May 2012 4. Damage because of shipping and handling. E. Recoating or repair of all cleaned and/or coated surfaces rejected by Contractor's inspector or RPR shall be Contractor's responsibility. Small affected areas may be touched up. Another complete coat shall be applied to large affected areas or areas where sufficient dry film thickness has not been attained. Runs, sags, or paint damaged in handling shall be removed prior to further application. 3.10 PROTECTIVE COATING INFORMATION A. See Table P-1 (eight parts) for protective coating systems. B. See Table P-2 for protective coatings and color schedule. C. See Table P-3 for protective coatings and color schedule of Owner furnished materials and equipment. Blue Lake Expansion Project – Contract No. 9 09900-11 General Construction May 2012 TABLE P-1 PROTECTIVE COATING SYSTEMS SYSTEM SYS-1 COATING SYSTEM TYPE ........................................... Hot-dip galvanizing SERVICE ...................................................................... Exterior structural steel and (ferrous) miscellaneous metal SERVICE PREPARATION ............................................ Sandblast cleaning to “Commercial” SSPC SP6 and pickling PRIMER COAT .............................................................. Hot-dip galvanized in accordance with ASTM A123 and A385 standards INTERMEDIATE COAT ................................................. -- FINISH COAT ................................................................ -- TOUCHUP .................................................................... Hot stick galvanized with zinc-based alloy per supplier’s instructions and in accordance with ASTM A780 SYSTEM SYS-2 COATING SYSTEM TYPE ........................................... High solids catalyzed epoxy SERVICE ...................................................................... Submerged and exterior steel surfaces SURFACE PREPARATION .......................................... Sandblast cleaning to "near white" SSPC-SP10 PRIMER COAT ............................................................. One coat high solids, amine cured, epoxy coating, TNEMEC, Series 104-1211 H.S. epoxy with a dry film thickness of 8.0 to 10.0 mils SURFACE CLEANING ................................................. -- FINISH COAT ................................................................ One coat high solids, amine cured, epoxy coating, TNEMEC, Series 104-Color H.S. epoxy with a dry film thickness of 8.0 to 10.0 mils Blue Lake Expansion Project – Contract No. 9 09900-12 General Construction May 2012 TABLE P-1 (continued) PROTECTIVE COATING SYSTEMS SYSTEM SYS-3 COATING SYSTEM TYPE ........................................... 100% solids polyurethane SERVICE ...................................................................... Penstock and steel liner SURFACE PREPARATION .......................................... Sandblast cleaning to "near white" SSPC-SP10 COATING ..................................................................... Lifelast Durashield 310-61 (25 mils dry film thickness) SITE WELDED JOINTS ................................................ Lifelast Durashield 310-61 JARS SYSTEM SYS-4 COATING SYSTEM TYPE ........................................... 100% solids polyurethane SERVICE ...................................................................... Buried penstock SURFACE PREPARATION .......................................... Sandblast cleaning to "near white" SSPC-SP10 COATING ..................................................................... Lifelast Durashield 310-61. (40 mils dry film thickness) SITE WELDED JOINTS ................................................ Canusa Aqua-Shield heat shrink sleeves Blue Lake Expansion Project – Contract No. 9 09900-13 General Construction May 2012 TABLE P-1 (continued) PROTECTIVE COATING SYSTEMS SYSTEM SYS-5 COATING SYSTEM TYPE ........................................... Polyamidoamine Epoxy SERVICE ...................................................................... Equipment and interior steel surfaces SURFACE PREPARATION .......................................... SSPC-SP3 power tool cleaning PRIMER COAT ............................................................. TNEMEC Series 135 Chembuild ...................................................................................... (7 to 9 mils dry film thickness) TOP COAT ................................................................... TNEMEC Series L69 Hi-Build Epoxoline II (4 to 8 mils dry film thickness) SURFACE CLEANING ................................................. -- SYSTEM SYS-6 COATING SYSTEM TYPE ........................................... Latex SERVICE ...................................................................... Powerhouse interior SURFACE PREPARATION .......................................... As recommended by the Supplier for achieving the best result for the substrate under the project conditions PRIMER COAT ............................................................. Devoe Primer, White or equal TOP COAT ................................................................... Devoe Wonder-Pro, Interior/Exterior Latex, Semigloss or equal SURFACE CLEANING ................................................. Clean excess coating materials, reinstall all items that have been removed to protect from contact with coatings, and remove protective materials Blue Lake Expansion Project – Contract No. 9 09900-14 General Construction May 2012 TABLE P-1 (continued) PROTECTIVE COATING SYSTEMS SYSTEM SYS-7 COATING SYSTEM TYPE ........................................... Touch-up paint SERVICE ...................................................................... Powerhouse overhead sectional doors and steel personnel doors and frames and all purchased equipment with factory applied paint systems. Owner supplied equipment and building. SURFACE PREPARATION .......................................... As recommended by Supplier for achieving the best result for the substrate under the project conditions PRIMER COAT ............................................................. Factory primed TOP COAT ................................................................... Factory finish and touch-up paint as needed Blue Lake Expansion Project – Contract No. 9 09900-15 General Construction May 2012 TABLE P-2 PROTECTIVE COATINGS AND COLOR SCHEDULE Items Coating System No. Coating System Description Finish Color Exterior and interior structural steel and (ferrous) misc. metals, including: grating, equipment covers, embedded frames, handrails, guardrails, chains, etc. SYS-1 Hot-dip galvanized NA Piping and equipment for BLU powerhouse, water treatment plant, FVU powerhouse, and gate house SYS-5 Polyamidonine Epoxy Varies (Note 1) Penstock and manifold interior and exposed exterior SYS-3 Polyurethane Buried penstock SYS-4 Polyurethane Tunnel liners SYS-3 Polyurethane 24 inch penstock drain piping SYS-4 Polyurethane (shop applied) 24 inch fixed cone valve SYS-2 High solids epoxy Blue Steel lined energy dissipater for 24 inch fixed cone valve SYS-2 High solids epoxy Light grey Powerhouse interior, including gypsum board, wood trim, exposed plywood and ducts SYS-6 Latex Note 1 Powerhouse sectional overhead doors and steel personnel doors and frames and interior windows SYS-7 Touch-up Paint Note 1 Existing Penstock - Epoxy (Note 2) Notes: 1. Color to be provided by Owner. 2. Contractor shall obtain paint samples from interior of existing penstock and recommend a compatible epoxy coating. Blue Lake Expansion Project – Contract No. 9 09900-16 General Construction May 2012 TABLE P-3 PROTECTIVE COATINGS ON OWNER FURNISHED EQUIPMENT AND MATERIALS Contract Number Equipment/Material Description Coating System Description Finish Color 1 Turbine and Generator Equipment - Turbine exterior - Turbine water passages - Turbine inlet valve exterior - Turbine inlet valve water passages - Generator and exciter - HPU - Turbine-generator control panel Equipment supplier’s standard coating High solids epoxy Equipment supplier’s standard coating Polyurethane Equipment supplier’s standard coating Equipment supplier’s standard coating Baked enamel Blue White Blue White Note 1 ANSI 61 Grey - 2 12.47 kV Switchgear Equipment supplier’s standard coating Note 1 3 Gates and Hoist - Bulkhead and fixed wheel gates - Gate guides - Gate hoist High solids epoxy Not painted Equipment supplier’s standard coating Black - Note 1 4 Penstock and Manifold Polyurethane Almond 5 Main Transformer Equipment supplier’s standard coating Note 1 6 Bridge Crane Equipment supplier’s standard primer and finish coat Note 1 7 Steel Building Hot dipped galvanized - Notes: 1. Color to be provided by Owner END OF SECTION DIVISION 10 SPECIALTIES Blue Lake Expansion Project – Contract No. 9 10800-1 General Construction May 2012 SECTION 10800 BATH ACCESSORIES PART 1 GENERAL 1.01 WORK INCLUDED A. Provide bathroom and toilet accessories in powerhouse As Shown. 1.02 RELATED SECTIONS A. Section 01300: Submittals. B. Section 06066: Decorative Plastic Laminate. C. Section 09290: Gypsum Board. 1.03 REFERENCE STANDARDS A. ASTM A 6: Annealed or Cold-Worked Austenitic Stainless Steel Sheet, Strip, Plate, and Flat Bar. B. ASTM A 153/A 153M: Zinc Coating (Hot-Dip) on Iron and Steel Hardware. C. ASTM A 666: Annealed or Cold-Worked Austenitic Stainless Steel Sheet, Strip, Plate, and Flat Bar. D. ASTM A 1008/A 1008M: Steel – Sheet, Cold-Rolled, Carbon, Structural, High- Strength Low-Alloy, High-Strength Low-Alloy, Improved Formability, Solution Hardened, and Bake Hardenable. E. ASTM C 1503: Silvered Flat Glass Mirror. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: For each product to be used, including operating characteristics, materials, and finishes, mounting requirements and rough-in dimensions. C. Product Warranty. 1.05 QUALITY ASSURANCE A. Use Supplier that has a minimum of 5 years experience in performing the Work of this Section. B. Obtain all products in this Section from a single Supplier. Blue Lake Expansion Project – Contract No. 9 10800-2 General Construction May 2012 1.06 PRODUCT HANDLING A. Deliver products to project site in original packaging with labels intact. 1.07 WARRANTY A. Submit standard warranty document. PART 2 PRODUCTS 2.01 SUPPLIERS A. Acceptable Suppliers include: 1. Bobrick. 2. Bradley Corporation. 3. Approved equal. 2.02 MATERIALS A. Stainless Steel: ASTM A 666 Type 304 (18-8); satin finish exposed surfaces unless otherwise indicated. B. Steel Sheet: ASTM A 1008/A 1008M, Designation CS, Supplier’s standard thickness. C. Galvanized-Steel Mounting Devices: ASTM A 153/A 153M, hot-dip galvanized after fabrication. D. Fasteners: 1. Exposed: Screws, bolts, and other devices of same material as accessory unit and tamper-and-theft resistant. 2. Concealed: Galvanized steel. E. Mirrors: ASTM C 1503, Mirror Glazing Quality, clear-glass mirrors, nominal 6.0 mm thick. F. ABS Plastic: Acrylonitrile-butadiene-styrene resin formulation. 2.03 BATHROOM ACCESSORIES A. Toilet Tissue Double-Roll Dispenser: 1. Basis-of-Design Product: Bobrick B-2888. 2. Mounting: Surface mounted. 3. Operation: Non-control delivery with theft-resistant spindle. 4. Capacity: Designed for 4-1/2 or 5 inch diameter tissue rolls. Blue Lake Expansion Project – Contract No. 9 10800-3 General Construction May 2012 5. Material and Finish: Stainless steel, No. 4 finish (satin). B. Paper Towel Folded Dispenser: 1. Basis-of-Design Product: Bobrick B-2620. 2. Mounting: Surface mounted. 3. Minimum Capacity: 400 C-fold or 525 multi-fold towels. 4. Material and Finish: Stainless steel, No. 4 finish (satin). 5. Refill Indicators: Pierced slots at sides or front. C. Waste Dispenser: 1. Basis-of-Design Product: Bobrick B-279. 2. Mounting: Surface mounted. 3. Minimum Capacity: 6.4 gallons. 4. Material and Finish: Stainless steel, No. 4 finish (satin). 5. Liner: Reusable vinyl liner. 6. Lockset: Tumbler type for waste-receptacle. D. Liquid Soap Dispenser: 1. Basis-of-Design Product: Bobrick B-2112. 2. Mounting: Horizontally oriented, surface mounted. 3. Minimum Capacity: 40 fl. oz. 4. Material and Finish: Stainless steel, No. 4 finish (satin). 5. Lockset: Tumbler type. 6. Refill Indicator: Window type. E. Mirror Unit: 1. Basis-of-Design Product: Bobrick B-165. 2. Frame: Stainless-steel angle, 0.05 inch thick. a) Corners: Welded and ground smooth. 3. Hangers: Produce rigid, tamper- and theft-resistant installation. a) One-piece, galvanized-steel wall-hanger device with spring-action locking mechanism to hold mirror unit in position with no exposed screws or bolts. 4. Size: As Shown. Blue Lake Expansion Project – Contract No. 9 10800-4 General Construction May 2012 2.04 FABRICATION A. General: Fabricate units with tight seams and joints and exposed edges rolled. Hang doors and access panels with full-length, continuous hinges. Equip units for concealed anchorage and with corrosion-resistant backing plates. B. Keys: Provide universal keys for internal access to accessories for servicing and resupplying. Provide minimum of six keys to Owner. PART 3 EXECUTION 3.01 INSTALLATION A. Assemble accessories and associated fittings and trim in accordance with Supplier’s instructions, using fasteners appropriate to substrate indicated and recommended by unit Supplier. Install units level, plumb, and firmly anchored in locations and at heights As Shown. B. Install supports attached to building structure for units requiring supports. 3.02 CLEANING AND PROTECTION A. Repair or replace defective work, including damaged units and components. B. Clean unit surfaces and leave in ready-to-use condition. C. Turn over keys, tools, maintenance instructions, and maintenance stock to Owner. 3.03 TESTING AND ADJUSTING A. Test each unit provided with moving parts to assure proper operation, freedom of movement, and alignment. B. Repair or replace malfunctioning units or units with parts that bind or are misaligned. END OF SECTION DIVISION 13 SPECIAL CONSTRUCTION Blue Lake Expansion Project – Contract No. 9 13100-1 General Construction May 2012 SECTION 13100 PENSTOCK AND MANIFOLD INSTALLATION PART 1 GENERAL 1.01 WORK INCLUDED A. Install steel penstock and manifold furnished by Owner to connect the lower tunnel to the powerhouse, including welding of joints, non-destructive testing (NDT), touchup painting, painting of the welded joints, and completion of Work such that the penstock and manifold can be utilized as intended. B. The Work includes: 1. Receipt of Owner furnished penstock and manifold at the Point of Destination 2. Transport to storage, storage and transport of equipment to the location of installation. 3. Perform all required excavation. 4. Lift or otherwise handle each penstock segment into position using a suitable crane. 5. Align penstock segments to required line, grade, and gap tolerances and stabilize prior to welding. 6. Trim and prepare pipe ends as needed. 7. Field weld penstock segments, flanges, and turbine inlet pipes. 8. NDT Test welds. 9. Provide cast-in-place concrete anchor blocks. 10. Provide all penstock supports. 11. Remove interior stulls and bracing. Apply protective coating and linings at welded joints and in locations where coatings and linings have been damaged during handling and installation. 12. Install sleeve couplings. 13. Furnish and install municipal water shut off valve, drain valves, penstock drain piping and penstock accessories. 14. Provide precast concrete block wall and bedding and backfill. C. Details of Owner furnished material are described in the Contract 4 specifications included in the reference documents. Blue Lake Expansion Project – Contract No. 9 13100-2 General Construction May 2012 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 01400: Quality Assurance C. Section 01700: Contract Closeout D. Section 02310: Fill Placement and Grading E. Section 02315: Rock Excavation and Scaling F. Section 02316: Unclassified Excavation G. Section 02620: Subdrainage System H. Section 02630: Site Drainage I. Section 03300: Cast-in-Place Concrete J. Section 03600: Structural Nonshrink Grout K. Section 09900: Painting and Protective Coatings L. Section 15300: Piping Systems 1.03 REFERENCE STANDARDS A. AISC: Manual of Steel Construction B. ASCE: Steel Penstocks Manual No. 79 C. ASME: Boiler and Pressure Vessel Code, Section VIII, Divisions 1 and 2 D. ASME: Boiler and Pressure Vessel Code, Section IX E. ASTM A53: Standard Specification for Steel Pipe F. ASTM A370: Test Methods and Definitions for Mechanical Testing of Steel Products G. ASTM A516: Specification for Pressure Vessel Plates, Carbon Steel, for Moderate and Lower Temperature Service H. AWS D1.1: Structural Welding Code I. AWWA: American Water Works Association, Section C210 J. OSHA Standards 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. Blue Lake Expansion Project – Contract No. 9 13100-3 General Construction May 2012 B. Shop Drawings: Penstock support shop drawings shall include details of members, cuts, connections, holes, and other pertinent data. Indicate welds by standard AWS symbols and show the size, length, and type of each weld. C. Coating information: Submit product information, MSDS sheets, and color samples for interior and exterior penstock coatings. D. Penstock installation procedures. Submit detailed installation procedures prior to commencement of the field installation work. Field work shall not commence until these procedures have been accepted by RPR. The procedures shall include all means and methods used to install the penstock with particular attention given to achieving tolerances, alignment, and welding procedures. Procedure for backfill around buried penstock segments. The procedure shall prevent damage to the protective coating on the penstock exterior. Submit separate procedures for: 1. Work to be performed prior to Generation Outage. 2. Work to be performed during the Generation Outage. 3. Work to be performed after Generation Outage. E. Elastomeric material for penstock anchor blocks. Submit manufacturer’s technical information for elastomeric material for penstock anchor blocks, with adhesive. F. Welder certifications: Submit written qualification records for each welder and welding operator. G. Welding procedure specifications (WPSs) and procedure qualification records (PQRs): Submit welding procedure specifications and procedure qualification records for full penetration butt welds and for fillet welds in accordance with Section VIII of the ASME Boiler and Pressure Vessel Code. WPSs shall include: preheat temperature, type of electrode, type of weld, amp range, and other variables necessary to ensure repeatability. PQRs shall include all variables recorded during welding and testing of the test coupon. H. Welding Corrections: Maintain a record of the locations of all defects or deficiencies and the corrective measures taken to effect repairs. Submit a copy of this record to RPR. I. Non-destructive testing records: Prepare reports of non-destructive testing in accordance with Section VIII of the ASME Boiler and Pressure Vessel Code, and in Part 3.04 of this Section. Submit reports to RPR. J. As Built Drawings: Submit as-built drawings for the installed penstock and manifold in accordance with Section 01700. PART 2 PRODUCTS 2.01 PENSTOCK AND MANIFOLD MATERIALS A. The penstock comprises straight segments of the pipe, and fabricated bends. The manifold comprises two wye braches. Bends will be delivered preformed, fully mitered and welded. Blue Lake Expansion Project – Contract No. 9 13100-4 General Construction May 2012 B. Each penstock segment will have match marks, provided by supplier, for ease of assembly in the field, and will be numbered consecutively As Shown. Match marks will indicate the true top of the pipe segment at each end. C. Provide interior and exterior protective coating systems under provisions of Section 09900. D. Welding electrodes shall be the low hydrogen type, and as specified by AWS Standard D1.1 for the particular metal being welded. The weld metal shall be at least equivalent in strength to the parent metal. E. Penstock bedding and backfill material shall be Bedding Material D-1 in accordance with Section 02310. F. Compressible resilient material for penstock anchor blocks shall be an elastomeric of flexible expanded rubber (closed cell) conforming to ASTM D1056, Grade 2B2. Material shall be 100% adhered to the penstock using 3M Scotch Weld Industrial Adhesive 4799, or equal. Material shall be a minimum of 3/8 inch thick and installed As Shown. G. Penstock subdrainage and surface drainage systems shall be in accordance with Sections 02620 and 02630 respectively. PART 3 EXECUTION 3.01 EXCAVATION A. Perform all penstock excavation to the lines and grades As Shown and in accordance with the requirements of Sections 02315 and 02316. 3.02 PENSTOCK ALIGNMENT A. Position penstock segments and transition pieces accurately in location, alignment and elevation, plumb, level, true and free of rack, measured from established lines and levels. B. Penstock bend segments will be delivered with match marks indicating the true top of the segment at each end. Install the bend segments such that the true top of bend is at the respective coordinates As Shown. C. Maintain records of installed alignment including survey records and as-built drawings in accordance with Section 01700. Such records shall become the property of Owner at completion of the Work. D. The steel penstock shall be installed to achieve the following tolerances: 1. The maximum allowable offset for circumferential welded joints shall be 1/16 inch. 2. The pipe segments shall be aligned so that their centerlines are within 3/8 inch of the true vertical location As Shown. 3. Ends of each completed shell segment shall be perpendicular to the longitudinal axis of the segment within 1/8 inch. Blue Lake Expansion Project – Contract No. 9 13100-5 General Construction May 2012 4. Fit up tolerances at the welded joints shall be as standard for the type of welded joints. Single V butt joints shall have a fit up tolerance of +1/4”/-1/16”. Double V butt joints shall have a fit up tolerance of +1/16”/-1/8”. 3.03 QUALITY CONTROL A. Site personnel engaged in the installation work shall be familiar with and shall follow the procedures outlined in the approved installation plan. B. Quality control shall be in accordance with Section 01400. Installation procedures shall include a hold point after pipe fit-up and before pouring anchor block concrete. 3.04 WELDING A. All welding of the steel pipe shall be in accordance Section VIII and Section IX of the Boiler and Pressure Vessel Code. B. All field welded joints in the pipe shall be welded in accordance with Reference Drawings 104-31-001 through 104-31-008, which are included in the Contract 4 specification. C. Flange welds shall be As Shown and in accordance with ASME Section VIII Div 1. D. Areas under the pipe where access is insufficient to perform welding shall be locally excavated by Contractor as necessary. E. The surfaces of plates to be welded shall be cleaned of all scale, rust, oil, paraffin, grease, paint, moisture, or any other potential contaminant for a distance of not less than 50 mm (2 inches) from the welding edge. F. All welded joints shall be dressed to produce a smooth uniform surface and be free of flux and scale to allow non-destructive examination, where applicable. G. All welded joints on the inside of the pipes shall be made with a reinforcement not exceeding 5/32 inch. H. Storage and rebaking of electrodes shall be in accordance with the requirements of the ASME Boiler and Pressure Vessel Code, Section II, Part C. I. All temporary lugs and devices welded to the outside of the steel shell shall be carefully removed by Contractor and the welds dressed smooth and flush with the surrounding metal. Care shall be exercised in removing such attachments to prevent cutting, tearing, or gouging into the steel pipe. J. The welding and fabricating procedure shall be such that residual stresses are a minimum and distortion avoided. K. Adequate ventilation and illumination shall be provided for welding on the pipe interior. L. Weather Conditions: 1. No welding shall be done when the surfaces of the parts to be welded are wet; nor during periods of high winds unless the welder or welding operator and work are properly protected. Blue Lake Expansion Project – Contract No. 9 13100-6 General Construction May 2012 2. No welding shall be done when the temperature of the base metal is below 10°C (50°F). The parts to be welded shall be preheated before welding when the ambient temperature is below 10°C (50°F). M. Welding Electrodes and Machines: 1. Welding electrodes shall be the low hydrogen type, and as specified by AWS Standard D1.1-90 for the particular metal being welded. The weld metal shall be at least equivalent in strength to the parent metal. Only stainless steel electrodes shall be used for welding stainless steel. 2. Supply all welding machines and welding equipment that may be required for erection at site. Suitable meters shall be provided to show the welding current and arc voltage at all times during welding. N. Welding procedure qualification tests shall be made or shall have been made in accordance with Section IX of the ASME Boiler and Pressure Vessel Code. The tests shall cover all sizes and types of joints processes and positions used on the steel pipe. Test plate thickness shall not be less than the plate thickness used in the pipe. O. All welders and welding operators assigned to the Work shall have passed, within the preceding 12 months, the qualification test for welders and welding operators in accordance with Section IX of the ASME Boiler and Pressure Vessel Code. P. All welds shall be stamp-marked identifying the welder. If, in the opinion of Owner’s welding inspector, the work of any welder or welding operator at any time appears unsatisfactory, he shall be required to pass the appropriate requalification test. All costs of qualification and requalification tests shall be borne by Contractor. 3.05 WELD QUALITY AND INSPECTION A. General: 1. Contractor’s welding inspector shall be certified and shall, at all times, have access to all places where equipment or materials are being field fabricated or prepared for use in this Contract. Such inspection and witnessing will be conducted by inspector in a manner which will minimize interference with the operation of installation. 2. Any defects or deficiencies shall be remedied by Contractor to the satisfaction of inspector. B. Pipe shall be checked for visual defects such as “weld spatter” or “undercut” and such defects shall be removed or repaired. 3.06 NONDESTRUCTIVE TESTING PROCEDURES A. All field welds on the penstock and manifold shall be 100% nondestructive tested as follows: 1. All circumferential field joints shall be visually examined. 2. All circumferential butt joints shall be 100 percent ultrasonically or 100 percent radiographically tested. Blue Lake Expansion Project – Contract No. 9 13100-7 General Construction May 2012 3. Fillet welds at flanges shall be 100% magnetic particle tested. B. Perform nondestructive testing in conformance with ASME Code, Section VIII, Division 1. In addition, Contractor shall perform, at no additional cost to Owner, any nondestructive testing and inspection requested by Engineer on any material or weldments in which defects are suspected. C. Ultrasonic examination of welds for pressure-containing parts, including the standard of acceptability, shall be in accordance with Appendix 12 of the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1. D. Radiographic examination of welds for pressure-containing parts, including the standards of acceptability, shall be in accordance with paragraph UW-51 and UW- 52 of the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1. E. Magnetic particle examination of welds, including the standard of acceptability, shall be in accordance with Appendix 6 to the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1. F. All nondestructive testing shall be done by Contractor at no additional cost to Owner. 3.07 CONCRETE AND ACCESSORY MATERIALS A. Compressible resilient material shall be adhered to the penstock using Sikaflex-1a construction adhesive, or equal, applied over the complete area of the resilient material. B. Concrete placement shall be As Shown. During concrete placement, vibrate concrete to obtain void-free penstock/concrete interface. C. The internal bracing/spiders shall be removed only after the penstock segment is fully supported, concreted and welded in its final location. Once removed, these bracings become the property of Contractor and shall be disposed of offsite in an environmentally-safe manner. Any resulting damage to the paint system shall be repaired by Contractor at site. 3.08 PROTECTIVE COATINGS A. Provide interior and exterior protective coatings in accordance with Section 09900. B. Adequate air for ventilation shall be ducted into the pipe during interior coating operations. Painting personnel shall be provided with filters, masks, protective clothing, and such additional protective devices required by OSHA regulations. C. Contractor shall provide adequate spark proof illumination during application of the paint. Successive coats shall be applied at intervals according to the paint Supplier’s instructions. Provide all necessary scaffolds, ladders, drape cloths, masking tape, wipers, and other supplies and materials to carry out the Work. Provide all necessary mechanical paint mixing equipment. Contractor shall take all precautions necessary to protect personnel and equipment from overspray and noxious fumes and against all fire hazards. Signs shall be posted, as needed, to prevent adverse or other harmful activities from being performed in the painting areas. 3.09 PENSTOCK BEDDING AND BACKFILL Blue Lake Expansion Project – Contract No. 9 13100-8 General Construction May 2012 A. Remove all loose rocks and debris from excavation prior to placement of bedding material. B. Place bedding material in the excavation loose. The loose material shall be uniformly graded to ensure full contact for the length of penstock to be installed. C. Contractor and RPR shall approve the placement of bedding material prior to installation of penstock. D. Penstock shall be handled and placed in the trench using fabric slings or provided pad eye lifting points. Do not drag penstock along bottom of trench. E. Install penstock according to tolerances of subsection 3.02. F. Place and compact backfill according to the lift and compaction requirements of Section 02310. Perform equal lifts on each side of the penstock. G. Do not dump backfill directly on penstock. Provide adequate protection measures as necessary. Hand place backfill along pipe. H. Take care not to damage penstock coating during compaction. All damages shall be repaired at Contractor’s expense. I. Install all subdrainage and surface drainage systems in accordance with Sections 02620 and 02630 respectively. J. Install precast concrete block walls to the lines, grades and according to the procedures As Shown. END OF SECTION Blue Lake Expansion Project – Contract No. 9 13110-1 General Construction May 2012 SECTION 13110 TUNNEL STEEL LINERS PART 1 GENERAL 1.01 WORK INCLUDED A. Provide steel liner sections complete with protective coatings and associated appurtenances at the North River Portal, South River Portal and Lower Portal in the existing tunnel system As Shown. The Work includes supply of materials, equipment, labor, and quality control program, preparation of shop drawings, fabrication drawings and as-built drawings, fabrication, testing, delivery to site, installation, site testing, and application of protective coating systems. 1.02 ALTERNATIVE LINER SYSTEMS A. Parts 2.03 and 2.04 of this Section describe possible fabrication and installation methods for the steel tunnel liner sections. In addition to these methods, the Contractor may propose alternate methods of installation, subject to acceptance by Owner. 1.03 RELATED SECTIONS A. Section 01300: Submittals B. Section 02105: Demolition and Salvage C. Section 02431: Contact and Steel Tunnel Liner Grouting D. Section 03300: Cast-In-Place Concrete E. Section 09900: Painting and Protective Coatings F. Section 13100: Penstock Installation 1.04 REFERENCE STANDARDS A. Pertinent provisions of the current issue of the following listed codes and standards shall apply to the Work of this Section, except as they may be modified on the drawings or as specified herein, and are hereby made a part of this Specification to the extent required. 1. American Society of Civil Engineers (ASCE) “Steel Penstocks”, ASCE Manuals and Reports on Engineering Practice No. 79 2. American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code: a) Section II: Materials Specifications Part A – Ferrous Blue Lake Expansion Project – Contract No. 9 13110-2 General Construction May 2012 b) Section VIII: Pressure Vessels c) Section IX: Welding and Brazing Qualifications 3. American Society for Testing and Materials (ASTM), Specifications for: a) A6: General Requirements for Rolled Steel Plates, Shapes, Sheet Piling, and Bars for Structural Use b) A20: General Requirements for Steel Plates for Pressure Vessels c) A516: Pressure Vessel Plates, Carbon Steel, for moderate and lower temperature service 4. American Welding Society (AWS) 5. American Water Works Association (AWWA) C200 Standard for Steel Water Pipe 6 Inch and Larger 6. American Water Works Association (AWWA) C222 Standard for Polyurethane Coatings for the Interior and Exterior of Steel Water Pipe and Fittings. 7. The Society for Protective Coatings (SSPC) 1.05 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Shop drawings: Submit shop drawings prior to fabrication. Shop drawings are required for all steel liner sections. Shop drawings shall be complete and shall show welding requirements, tolerances, bell and spigot details, lifting lugs, temporary strapping (if any), wrapping details (if any), protective coating requirements and other information required for proper fabrication. C. Coating information: Submit product information and MSDS sheets for interior and exterior coating. Submit certificate of compliance for protective coating system. D. Quality assurance documentation: Submit mill certificates, Charpy V-notch impact test results, welding procedures, welders’ qualifications. E. Installation drawings and procedure: Submit an installation procedure as specified in Section 13110 - 3.03 that shows the sequence of Work, method of attaining access into the tunnel, method for support and alignment of liner sections, care of water, and schedule. Note: procedures should incorporate appropriate methods and details of the Tunnel Liner Grouting Plan (See Section 2431). The installation drawings and procedures may be submitted with the Tunnel Liner Grouting Plan. PART 2 PRODUCTS 2.01 MATERIALS A. General Blue Lake Expansion Project – Contract No. 9 13110-3 General Construction May 2012 1. Unless otherwise authorized in writing by Owner, only materials conforming to the requirement of these Specifications and As Shown shall be incorporated in the Work. 2. Reference to specifications or test methods of the ASTM or other authority shall be to the specification or test method in effect on the date of the Contract, unless otherwise specified. 3. Materials specified by reference to specifications or test methods of the ASTM or other authority shall be tested in accordance therewith. 4. In case of revisions to ASTM or other authority documents, after the date of Contract, rendering available material as manufactured not compatible with the controlling document, Contractor shall list the differences between the revision at contract date and later revisions and submit to Owner for approval. 5. Materials shall be in accordance with these Specifications and As Shown. B. Steel 1. ASTM A516 Grade 70 shall be used for rolled and welded steel plates in the fabrication of the steel liner sections. 2. Pressure vessel quality plates shall be supplied in the normalized condition and shall be produced to fine grain practice. All specified mill tests shall be performed on each plate used. 3. In addition to normal mill tests, Charpy V-notch impact tests shall be performed on each plate as-rolled in accordance with ASTM A20 and A370. The average minimum impact strength of each set of three specimens, tested at -40°F, shall be 13 ft-lb, and no individual test result at -40°F shall be less than 10 ft-lb. C. Other Materials 1. Materials not specified shall be subject to the review and acceptance by Engineer. 2.02 STEEL LINER SECTIONS A. At the option of the Contractor the steel liner sections shall either be provided with one longitudinal field weld, or with three longitudinal field welds. The use of only one longitudinal weld requires that the liner section be wrapped (compressed to an outside diameter less than 84 inches) for field installation through the existing 7 foot diameter tunnel. 2.03 STEEL LINER SECTIONS – ONE LONGITUDINAL WELD A. Steel lining sections shall be rolled and fabricated leaving one longitudinal weld seam for completion at site. Contractor shall collapse the liner section by overlapping the edges at the longitudinal seam. A collapsing apparatus shall be used to uniformly reduce the diameter to that required for installation. Temporary strapping shall be used to maintain the reduced collapsed diameter. Blue Lake Expansion Project – Contract No. 9 13110-4 General Construction May 2012 B. Tests were performed in July 2011 by Owner on a test section of steel lining to determine the practicality of collapsing the liner sections to an external diameter of 6 feet - 9 inches. This collapsed diameter allows installation of the liner section though the 7 foot diameter tunnel with 1-1/2 inches clearance all around. The results of this test are provided in Reference Document “TLCT-1” for Contractor’s information, in order to assist in the Contractor’s decision of installation method. Note that the final diameter of the liner section must be “relaxed” with nominally zero stress in the liner plates. C. Steel liner sections shall be fabricated in 20 foot long sections as a maximum and shall use a minimum of three temporary restraining straps. All circumferential welds within each section shall be done in the shop. Circumferential seams for completion at site shall be of the bell and spigot type with the internal diameter of the bell matching the external diameter of the liner. The bell may be cold formed, using a hydraulic expander, or use continuous welded backer strips. During installation the adjoining liner section shall be expanded to contact the bell internal diameter and the circumferential weld seam completed at site. D. Steel liner sections shall include grout holes As Shown. The external restraining strap shall be located over the grout holes to facilitate cutting of the strap from the liner interior. E. Interior surfaces of the steel liner sections shall be painted at site. Exterior surfaces of the liner section shall not be painted. 2.04 STEEL LINER SECTIONS – THREE LONGITUDINAL WELDS A. Steel lining sections shall be rolled and fabricated in three pieces per section requiring three longitudinal weld seams for completion at site. The length of sections may be maximized by Contractor to facilitate installation and reduce installation time. The longitudinal pieces shall be provided with backing strips to enable welding of all joints from inside of the lining. B. Interior surfaces of the steel liner sections may be painted at site or in the shop. Shop painting shall leave a 2” strip either side for field welding. The strip shall be coated with a weldable primer. Exterior surfaces of the liner section shall not be painted. C. Design and fabrication of the three-section liners shall provide for field welded joints that maintain the true circular shape of the liner to the tolerances specified in subsection 3.02. PART 3 EXECUTION 3.01 FABRICATION PROCEDURES A. General 1. The liner sections shall be fabricated in accordance with the applicable provisions of Section VIII, Division 1, of the ASME Boiler and Pressure Codes or AWWA C200 Standards for Steel Water Pipe. Blue Lake Expansion Project – Contract No. 9 13110-5 General Construction May 2012 2. The minimum liner thickness shall be As Shown. All dimensions and details not shown on the drawings shall be subject to review and acceptance by the Owner. B. Bending 1. Plates shall be bent to the required radii in the direction in which they were rolled. The grain of the plates shall run in the direction of the circumferential stress. C. Joints 1. Joints shall be welded as specified herein. The location of all joints shall be subject to acceptance by Owner. 2. All welds shall be complete penetration unless indicated otherwise. Backer bars shall be located on the outside of the liner sections. 3.02 QUALITY CONTROL A. General The Contractor shall be responsible for preparing an Inspection and Quality Control Program. This program shall be an integral part of the fabrication and shall be submitted for review and acceptance by the Owner. A minimum quality control program shall be in accordance with ANSI Z1.8 and shall include but not be limited to: 1. Identification of all materials used in the fabrication of the liner sections. 2. Documentation of all tests required for Quality Control. 3. Qualification of the welding procedures before they are used in the fabrication. 4. Qualification of welders and welding operation before using the welders in production work. 5. Documentation of Charpy V Notch Impact Tests as specified in ASTM A370 and A673. B. Inspection and Testing 1. All materials, equipment, and processes shall be subject to inspection and testing as specified in the General Conditions and in accordance with the approved Inspection and Quality Control Program. All shop operation, tests, and records of tests shall be subject to Inspection by the Owner. Materials shall not be incorporated in the final product until all tests, analyses and inspections shall have been completed, or certified copies of report of results of test analyses shall have been accepted. All records shall be the property of the Owner. 2. All component parts shall be visually inspected for dimensional compliance to determine conformance to detail drawings and established tolerances. Mating sections shall be match marked. Blue Lake Expansion Project – Contract No. 9 13110-6 General Construction May 2012 3. Edges of plates prepared for welding shall be visually examined for signs of laminations, shearing cracks, and other imperfections before and after forming. Pieces showing signs of laminations (cracks of visible seams) shall be ultrasonically examined to determine extent. If laminations extend more than 3 inches then the plate shall either be rejected or have the defective section removed, subject to acceptance by Owner. 4. All personnel performing nondestructive testing shall be qualified in accordance with the American Society for Nondestructive Testing’s Recommended Practice No. SNT-TC-1A, Supplement A, B, C, D, and E. C. Fabrication Tolerances: The tolerances for the steel liner installation shall agree with the following guidelines: 1. Difference between measured outside circumference and nominal outside circumference shall be no greater than 3/4 inch per ASCE Manual 79 Section 11.4.3. 2. All out of roundness shall be in the form of smooth ovals. 3. Ends are perpendicular to the longitudinal axis within a tolerance of 1/8 inch as measured in a plane perpendicular to the longitudinal axis. 4. Difference between maximum and minimum diameter shall be less than or equal to 1% of the nominal diameter per ASCE Manual 79 Section 11.3.4.1. 5. The straightness of the finished pipe shall not deviate more than 1/8 inch from a 10 foot long straight edge placed against the pipe. 3.03 INSTALLATION A. Contractor shall prepare and submit to RPR at least 90 days prior to commencement of site installation work, detailed installation procedures including schedules. Site work shall not commence until these procedures have been accepted by RPR. The procedures shall include all means and methods used to install the steel liner sections. Site personnel engaged in the installation work shall be familiar with and shall follow these procedures. B. Installation procedures shall address the following, as a minimum: 1. Access the tunnel only during the Generation Outage (Refer to Section 01013.) All Work in the tunnel, including steel liner installation, shall be performed during the Generation Outage. 2. Demolishing and removing existing concrete liner at the Lower Portal. 3. Method of movement of liner section within the existing penstock and tunnel. 4. Placing steel liner sections in position. 5. Ensuring that each steel liner is properly aligned and braced before welding, and again before grouting. Blue Lake Expansion Project – Contract No. 9 13110-7 General Construction May 2012 6. Installing bracing, piping, formwork, and other materials required for grouting and concrete backfill. 7. Grouting the steel liners (See Section 02431) and placing new concrete. 8. Application of protective coating systems to new and existing tunnel liners, including touch-up. 9. Performing site restoration of penstock and tunnel access areas. 3.04 CLEANING OF EXSTING CONCRETE SURFACES A. After necessary concrete demolition and prior to installation of tunnel liner sections, all existing concrete surfaces that will be in contract with new concrete or grout shall be power washed with high pressure water (>= 2500 psi) to remove all deleterious material. 3.05 MOVEMENT OF LINER COMPONENTS WITHIN THE EXISTING PENSTOCK A. Contractor plan for moving steel liner sections within the existing penstock shall preclude any overall or local yielding of the existing penstock steel. All damage to the penstock including damage to the penstock coating relating to the steel liner installation Work shall be repaired by Contractor. B. Where existing penstock sections are removed, the seals on any of the flexible couplings that are disturbed shall be replaced with new seals of the same or equivalent design. 3.06 WELDING A. General 1. All welding of the steel liner shall be in accordance with the requirements of Section VIII Division 1 – Part UW, and Section IX of the ASME Boiler and Pressure Vessel Code. 2. All longitudinal joints in the liner sections shall be single V groove welded with backing strip (ASME Type No. 2 Table UW-12). Tack welds shall not be included in the groove weld. Contractor shall fully prepare pipe ends for field welds. 3. All circumferential shop welds shall be butt-welded with complete penetration double V-groove welds (ASME Type No. 1 Table UW-12). Tack welds shall not be included in the groove weld. 4. All circumferential field welds shall be bell and spigot joints with single full fillet lap welds (ASME Type No.6 Table UW-12). 5. The surfaces of plates to be welded shall be cleaned of all scale, rust, oil, paraffin, grease, paint, moisture, or any other potential contaminant for a distance of not less than 3 inches from the welding edge. Blue Lake Expansion Project – Contract No. 9 13110-8 General Construction May 2012 6. After deposition, each bead of weld shall be cleaned with a descaling hammer and wire brush to remove all slag and scale, and shall be ground, if necessary, to prepare for the proper deposition of the next bead of weld metal. All welds found defective shall be rewelded and inspected again at the expense of Contractor. 7. All welded joints shall be dressed to produce a smooth uniform surface and be free of flux and scale to allow non-destructive examination, where applicable. 8. Welded joints on the inside of the pipes shall be made with a reinforcement not exceeding 5/32 inch. 9. Storage and rebaking of electrodes shall be in accordance with the requirements of the ASME Boiler and Pressure Vessel Code, Section II, Part C. 10. All temporary lugs and devices welded to the outside of the steel shell shall be carefully removed by Contractor and the welds dressed smooth and flush with the surrounding metal. Care shall be exercised in removing such attachments to prevent cutting, tearing, or gouging into the steel liner. 11. The welding and fabricating procedure shall be such that residual stresses are kept to a minimum and distortion is avoided. 12. Adequate ventilation and illumination shall be provided for welding on the pipe interior. B. Weather Conditions 1. No welding shall be done when the surfaces of the parts to be welded are wet; nor during periods of high winds unless the welder or welding operator and work are properly protected. 2. No welding shall be done when the temperature of the base metal is below 50°F. The parts to be welded shall be preheated before welding when the ambient temperature is below 50°F. C. Welding Electrodes 1. Welding electrodes shall be the low hydrogen type, and as specified by AWS Standard D1.1-90 for the particular metal being welded. The weld metal shall be at least equivalent in strength to the parent metal. D. Welding Procedures 1. All welding procedure specifications and procedure qualification records shall be submitted to Owner for information seven days prior to commencing any welding. Owner may optionally review these procedure specifications and qualification records for compliance with these Specifications. Blue Lake Expansion Project – Contract No. 9 13110-9 General Construction May 2012 2. Welding procedure qualification tests shall be made or shall have been made in accordance with Section IX of the ASME Boiler and Pressure Vessel Code. The tests shall cover all sizes and types of joints processes and positions used on the steel pipe. Test plate thickness shall not be less than the plate thickness used in the pipe. Tests shall include tensile, bend, and Charpy V-notch impact tests. Charpy tests shall include: a) One set of three impact tests with the load applied across the weld and the weld and the notch in the weld metal; and b) One set of three impact tests with the notch in the adjacent heat-affected zone of the parent metal. 3. The above tests shall be performed in accordance with ASTM A370. 4. Charpy impact requirements shall be in accordance with ASME Section VIII, Division 1. E. Qualification of Welders 1. Contractor’s welding inspector shall be qualified in accordance with Section 5-3 of ASME QAI-1 “Qualifications for Authorized Inspection” and shall, at all times, have access to all places where equipment or materials are being field fabricated or prepared for use in this Contract. Such inspection and witnessing will be conducted by inspector in a manner which will minimize interference with production. 2. Any defects or deficiencies shall be remedied by Contractor to the satisfaction of inspector. 3. A record shall be maintained by Contractor of the location of all defects or deficiencies and the corrective measures taken to affect repairs. F. Nondestructive Testing 1. Perform nondestructive testing in conformance with the ASME Code, Section VIII, Division 1. In addition, Contractor shall perform, at no additional cost to Owner, any nondestructive testing and inspection requested by Owner on any material or weldments in which defects are suspected. 2. All longitudinal welds shall be 100% ultrasonically tested. Circumferential welds in the liner are not required to be tested. All fillet welds at the bell and spigot joints shall be 100% magnetic particle tested. 3. Ultrasonic examination of welds for pressure-containing parts, including the standards of acceptability, shall be in accordance with Appendix 12 to the ASME Code, Section VIII, Division 1. 4. Magnetic particle examination of welds, including the standard of acceptability, shall be in accordance with Appendix 6 to the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1. Blue Lake Expansion Project – Contract No. 9 13110-10 General Construction May 2012 5. All nondestructive testing shall be done by Contractor at no additional cost to Owner. 6. Steel liners and welds shall be checked for visual defects, such as weld spatter or weld undercut, and such defects shall be removed or repaired. 3.07 PROTECTIVE COATINGS A. Provide protective coatings in accordance with Section 09900. END OF SECTION Blue Lake Expansion Project – Contract No. 9 13120-1 General Construction May 2012 SECTION 13120 STEEL BUILDING INSTALLATION PART 1 GENERAL 1.01 WORK INCLUDED A. Installation of the Steel Building for the Blue Lake Powerhouse. The Steel Building is being furnished by the owner via Contract 7 – Supply of Steel Building. Refer to reference documents for all shop drawings and technical data for the Steel Building. 1. The Steel Building is designed and furnished by CHG Building Systems, Inc. herein referred to as Steel Building Supplier. B. The work shall include the following: 1. Coordinate the installation of the building with the concrete foundations, crane, anchor locations, interior steel superstructure and precast concrete hollow-core slabs, and other miscellaneous related work. 2. Install anchor bolts and anchor bolt templates. 3. Install steel building system primary and secondary framing, crane beam supports, roof trusses, roof platform, double pitch steel roof system, connections and accessory materials. 4. Install precast concrete exterior wall panel system. 5. Install pre-insulated metal roof system. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 03300: Cast-In-Place Concrete C. Section 03480: Precast Concrete Hollow-Core Slabs D. Section 03600: Structural Grout E. Section 05100: Structural Steel F. Section 07900: Building Joint Sealers G. Section 09900: Painting and Protective Coatings 1.03 REFERENCE STANDARDS A. AISC Manual of Steel Construction Blue Lake Expansion Project – Contract No. 9 13120-2 General Construction May 2012 B. AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts C. AWS D1.1: Structural Welding Code D. IBC 2006: International Building Code (2006) 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Proposed Steel Building Modifications: Prior to making any modifications to the steel building materials the Contractor shall obtain written approval for the modification from the Steel Building Supplier. Upon receipt, the Contractor shall submit a copy of the written approval. The Contractor shall follow all procedures and recommendations of the Steel Building Supplier. C. Certificates: Welders Certificates for all welders employed on the Work, verifying qualifications per AWS D1.1 within the previous 12 months. 1.05 QUALIFIED INSTALLERS A. In order to maintain steel building warranties, the installation of the Steel Building shall be performed by a qualified Building Construction Contractor as identified by the Steel Building Supplier. At the discretion of the Contractor, he may discuss with the Steel Building Supplier the potential of becoming a qualified installer. Below are the Building Construction Contractors identified by the Steel Building Supplier, who are prequalified for installation. 1. CHG Building Systems, Inc. 1120 SW 16th Street, Suite A-4 Renton, WA 98055 Tel. 425-255-5747 http://www.chgbuildingsystems.com/default.asp Contact: Ryan Grouws 2. Ron’s General Construction 282 E Leota St. Wasilla, AK 99654 Tel. 907-373-1944 Contact: Ron Norquist 3. Superstructures 224 Kenai Ave, Suite 201 Soldotna, AK 99669 Tel. 907-262-5888 Contact: Dick Ruckman PART 2 PRODUCTS 2.01 MATERIALS A. Steel Building materials furnished by Owner. Blue Lake Expansion Project – Contract No. 9 13120-3 General Construction May 2012 B. Welding Electrodes: Conform to AWS D1.1, and shall have a minimum tensile strength of 70,000 psi. C. Structural Grout shall conform to Section 03600. D. Joint sealers as designated by Steel Building Supplier. See Section 07900. E. Refer to Section 05100 for any steel connection hardware not furnished by Owner. F. Galvanizing Repair Paint: See Section 09900. PART 3 EXECUTION 3.01 GENERAL A. A receiving inspection of the goods shall take place with the RPR and Contractor as specified in the Supplementary Conditions. This inspection will take place at the SCIP as the goods are unloaded by the Contractor. B. Use all lifting devices furnished by Owner, which are specific to Steel Building materials. Follow Steel Building Supplier’s instructions for lifting device rigging and lifting procedures. Conform to Occupational Health and Safety Agency’s regulations for all other lifting devices and rigging. C. Steel Building Supplier’s Site Representative shall be present early in the installation process to observe the work and to certify that the installation work is acceptable. See Supplemental Conditions. D. Contractor is responsible for the stability of the Steel Building during installation. E. Follow installation methods and procedures as recommended by the Steel Building Supplier. 1. Provide all temporary shoring and bracing as recommended by Steel Building supplier. Provide temporary shoring and bracing members with connections of sufficient strength to bear imposed loads. Remove temporary members and connections when permanent members are in place and final connections are made. Provide temporary guy lines to achieve proper alignment of structures as required and as erection proceeds. 2. Conform field welding to ANSI/AWS D1.1. All field welding shall be made by welders or welding operators certified for the weld and positions executed to current AWS certification standards by a licensed third party control agency. 3.02 PRODUCT STORAGE AND HANDLING A. Store, support, protect and handle all Steel Building materials in accordance with Supplier’s instructions. B. Contractor is responsible for the storage of materials in material in such a manner and location as will prevent damage and minimize contamination and deterioration. Blue Lake Expansion Project – Contract No. 9 13120-4 General Construction May 2012 1. Store products in supplier’s unopened packaging until ready for installation. 2. Store products off the ground, sloped for drainage and covered to protect factory finishes from damage. 3. Keep identification marks readily visible. C. All materials shall be protected and handled so that they will not be over-stressed, bent, broken, deformed or otherwise damaged before and during installation. D. Care shall be taken to avoid damage to protective coating finishes. E. Any damage to materials caused by the Contractor shall be repaired or the goods replaced, if deemed unfit for installation by RPR. Repair or replacement shall be at Contractor’s expense. F. Precast Concrete Exterior Wall Panels: 1. Do not store or stockpile on site by methods permitting staining of concrete. Place products on sleepers, bunks, or cradles, firmly bedded. DO NOT PLACE ON GROUND. Store in same position as transported with non-staining, resilient supports in same position as when transported. Place with identification and date marks discernible. 2. Do not mar or damage concrete surfaces. 3. Locate lifting inserts to minimize stresses. 4. Provide strong-backs, bracing frames, and lifting beams in accordance with Steel Building Supplier’s recommendations. 5. Contractor shall seek to minimize the handling and any repetitive lifting of precast panels. 3.03 FIELD EXAMINATION A. Prior to beginning installation, Contractor shall verify installation conditions are satisfactory to receive materials of this Section. Verify concrete substructure and anchorage inserts are within required tolerances for installation of materials. If Contractor notices any damaged materials deemed unfit for installation, he shall promptly notify RPR in order that Steel Building Supplier can be notified. B. Confirm all connections fit accurately together to form tight hairline joints. 3.04 INSTALLATION OF STRUCTURAL STEEL MEMBERS A. Contractor shall obtain written approval from RPR and Steel Building Supplier prior to field cutting or altering of structural members. B. Accurately place metal fabrications accurately in location, alignment and elevation, plumb, level, true and free of rack, measured from established lines and levels. Blue Lake Expansion Project – Contract No. 9 13120-5 General Construction May 2012 C. Installation of structural steel members shall be in accordance with Steel Building Supplier’s erection instructions and Section 05100. D. Setting Bases and Bearing Plates: Install in accordance with Steel Building Supplier’s recommendations and in accordance with Section 05100. 1. Perform grouting in accordance with Section 03600 and Supplier’s instructions. E. Galvanized Repair Painting: Immediately after erection, clean field welds, bolted connections, and abraded areas. Perform application of repair painting in accordance with Section 09900. 3.05 INSTALLATION OF PRECAST CONCRETE EXTERIOR WALL PANELS A. Set panels straight, level, plumb, and square and within Steel Building Supplier’s tolerances. The face of the precast panels on each side of the building are to have a common plane. B. Contractor shall review the precast panel shop drawings for required clearances and rebar locations and obtain approval from Supplier and RPR prior to any cutting or coring of the precast panels. C. Clean and prepare all surfaces and install joint sealers in accordance with Steel Building Supplier’s instructions and Section 07900. D. Place the Owner furnished steel shims on a dry concrete substructure, without grout, to attain the Steel Building Supplier’s specified joint dimensions. Perform grouting in accordance with Steel Building Supplier’s recommendations and Section 03600. E. Fasten precast panels in place by connections furnished by Owner and in accordance with Steel Building Supplier’s recommended procedures. 1. Protect adjacent surfaces while welding. 2. Prepare steel surfaces for welding in accordance with Steel Building Supplier’s recommendations. 3. Provide temporary erection anchorage for welded anchorage systems. 4. Tighten bolted connections with equal torque. 5. Secure bolts with lock washers or tack-weld nut to bolt. F. Patching: Following precast panel installation, Contractor shall perform patching of any damaged surfaces identified for repair by RPR. 1. Mix and place patching mixture to match color and texture of surrounding and to minimize shrinkage. 2. Adhere patch to hardened concrete with bonding agent. G. Cleaning: Following precast panel installation and any required patching, Contractor shall clean the precast panel surfaces. Blue Lake Expansion Project – Contract No. 9 13120-6 General Construction May 2012 1. After installation, clean soiled precast concrete surfaces with detergent and water, using fiber brush and sponge, and rinse thoroughly with clean water. 2. Only use other products recommended by Steel Building Supplier to clean particularly stubborn stains after more conservative methods have been unsuccessful. 3. Use care to prevent damage to precast concrete surfaces and to adjacent materials. 4. Rinse thoroughly with clean water immediately after using cleaner. 3.06 INSTALLATION OF PRE-INSULATED METAL ROOF PANELS A. Install panels as indicated on Steel Building Supplier’s shop drawings, accurate in size, square, and free from distortion or defects. B. Install flashing and trim true and in proper alignment. C. There shall be no field swaging or cutting of panels without written approval from Steel Building Supplier and RPR. D. Clean and prepare all surfaces and install joint sealers in accordance with Steel Building Supplier’s recommendations and Section 07900. E. Following installation, wipe finished surfaces clean of any filings caused by drilling or cutting to prevent rust staining. END OF SECTION Blue Lake Expansion Project – Contract No. 9 13210-1 General Construction May 2012 SECTION 13210 INSTALLATION OF OWNER-FURNISHED GATES, GUIDES AND HOIST PART 1 GENERAL 1.01 WORK INCLUDED A. Install gates, guides and hoist furnished by Owner for the intake and gate shaft, including startup, testing and commissioning and completion of Work such that the equipment can be utilized as intended. B. The Work also includes: 1. Receipt of Owner furnished equipment at the Point of Destination. 2. Transport to storage, storage and transport of equipment to the location of installation. C. Owner furnished gates, guides, and hoist will include: 1. One fixed-wheel vertical lift gate and associated parts. 2. One set of gate guides for the fixed wheel gate including vertical wheel and seal path members, sill beams and lintel beams, guide extensions, anchors and other embedded and non-embedded parts. 3. One wire rope hoist for the fixed wheel gate. 4. One bulkhead gate and associated parts. 5. One set of bulkhead gate guides including seal path members, sill beams, and lintel beams, guide extensions, anchors and other embedded and non-embedded parts. D. Details of Owner furnished gates, guides and hoist are described in the Contract 3 specifications included in the Reference Documents, and on the equipment supplier’s shop drawings included in the Reference Documents. E. Contractor shall provide: 1. Necessary consumables such as welding rod necessary for installing the Owner furnished equipment and placing the equipment into operation. 2. Additional supports for embedded parts required by Contractor’s method of concreting. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 01400: Quality Assurance Blue Lake Expansion Project – Contract No. 9 13210-2 General Construction May 2012 C. Section 03300: Cast-In-Place Concrete D. Section 09900: Painting and Protective Coatings 1.03 REFERENCE STANDARDS A. AISC Specification for Structural Steel Buildings B. AISC Code of Standard Practice C. AISC Specification for Structural Joints using ASTM A325 or A490 Bolts D. AWS Standard D1.1 – Structural Welding Code - Steel 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review: B. Submit the following: 1. Installation procedure for fixed wheel gate, guides and hoist. 2. Installation procedure for bulkhead gate and guides. 3. Alignment checks for the fixed wheel and bulkhead gate guides. 4. Report of installation, testing and commissioning of fixed wheel gate and hoist. 1.05 INSTALLATION PROCEDURES A. Contractor shall prepare detailed installation procedures, including schedules, and submit them to RPR prior to commencement of the installation Work. Site work shall not commence until these procedures have been accepted by RPR. B. Installation procedures for the fixed wheel gate hoist will be furnished by Owner. Deviations from these procedures must be accepted by RPR. Contractor shall review the hoist installation procedures and submit comments and concerns to RPR for address by equipment supplier. PART 2 PRODUCTS 2.01 MATERIALS A. Concrete: Conform to the requirements of Concrete Mix E, see Section 03300. PART 3 EXECUTION 3.01 RESPONSIBILITY FOR INSTALLATION A. Contractor shall have overall responsibility for satisfactory installation and testing of the Owner furnished gates, guides and hoist. RPR, at its discretion will have a Blue Lake Expansion Project – Contract No. 9 13210-3 General Construction May 2012 hoist supplier’s Site Representative at Site during specific periods of the installat ion and testing Work. The Site Representative will provide technical advice on the installation and testing of the fixed wheel gate hoist. The requirement for Site Representative will be reviewed with Contractor prior to start of the installation Work. B. Contractor shall have overall responsibility for satisfactory installation of the Owner furnished equipment. Contractor shall immediately advise RPR in writing of any dispute or misunderstanding between Contractor and equipment supplier’s Site Representative. 3.02 INSTALLATION A. General 1. Installation shall conform to the requirements of AISC Specification, Structural Steel for Buildings, except as noted herein. 2. Prior to installation of embedded parts, all loose scale and foreign material shall be removed from all surfaces which will be in contact with concrete. 3. At all bolted connections, stillson wrenches, cold-chisels or other tools likely to cause damage to the surfaces of bolts, nuts or other machined surfaces shall not be used for assembling or tightening parts. Bolts and screws shall be tightened firmly and uniformly, but care shall be taken not to overstress the threads by using excessive force or wrenches of excessive length. When a half-nut is used for locking a full nut, the full nut shall be placed first followed by the half nut. B. Installation for gate guides shall include the following: 1. Install anchor bolts and materials in first-stage concrete construction formwork. Note that a majority of the anchor bolts for the fixed wheel gate guides are designed for drilled installation into the first-stage concrete. At the Contractor’s option, these anchor bolts may be cast in place in the first-stage concrete using formwork templates provided by the Contractor. 2. Cast in place the first-stage concrete. 3. Lift each guide section into position. 4. Drill concrete for drilled anchor placement, as necessary. 5. Bolt in place and adjust the guide members. 6. Place concrete Mix E at lintel, side seal and sill members. 7. Prior to and after embedment of the parts, all necessary alignment checks shall be made to determine that the specified tolerances have been achieved. Any deviations on the surfaces shall be gradual. Dimensional and alignment checks shall be recorded. Alignment checks shall be recorded and submitted to RPR. 8. Temporary bracing shall be used as needed during concreting. Bracing required to be attached to the guides or equipment shall be subject to RPR acceptance. Blue Lake Expansion Project – Contract No. 9 13210-4 General Construction May 2012 9. At the junction between the sill beam and vertical guide seal surfaces and between the lintel beam and the vertical guide seal surfaces, the welds shall be finished ground. 10. Touch up paint guides on completion of guide installation, except for stainless steel surfaces. C. Installation of the fixed wheel gate and hoist shall include the following: 1. Remove protective retainers from gate seals 2. Lift complete gate assembly into position and set on dogging devices. Care shall be taken to protect the rubber seals on the gates from damage during installation. 3. Install the hoist operating system for the gate, including related accessories and controls. 4. Install electric power supply to the hoist. 5. Apply lubricant as required. 6. Test the operation of the gate, gate controls, limit switches, and seals. Visually confirm that side, sill and lintel seals maintain continuous contact with sealing surfaces. Adjust gate and hoist and repeat tests as necessary. Do not proceed with installation until testing has been inspected by RPR. 7. After test operation of the gate and hoist, set the gate at the “FULL CLOSED”, “TUNNEL FILL”, “GATE RAISED” and “MAINTENANCE” positions. Set the gate position limit switches for each of these positions. In each case directly measure and confirm the gate is in each position prior to setting the switches. 8. While the gate is in the “FULL CLOSED”, “TUNNEL FILL” and “GATE RAISED” positions, solvent clean and paint a 2-inch wide band on each hoist wire rope line part in the gate maintenance room. The painted band shall be matched to the Owner furnished gate position pointer installed in the gate maintenance room. At the center of each painted band weave a stainless steel wire into the main hoist cable to mark the center of each colored band. 9. Once the limit switches are set, demonstrate the proper operation of the limit switches, and that the colored bands on the wire rope match the gate position pointer in the gate maintenance room. 10. Adjust and confirm the proper operation of the upper travel limit switch below the gate hoist. 11. Touch up paint gate and hoist coating system on completion of gate installation, except for stainless steel surfaces. D. Installation of the bulkhead gate shall include the following: 1. Remove protective retainers from gate seals Blue Lake Expansion Project – Contract No. 9 13210-5 General Construction May 2012 2. Lift complete gate assembly into position and place in guides. Care shall be taken to protect the rubber seals on the gates from damage during installation. 3. Test the operation of the fill valve. 4. Visually confirm that side, sill and lintel seals maintain continuous contact with sealing surfaces. Do not proceed with installation until testing has been inspected by RPR. 5. Remove gate. 6. Touch up paint gate, except for stainless steel surfaces, and place gate in storage area near gate house. 7. Note that the bulkhead gate may be left in place at Contractor’s option, to allow the gate to keep the tunnel dry if the lake rises above the intake level. E. Tolerance and Alignment Control 1. Installation tolerances shall be As Shown. 3.03 SITE TESTING A. Site tests of individual components and completed units shall be performed to demonstrate to the satisfaction of RPR that Owner furnished gates, guides and hoist equipment are correctly installed and operating. B. Any defects related to equipment installation that becomes evident while testing and commissioning shall be immediately corrected. Defects related to equipment manufacture will be corrected by gate or hoist supplier. C. Site tests shall include: 1. Raising and lowering fixed wheel gate in the dry to the tunnel fill position, gate raised position, fully closed position, and maintenance position. Test limit switches during this dry operation test and confirm that the gate position pointer in the gate maintenance room matches the limit switch indication. 2. Confirmation of proper operation of the gate position digital indication, the upper travel limit switch and all control devices and indicators. 3. Lowering the fixed wheel gate on hoist electric motor and on the fan brake. 4. Demonstration of lowering of the gate in the dry, using the emergency lower remote control from the powerhouse. 5. Raising fixed wheel gate to its maintenance position and demonstrating use of dogging beams. 6. Raising the fixed wheel gate to the tunnel fill position to fill the tunnel and then lowering the gate from the tunnel fill position under flowing water conditions to demonstrate closure of the gate against flow. Blue Lake Expansion Project – Contract No. 9 13210-6 General Construction May 2012 D. At the completion of the installation and testing Work, Contractor shall provide a complete report for the gates, guides and hoist, presenting all installation and testing measurements, records and documentation. 3.04 USE OF BULKHEAD GATE DURING CONSTRUCTION A. If Contractor uses bulkhead gate for isolating the intake tunnel during construction, Contractor shall fully recondition the gate after it is removed, including cleaning and repair of damaged coating, surfaces and seals to satisfaction of RPR. END OF SECTION Blue Lake Expansion Project – Contract No. 9 13310-1 General Construction May 2012 SECTION 13310 INTAKE TRASHRACKS AND SUPPORTS PART 1 GENERAL 1.01 WORK INCLUDED A. Provide all labor and materials necessary for the supply, fabrication, delivery, and installation of trashracks and supports As Shown and specified herein, and as follows: 1. Two sets of intake trashracks. 2. Two sets of intake trashrack supports. 3. Temporary bracing to be used during installation of trashrack supports. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 05100: Structural Steel C. Section 05500: Miscellaneous Metal D. Section 09900: Painting and Protective Coatings 1.03 REFERENCE STANDARDS A. Pertinent provisions of the current issue of the following listed codes and standards shall apply to the work of this Section, except as they may be modified on the drawings or as specified herein, and are hereby made a part of this Specification to the extent required. 1. American Institute of Steel Construction (AISC) "Specification for the Design, Fabrication, and Erection of Structural Steel for Buildings” 2. American Society for Testing and Materials (ASTM), Specifications for: a) A123: Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products b) A153: Zinc Coating (Hot-Dip) on Iron and Steel Hardware c) A325: Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength d) A780: Repair of Damaged Hot-Dip Galvanized Coatings 3. The Society for Protective Coatings (SSPC) Blue Lake Expansion Project – Contract No. 9 13310-2 General Construction May 2012 4. American Welding Society (AWS): a) D1.1: Structural Welding Code – Steel b) D1.6: Structural Welding Code – Stainless Steel American Society for Nondestructive Testing (ASNT): SNT-TC-1A - Recommended Practice for Non-Destructive Testing Personnel Qualification and Certification 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for Review. B. Shop Drawings: Submit fabrication drawings of trashracks and associated supports. The drawings shall be complete and shall show welding requirements, tolerances, lifting lugs, temporary bracing, and other information required for proper fabrication. Also provide installation procedures and schedule. C. Catalog and material data for all purchased parts, hardware, and accessories. D. Welding procedure specifications and qualification records. E. Weld inspections. F. Non-destructive testing results. G. Certificate of compliance for hot dip galvanized coating. 1.05 SHIPMENT AND STORAGE A. The Work shall be prepared for shipment and storage in such a manner as to protect it from damage or deterioration. Where necessary, lifting lugs and/or special lifting devices shall be provided for proper handling during shipment and installation at site. B. The trashracks shall be shipped as individual panel sections and the supports shipped disassembled. PART 2 PRODUCTS 2.01 MATERIALS A. General 1. Unless otherwise authorized in writing by RPR, only materials conforming to the requirement of this Specification and As Shown shall be incorporated in the Work. 2. Materials shall be in accordance with this Specification and As Shown. 3. Materials not specified shall be subject to the review and acceptance by RPR. 4. Threaded nylon bolts or plugs shall be provided for all threaded holes on the supports used for temporary bracing and for future anodes. Blue Lake Expansion Project – Contract No. 9 13310-3 General Construction May 2012 B. Welding Materials 1. All filler metal shall have a minimum tensile strength of 70 ksi and shall conform to the appropriate AWS specification for the base metal and welding process being used. Only low hydrogen electrodes shall be used for the manual SMAW process. To maintain low moisture content for hydrogen electrodes, a controlled temperature storage oven shall be used at the job site as prescribed by Article 5.3.2 (Low Hydrogen Electrode Storage Conditions) of AWS D1.1. Electrodes used for welding stainless steel shall be selected according to Table 3.2 or 3.3 of AWS D1.6. Generally, E308 electrodes shall be used for welding Type 304 stainless steel. C. Bearing Strip Materials 1. Bearing strips and bumper strips shown on the drawings shall be a woven material with solid lubricants within a thermosetting resin matrix. Bearing strips shall be Orkot TXM material, or approved equal. D. Spare Parts: Furnish spare parts As Shown. PART 3 EXECUTION 3.01 SHOP FABRICATION A. Fabrication shall comply with the requirements of Chapter M of AISC Specification for Structural Steel Buildings except where otherwise specified herein or indicated on the drawings. B. All plate and structural steel shall be accurately fabricated true to line and free from warp or rust. The edges to be joined shall expose sound metal, free of visual laminations, cracks, and other injurious defects. C. All welding shall be done in the shop. Do not field weld trashrack panels or trashrack supports. D. Fabrication tolerances shall be As Shown. 3.02 PLATE AND STRUCTURAL STEEL A. All plate and structural steel shall be accurately fabricated, free of injurious laminations or other defects, true to line and free from warp or twist. All sharp edges shall be ground. 3.03 WELDING A. Welders and welding operators shall be qualified for the particular type of work to be done. Qualification shall be in accordance with Section 4, Part C of AWS D1.1 for joints in structural steel, and Section 4, Part B of AWS D1.6 for joints involving stainless steel. Blue Lake Expansion Project – Contract No. 9 13310-4 General Construction May 2012 B. Welding shall be carried out under the direct supervision of a certified welding inspector. Inspection shall be in conformance with Section 6, Part A and B of AWS D1.1, or, Section 6, Part A of AWS D1.6, as applicable. C. Welding shall be carried out according to qualified procedures. D. Welding, unless specified otherwise, shall conform to the applicable provisions of Sections 1 through 7 of AWS D1.1 for steel and Sections 1 through 7 of AWS D1.6 for stainless steel. E. Welding shall be performed by shielded metal arc (SMAW), submerged arc (SAW), gas metal arc (GMAW), or flux cored arc (FCAW) welding processes. Gas tungsten arc (GTAW) welding may also be used where necessary, subject to acceptance by Owner. F. Prior to any welding, the base metal shall be visually inspected to assure compliance with Section 5 of AWS D1.1. Welds shall be visually inspected for compliance with Table 6.1 of AWS D1.1 for steel and Section 6.28 of AWS D1.6 for stainless steel. G. All welds shall be continuous unless otherwise stated in the Contract Documents or As Shown. H. Welding shall be subject to inspection by Owner. All weldments shall be identified with Contractor's and welder's or welding operator's assigned symbol. Welder qualification records shall be available for examination and acceptance by Owner’s inspector, when so requested. I. Joints in structural steels shall be prequalified or qualified in conformance with the provisions of Sections 2, 3, and 4 of AWS D1.1 or D1.6, as applicable. Procedures shall be qualified by tests as required and prescribed in Section 4 of the respective codes. J. Prequalified welding procedures need not be submitted to RPR for acceptance. Qualified procedures and qualification records shall be submitted to Engineer for acceptance. Current copies of these procedures must be available for welding personnel and Owner's inspectors, for their examination. 3.04 NONDESTRUCTIVE TESTING A. Magnetic particle testing shall be conducted on all welds except stainless steel welds. Magnetic particle inspection shall be in accordance with ASTM E-709. Acceptance criteria shall be as described by Section 6, Part C, of AWS D1.1. B. All stainless steel welds shall be liquid penetrant tested. Liquid penetrant inspection shall be in accordance with ASTM E-165. Acceptance criteria shall be as described by Section 6.7.6 of AWS D1.6. C. For automatic welds the extent of inspection shall be 2 feet at start and stop and 10% on remainder. D. Ultrasonic inspection shall be in accordance with ASTM E-587 for angle-beam detection or ASTM E-114 for straight beam detection, as applicable. Acceptance Blue Lake Expansion Project – Contract No. 9 13310-5 General Construction May 2012 criteria shall be as described by the relevant sections of AWS D1.1 or AWS D1.6 as applicable. E. If defects requiring repair are found during inspection, Owner shall have the right to require additional inspection of a 10% joint footage at no additional cost to Owner. If defects requiring repair continue to be evident, Owner shall have the right to order 100% inspection at no additional cost to Owner. F. Supplier may select ultrasonic inspection in lieu of magnetic particle or liquid penetrant inspection to demonstrate to Owner the quality of the welds. G. All non-destructive testing shall be performed by personnel qualified and certified in accordance with recommendations of ASNT-SNT-TC-1A, as a minimum. 3.05 SHOP ASSEMBLY AND FIT UP A. Contractor shall fully assemble the trashrack panels, trashrack supports and temporary bracing in the shop to check fit up, alignment and tolerances. Match mark the supports and temporary bracing for subsequent reassembly on site As Shown. Match markings shall be permanent. Use chisel marks, punch marks, or other approved method. B. Assemble the bearing strips onto each trashrack panel assembly and measure dimensions of each panel. Assembly dimensions (diagonals, overall width at each bearing strip, and panel thickness at the bearing strips) shall be recorded after shop assembly, and submitted to Owner for acceptance, prior to shipping. 3.06 INSTALLATION A. General 1. Installation shall conform to the requirements of AISC Specification, Structural Steel for Buildings, except as noted herein. 2. At all bolted connections, stillson wrenches, cold-chisels or other tools likely to cause damage to the surfaces of bolts, nuts or other machined surfaces shall not be used for assembling or tightening parts. Bolts and screws shall be tightened firmly and uniformly, but care shall be taken not to overstress the threads by using excessive force or wrenches of excessive length. When a half-nut is used for locking a full nut, the full nut shall be placed first followed by the half nut. B. Installation Procedures 1. Contractor shall prepare detailed installation procedures, including schedules, and submit them to RPR prior to commencement of the field installation work. Field work shall not commence until these procedures have been accepted by RPR. The procedures shall include all means and methods used to re-establish dimensions and tolerances achieved in the shop assembly and then to install the trashrack supports, temporary bracing and panels. Site personnel engaged in the installation work shall be familiar with and shall follow these procedures. C. Trashrack Guide Installation Blue Lake Expansion Project – Contract No. 9 13310-6 General Construction May 2012 1. Prior to and after embedment of the parts, all necessary alignment checks shall be made to determine that the specified tolerances have been achieved. Any deviations on the surfaces shall be gradual. Dimensional and alignment checks shall be recorded. 2. Temporary bracing shall be reassembled at site to ensure alignment of supports during concreting, following which the bracing shall be removed. Contractor may add further temporary bracing if deemed necessary by Contractor to maintain alignment, subject to acceptance by RPR. Following concreting work, nylon bolts or threaded inserts shall be installed in the holes used for bolting the temporary bracing. 3. Slip-critical bolted connections shall be used for all temporary bracing. D. Trashrack Panel Installation 1. Set the bottom trashrack panel into each guide. Measure the gaps between the bottom panel feet and the concrete surface. Grind the concrete face at the feet locations to provide uniform bearing of the bottom panel onto the concrete. 2. After grinding the concrete beneath the bottom panel, install the middle and top trashrack panels individually into the guides to provide a stack of three panels in each guide. E. Tolerance and Alignment Control 1. Installation tolerances shall be As Shown. 2. Installation shall be within 1/8 inch of drawings locations, unless otherwise stated or shown. 3. Contractor shall perform dimensional and checks, to demonstrate to the satisfaction of RPR that the Work has been correctly installed. F. Testing 1. Any defects related to equipment fabrication or installation that becomes evident while testing shall be immediately corrected. 2. Raise each trashrack panel out of its support and lower the panel back in. . 3.07 PROTECTIVE COATINGS A. After completion of installation, any damage to the galvanized coating shall be repaired in accordance with SYS-2 in Section 09900. END OF SECTION DIVISION 14 CONVEYING SYSTEMS Blue Lake Expansion Project – Contract No. 9 14600-1 General Construction May 2012 SECTION 14600 INSTALLATION OF OWNER-FURNISHED BRIDGE CRANE PART 1 GENERAL 1.01 WORK INCLUDED A. Install bridge crane furnished by Owner for the Blue Lake powerhouse including startup, testing and commissioning and completion of Work such that the equipment can be utilized as intended. B. The Work also includes: 1. Receipt of Owner furnished equipment at SCIP storage area 2. Transportation of the equipment from the storage area to the location of installation. C. Owner furnished bridge crane will include: 1. Electric overhead travelling bridge crane with 45 ton main hoist and 5 ton auxiliary hoist, and with variable speed drive for bridge, trolley and hoists. 2. Radio control for crane with pendant backup. 3. Runway conductor. 4. Limit switches and cam plates. D. Details of Owner furnished bridge crane are described in the Contract 6 specifications included in the Reference Documents, and on the equipment supplier’s shop drawings included in the Reference Documents. E. The crane runway and beam support, crane rails, crane end stops, and all connection and accessory materials are also being furnished by the Owner as described in Section 13120. F. Contractor shall furnish 1. Necessary consumables such as welding rod necessary for installing the Owner furnished equipment and placing the equipment into operation. 2. Bolting hardware for attaching runway conductor and terminal box to the runway beam. G. The installation Work shall include provision of necessary standard tools and equipment, lifting slings, required to accomplish the Work. 1.02 RELATED SECTIONS A. Section 01300 – Submittals Blue Lake Expansion Project – Contract No. 9 14600-2 General Construction May 2012 B. Section 09900: Painting and Protective Coatings C. Section 13120: Pre-Engineered Building Installation 1.03 REFERENCE STANDARDS A. The Work of this section shall be in accordance with the following references except as they are modified and supplemented herein: 1. ANSI/NFPA 70: National Electric Code 2. ANSI/AWS D1.1: Structural Welding Code - Steel: Welding 3. ASME B30.2: Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist): Safety 4. CMAA No. 70: Specifications for Top Running Bridge and Gantry type Multiple Girder Electric Overhead Traveling Cranes 5. OSHA Compliance Recommendations for Crane Applications with Motorized Hoist 6. Performance Standard for Overhead Electric Wire Rope Hoists (ASME HST-4- 1999) 1.04 SUBMITALS A. Submit under provisions of Section 01300 for review. B. Submit the following: 1. Documentation of installation and alignment checks. 2. Report of installation, testing and commissioning. 1.05 INTERFACE POINTS WITH OWNER FURNISHED EQUIPMENT A. Interface points between Owner furnished equipment and Contractor furnished piping and wiring shall be as follows: 1. Owner furnished runway conductor system will include conductor and mounting bracket. Contractor shall furnish bracket bolting. 2. Owner furnished conductor system will terminate at a terminal box at the south end of the crane runway. Contractor shall furnish conduit and wiring from the power source to the terminal box. 1.06 INSTALLATION PROCEDURES A. Installation procedures for the bridge crane will be provided by Owner. Deviations from these procedures must be accepted by RPR. B. Contractor shall review installation procedures and submit comments and concerns to RPR for address by equipment supplier. Blue Lake Expansion Project – Contract No. 9 14600-3 General Construction May 2012 PART 2 PRODUCTS 2.01 HARDWARE A. Bolting and attachment hardware for the runway beam power supply, and interconnecting wiring to the runway beam power supply shall be compatible with Owner furnished bridge crane. PART 3 EXECUTION 3.01 RESPONSIBILITY FOR INSTALLATION A. RPR, at its discretion, will have an equipment supplier’s Site Representative at Site during specific periods of the installation and testing Work. The Site Representative will provide technical advice on the installation and testing of the bridge crane. The requirement for Site Representative will be reviewed with Contractor prior to start of the installation Work. B. Contractor shall have overall responsibility for satisfactory installation and testing of the Owner furnished bridge crane. Contractor shall immediately advise RPR in writing of any dispute or misunderstanding between Contractor and equipment supplier’s Site Representative. 3.02 INSTALLATION A. Owner furnished equipment shall be installed as specified in the equipment supplier’s installation procedure. Care shall be taken to ensure all specified tolerances are achieved. B. Contractor shall complete at Site the records sheets contained in equipment suppliers installation procedures. As information in each sheet is recorded, dated and approved by Contractor, a copy shall be submitted to RPR for review and for final records. C. When installation of bridge crane is complete, Contractor shall remove all tools, debris, and other items from the work area and complete the application of paint and protective coatings as specified in Division 9. The work area around the bridge cranes shall be kept clean by Contractor during installation and testing. 3.03 SITE TESTING A. Site tests of individual machinery components and completed units shall be performed to demonstrate to the satisfaction of RPR that Owner furnished bridge crane is installed and operating in accordance with procedures and equipment supplier’s requirements. B. The tests shall be performed under the general direction of equipment supplier’s Site Representative using Owner furnished testing and commissioning plan and procedures. Contractor shall be satisfied that each step of the tests is being conducted in a prudent and proper sequence and manner. Any defects related to equipment installation that become evident during the tests shall be immediately Blue Lake Expansion Project – Contract No. 9 14600-4 General Construction May 2012 corrected and the tests continued until the Work is proved to be in working order to the satisfaction of RPR and the equipment supplier’s Site Representative. Any defects related to Owner furnished equipment design or manufacture will be corrected by the respective equipment supplier in accordance with Owner’s contract with the equipment supplier. C. Testing shall be in accordance with OSHA Standards and ANSI/ASME B30.2 and shall also include a check of the following functions for all modes of operation. Testing shall include but not be limited to the following: 1. Hoisting and lowering. 2. Ability of crane to handle rated load at design speeds. 3. Operating speeds with and without load. 4. Wheel alignment with respect to crane rails. 5. Starting, stopping and brake response. 6. Controls and limit switches. 7. Ability to lift 125 percent of rated load on the main hoist and travel with both bridge and trolley motion. 8. Ability to lift 125 percent of rated load on the auxiliary hoist. 9. Mapping and verification of hook coverage. D. Contractor shall provide test loads for the 125% load tests. E. At the completion of the installation and testing Work, Contractor shall provide a complete report for the bridge crane, presenting all installation and testing measurements, records and documentation. 3.04 RECONDITIONING A. Fully recondition the crane upon completion of its use for installation of equipment in the powerhouse. This shall include, draining, filtering and refilling the oil in the gear boxes, applying new lubricant to all manually lubricated components, cleaning crane components, touch-up painting, checking brake wear and replacement of damaged components. B. When reconditioning is complete, Contractor shall perform an operational test to demonstrate to RPR that the crane is fully functional and operating as originally designed and installed. END OF SECTION DIVISION 15 MECHANICAL Blue Lake Expansion Project – Contract No. 9 15020-1 General Construction May 2012 SECTION 15020 MECHANICAL GENERAL PROVISIONS PART 1 GENERAL 1.01 DESCRIPTION A. This Section describes the general mechanical provisions and applies to all sections of Division 15. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 01700: Contract Closeout C. Section 03600: Structural Nonshrink Grout D. Section 07900: Building Joint Sealers E. Section 09900: Painting and Protective Coatings 1.03 APPLICABLE STANDARDS A. When this Specification requires material or equipment of better quality or larger size than required by governing codes, rules, regulations, and industry standards, the requirements of this Specification shall take precedence. B. When conditions are encountered that are not specified in Division 15, the requirements of the applicable standards referred to in the various sections shall govern the Work to the extent required. 1.04 SUBMITTALS A. Submit under the provisions of Section 01300 for review. B. Refer to Division 15 subsections for requirements. C. Testing and Commissioning Reports: 1. Documentation of testing and commissioning as required in Section 15020.3.06. 1.05 SEISMIC LOADINGS FOR MECHANICAL EQUIPMENT A. The base or feet for mounting or supporting equipment on concrete floors shall be designed so that none of the equipment parts are stressed beyond 67% of the equipment’s material yield point and to prevent shifting of the equipment during or following a seismic event. Blue Lake Expansion Project – Contract No. 9 15020-2 General Construction May 2012 1. Horizontal acceleration (minimum) ............... 0.37 g 2. Vertical acceleration (minimum) ................... 0.25 g PART 2 PRODUCTS 2.01 CONCRETE BASES A. Refer to Drawing 109-90-008. Bases shall be 6 inches high with 1 inch grout pad that extends one inch beyond equipment support. B. Provide templates, anchor bolts, and accessories for mounting and anchoring equipment. C. All equipment shall be anchored securely to resist movement from seismic events. Provide suitable flexible connections in ductwork and piping where required. 2.02 MECHANICAL SLEEVE SEALS A. Modular, watertight mechanical type. Components include interlocking synthetic rubber links shaped to continuously fill annular space between pipe and sleeve. connecting bolts, and pressure plates that cause rubber sealing elements to expand when tightened. Link-Seal, equal. Refer to Drawing 109-90-012. 2.03 GROUT A. Nonshrink grout in accordance with Section 03600. PART 3 EXECUTION 3.01 PIPING SYSTEMS--COMMON REQUIREMENTS A. Pipe Sleeves, General: Install sleeves for pipes passing through concrete As Shown. 1. Cut sleeves to length for mounting flush with both surfaces, except that sleeves installed in floors shall extend 2 inches above finished floor level as required. 2. Build sleeves into new walls and slabs as work progresses. 3. Install large enough sleeves to provide minimum 1/4-inch annular clear space between sleeve and pipe, pipe insulation or widest fitting required to pass through the sleeve. a. Increase annual space where required to allow for movement of pipes during a seismic event. b. Insulation requirements shall be As Shown and as required in Section 15400. 4. Except for below-grade wall penetrations, seal annular space between sleeve and pipe or pipe insulation, using elastomeric joint sealants specified in Section 07900. Blue Lake Expansion Project – Contract No. 9 15020-3 General Construction May 2012 B. Above Grade, Exterior Wall, Pipe Penetrations: Seal penetrations using sleeves and mechanical sleeve seals. Size sleeve for 1-inch annular clear space between pipe and sleeve for installation of mechanical seals. 1. Install steel pipe for sleeves smaller than 6 inches. 2. Install cast-iron wall pipes for sleeves 6 inches and larger. 3. Assemble and install mechanical seals according to manufacturer's printed instructions. C. Below Grade, Exterior Wall, Pipe Penetrations: Install ductile-iron wall penetration system sleeves according to manufacturer's printed installation instructions. D. Verify final equipment locations for roughing in. E. Refer to equipment specifications in other sections for roughing-in requirements. 3.02 PAINTING AND FINISHING A. Damage and Touch Up: Repair marred and damaged factory-painted finishes with materials and procedures to match original factory color and finish. B. After completion of installation and testing, mechanical systems shall be painted as specified in Section 09900 and as follows: a. Carbon steel piping, supports, exposed ductwork and miscellaneous steel shall be primed and finished. b. Shop finished equipment in piping systems, including pumps, motors, compressors and tanks shall be repainted to match piping/system color. 3.03 ERECTION OF METAL SUPPORTS AND ANCHORAGE A. Cut, fit, and place miscellaneous metal supports accurately in location, alignment, and elevation to support and anchor mechanical materials and equipment. B. Field Welding: Comply with AWS D1.1 "Structural Welding Code - Steel." 3.04 CUTTING AND PATCHING A. Cut, channel, chase, and drill floors, walls, partitions, ceilings, and other surfaces necessary for mechanical installations. Perform cutting by skilled mechanics of the trades involved. B. Repair cut surfaces to match adjacent surfaces. Blue Lake Expansion Project – Contract No. 9 15020-4 General Construction May 2012 3.05 GROUTING A. Install nonshrink grout for mechanical equipment base bearing surfaces in accordance with Section 03600. 3.06 TESTING AND COMMISSIONING A. Piping systems shall be pressure and leak tested as specified elsewhere in Division 15, to demonstrate that the piping systems are properly installed and to verify piping integrity. Complete pressure testing before functional testing. B. Mechanical equipment and connections shall be site tested as recommended by the equipment supplier to demonstrate that the equipment has been manufactured and installed as designed. C. All equipment and systems specified in Division 15 shall be tested under all functional modes of operation. a. Air handling units and controls shall operated in all operational modes As Shown to verify proper operation. Operate air handlers over full range of outside air, from minimum set point to 100%. b. Units thermostatically controlled shall be operated to verify proper operation. For 2 stage thermostats, verify each stage of operation. c. Generator exhaust damper controls shall be verified under all operating modes and over full range from 0% to 100% of return air. d. Fans shall be operated to demonstrate performance As Shown, including demonstrated air flow rate under normal operating conditions and proper response to controls. e. Compressed air systems shall be operated to verify proper operation and set point. For duplex controls, verify controls including compressor sequencing and lead-lag operation. Verify operation under typical loads, including recharging the intake screen air backwash system. f. Pumping systems shall be operated under normal design conditions to verify operation and response to controls. For duplex controls, verify controls including pump sequencing and lead-lag operation. g. Piping systems shall be operated under normal and peak operating conditions. Verify operation of all controls. Verify set point and operation of instruments, pressure regulating and safety devices. h. Potable and sanitary systems shall be operated under normal operating conditions. i. All other equipment and systems shall be tested as per the manufacturer’s recommendations and as directed by RPR. Blue Lake Expansion Project – Contract No. 9 15020-5 General Construction May 2012 D. Complete systems shall be tested and commissioned following procedures to be provided by RPR. The procedures will include data sheets and forms to be filled out by Contractor as tests and commissioning proceeds, to document the testing and commissioning. E. Documentation of site tests and commissioning shall be provided to RPR by Contractor. All documentation for each systems shall be completed and assembled by system, and shall include all completed forms, test reports, certifications, data sheets and supporting information, including testing procedure, as required. END OF SECTION Blue Lake Expansion Project – Contract No. 9 15061-1 General Construction May 2012 SECTION 15061 PIPE HANGERS AND SUPPORTS PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install pipe hangers, supports and accessory materials at the powerhouse, including the following: 1. Pipe, and equipment hangers, supports, and associated anchors. 2. Sleeves and seals. 3. Flashing and sealing equipment and pipe stacks. 4. Concrete equipment bases and supports. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 03300: Cast-in-Place Concrete C. Section 15020: Mechanical General Provisions 1.03 REFERENCES A. Alaska State Building, Plumbing and Mechanical Codes B. ANSI/ASME B31.1 – Power Piping C. ANSI/ASME B31.9 – Building Services Piping D. International Building Code, 2006 E. International Mechanical Code, 2006 F. SMACNA Seismic Restraint Manual 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Shop Drawings: Show all details necessary for installation of pipe hangers and supports. 1. Provide system layout with location and detail of all supports. 2. Indicate hanger and support framing and attachment methods. Blue Lake Expansion Project – Contract No. 9 15061-2 General Construction May 2012 C. Product Data: Include supplier’s technical product data for all pipe hangers, supports and accessory materials. PART 2 PRODUCTS 2.01 APPROVED SUPPLIERS A. Anvil International, 110 Corporate Drive, Suite 10, Portsmouth, NH 03801. B. Piping Technology & Products, 3701 Holmes Road, Houston, TX 77051. C. Power Piping Company, 436 Butler St., Pittsburgh, PA 15223. 2.02 PIPE HANGERS AND SUPPORTS A. Hangers for Pipe Sizes 1/2 to 1-1/2 Inch: Malleable iron, adjustable swivel, split ring. B. Hangers for Pipe Sizes 2 to 4: Galvanized carbon steel, adjustable, clevis. C. Wall Support for Pipe Sizes to 3 Inches: Cast iron hook. D. Vertical Support: Galvanized steel riser clamp. E. Floor Support for Pipe Sizes to 4 inches: Cast iron adjustable pipe saddle, locknut nipple, floor flange, mounted on a 1 inch high grout pad. F. All pipe hangers and supports in wet locations shall be stainless steel or equivalent corrosion resistant materials. Wet locations include below elevation 13.0 ft in the powerhouse and below elevation 428.0 ft in the gate house and gate chamber. 2.03 HANGER RODS A. Steel Hanger Rods: Continuous threaded. 2.04 INSERTS A. Inserts: Malleable iron case or galvanized steel shell and expander plug for threaded connection with lateral adjustment, top slot for reinforcing rods, lugs for attaching to forms; size inserts to suit threaded hanger rods. 1. Concrete inserts in wet locations (see above description) shall be stainless steel. 2.05 FLASHING A. Metal Flashing: 26 gage galvanized steel. 2.06 SLEEVES A. Sleeves for pipes through floors and walls shall be Schedule 40 carbon steel. B. Caulk: Acrylic sealant. Blue Lake Expansion Project – Contract No. 9 15061-3 General Construction May 2012 2.07 FABRICATION A. Size sleeves large enough to allow for movement due to expansion and contraction. Provide for continuous insulation wrapping. B. Design hangers to allow for installation and removal without disengagement of supported pipe, with the exception of where penetrations provided in the building columns are utilized. 2.08 FINISH A. Steel support hardware shall be galvanized or stainless steel. B. Support hardware on exposed copper piping shall be copper plated. 2.09 HYDRAULIC PIPING SUPPORTS A. High-pressure bracket system, galvanized or stainless steel. B. Behringer Standard Series clamps, or equal. 2.10 SUPPORTS IN WET LOCATIONS A. Pipe hangers and supports in wet locations shall be stainless steel or equivalent corrosion resistant materials. Wet locations include below El. 13.0 in the powerhouse and below El. 428.0 in the gate house and gate chamber. PART 3 EXECUTION 3.01 PIPING SUPPORTS, GENERAL A. Piping shall be run parallel with the lines of the building except As Shown. Water supply pipes, where practicable, shall be placed at same elevation and hung on separate hangers. The pipes for different services shall be installed so that after the covering is applied, there shall be not less than 1/2 inch clear space between the finished covering and other work and between the finished covering of parallel adjacent pipes. Valves, fittings, and similar specialty piping, including covering where required, shall be installed so that they are accessible for operation and sufficient space is provided for access for maintenance, repair and replacement. Hangers on different service lines running close to and parallel with each other shall be in line with each other and parallel to the lines of the building. Exact location of piping, ducts, and the like shall be coordinated to avoid interferences between lighting fixtures, piping, duct, and similar items. Unless otherwise specified or As Shown, piping shall be supported as specified below: B. Vertical runs of pipe not over 15 ft long shall be supported by hangers placed not more than 1 ft from the elbows on the connecting horizontal runs. Runs over 15 ft shall have an intermediate support for every additional 10 ft or portion thereof, equally spaced. C. Support piping from structural steel as much as possible. Where possible, avoid supporting piping from concrete plank construction. Blue Lake Expansion Project – Contract No. 9 15061-4 General Construction May 2012 D. Concrete inserts may be provided as required at concrete beams, columns and walls for securing mechanical and electrical pipes, conduits, and equipment. The inserts shall be, unless otherwise indicated, zinc-electroplated and shall incorporate specially cold formed, lipped channels, not less than 1-4/8 x 1-3/8 inch, No. 12 gage steel, designed to accept special held, hardened steel nuts for securing hanger rods or other attachments. Electroplated coating shall be treated with chromic acid, immediately after coating, in such a manner that the coating shall withstand standard salt spray cabinet test for average time of 120 hours without formation of a white deposit on the surface. Concrete inserts in wet locations shall be stainless steel. E. Welding shall not be used for securing hangers to steel structural members, except where approved by RPR. Unless otherwise specified or indicated, welded attachments shall be designed so that the fiber stress at any point of the weld or attachment shall not exceed the fiber stress in the hanger rod. Galvanized steel surfaces shall be prepared for welding in accordance with Section 05100 and repaired in accordance with Section 09900. Welding shall be in accordance with ANSI B31.1. 3.02 HANGERS A. Single or multiple hangers shall be utilized as appropriate. Hangers shall include means for adjusting and controlling the level and slope of pipes. Where turn- buckles are used, they shall provide a minimum of 1-1/2 inch of adjustment and incorporate locknuts. Where turnbuckles are not used, rods shall be threaded to provide not less than 1-1/2 inch of adjustment. Rods threaded for their entire length are acceptable. B. Fabricated hangers shall be constructed of a horizontal member made of an angle or channel supported from a hanger rod near each end. Individual pipes shall be attached to the horizontal member using a U-bolt As Shown except when pipes are subject to expansion and must move freely. C. Commercially available hangers shall be galvanized or stainless steel and shall incorporate specially cold formed, lipped channels, not less than 1-5/8 x 1-5/8 inch No. 12 gauge, designed to accept special spring held, hardened steel nuts for securing hanger rods or other attachments. Electroplated coating shall be treated with chromic acid, immediately after coating, in such a manner that the coating shall withstand standard salt spray cabinet test for average time of 120 hours without formation of a white deposit on the surface. Two or more such channels may be welded together to form horizontal members of greater strength than single channels. D. Support horizontal schedule 80 PVC piping as follows: Pipe Size Max. Hanger Spacing Hanger Rod Diameter 1/2 to 2 inch 5 ft 3/8 inch 2-1/2 to 3 -1/2 inch 6 ft – 0 inch 1/2 inch 4 to 5 inch 6 ft – 6 inch 5/8 inch 6 inch 7 ft – 6 inch 3/4 inch 8 to 12 inch 8 ft – 0 inch 7/8 inch Blue Lake Expansion Project – Contract No. 9 15061-5 General Construction May 2012 E. Support horizontal steel piping as follows: Pipe Size Max. Hanger Spacing Hanger Rod Diameter 1/2 5 ft 3/8 inch 3/4 inch 6 ft 3/8 inch 1 to 1-1/4 inch 7 ft 3/8 inch 1-1/2 inch 9 ft 3/8 inch 2 inch 10 ft 3/8 inch 2-1/2 to 5 inch 12 ft 5/8 inch 6 inch and larger 12 ft 3/4 inch F. Support copper pipe and tubing as follows: Pipe Size Max. Hanger Spacing Hanger Rod Diameter 1-1/2 and smaller 6 ft 3/8 inch 2 inch to 5 inch 10 ft 5/8 inch 6 inch and larger 10 ft 3/4 inch G. Install hangers to provide minimum 1/2 inch space between finished covering and adjacent work. H. Place a hanger within 12 inches of each horizontal elbow. I. Support vertical piping at every floor. J. Support riser piping independently of connected horizontal piping. K. Wire or perforated strapping shall not be used for hanging pipe. 3.03 PIPE EXPANSION A. Pipe expansion shall be absorbed through expansion loops. Piping mains, branches and runout shall be so installed as to allow for free expansion and contraction without exceeding 80 percent of the maximum allowable stress in accordance with ANSI B31.1. 3.04 ANCHORS A. Securely supported pipe anchors shall be supplied and installed at locations as required. Type of anchors and methods of installation shall be approved by RPR prior to installation. 3.05 GUIDES A. Provide pipe guides in order to maintain alignment of piping. 3.06 SPRING SUPPORTS A. Spring supports shall be constant support type. Blue Lake Expansion Project – Contract No. 9 15061-6 General Construction May 2012 3.07 UNIONS A. No union shall be placed in a location which will be inaccessible after completion of the Work. Unless otherwise specified or indicated, a union shall be installed at all pieces of equipment such as pumps, compressors, tanks, and similar items; in order that such equipment may be readily disconnected. Where flanged valves, regulators, and similar items do not permit the removal of flange bolts, two such devices must be separated by a spool. 3.08 INSERTS A. Provide inserts to Section 03300 for placement in concrete formwork. B. Provide inserts for suspending hangers from reinforced concrete slabs and sides of reinforced concrete beams. C. Where concrete slabs form finished ceiling, provide inserts to be flush with slab surface. D. Where inserts are omitted, drill through concrete slab from below and provide thru-bolt with recessed square steel plate and nut recessed into and grouted flush with slab. 3.09 CONCRETE BASES A. Provide minimum 1 inch high grout pad for each pipe support base. 3.10 SEISMIC A. Support all piping, conduit, and ductwork for seismic as per SMACNA Seismic Restraint Manual, latest edition. B. All equipment shall be anchored securely to resist movement from seismic events. Provide suitable flexible connections in ductwork and piping where required. C. Refer to Section 15020 for seismic design criteria. END OF SECTION Blue Lake Expansion Project – Contract No. 9 15131-1 General Construction May 2012 SECTION 15131 DRAINAGE PUMPS PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install drainage sump pumps including the following: 1. Pumps including drive motors and control panels 2. Eductor 3. Lift-out rail system 4. Alarm panel 5. Spare parts as specified in Paragraph B below. B. Spare Parts: Supply one spare set of mechanical seals for each size and type of pump equipped with mechanical seals. Supply seals of type required for the particular pump application. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 15020: General Mechanical Provisions C. Section 15300: Piping Systems 1.03 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: 1. Provide drawings of the entire assembly including pumps, base, rails, control panel and all other components. 2. Provide certified pump curves showing pump performance characteristics with pump and system operating point plotted. Include NPSH curve. 3. Provide electrical characteristics, schematics, and connection wiring diagrams. C. Quality Control Submittals: 1. Certificates: Certify that the pumps have been factory tested in accordance with accepted practices of the Hydraulic Institute Standards Manual and that the characteristics of the pump conforms to the performance curve published by the manufacturer for that class pump. Blue Lake Expansion Project – Contract No. 9 15131-2 General Construction May 2012 D. Installation instructions, including shipping support removal, mounting, support, and anchor requirements, installation, start-up and commissioning. PART 2 PRODUCTS 2.01 GENERAL A. Design pumps to operate continuously without overheating bearings or motors at every condition of operation on the pump curve, or produce noise audible outside the room or space in which installed. B. Pumps shall be complete with electric motor and drive assembly, unless otherwise indicated. Design pump casings for the indicated working pressure and factory test at 1.5 times the design pressure. C. Pumps of the same type shall be the product of a single manufacturer, with pump parts of the same size and type interchangeable. D. Provide oil lubricated pumps with constant level oilers, with the exception of in-line circulating and close coupled pumps. E. Equip base mounted pumps with OSHA compliant metal guards over the moving drive assembly. Fabricate from expanded galvanized sheet metal. Secure guards as required and approved. 2.02 SUBMERSIBLE PUMPS (P-1A, P-1B) A. Rail mounted, submersible centrifugal pump, cast iron construction. B. Watertight construction for continuous duty operation in a wet pit. Cable entry shall be watertight complete with strain relief. C. Permanently sealed bearings, rated in excess of 50,000 hours of operation (L10 rated life). Bearings shall handle axial and radial thrust loads. D. Motor shall be direct coupled to the pump, Class H insulation. Provide with integral thermal overloads on each phase. E. Shaft seals: Dual, independent mechanical seals. F. Impeller: Single vane, cast iron construction, non-clogging design, dynamically balanced. G. Wear Rings: Replaceable type, bronze/stainless steel. H. Additional Features: Provide with float switch to monitor leakage in the lower stator housing. I. Electrical Characteristics: 460VAC, 3 phase, 60 Hz, 5 HP. J. Duty point: 300 GPM at 40 ft total dynamic head; minimum efficiency 65%. K. Manufacturer/Model: ITT Flygt, Model CP3102 MT, or equal. Blue Lake Expansion Project – Contract No. 9 15131-3 General Construction May 2012 2.03 LIFT-OUT RAIL SYSTEM A. General: The lift-out rail system shall be of non-sparking design and complete with all required appurtenances for a complete installation. 1. Each pump shall be removable independently of the other. 2. Lift-out rail system does not include Eductor ED-1. 3. Each lift-out rail system shall consist of a ductile iron discharge base, pump attaching and sealing plate, pump guide plate, and cast iron elbow. All exposed nuts, bolts, and fasteners shall be of 300 series stainless steel. No carbon steel parts shall be used. 4. Discharge elbow shall be 4 inch by 4 inch. Elbow shall bolt onto base and have a standard pipe flange on the discharge. 5. All shims, bolts, supports and related hardware shall be stainless steel. B. Sealing: A sealing plate shall be attached to the pump. A simple downward sliding motion of the pump and guide plate on the guide rails shall cause the unit to be automatically connected and sealed to the base. The mating faces of the sealing plate and base shall be machined to provide a metal-to-metal, leak-proof seal at all operating pressures. C. Rails: Two rail pipes shall be used to guide each pump from the surface to the discharge base connection. The guide rails shall be minimum 1½ inch Schedule 40 stainless steel pipe. The weight of the pump shall bear solely on the discharge base and not on the guide rails. Rail systems which require the pump to be supported by legs will not be considered equal. Guide rails shall be firmly attached to the concrete sidewall of the hatch opening, using a surface-mounted bracket as manufactured by the pump supplier. Systems deeper than 21 ft shall use an intermediate guide for each 21 ft of wetwell depth. D. Lifting Chain: An adequate length of stainless steel lifting chain shall be furnished for removing the pump. The chain shall be of sufficient length and shall include an adequate number of lifting rings for easy removal. 2.04 EDUCTOR (ED-1) A. General: Two piece cast bronze liquid motive eductor with threaded connections. Nozzle shall be removable from body. Unit shall be ASME rated. B. Design rating, 140 GPM suction flow based on: 1. 120 psig motive pressure. 2. 0 ft suction head. 3. 30 ft discharge head. C. Manufacturer / Model: 2-1/2” Jacoby-Tarbox Model SL, or equal. Blue Lake Expansion Project – Contract No. 9 15131-4 General Construction May 2012 2.05 DUPLEX PUMP CONTROLS (P-1A, P-1B) A. Liquid Level Control Device: Construct of corrosion resistant materials, with components designed for installation within the sump completely waterproof, including oil resistant grounding type power cord. Cords shall be of sufficient length to reach the control panel without splicing. Float switches shall be designed for remote installation. Furnish with stainless steel mounting clamps and stainless steel fasteners. B. High Liquid Alarm: Factory wired assembly consisting of a transformer, warning light, silencing switch, housed in a NEMA-12, fully gasketed enclosure, and liquid level control actuated. C. Control Panel: Factory wired, housed in a NEMA-12 enclosure; automatic electric alternator, liquid level control actuated. Include motor starters, elapsed time meters, local visual and audible alarms with silencer, remote alarm contact, H-O-A switches, run lights, and circuit breaker for each pump motor. Panel shall contain a disconnect switch with lockable handle. D. All control and electrical components shall conform to National Electrical Code and shall be UL listed. All other components shall be NEMA-12 rated or be located in a NEMA-12 panel. E. Pump controls shall be duplex with lead-lag control for alternating pump operations. For a failure of either pump, the high alarm warning light shall be activated and alternating operation shall be suspended and the remaining pump shall be in operation at all times. F. Controller shall be compatible with the pumps specified in Section 2.02. The controller shall be capable of receiving all inputs from the pump, including, but not limited to heat/moisture sensors and shut-down the pump on thermal overload. 2.06 SUMP ALARM PANEL A. Liquid Level Control Device: Construct of corrosion resistant materials, with components designed for installation within the sump completely waterproof, including oil resistant grounding type power cord. Cords shall be of sufficient length to reach the control panel without splicing. Float switches shall be designed for remote installation. Furnish with stainless steel mounting clamps and stainless steel fasteners. B. High Liquid Alarm: Factory wired assembly consisting of a transformer, warning light, silencing switch, housed in a NEMA-12, fully gasketed enclosure, and liquid level control actuated. C. Control Panel: Factory wired, housed in a NEMA-12 enclosure. Each sump shall be monitored independently and shall be provided with the following for each sump: 1. Local audible alarm with silencer. 2. Local visual alarm. 3. Dry contact for remote alarm. Blue Lake Expansion Project – Contract No. 9 15131-5 General Construction May 2012 D. All control and electrical components shall conform to National Electrical Code and shall be UL listed. All other components shall be NEMA-12 rated or be located in a NEMA-12 panel. PART 3 EXECUTION 3.01 INSTALLATION A. Install pump and rails per manufacturer’s instructions. Level, align, and true the equipment utilizing steel shims. Bolt to construction and grout as required. 3.02 SITE TEST A. Preliminary System Tests: 1. Preparation: Adjust the completed system and then operate it long enough to assure that it is performing properly. 2. Run a preliminary test for the purpose of: a) Determining whether the system is in a suitable condition to conduct the acceptance test. b) Checking control equipment. c) Training facility personnel. B. System Acceptance Test: 1. Preparation: Notify RPR at least five days prior to the system acceptance test. 2. Make the following tests: a) Individually test control devices. b) Test alarm indicating devices. c) Test each system function step by step. 3. Supply equipment necessary for system adjustment and testing. 4. Submit a report of the of the test results, signed by Contractor and RPR. END OF SECTION Blue Lake Expansion Project – Contract No. 9 15132-1 General Construction May 2012 SECTION 15132 VERTICAL TURBINE PUMPS PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install four vertical turbine pumps and motors for the raw water supply system. B. Supply of Spare Parts: 1. Supply for each pump type: a) Complete set bearings. b) Complete set gaskets and O-ring seals. c) Complete set of shaft sleeves. d) Complete set keys, dowels, pins, etc. e) Complete mechanical seal. f) One complete set of any special tools required to dismantle pump. 2. Supply for each motor type: a) Complete set of bearings. b) Complete set of gaskets. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 15300: Piping Systems C. Section 16480: Pump Control System 1.03 REFERENCES A. AISI Type 1045 Carbon Steel B. ASTM: 1. A48, Standard Specification for Gray Iron Castings 2. A53, Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc- Coated, Welded and Seamless Blue Lake Expansion Project – Contract No. 9 15132-2 General Construction May 2012 3. A276, Standard Specification for Stainless and Heat-Resisting Steel Bars and Shapes 4. B148, Standard Specification for Aluminum-Bronze Sand Castings C. AWWA E103-07 – Horizontal and Vertical Line-shaft Pumps D. Hydraulic Institute Standards E. IEEE 112 – Standard Test Procedure for Polyphase Induction Motors and Generators F. NEMA MG 1 – Motors and Generators G. OSHA 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submittals shall be provided as follows: 1. Make, model, weight and horsepower of each equipment assembly. 2. Complete catalog information, descriptive literature, specifications and identification of materials of construction. 3. Performance data curves showing head, capacity, NPSH requirements, horsepower demand and pump efficiency over the entire operating range of the pump, from shutoff to maximum capacity. Indicate separately the head, capacity, horsepower demand, overall efficiency and minimum submergence required at the guarantee point. 4. Pump maximum downthrust or upthrust in pounds. 5. Detailed structural, mechanical and electrical drawings showing the equipment dimensions, size and locations of connections and weights of associated equipment. 6. Complete motor nameplate data, as defined by NEMA, motor manufacturer and including any motor modifications. 7. Factory paint system. 8. Piping shop drawings and valve product data. 9. Certified Factory Test Reports: a) Factory test report with performance curve test results. b) Functional test reports. c) Pump performance test reports. d) Motor test results. Blue Lake Expansion Project – Contract No. 9 15132-3 General Construction May 2012 e) Hydrostatic test results. 10. Special shipping, storage and protection and handling instructions. 11. Manufacturer’s printed installation instructions. 12. Start-up and testing instructions. 13. Suggested spare parts list to maintain the equipment in service for a period of five years. Include a list of special tools required for checking testing, parts replacement and maintenance with current price information. 14. List special tools, materials and supplies furnished with equipment for use prior to and during startup and for future maintenance. 1.05 DESIGN CONDITIONS AND PERFORMANCE REQUIREMENTS A. Water Conditions: 1. The pumps shall be designed to pump river water with the following properties: a) Temperature: Maximum: 80°F, Normal: 40°F, Minimum: 33°F b) Vapor pressure: 0.26 psia c) pH: 6 to 9 B. Industrial Water Supply Pumps (P-3A/P-3B): 1. Two vertical turbine pumps will be used to provide river water to industrial users (NSRAA). 2. Pumps to cover a range of flows from 600 GPM to 4,600 GPM (combined flow from two pumps). Flow will vary as follows: 4,600 GPM for seven months, 3,700-1,000 GPM for four months, 600 GPM for one month of the year. 3. Each pump shall be rated at 2,300 GPM at a total dynamic head of 62 ft. Pump efficiency at rated duty point shall be a minimum of 76%. 4. Pumps shall be capable of operating in sump As Shown. Normal minimum water level will be El. 8.0. Minimum water level in the sump will be El. 6.0. The invert of the sump is at El. 2.0. 5. Pumps shall be inverter rated for use with Owner-furnished VFD. Pumps shall be capable of meeting the flow range specified above using VFD motor driven pumps. 6. Motors shall be NEMA MG-1 compliant, Class F insulation system (minimum), TEFC, service factor of 1.15, premium efficiency and rated for inverter duty in accordance with Part 31. Motor shall be 480 V, three phase power supply. Motors shall be sourced from manufacturers with sales and support in North America. Blue Lake Expansion Project – Contract No. 9 15132-4 General Construction May 2012 7. Pumps and motors shall be designed for continuous operation in outdoor service. C. Municipal Potable Water Supply Pumps (P-4A/P-4B): 1. Two vertical turbine pumps will be used to provide river water for treatment for potable water supply to the City. 2. Pumps to cover a range of flows from 2 to 5 MGD (1,400-3,500 GPM) (combined flow from two pumps). 3. Each pump shall be rated at 1,800 GPM with 285 feet total dynamic head. Pump efficiency at rated duty point shall be a minimum of 74%. 4. Pumps must be capable of operating in As Shown. Normal minimum water will be El. 8.0. Minimum water level will be El. 6.0. The invert of the sump is at El. 2.0. 5. Pump components shall comply with requirements for NSF/ANSI 61 for potable water systems. 6. Pumps shall be suitable for pressure regulating valve control (by Others). 7. Motors shall be NEMA MG-1 compliant, TEFC, premium efficiency, class F insulation system (minimum), with 1.15 service factor. Motor shall be 480 V three phase power supply. Motors shall be sourced from manufacturers with sales and support in North America. 8. Pumps and motors shall be designed for continuous operation in outdoor service. PART 2 PRODUCTS 2.01 APPROVED SUPPLIERS A. Flowserve B. American-Turbine C. Goulds D. Fairbanks Morse 2.02 GENERAL A. Pumps shall be vertical turbine type with open impeller of stainless steel construction, stainless steel shaft, and carbon steel pump column. B. Motor shall have 120vac, single phase, 60 HZ space heater off off-load heating. C. VFD for industrial water supply pumps drive will be furnished by Owner. Contractor shall coordinate with Owner to ensure pump is compatible with VFD drive. Blue Lake Expansion Project – Contract No. 9 15132-5 General Construction May 2012 2.03 ACCESSORIES A. Equipment Identification Plate: 16-gauge stainless steel with ¼-inch die-stamped equipment tag number securely mounted in a readily visible location. B. Lifting Lugs: Provide on all equipment weighing over 100 lbs. 2.04 FACTORY FINISHING A. Prepare, prime and finish paint with high build two part epoxy suitable for outdoor marine environment. 2.05 FACTORY TESTS A. Factory Inspections: Notify RPR in advance of all factory inspections of components. B. Factory Tests and Adjustments: Test all equipment actually furnished. C. Factory Test Report: Include certified curve test results. D. Functional Test: Perform manufacturer’s standard test on equipment. Include vibration test, as follows: 1. Dynamically balance rotating parts of each pump and its driving unit before final assembly. 2. Limits: a) Driving Units Alone: Less than 80% of NEMA MG 1 limits. 3. Complete Rotating Assembly Including Coupling, Drive Unit and Motor: Less than 80% of limits established in the Hydraulic Institute Standards. E. Pump Performance Test: 1. Conduct on each pump. 2. Perform under simulated operating conditions. 3. Test for a continuous one hour period without malfunction. 4. Test Log: Record the following. a) Total head. b) Capacity. c) Horsepower requirements. d) Flow measured by factory instrumentation and storage volumes. e) Average distance from suction well water surface to pump discharge centerline for duration of test. Blue Lake Expansion Project – Contract No. 9 15132-6 General Construction May 2012 f) Driving motor voltage and amperage measured for each phase. 5. Adjust, realign or modify units and retest in accordance with Hydraulic Institute Standards, if necessary. F. Motor Test: Motor shall receive a Factory Acceptance Test (FAT). The FAT shall confirm motor efficiency, temperature rise, locked rotor current and temperature rise. A certified FAT report shall be submitted. G. Hydrostatic Tests: Pump casing(s) tested at 150% of shutoff head. Test pressure maintained for not less than five minutes. PART 3 EXECUTION 3.01 INSTALLATION A. Installation shall be As Shown and as recommended by pump supplier. 3.02 MANUFACTURER’S SERVICES A. Manufacturer’s Representative: Present at Site or classroom designated by RPR, for minimum person-days listed below, travel time excluded. 1. Three person-days at Site for inspection, functional and performance testing, completion of Manufacturer’s Certificate of Proper Installation and prestartup classroom or site training. END OF SECTION Blue Lake Expansion Project – Contract No. 9 15300-1 General Construction May 2012 SECTION 15300 PIPING SYSTEMS PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install piping for the mechanical services, including piping, fittings, strainers, valves and miscellaneous items, including: 1. Pipe and fittings. 2. Valves. 3. Miscellaneous items. 4. Aboveground piping and valves for Water Supply Mains at the powerhouse and water treatment plant. a) Refer to Section 02510 for underground Water Supply Mains. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 02510: Water Supply Mains C. Section 09900: Protective Coatings D. Section 15061: Pipe Hangers and Supports E. Section 15400: Plumbing System F. Section 15480: Compressed Air Systems G. Section 15700: Instrumentation H. Section 15905: Automatic Backwash Strainer. 1.03 REFERENCE STANDARDS A. The piping covered by this Section shall be performed in accordance with the applicable requirements and recommendations of ANSI B31.1, "Power Piping," except as modified in this Section. B. Alaska State Plumbing and Mechanical Codes C. ANSI – American National Standards Institute D. ASME – American Society of Mechanical Engineers E. International Building, Plumbing and Mechanical Codes Blue Lake Expansion Project – Contract No. 9 15300-2 General Construction May 2012 F. ISO 8434-3 – Metallic Tube Connections for Fluid Power and General Use G. SAE J1453 – Fitting O-Ring Face Seal 1.04 SUBMITTALS A. Submit under provisions of Section 01300. B. Product Data: 1. Catalog sheets and specifications indicating manufacturer name, type, applicable reference standard, schedule, or class for specified pipe and fittings. 2. Material Schedule: Itemize pipe and fitting materials for each specified application in Pipe and Fittings Schedule in Part 3 of this Section. Where optional materials are specified, indicate option selected. C. Submit, for record purposes manufacturer's letters of compliance indicating compliance with all applicable referenced standards. Letters shall be specific; statements such as "materials comply with all specification requirements" will not be accepted. D. Welders Certificate: Include welders certification of compliance with ASME SEC 9, AWS D1.1. PART 2 PRODUCTS 2.01 GENERAL A. Piping, valves and specialty items not specified shall be selected by Contractor to provide a long service life consistent with normal hydroelectric design practice. 2.02 CARBON STEEL PIPE AND FITTINGS A. Standard Weight: ASTM A106 or A 53 Grade A or Grade B, or ASTM A 135. B. Fittings: 1. 2 inch and smaller: 3,000 lb forged steel per ASTM A105 GR2 and ANSI/ASME B16.11, threaded connections. 2. 2-1/2 inch and larger: Standard weight carbon steel per ASTM A234, GR B and ANSI/ASME B16.9, butt weld connections. C. Branch Connections: 1. 2 inch pipe and smaller: Branch type shall be straight tee and reducing bushing or a reducing tee. 2. 2-1/2 inch pipe and larger with a branch connection ½ the line size or larger: Branch type shall be straight tee and reducer, or reducing tee. 3. 2-1/2 inch pipe and larger with a branch connection less than ½ the line size: Branch type shall be threadolet or weldolet. Blue Lake Expansion Project – Contract No. 9 15300-3 General Construction May 2012 D. Flanges: ASTM A105 150 lb forged carbon steel per ANSI/ASME B16.5. 1. Remove raised face when mating with flat face flanges. 2. Provide 300 lb flanges where indicated on the drawings or as required to match the matching flange of valves or equipment. E. Bolts: 1. ASTM A193 Grade B7 heavy hex bolts with ASTM A194 Grade 2H heavy hex nuts. 2.03 STAINLESS STEEL PIPE AND FITTINGS A. Piping: Stainless steel piping per ASTM A312, TP304. 1. 2 inch and smaller: Seamless, schedule as defined in section 3.01.A. If threaded pipe is required at equipment connection, provide schedule 80 seamless. 2. 2-1/2 inch and larger: Seamless or welded, schedule as defined in section 3.01.A. B. Fittings: 1. 4 inch and smaller, Class 3000 stainless steel per ASTM A182 and ANSI/ ASME B16.11, socket welded. At threaded equipment connections, Class 3000 stainless steel per ASTM A182 and ANSI/ ASME B16.11. 2. 6 inch and larger: Butt weld fittings per ASTM A403 and ANSI/ASME B16.9, schedule to match piping C. Branch Connections: 1. 4 inch pipe and smaller: Branch type shall be straight tee and reducing bushing or a reducing tee. 2. 6 inch pipe and larger with a branch connection ½ the line size or larger: Branch type shall be straight tee and reducer, or reducing tee. 3. 6 inch pipe and larger with a branch connection less than ½ the line size: Branch type shall be threadolet or weldolet. D. Flanges: 150 lb stainless steel per ASTM A182 and ANSI/ASME B16.5. 1. Remove raised face when mating with flat face flanges. 2. Provide 300 lb flanges where indicated on the drawings or as required to match the matching flange of valves or equipment. E. Bolts: 1. 5/8 inch and smaller: ASTM B320 Gr B8 heavy hex head bolts with ASTM A194 Grade 8 or 8A heavy hex nuts. Blue Lake Expansion Project – Contract No. 9 15300-4 General Construction May 2012 2. 3/4 inch and larger: ASTM A193 Grade B7 heavy hex bolts with ASTM A194 Grade 2H heavy hex nuts. 3. Nuts shall be supplied with factory installed anti-galling coating (Fluorlon 325, Impreglon 218 or Xylan 1014 or equal). 2.04 STAINLESS STEEL TUBING A. Tubing: Stainless steel hydraulic tubing per ASTM A269, TP304, seamless. 1. Minimum wall thickness shall be as follows: a) 1/2 inch and smaller – 0.028 inch b) 5/8 inch to 7/8 inch – 0.049 inch c) 1 inch to 1-1/2 inch – 0.065 inch d) The thicknesses above are based on applications to 1,800 psi working pressures. For applications above 1,800 psi size tubing accordingly and provide design calculations for review and approval prior to purchasing material. 2. Fittings: a) Stainless steel Swagelock fittings suitable for the design pressure of the application. 2.05 PE-AL-PE AIR LINE A. Rigid, flexible air line, comprised of 2 layers of high density polyethylene plastic bonded to an intermediate layer of aluminum. B. Fittings: As recommended and supplied by manufacturer of air line. C. Manufacturer / Model: Ipex USA LLC, Duratec, or equal. 2.06 CAST IRON PIPE AND FITTINGS A. Piping: Hubless Pipe: Standard weight, bitumin coated per Cast Iron Soil Pipe Institute Standard (CISPI) No. 301 and ASTM A74. B. Fittings: Drainage Pattern, Bitumin coated per CISPI-301. C. Joint Couplings: Stainless steel shield and clamp assembly, and elastomer sealing sleeve per CISPI-310. 2.07 DUCTILE IRON PIPE AND FITTINGS A. Refer to Section 02510. 2.08 PVC PIPE AND FITTINGS A. Piping: PVC per ASTM D1785. B. Fittings: PVC fittings, socket ends, conforming to ASTM D2467. Blue Lake Expansion Project – Contract No. 9 15300-5 General Construction May 2012 2.09 VALVES – GENERAL A. Valve Standardization: Valves from one or more manufacturers may be used; however, valves supplied for each specific valve type shall be the product of one manufacturer. B. Valves shall be first quality, free from all imperfections and defects, with body markings indicating manufacturer and rating. C. Valve parts of same manufacturer, size and type shall be of rising stem type, unless otherwise specified. D. Manually-operated gate, globe, and angle valves shall be of rising stem type, unless otherwise specified. E. Valves which use packing shall be capable of being packed when wide open and under full working pressure. F. Size valves the same size as the piping in which they are installed, unless specified otherwise. G. All valves shall be provided with lockable handles. 2.10 VALVES – AIR SERVICE (V-301A thru V-346A) A. Globe Valves (2 inch and smaller): 200 psig WSP, 400 psig WOG, bronze body, union or bolted bonnet, with 500 Brinell hardness stainless steel renewable plug, 500 Brinell hardness stainless steel replaceable seat ring, and threaded ends. Acceptable Valves: Crane 212P, Hammond IB434, Jenkins 556P & 558P, Lunkenheimer 73PS, Milwaukee 592 & 593, Nibco T276AP & T376AP, Powell 2608, 2609, &2610, Stockham B62, and Walworth 3245P & 3246P. B. Check Valves (2 inch and smaller): 150 psig WSP, 300 psig WOG, bronze body, brass or bronze trim, horizontal swing, renewable and regrindable disc, and threaded ends. Face discs for cold water service with Buna-N or Teflon. Acceptable Valves: Crane 137, Hammond 1B944, Jenkins 4092, Nibco T4331, Stockham B321, and Walworth 3412. C. Ball Valves (2 inch and smaller): 300 psig WOG, 2 piece bronze body, solid blow- out proof stem, teflon seats, chrome plated brass ball, Teflon seals, corrosion resistant steel lever handles with vinyl grips, balancing stop, and threaded ends. Acceptable Manufacturers: Conbraco, Jenkins, Milwaukee, Nibco, and Watts. 2.11 VALVES – WATER SERVICE (V-101W thru V-124W, V-201 thru V-232W, V-401P thru V-436P, V-912W, V-913W, V-916D, V-919W, V-920D) A. Gate Valves 1. 3 inch and smaller: a) 125 psig WSP, 200 psig WOG, bronze body, bronze trim, union bonnet, solid wedge disc, and threaded ends. Acceptable Valves: Hammond IB617, Jenkins 47CU B105, and Walworth 11. Blue Lake Expansion Project – Contract No. 9 15300-6 General Construction May 2012 b) 125 psig WSP, 200 psig WOG, bronze body, threaded bonnet, solid wedge disc, and solder ends. Acceptable Valves: Hammond IB635, Lunkenheimer 2132, Milwaukee 149, Nibco S111, Powell 1821, Stockham B109. 2. 4 inch and larger: 125 psig WSP, 200 psig WOG up to 12 inch size, and 150 psig WOG for 14 inch and 16 inch sizes; IBBM OS&Y, bolted bonnet, solid wedge disc, and flanged ends. Acceptable Valves: Crane 464-1/2 & 465-1/2, Hammond 1R1140, Jenkins 650C & 651C, Lunkenheimer 1430, Milwaukee F2885, Nibco T6170 & F6170, Powell 1792 & 1793, Stockham G620 & G623, and Walworth W726 & W726F. 3. Valves V-117W and V-118W supplied by others B. Globe Valves 1. 3 inch and smaller: a) 125 WSP, 200 psig WOG, bronze body, threaded bonnet, and threaded ends. Acceptable Valves: Crane 1, Hammond IB440 and IB463, Lunkenheimer 2140 & 2141, Nibco T211 & T311, Powell 650, Stockham B16 and B216, and Walworth 3058 and 3096. b) 125 psig, 200 psig WOG, bronze body, threaded bonnet, and solder ends. Acceptable Valves: Crane 1310, Hammond IB423, Jenkins 1200C, Lunkenheimer 126, Milwaukee 1502, Nibco S211 and S311, Powell 1823, Stockham B17, and Walworth 3058SJ. 2. 4 inch and larger: 125 psig WSP, 200 psig WOG, IBBM OS&Y, bolted bonnet, and flanged ends. Acceptable Valves: Crane 351 & 353, Hammond 1R116, Jenkins 613C & 615C, Lunkenheimer 1123, Milwaukee F2981, Nibco F718B & F818B, Powell 240, 241, 242 & 243, Stockham G512 & G515, and Walworth W906 & W906F. C. Check Valves 1. 3 inch and smaller: a) 125 psig WSP, 200 psig WOG, bronze body, brass or bronze trim, horizontal swing, renewable and regrindable disc, and threaded ends. Face discs with Buna-N or teflon. Acceptable Valves: Crane 37, Hammond 1B940, Jenkins 4092, Lunkenheimer 2144, Milwaukee 509, Nibco T413, Powell 578, Stockham B319, and Walworth 3406. b) 125 psig WSP, 200 psig WOG, bronze body, brass or bronze trim, horizontal swing, renewable and regrindable disc, and solder ends. Face discs for cold water service with Buna-N or Teflon. Acceptable Valves: Crane 1342, Hammond IB912, Jenkins 4093, Lunkenheimer 2145, Milwaukee 1509, Nibco S413, Powell 1825, Stockham 309, and Walworth 3406SJ. 2. Raw Water Pump Discharge (V-217W, V-220W, V-225W, V-228W) a) General: 1O inch flanged, slanted seat, tilted disc check valve with internal damper. Blue Lake Expansion Project – Contract No. 9 15300-7 General Construction May 2012 b) Construction: i. Cast iron, slanted seat, tilted disc check valve with internal damp and 150 lb. raised face flanges. ii. Ductile iron valve disk, stainless steel shaft, bronze bearings and chrome-nickel plated seat. iii. Furnish with mechanical position indicator and internal damper. c) Manufacturer / Model: VAG-Armaturen model SKR, or equal. Flanges to match ANSI Class 150 flange pattern. Provide with mechanical position indicator and internal damper. D. Butterfly Valves 1. 3 inch thru 12 inch: 200 psig WOG , iron body, lugged type (lug for each bolt hole, drilled and tapped for cap screws), with replaceable Buna-N seats, stainless steel disc and shaft, and raised neck able to accommodate 2 inches of insulation. Acceptable Valves: ITT Grinnell Series 8000, Model LD-5, Keystone AR2. a) V-913W shall be stainless steel body, Class 150 flange pattern with lockable handle. 2. 20 inch: Refer to Section 02510. E. Ball Valves 1. 2 inch and smaller: 2 piece bronze body, solid blow-out proof stem, EPT composition seat, bronze ball, corrosion resistant steel lever handles with vinyl grips, balancing stop, and threaded or solder ends. Acceptable Manufacturers: Conbraco, Jenkins, Milwaukee, Nibco, and Watts. Minimum pressure rating: 400 psig WOG. a) V-916D shall be stainless steel with locking handle. 2. Service Water Root Valves (V-101W, V-111W) a) 4 inch, 2 piece body, full port, stainless steel ball valve with 300 lb flanged ends, RPTFE seals and seals, stainless steel ball, trim, stem and hardware and 2 position locking handle. Acceptable Valves: Apollo 87A-900, or approved equal. i) Provide with flange dielectric insulating kit. F. Hose Valves 1. 1-1/2 inch and smaller: Gate type, 200 psig, bronze body, renewable wedges, integral bronze seat, inside screw, non-rising stem, female threaded inlet, male hose thread outlet, with cap and chain. Acceptable Valves: Powell 502H or approved equal. Blue Lake Expansion Project – Contract No. 9 15300-8 General Construction May 2012 2.12 PRESSURE RELIEF VALVE (PSV-1, PSV-2) A. Spring operated pressure relief valve, cast iron body, flanged inlet and outlet, stainless steel trim and Teflon seat. B. Design conditions: 125 GPM based on 75 psig set pressure and 178 psig inlet pressure. C. Manufacturer: Anderson Greenwood 1-1/2 inch x 2 inch Model 81P with 0.503 in2 (G) orifice. 2.13 2 INCH PRESSURE REDUCING VALVE (PCV-1, PCV-2) A. Spring operated pressure reducing valve, cast iron construction, 2 inch threaded connections and composite diaphragm. B. Design conditions: 1. Flow rate: 75 gpm 2. Min/Max pressure: 130 psi / 178 psi 3. Set pressure: one at 55 psig, one at 60 psig. C. Max cV: 10.0 D. Manufacturer / Model: Cashco, 2” DL series with composite diaphragm and handwheel / locking lever. 2.14 FLEXIBLE CONNECTORS A. Raw Water Pump Connectors 1. Provide stainless steel braided metal base. 2. Design pressure: 200 psig. 3. 12 inch live length. 4. End fittings to match piping. B. Hydraulic Lines 1. High-pressure hydraulic hose, rubber with spiralled layers of high tensile steel per S.A.E. 100 R12. 2. Design pressure: 125 psig minimum or equal to equipment pressure rating. 3. Minimum length: 3 ft 4. Hose assemblies shall be laid out to provide at least the minimum bend radius as specified by the manufacturer. C. Expansion Joint for 24” Penstock Drain Line: 1. Mechanically fastened flexible coupling, consisting of the following components: a) Split sleeve body with closure plates. Body and hardware shall be corrosion resistant. Blue Lake Expansion Project – Contract No. 9 15300-9 General Construction May 2012 b) EPDM o-rings c) Sealing plate/pad d) Bolts and nuts – Stainless steel 2. Joint shall be capable of 4° angular movement. 3. Manufacturer: Victaulic Depend-O-Lok ExE for carbon steel pipe, 300 psig pressure rating. D. Expansion Joint - Ductile Iron Sanitary Pipe (6 inch and smaller): 1. Provide Flex-Ring Joint Pipe As Shown. Provide coupling at all locations As Shown. 2. Pipe shall be ductile iron per paragraph 2.07. 3. Allowable deflection: 5° 4. Manufacturer: American Flex-Ring Joint Pipe E. Expansion Joint – Raw Water Piping in Water Treatment Plant (WTP): 1. Restrained coupling joint capable of field alignment of pipe, restraining internal line pressure and mechanical restraint to prevent joint separation. 2. Design Conditions: 200 psig to 100 degrees F. 3. Joint sealing: Steel followers with Buna S armoured/pinned gasket. Bolts per ANSI A21.1 4. Mechanical restraint: Mechanical clamps to secure to outside of pipe and carbon steel tie rods. 5. Manufacturer / Model: Dresser Style 38 Coupling and Style 443 TieAnchor restraint, or equal. F. Miscellaneous Flexible Connectors: 1. Where specified on the drawings or as required per equipment manufacturer’s installation instructions, provide Dresser Style 38 or Garlock Style 204 expansion joints. 2. For lines 2 inch and smaller, Anaconda corrugated metal hose LW -21-1, Type 321 stainless steel hose with 304 screwed nipples (PMW -4) shall be used unless otherwise stated on the drawings. 3. Design Conditions: 200 psig to 100 degrees F. 2.15 JOINING AND SEALANT MATERIALS A. Thread Sealant: 1. LA-CO Industries’, Slic-Tite Paste with Teflon. Blue Lake Expansion Project – Contract No. 9 15300-10 General Construction May 2012 2. Loctite Corp.’s No. 565 Thread Sealant. 3. Thread sealants for potable water shall be NSF approved. B. Gaskets: 1/16 inch thickness non-asbestos per ASTM F104 Gr P7161A (Crane Style 2150). 1. Raised face flange: Gasket shall be ring type 2. Flat face flange: Gasket shall be full face C. Anti-Seize Lubricant: Bostik Inc.’s Never Seez or Dow Corning Corp.’s Molykote 1000. D. Corrosion Protective Tape System: By 3M Co., St. Paul, MN. 1. Tape: Scotchrap 50 or 51 2. Primer: Scotchrap pipe primer 3. Putty (if required): Strip caulk insulation putty 2.16 PACKING MATERIALS FOR BUILDING CONSTRUCTION PENETRATIONS A. Oiled Oakum: Manufactured by Nupak of New Orleans, Inc., 931 Daniel St., Kenner, LA 70062, (504) 466-1484. B. Mechanical Modular Seals: Thunderline Corp.’s Link Seal wall and floor seals designed for the service of piping system in which installed. 2.17 DIELECTRIC CONNECTORS A. Unions: 1. Rated 250 psig at 180 degrees F; ASME B16.39; Wilkins Model DU 2. Rated 100 psig at 210 degrees F; ASME B16.39; Wilkins Model DU with high temperature gasket. 3. Rated Above 100 psig and 210 degrees F: Use Flange Electrical Insulation Kit specified below. B. Flange Electrical Insulation Kit: Consisting of dielectric sleeves and washers, and dielectric gasket. 1. Rated 150 psig at 250 degrees F: ANSI Class 150, full faced neoprene gasket with bolt holes, double phenolic washers, and mylar sleeves; Model 150 by APS, Lafayette, LA 70596, (337) 233-6116. 2.18 24 INCH FIXED CONE VALVE (V-918D) A. General 1. The fixed cone valve for the penstock drain system shall be a standard design, 24 inch diameter, with a manual screw stem operator. Blue Lake Expansion Project – Contract No. 9 15300-11 General Construction May 2012 2. The pressure-containing parts of the valve shall be designed for a head of at least 520 ft of water. Maximum normal operating head shall be 420 ft. The valve shall be capable of passing at least 240 cfs at maximum opening with 260 ft of net head. The valve shall be free of abnormal or detrimental vibration at all openings. B. Design: The valve shall be designed for safe and satisfactory operation within the specified operating conditions. Conservative factors of safety shall be used throughout especially in the design of parts subject to intermittent and/or alternating stresses. In general, working stresses shall not exceed one-third of the yield strength or one-fifth of the ultimate strength of the material, whichever is lower. C. Valve Body: The valve body shall consist of a cylinder with a conical deflector head on the downstream end, internal radial ribs and an upstream mounting flange for attachment to a conduit liner or penstock. The internal ribs and deflector head shall extend beyond the downstream end of the valve body a sufficient distance to permit the rated discharge capacity. The sealing and sliding surfaces of the valve body shall be stainless steel. The mounting flange shall be in accordance with AWWA C207 Class "E" and shall be provided with an o-ring gasket. The valve body shall be constructed of steel plate conforming to ASTM A516 Grade 70. D. Valve Gate: The valve gate shall consist of a cylinder designed to slide over the valve body. The gate shall slide upstream to open and downstream to close off the valve ports. The upstream end of the gate shall be counter-bored to receive the body seal. The downstream end shall have a stainless steel seat machined to fully contact the valve body seat. The interior sliding surface of the gate shall be bronze. The valve gate shall be constructed of steel plate conforming to ASTM A516 Grade 70. E. Seals: The valve body shall have a removable seat attached to the downstream end of the valve body with bolts and gasket. The sealing contact surface of the seat shall be stainless steel. The downstream end of the gate shall have a removable seat attached to the gate with bolts and gasket. The sealing contact surface shall be stainless steel and machined to a contour to provide a satisfactory hydraulic profile. The upstream end of the gate shall be counter-bored to receive a U shape packing to seal between the gate and the stainless steel outside the valve body. The U packing shall be retained by a bronze or stainless steel gland and fasteners. F. Operating System: Valve operation shall be by a mechanical dual screw stem system consisting of two screw stem actuators mounted diametrically opposite and connected to a miter gearbox. Inter-connecting shafting shall be stainless steel and shall be connected by flexible couplings. Screw stems shall be type 304 stainless steel and drive nuts shall be bronze. The vertical operating stem from the miter gear box shall extend to El. 27.0 with a 2 inch square operating nut and removable valve operating wrench consisting of nut socket, extension stem and hand wheel or T- handle. Maximum hand wheel effort shall not exceed 60 lbs. G. Shop Testing: The fully assembled valve shall be hydrostatically tested at a pressure of two times the rated valve pressure for 30 minutes. There shall not be any evidence of leakage except at the valve seats. The fully assembled valve shall be leak tested at the rated pressure for 5 minutes. The allowable leakage through Blue Lake Expansion Project – Contract No. 9 15300-12 General Construction May 2012 the seats shall not exceed 0.4 ounces per minute per inch of valve diameter. The valve shall be opened and closed three times using the actuating mechanism. H. Painting: All unmachined portions of the valve shall be blast cleaned per SSPC-SP 10 (near white) and shall receive two coats of high solids epoxy paint. I. Manufacturers: Rodney Hunt, Adams, VAG-Armaturen, or approved equal. 2.19 24 INCH GATE VALVE (V-917D) A. General: AWWA resilient wedge gate. All ferrous components shall be ductile iron per ASTM A536. Valve shall meet the requirements of AWWA C515. B. Body: Ductile iron per ASTM A536. Provide with Class 250 flanges per ANSI B16.1. All internal surfaces shall be epoxy coated per ANSI/AWWA C550. C. Wedge: The wedge shall be symmetrical and seal equally well with flow in either direction. The wedge nut shall be independent of the wedge and held in place on three sides by the wedge to prevent possible misalignment. D. Trim: Bolting materials shall be 304 stainless steel unless otherwise specified. Bolts shall have hexagonal shaped heads with dimensions conforming to ANSI B18.2.1. Metric size socket head cap screws are not allowed. The operating nut shall be constructed of ductile iron. E. Seals: All gaskets shall be pressure-energized O-Ring type seals. Stem shall be sealed by three O-Rings. The top two O-Rings shall be replaceable with the valve fully open and while subject to full rated working pressure. O-Rings set in a cartridge shall not be allowed. The valve shall have thrust washers located with (1) above and (1) below the thrust collar to assist operation of the valve. F. Actuator: Provide with spur gear actuator. Provide T-handle operating wrench for personnel standing at the ground surface over the valve box. G. Furnish with fully adjustable cast iron valve box and galvanized steel square tube stem extension to extend operating nut to grade. Extension shall be guided at the top of the valve box and shall be rated for a minimum torque of 1000 ft-lb. H. Manufacturer: American Series 2500 2.20 AIR/VACUUM VALVES (AV-1, AV-2) A. General: Combination air release / vacuum breaker to exhaust air when starting pumps and to admit air when draining the pipeline. B. Valve shall consist of cast iron valve body and baffle, stainless steel float and Buna- N seat. 1. 3 inch valves shall be provided with Double Acting Throttle Device and air release valve. Blue Lake Expansion Project – Contract No. 9 15300-13 General Construction May 2012 2. 4 inch valve shall have a discharge orifice area equal to or larger than the valve inlet area. C. Manufacturer / MODEL: 1. AV-1: 3 inch, APCO 146DAT with air release valve, or equal 2. AV-2: 4 inch, APCO 152 with protector hood 2.21 CAST IRON BUTTERFLY VALVES (V-911W, V-912W, V-914W , V-915W) A. Butterfly valves shall be manufactured in accordance with the latest revision of AWWA Standard C504 Class 250B, Valve shall be suitable for a differential pressure of 250 psig, and be certified to NSF Standard 61. B. Valve body: The body shall be constructed of Ductile Iron ASTM A536 Gr. 65-45-12, with flanged end connections drilled in accordance with ANSI B16.1, Class 125, or Mechanical Joint ends. The body wall thickness shall be in strict accordance with AWWA C504 C. Valve Shaft: The shaft shall be made of ASTM A-564 Type 630 condition H-1150. The shaft seals shall be “V” type packing. Shaft seals shall be of a design allowing replacement without removing the valve shaft. No O-ring or “U” cup packing shall be allowed. The bearing shall be a stainless steel backed Teflon material. Bearing load shall not exceed 1/5 of the compressible strength of the bearing or shaft material. D. Valve Disc: The disc shall utilize an on-center shaft and symmetrical design, cast from Ductile Iron ASTM A536 Gr. 65-45-12. The disc edge shall be stainless steel type 316. Disc shall be retained by pins that extend thought the full diameter of the shaft. The pin material shall be the same as the shaft material. Torque plugs or tangential fasteners shall not be allowed. For valve sizes 3" through 20" the rubber seat shall be of one piece construction, simultaneously molded and bonded directly into the body. The seat material shall be either Buna-N or EPDM rubber. E. Valve Actuator: Manual actuators shall be of the traveling nut, self-locking type and shall be designed to hold the valve in any intermediate position between fully open and fully closed without fluttering or creeping. The actuator shall have mechanical stops that will withstand and input torque of 450 ft/lb. against each stop. Manual actuators shall conform to AWWA Standard C504. Provide with handwheel. F. Manufacturer: Henry Pratt Model HP250II or approved equal. 2.22 12 INCH PRESSURE REGULATOR (PRV-1WTP, PRV-2WTP, PRV-1FP) A. General: Pilot operated pressure reducing valve to reduce a high incoming pressure to a lower, constant discharge pressure regardless of variations in upstream pressure or flow rate. B. Design: Cast iron, globe type valve with inline flanged end connections, with factory installed pilot operator. Blue Lake Expansion Project – Contract No. 9 15300-14 General Construction May 2012 1. Free floating piston (operated without springs, diaphragm or levers). a. PRV-1FP shall stainless steel cylinder. 2. Seat shall be full port, with seat bore equal to valve inlet size. a. PRV-1FP shall have parabolic seat. 3. Valve shall be repairable inline without having to remove the valve. 4. Seat and piston shall be fully guided to ensure positive shut-off. 5. Cast iron body with bronze and/or stainless steel trim. 6. Ferrous surfaces of the valve shall be coated with NSF Certified Epoxy (Tnemec Series FC20) in accordance with ANSI/NSF Std. 61, and conforming to AWWA D102 Inside System No. 1. 7. ANSI B16.1 Class 250 body with Class 125 flanges. C. Design Conditions: 1. Service: a. PRV-1WTP / PRV-2WTP: Water treatment plant for municipal water supply. b. PRV-1FP: Fire protection. Design valve for sleeper service. 2. Temperature: Varies between 40 to 75 Degrees F. 3. Flow: a. PRV-1WTP / PRV-2WTP: Flow varies, average daily flow: 3.4 million gallons per day total for plant. Station has two 12 inch strainers. b. PRV-1FP: Varies on demand for fire water. No flow normally, max demand estimated at 5,000 gpm. 4. Inlet Pressure: Varies from 108 psig to 192 psig; valve to be rated for 200 psig minimum. 5. Outlet Pressure: a. PRV-1WTP / PRV-2WTP: Shall be field adjustable. Set at 80 psig. b. PRV-1FP: Shall be field adjustable. Set at 100 psig. D. Pilot valve: Shall have a range of adjustment, be easily accessible, and arranged to allow for easy removal from the main valve while the main valve is under pressure. The pilot valve, speed control valve, external strainer with blow-off, isolation valves, and all associated rigid brass piping and fittings (with the exception of a separate Blue Lake Expansion Project – Contract No. 9 15300-15 General Construction May 2012 static pressure sensing line, if required) shall be factory assembled and furnished with the valve. E. Completed valve shall be factory tested prior to shipping. F. Manufacturer / Model: a. PRV-1WTP, PRV-2WTP: Ross Model 40WR, or equal. b. PRV-1FP: Ross Model 40WR-RP, 12” with 16” flanges, or equal. PART 3 EXECUTION 3.01 SYSTEM APPLICATIONS A. Piping System Description Designation Piping Backwash from automatic strainers to sump BWS Sch 10 Stainless (Section 2.03) Compressed air from air compressor to service air drops and intake screen backwash. CA Stainless Steel Tubing (Section 2.04) Service water from penstock to turbine and generator connections, pressure reducing valves and eductor. SW Sch 40 Stainless (Section 2.03) Service water from pressure reducing valves to hoses. SW -2 Sch 10 Stainless (Section 2.03) Gravity drain lines from floor/equipment drains to drainage sump and oil / water separator. DR Cast Iron (Section 2.06) Pressure drain lines from drainage sump pumps to discharge PDR Sch 10 Stainless (Section 2.03) Pressure sanitary discharge from sanitary lift station to packaged treatment plant PSAN HDPE(Section 02510) Domestic water – cold CW Sch 10 Stainless (Section 2.03) Domestic water – Hot HW Sch 10 Stainless (Section 2.03) Raw Water Piping --- Sch 40 Stainless (Section 2.03) / HDPE (Section 02510) Gravity Sanitary drainage from plumbing fixtures to sanitary lift station. SAN Cast Iron (Section 2.06) Sanitary Connections at lift station, at transformer pit drain connections, and existing utility connections. SAN, PSAN Flex-Ring Joint ductile iron pipe (Section 2.14.D) Sanitary vent piping V Cast Iron (Section 2.06) Intake level monitoring piping – within gate shaft / exposed --- Sch 10 Stainless (Section 2.03) Intake level monitoring piping – embedded --- Sch 40 PVC (Section 2.08) Gatehouse air bubbler piping - within gate shaft / exposed --- Sch 10 Stainless (Section 2.03) Gatehouse air bubbler piping - embedded --- PE-AL-PE Air Line (Section 2.05 24” Drain --- Carbon steel (Section 2.02), Pipe schedule As Shown, Protective Coating per Section 09900. Blue Lake Expansion Project – Contract No. 9 15300-16 General Construction May 2012 3.02 INSTALLATION – GENERAL A. Prior to fabrication, assembly, or erection of any items, Contractor shall verify field measurements required for completion of the Work including actual sizes, locations, and details of equipment connections, embedded piping, and embedded sleeves and location of connection points in powerhouse. B. Contractor shall install sufficient unions and/or flanged connections to permit convenient removal of equipment, valves, and specialties. C. Where air pockets or water traps cannot be avoided, provide means for draining traps with valved hose connection and provide air vent valves for air pockets. D. Piping specialties shall be installed in accordance with the manufacturers' instructions. E. In liquid service where dissimilar metals, including stainless steel and carbon steel materials are joined together, insulated connectors shall be used to prevent electrolytic corrosion. Contractor shall be sure that other attachments to the piping, such as common pipe supports, do not short circuit the insulation. 3.03 PIPELINE SLOPES A. Horizontal pipelines shall be installed using the following minimum slopes unless otherwise specified herein or required for the system design. System Minimum Slope Drainage 1% Service Water 0.5 % Potable Water 0.5 % 3.04 PIPE SUPPORTS AND RESTRAINTS A. Embedded Pipe Supports: 1. All embedded piping shall be supported by structural steel shapes in such a manner that alignment will not be disturbed during concreting operations. Pipe materials and their supports shall not be welded to reinforcing steel under any circumstances. Contractor may install embedded anchor plates or pipe supports in lower or adjacent concrete pours to accommodate pipe supports for subsequent pours. Embedded horizontal pipe runs shall be supported rigidly on the formwork where they terminate at concrete faces. Elsewhere, horizontal pipe runs shall be adequately supported at branch and elbow connections and at the following maximum spacing locations: Pipe Diameter and Type Minimum Support Spacing Steel: ½ inch and smaller 6 ft Steel: ¾ inch and larger 10 ft 2. Embedded vertical piping shall be supported at the base of risers, at the head of risers, and at intervals not exceeding 6 ft. 3. Stainless steel pipe that is to be embedded in concrete may be directly attached to carbon steel supports. In cases where carbon steel and stainless Blue Lake Expansion Project – Contract No. 9 15300-17 General Construction May 2012 steel pipe are to be supported by the same structural steel member, the stainless steel pipe shall be insulated from the support by wrapping a piece of insulating material around the pipe and clamping securely with a U-bolt or welded steel strap. B. Exposed Pipe Supports: 1. Pipe supports and restraints shall be designed with provision for expansion, contraction, vibration, drainage, and protection of connected equipment and vessels. Pipe supports shall be fabricated from galvanized Unistrut metal framing components unless otherwise Shown. Plastic inserts shall be installed in exposed frame member ends for safety purposes. 2. Pipe supports in wet locations shall be stainless steel. 3. For attaching pipe supports and restraints to concrete surfaces, Contractor shall use "Unistrut" concrete inserts. Alternatively, pipe supports shall be attached to concrete surfaces using Hilti expansion anchors, or approved equal. All expansion anchors in outdoor service shall be epoxy sealed. The pipe supports shall be arranged so that loads on the drilled anchors are below the manufacturer's recommended design loads. C. Pipe hangers shall be of a positive type not subject to slippage from steel or pipe because of vibration or accidental impacts. Clamps similar to Unistrut P-1272S are acceptable; those similar to Unistrut P-2675 are not acceptable. All threaded fasteners shall be galvanized or cadmium-plated and shall have double nuts, lock- nuts, and/or peened threads. D. Supports for insulated pipe shall have protected saddles or insulation shields to protect the insulation from damage. 3.05 WELDED STEEL JOINTS A. Butt-welded joints shall be made without the use of backing rings. B. Care shall be taken that the welding of joints does not cause projections to form on the interior of the pipe. Where possible, projection exceeding requirements shall be removed by grinding to make a smooth joint. Minimum required pipe thickness shall be maintained. 3.06 FLANGED JOINTS A. Raised-faced flanges shall not be mated with flat-face flanges of equipment, valves, or piping specialties. The raised face must be removed. Flat-face flanged joints shall have "full face" gaskets with the gasket outside diameter matching the flange outside diameter. 3.07 THREADED JOINTS A. Threaded pipe connections shall conform to the ANSI Standard B2.1 for taper pipe threads. All threads shall be cut with clean, sharp dies, and accurately set. Pipe ends shall be reamed after threading to remove burrs and the start of each thread shall be chamfered for ease of assembly. B. Threads shall be solvent cleaned and wiped dry to remove oil and grease which would prevent adherence of the thread seal. Teflon pipe dope shall be used on all Blue Lake Expansion Project – Contract No. 9 15300-18 General Construction May 2012 threaded connections in accordance with the manufacturers' recommended procedures. 3.08 CEMENTED JOINTS (PVC PIPE) A. Solvent cemented joints shall be made in accordance with manufacturers' recommendations or in accordance with ASTM D2855. Only properly trained installation crews shall be used. Solvent cements used in assembly of PVC pipe shall meet requirements established by ASTM D2564. 3.09 EXPANSION JOINTS A. Provide expansion joints at all buried pipes at Powerhouse to allow for differential settlement. B. Expansion joints on buried pipe: Pipe and expansion joints shall be wrapped with burlap to a thickness of 1 inch over ring and a minimum of 2 inch beyond the coupling and sealed with a heavy polyethylene cover. 3.10 VALVES A. Valves shall be installed as detailed on the drawings and with their pressure ratings visible. Globe valves shall be installed with pressure under the disc unless otherwise specified on the drawings. Unless otherwise detailed, all safety and relief valves shall be installed in a vertical position. Contractor shall tighten valve glands, add additional packing, if required, and retighten glands after valves are in operation. 3.11 CLEANING A. After fabrication and before installing, the inside of all piping shall be cleaned as necessary to remove loose scale and foreign material by means of a mechanical device such as an air driven centrifugal rotary cleaner or by compressed air, depending upon the pipe size. Open ends of all pipe pieces shall then be suitably and securely covered to ensure that foreign matter and moisture is excluded. B. After piping systems have been embedded, each line shall be thoroughly flushed to ensure the line is free of any obstruction. C. After final cleaning of embedded piping, Contractor shall protect all pipes to prevent entry of foreign objects and to maintain cleanliness. All drainage fittings shall be covered in a satisfactory manner. D. Contractor shall identify the terminating points of all embedded pipelines using metal tags. These tags shall be permanently attached to the pipe. (Note: It is not necessary to mark drainage fittings.) E. After the piping systems have been installed and successfully pressure tested, but before connection to the pumps or other equipment, each line shall be thoroughly flushed as specified below. 1. Fine mesh cloth or screen shall be installed in the pipeline to remove contaminants dislodged by the flushing medium during circulation. The screens shall be frequently inspected and cleaned. Blue Lake Expansion Project – Contract No. 9 15300-19 General Construction May 2012 2. During flushing, the system shall be evaluated by examining a 14-mesh (ASTM E11) or fine filter, or the equivalent, installed on the outlet of the cleaning circuit. The system shall be flushed at its normal velocity until the screen shows no more than occasional particle speckling. There shall be no evidence of organic contamination on the screen; considerable rust-staining is acceptable. 3. The flushing media used for the piping system shall be clean water for all water lines and dust-free air for compressed air lines. 3.12 TESTING A. Contractor shall leak test all the piping except those lines open to atmosphere, in accordance with the procedures prescribed in ANSI B31.1, Paragraph 137 unless specified otherwise herein. Tests shall be conducted before embedment, insulation or painting. Contractor shall provide all pumps and ancillary items necessary for the tests. Service Identification Test Pressure Service Water (SW -1) 300 psig Service Water (SW -2) 112 psig Pump discharge lines 75 psig Vent lines None required Compressed air 225 psig Hydraulic 125% of design pressure Gravity Drain Lines Per International Plumbing Code Other piping 150% of design pressure B. Clean water shall be used for pressure testing of all lines. C. The hydrostatic test pressure shall be measured at the highest elevation in the system. D. The testing of piping systems shall be performed after the lines have been inspected and accepted by RPR for testing. Piping may be tested in sections using suitable blind flanges, pipe caps or closed valves. Contractor shall isolate all equipment, controls, or piping specialties that could be damaged by the test pressure, procedures, or water. E. The test pressure shall be held for at least one hour before the joints and pipes are checked for leaks. Joints that leak shall be taken apart, checked, cleaned, reassembled, and retested. F. Contractor shall provide written and signed test reports for RPR's records. 3.13 FLUSHING OF HYDRAULIC SYSTEMS A. Contractor shall be responsible for complete flushing of the hydraulic system, including the HPU, accumulators, all Owner furnished equipment, as well as Contractor furnished piping. B. Provide all materials, labor equipment, and oil required to flush the hydraulic system in accordance with the manufacturer’s instructions and to RPR’s satisfaction. Blue Lake Expansion Project – Contract No. 9 15300-20 General Construction May 2012 C. Contractor shall dispose of all materials, including used oil, after the test. 3.14 INSULATION A. Refer to Section 15400. 3.15 GALVANIZING REPAIR A. Repair any galvanizing damaged or affected by work. Repair shall be per ASTM A780. 3.16 DISSIMILAR METAL JOINTS A. Provide dielectric connection at all dissimilar metal joints, including carbon steel – stainless steel interface. END OF SECTION Blue Lake Expansion Project – Contract No. 9 15400-1 General Construction May 2012 SECTION 15400 PLUMBING SYSTEM PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install of the following: 1. General plumbing requirements. 2. Miscellaneous plumbing materials. 3. Floor Drains 4. Transformer Oil Spill Drain Shut-off 5. Washdown Hose Station 1.02 RELATED SECTIONS A. Section 01300 – Submittals B. Section 15020 – General Mechanical Provisions C. Section 15061 – Pipe Hangers and Supports D. Section 15300 – Piping Systems E. Section 15405 – Sanitary Lift Station F. Section 15415 – Backflow Preventers G. Section 15420 – Eye Wash Station H. Section 15440 – Plumbing Equipment and Fixtures 1.03 REFERENCE STANDARDS A. ASME A112.1.2 - Drainage Funnels and Air Gaps B. ASME A112.21.1M - Floor Drains C. ASME A112.36.2M – Cleanouts D. International Plumbing Code E. International Mechanical Code F. Local and State Plumbing Codes Blue Lake Expansion Project – Contract No. 9 15400-2 General Construction May 2012 G. National Sanitation Foundation (NSF) Standard 61, Drinking Water System Components – Health Effects 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submit for review, a complete schedule of all proposed materials. Schedule shall be arranged by piping systems (and size ranges, where appropriate), and shall indicate material and manufacturer. Provide manufacturer’s catalog sheets and any other pertinent data. C. Submit, for record purposes manufacturer's letters of compliance indicating compliance with all applicable referenced standards. Letters shall be specific; statements such as "materials comply with all specification requirements" will not be accepted. D. Operation and Maintenance Manuals. PART 2 PRODUCTS 2.01 PIPE AND FITTINGS A. Refer to Section 15300. 2.02 HOSE BIBB WITH BACKFLOW PREVENTERS A. Hose Bibbs shall be ¾ inch angle brass body and cast iron handwheel, 150 psig ratting, male hose connection outlet, per ASME B 1.20.7. B. Backflow preventers shall be of brass construction with a silicone disc primary check valve, rubber seat, atmospheric vent, and a “non-removable” feature. C. Watts Series SC-8, or equal. 2.03 FLOOR DRAINS A. General Requirements 1. Shall comply with ASME A112.21.1M - Floor Drains. B. General Purpose (FD) 1. Floor and shower drain, Dura-Coated cast iron body with bottom outlet, combination invertible membrane clamp and adjustable collar with seepage slots and round "TYPE B" polished nickel bronze strainer. 2. Zurn ZB-400 or equal. C. Medium Duty (FD-2) 1. 7” diameter top, medium duty, Dura-Coated cast iron body with bottom outlet, combination invertible membrane clamp and frame with seepage pan and round cast iton slotted grate. Blue Lake Expansion Project – Contract No. 9 15400-3 General Construction May 2012 2. Zurn Z-507 or equal. D. Heavy Duty (FD-3) 1. 12” square top, heavy duty, Dura-Coated cast iron body with side outlet, combination membrane clamp and cast iron frame with seepage pan, square cast iron slotted grate and suspended sediment bucket with secondary strainer. 2. Zurn Z-645 or equal. E. Perimeter Trench Drop Inlet (FD-4) 1. Type “J” rectangular adjustable strainer top with Dura-Coated cast iron head, polished frame and slotted grate. 2. Zurn Z-400-8J or approved equal. F. Sump Vents (SV) 1. 12” square top, heavy duty, Dura-Coated cast iron body with bottom outlet, combination invertible membrane clamp and frame with seepage pan, square cast iron slotted grate. Deduct sediment bucket. Provide with standard cover and optional solid cover (-SC). 2. Zurn Z-610-LY plus additional solid cover (-SC). 2.04 CLEANOUT PLUG A. Cast iron, with threaded end, and raised or countersunk head. 1. Tapped head for attachment of cleanout wall or deck plate covers where required. B. Anti-Seize Lubricant: Never-Seez by Bostik Chemical Group, Broadview, IL; Molycote 1000 by Dow Corning Corp, Midland, MI; Anti-Seize Lubricant by Loctite Corp, Newington, CT. 2.05 CLEANOUT A. Threaded pipe fitting or cast iron ferrule with gas tight cleanout plug per ASME A112.36.2M – Cleanouts. B. Cleanout wall plate: Round, stainless steel cover plate with stainless steel vandal resistant fastener to secure to cleanout plug. C. Cleanout deck plate: Standard duty floor cleanout fitting with coated cast iron body; round, coated cast iron cover secured to cleanout plug with stainless steel vandal resistant fastener; threaded height adjustment, cast iron head, gas tight cleanout plug, and connection to match piping option selected. 2.06 HUB DRAIN A. Combination Funnel Drain and P Trap: Coated cast iron construction per ASME A112.1.2 - Drainage Funnels and Air Gaps. 1. Funnel: 4 inch top dia., 4 inches deep, with threaded outlet. Blue Lake Expansion Project – Contract No. 9 15400-4 General Construction May 2012 2. P Trap: Bottom cleanout, threaded inlet, and outlet connection to match piping option selected. 2.07 FASTENERS A. Corrosion Resistant Fasteners: Type 302 or 304 stainless steel bolts. 2.08 PIPE INSULATION A. Flexible, preformed, elastomeric closed-cell cylindrical pipe insulation. 1. K-value of 0.27 from -40 degrees F to 220 degrees F. 2. Flame spread rating 25 or less per ASTM E 84. 3. Armstrong Armafex, or equal. B. High Density Jacketed Insulation Inserts for Hangers and Supports: 1. Polyurethane Foam: Minimum density 4 pcf, K of 0.13 at 75 degrees F, minimum compressive strength of 125 psi. C. Adhesive: 1. Armstrong 520 Adhesive, or equal. D. Jacket: 1. Indoor: One piece, premolded PVC per ASTM C1784. 2. Outdoor: Aluminum per ASTM B209, factory preformed sectional pipe jacketing, 0.016-inch thick, smooth exterior, 2-inch overlapping circumferential joints with integral locking clips or butt joints sealed with 2-inch wide mastic backed aluminum snap bands 2.09 HOSE STATION A. Washdown hose station consisting of the following: B. Hose: 1-1/2 inch diameter lay-flat hose 1. Nitrile/PVC hose with abrasion resistant outer jacket. 2. Minimum pressure rating: 200 psig. 3. 100 foot length per station. 4. Hose shall be suitable for washdown service. 5. Manufacturer/Model: Goodyear Spiraflex. C. Reel: Heavy duty manual hose reel 1. Steel construction, epoxy coated. Blue Lake Expansion Project – Contract No. 9 15400-5 General Construction May 2012 2. Compatible with length, diameter and design pressure of hose specified in paragraph B above. 3. Provide with bevel gear and manual hand crank. 4. Manufacturer/Model: New Line Model 1185-2024. D. Spray Nozzle: Spray nozzle, adjustable flow, complete with pistol grip. 1. Brass, stainless steel or cast iron construction. 2.10 TRANSFORMER OIL SPILL DRAIN SHUT-OFF A. Vertical, transformer drain shut-off with hydrophobic, oleophilic oil absorbing media. Media shall swell to shut off the drain in the event of an oil spill. B. Housing shall be galvanized steel construction. C. Provide complete with all sand discs, shut-off discs and media pillows. D. Provide oil sample to IMBTEC prior ordering to confirm compatibility. E. Manufacturer / Model Number: 1. Single Chamber: IMBTEC Model IMOH 242430-AA 2. Two Chamber: IMBTEC Model IMOH 244430-AA PART 3 EXECUTION 3.01 INSTALLATION – GENERAL A. Refer to Section 3 of Section 15300. 3.02 GENERAL PLUMBING ARRANGEMENT A. Drawings show the general locations and arrangement for equipment, piping, drain lines and hose connections. Adjust the final locations and arrangements of piping to fit the actual conditions and coordinate with other trades. Provide all necessary fittings and offsets. B. Install piping as high as possible, but in a manner as to ensure ready access to valves and similar accessories. C. Install piping parallel to general building lines unless specifically indicated otherwise. D. Install piping clear of all structural members except where a penetration is specifically indicated. E. Keep all piping clear of equipment removal areas and erect all risers plumb and true. Blue Lake Expansion Project – Contract No. 9 15400-6 General Construction May 2012 F. Provide separable joints at all equipment, located for convenient equipment removal. G. Install all piping systems so as to be completely drainable. Provide drain valves at all low points and vents at all high points. H. Provide pipe sleeves for all construction wall penetrations, as applicable. I. Provide pipe escutcheons, as applicable, for all construction penetrations exposed to view. Take care in laying out piping systems so as to avoid having to cut or overlap escutcheons on adjacent pipes. J. Obtain approval for the backflow preventer equipment and installation from the City Water Department. Contractor shall be responsible for all permit fees. K. Obtain approval and inspections for the new water service connections from the City Water Department, including requirements for connections and work to be performed by a licensed plumber. Contractor shall be responsible for all fees. L. Coordinate with the Local Plumbing Authority for the supply and installation of the water meter. Contractor shall be responsible for all applicable fees. 3.03 PLUMBING PIPING INSTALLATION A. General: Install plumbing specialty components, connections, and devices according to manufacturer's written instructions. B. Install backflow preventers of type, size, and capacity indicated, at each water- supply connection to mechanical equipment and systems, and to other equipment and water systems As Shown. Comply with authorities having jurisdiction. Locate backflow preventers in same room as connected equipment. Install air-gap fitting on units with atmospheric-vent connection and pipe relief outlet drain to nearest floor drain. C. Install pressure regulators with inlet and outlet shutoff valves and balance valve bypass. Install pressure gages on inlet and outlet. D. Install strainers on supply side of each control valve, pressure regulator, and solenoid valve, and where indicated. E. Install hose bibbs with integral or field-installed vacuum breaker. F. Install cleanouts in aboveground piping and building drain piping as indicated, and where not indicated, according to the following: 1. Size same as drainage piping up to 4-inch NPS. Use 4-inch NPS for larger drainage piping unless larger cleanout is indicated. 2. Locate at each change in direction of piping greater than 45 degrees. 3. Locate at minimum intervals of 50 feet for piping 4-inch NPS and smaller and 100 feet for larger piping. 4. As required by International and Local Plumbing Codes. Blue Lake Expansion Project – Contract No. 9 15400-7 General Construction May 2012 G. Install cleanout deck plates, of types indicated, with top flush with finished floor, for floor cleanouts for piping below floors. H. Install cleanout wall access covers, of types indicated, with frame and cover flush with finished wall, for cleanouts located in concealed piping. I. Install vent flashing sleeves on stacks passing through roof. Secure over stack flashing according to manufacturer's or prefabricated building suppliers written instructions. J. Fasten wall-hanging plumbing specialties securely to supports attached to building substrate if supports are specified and to building wall construction if no support is indicated. K. Fasten recessed, wall-mounting plumbing specialties to reinforcement built into walls. L. Install individual stop valve in each water supply to plumbing specialties. Use ball, gate, or globe valve if specific valve is not indicated. M. Install water-supply stop valves in accessible locations. N. Install traps on plumbing specialty drain outlets. Omit traps on indirect wastes unless trap is indicated. O. Locate drainage piping as close as possible to bottom of floor slab supporting fixtures and drains. P. Install escutcheons at wall, floor, and ceiling penetrations in exposed finished locations and within cabinets and millwork. Use deep-pattern escutcheons if required to conceal protruding pipe fittings. Q. Install vents As Shown and as per International and Local Plumbing Codes. 3.04 CONNECTIONS A. Piping installation requirements are specified in other Division 15 Sections. Drawings indicate general arrangement of piping, fittings, and specialties. The following are specific connection requirements: 1. Install piping connections between plumbing specialties and piping specified in other Division 15 Sections. 2. Install piping connections indicated between appliances and equipment specified in other Sections; connect directly to plumbing piping systems. 3. Install piping connections indicated as indirect wastes from appliances and equipment specified in other Sections, to spill over receptors connected to plumbing piping systems. B. Install hoses between plumbing specialties and appliances as required for connections. C. Supply Runouts to Plumbing Specialties: Install hot- and cold-water-supply piping of sizes indicated, but not smaller than required by authorities having jurisdiction. Blue Lake Expansion Project – Contract No. 9 15400-8 General Construction May 2012 D. Drainage Runouts to Plumbing Specialties: Install drainage and vent piping, with approved trap, of sizes indicated, but not smaller than required by authorities having jurisdiction. 3.05 ISOLATION VALVE A. Provide isolation valves at water supply take-off As Shown. Valves shall be located so as to allow removal of the equipment with the least possible disruption to the piping systems. B. Valves shall be located as close as possible to the take-off. 3.06 HOSE CONNECTION VALVES A. Provide hose connection valves at all locations As Shown. Valves shall be located so as to allow removal of equipment with the least possible disruption to the piping systems. B. Install hose connection valves 36 inches above the finished floor. C. Anchor the supply pipe immediately above the hose connection valve. D. Provide an appropriate means of backflow prevention on every device with a hose thread outlet including drain valves for the piping system. 3.07 FLUSHING A. Prior to connection to any equipment, thoroughly flush all newly installed piping systems with clear water. B. Continue flushing until the water leaving the system is clear, but not for less than 10 minutes. C. Use adequate water quantities to assure a sufficient flushing velocity in all piping. 3.08 PRESSURE TESTING A. Pressure test all pressure piping systems in sections as the systems are erected, correcting any leaks and retesting as necessary before proceeding with the erection of subsequent sections. B. Do not insulate any section of piping until the section has been successfully tested. C. Unless otherwise specified, following completion of the entire system and final connections to all equipment, fill and vent the entire system. Subject the entire system to a hydrostatic pressure as per International Plumbing Code, and maintain this pressure for not less than three hours, isolating only that equipment which would be damaged by such a pressure. D. Repair any leaks occurring during the above tests, and retest as necessary. Follow this sequence until no leaks occur. E. Test drainage lines by flushing water through the system and visually inspecting the system. Blue Lake Expansion Project – Contract No. 9 15400-9 General Construction May 2012 3.09 SYSTEM DISINFECTION A. Review disinfection procedure with the City Water Department prior to starting work. B. Prior to starting Work, verify system is complete, flushed, and clean. C. Ensure pH of water to be treated is between 7.4 and 7.6 by adding alkali (caustic soda or soda ash) or acid (hydrochloric). D. Inject disinfectant, free chlorine in liquid, powder, tablet or gas form, throughout system to obtain 50 to 80 mg/l residual. E. Bleed water from outlets to ensure distribution and test for disinfectant residual at minimum 15 percent of outlets. F. Maintain disinfectant in system for 24 hours. G. If final disinfectant residual tests less than 25 mg/l, repeat treatment. H. Flush disinfectant from system until residual concentration is 1.0 mg/l or equal to that of incoming water. I. Take samples no sooner than 24 hours after flushing, from 10 percent of outlets and from water entry, and analyze in accordance with AWWA C651. J. Provide test reports to RPR. 3.10 THERMAL INSULATION, HOT AND COLD WATER SYSTEMS A. Insulate plumbing piping as follows: 1. Potable Water, Hot (HW): 1-1/2 inches elastomeric foam with PVC jacket. 2. Potable Water, Cold (CW): 1 inch elastomeric foam with PVC jacket. 3. Outdoor water lines: 2 inches elastomeric foam, with self-limiting heat tracing, and aluminum jacket. a. Heat tracing: Electric, self-limiting heat trace, 150 degrees F maximum temperature, 5 watts per linear foot, 120 vac. b. Raychem BTV, or equal. B. Insulate piping as follows: 1. All hot water potable lines (HW). 2. All cold water potable lines (CW) within the wash room, lavatory, break room. 3. All water lines routed above non-NEMA 4 rated electrical equipment. Insulation shall extend 3 feet beyond the equipment. Blue Lake Expansion Project – Contract No. 9 15400-10 General Construction May 2012 C. The following components need not to be insulated: 1. Separable joints 2. Drain valves 3. Hose connection valves 3.11 FLOOR DRAINS A. Install in accordance with the manufacturer’s printed installation instructions, unless otherwise specified. B. Set drainage flange flush with top of structural floor slab, or at elevation otherwise indicated. C. Position floor drains for easy access and maintenance. D. Adjust strainer head to height indicated. If height not indicated, set at 1/2 inch below finished floor elevation. END OF SECTION Blue Lake Expansion Project – Contract No. 9 15405-1 General Construction May 2012 SECTION 15405 SANITARY LIFT STATION PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install sanitary lift station comprised of a sewage pumping system including duplex pumps, valves, piping lift-out rail system, access cover and duplex pump controls (refer to Drawing 109-45-068). B. Supply of Special Tools: One set of factory made tools required for routine maintenance. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 15020: General Mechanical Provisions. C. Section 15300: Piping Systems D. Section 15400: Plumbing Systems 1.03 REFERENCES A. National Electric Code Class 1, Division 1 (explosion-proof) rated service, Class 1, group C and D in air or submersible in sewage. B. U.L. (Underwriter’s Laboratory) Listed. C. Perform work in accordance with the International Plumbing Code and local plumbing authority. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: 1. Provide dimension drawings of the entire assembly including basin, pumps, control panel and all other components. 2. Indicate pump type, capacity, power requirements. 3. Provide certified pump curves showing pump performance characteristics with pump and system operating point plotted. Include NPSH curve. 4. Provide electrical characteristics, schematics, and connection wiring diagrams. Blue Lake Expansion Project – Contract No. 9 15405-2 General Construction May 2012 C. Quality Control Submittals 1. Certificates: Certify that the pumps have been factory tested in accordance with accepted practices of the Hydraulic Institute Standards Manual and that the characteristics of the pump conforms to the performance curve published by the manufacturer for that class pump. 2. Installation instructions, including mounting, support and anchoring requirements, installation, start-up and commissioning.. 1.05 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing the Products specified in this section with minimum five years documented experience. 1.06 WARRANTY A. Refer to Division 1. B. Provide a five (5) year warranty from the manufacturer. 1.07 DELIVERY, STORAGE AND HANDLING A. Delivery of Equipment: Deliver the system as a complete, unitized, factory assembled, wired and packaged assembly, requiring only mounting, wiring and piping connections to put the unit into operation. PART 2 PRODUCTS 2.01 SEWAGE PUMPS (P-2A, P-2B) A. Design: 1. Duplex, submersible grinder pumps. The grinder unit shall be capable of macerating all material in normal domestic and commercial sewage including reasonable amounts of foreign objects such as small wood, sticks, plastic, thin rubber, sanitary napkins, toilet paper and the like to a fine slurry that will pass freely through the pump and 2 inch discharge pipe. Pump and motor assembly shall be UL listed for Class 1, Group D explosion-proof service. 2. For arrangement of the sewage pumping system, see Drawing 109-45-068. B. Manufacturer: 1. Pumps shall be FE Meyers WGX30H grinder pump or approved equal. C. Operating Conditions: Each pump shall have a capacity of 55 gpm at a total head of 70 ft, and 0 gpm at 100 feet of head. D. Motor: 1. Pump motor shall be of the sealed submersible type rated at 3 hp at 3,450 rpm. Motor shall be for 460 volts / 3 phase / 60Hz. Blue Lake Expansion Project – Contract No. 9 15405-3 General Construction May 2012 2. Stator winding shall be of the open type with Class F inverter duty insulation good for 155C (311F) maximum operating temperature. Motor housing shall be filled with a clean, high dielectric oil that lubricates bearings and seals and transfers heat from windings and rotor to outer shell. 3. Motor shall have two heavy-duty ball bearings to support pump shaft and take radial and thrust loads and a sleeve guide bushing directly above the lower seal to take radial load and act as flame path for seal chamber. Ball bearings shall be designed for 50,000 hours B-10 life. Stator shall be heat shrunk into motor housing. 4. A heat sensor thermostat shall be attached to and embedded in the winding and be connected in series with the motor starter contactor coil to stop motor if temperature of winding is more than 120C (248F). Thermostat to reset automatically when motor cools to safe operating temperature. The common pump, motor shaft shall be of 416 stainless steel. E. Seals: 1. Motors shall be protected by two mechanical seals mounted in tandem with a seal chamber between the seals. Seal chamber shall be oil filled to lubricate seal face and to transmit heat from shaft to outer shell. 2. Seal face shall be carbon and ceramic and lapped to a flatness of one light band. 3. A double electrode shall be mounted in the seal chamber to detect any water entering the chamber through the lower seal. Water in the chamber shall cause a red light to turn on at the control box. This signal shall not stop motor but shall act as a warning only, indicating service is required. F. Impeller: The pump impeller shall be of recessed type to provide an open unobstructed passage through the volute for the ground solids. Impeller shall be of 85-5-5-5 bronze and shall be threaded onto stainless steel shaft. G. Grinder Construction: 1. Grinder assembly shall consist of a single rotating grinder impeller and a single stationary shredding ring mounted directly below pump volute inlet. Grinder impeller shall thread onto shaft and shall be locked with a screw and washer. Shredding ring shall be held in place by a steel retaining clamp. Both shredding ring and grinder impeller shall be removable without dismantling pump. No adjustment of grinder assembly shall be necessary for proper grinder operation. Multiple grinder impeller assemblies requiring initial or periodic axial adjustment for proper operation shall not be considered equal. Grinder impeller and shredding ring shall be made of 440C stainless steel hardened to 58-60 Rockwell. H. Pump and Motor Casting: 1. All castings shall be of high tensile cast iron and shall be treated with phosphate and chromate rinse. 2. All fasteners shall be 302 stainless steel. Blue Lake Expansion Project – Contract No. 9 15405-4 General Construction May 2012 I. Bearing End Cap: 1. Upper motor bearing cap shall be a separate casting for easy mounting and replacement. J. Cables: 1. Power cord and control cord shall be double sealed. The power and control conductor shall be single strand sealed with epoxy potting compound and then clamped in place with rubber seal bushing to seal outer jacket against leakage and to provide for strain pull. Cords shall withstand a pull of 300 pounds to meet U.L. requirements. 2. Insulation of power and control cords shall be Type SOOW. Both control and power cords shall have a green carrier ground conductor that attaches to motor frame. 2.02 DUPLEX PUMP CONTROLS A. Liquid Level Control Device: Construct of corrosion resistant materials, with components designed for installation within the sump completely waterproof, including oil resistant grounding type power cord. Cords shall be one piece and of sufficient length to reach the panel. 1. Float switches, intrinsically safe, Designed for remote installation. Furnish with stainless steel mounting clamps and stainless steel fasteners. B. High Liquid Alarm: Factory wired assembly consisting of a transformer, warning light, silencing switch, housed in a NEMA-4X enclosure, and liquid level control actuated. C. Control Panel: Factory wired, housed in an outdoor NEMA-4X enclosure; automatic electric alternator, liquid level control actuated. Include motor starters, elapsed time meters, dry contact for remote alarm, H-O-A switch, lights (run status of each pump, high level alarm, pump failure), and circuit breaker for each pump motor. Run indicators shall be green, failure indicators shall be red. D. Terminations: All power and controls shall terminate with plug / receptacle connectors on the bottom of the panel. 1. Female connectors shall be located on the panel, male connectors on the cord. 2. Connectors shall be weathertight, complete with hinged watertight cover on the female end. 3. Provide with mechanical lock. Twist lock plugs are not acceptable. E. All controls and electrical components located inside the lift station shall conform to National Electrical Code Class 1, Division 1 (explosion-proof) rated service; UL listed for Class 1, Group C and D in air or submersible in sewage. All other components shall be NEMA-4X rated or be located in a NEMA-4X panel. F. Pump controls shall be duplex with lead-lag control for alternating pump operation. For a failure of either pump, the high alarm warning light shall be activated and Blue Lake Expansion Project – Contract No. 9 15405-5 General Construction May 2012 alternating operation shall be suspended and the remaining pump shall be in operation at all times. G. Controller shall be compatible with the pumps as described in paragraph 2.01. The controller shall be capable of receiving all inputs from the pumps, including, but not limited to heat/moisture sensors and shut-down the pump on thermal overload. 2.03 PUMP BASIN A. Pre-cast concrete circular sanitary manhole. 1. Diameter and depth As Shown. 2. Steel reinforced 4,000 psi compressive strength concrete per ASTM C-478. 3. Cement for grout used in the construction of manholes shall conform to the requirements of ASTM C-150, Type II. Sand shall conform with AASHTO Specification M-45. The grout shall be composed of one (1) part cement and three (3) parts sand. The joints shall be constructed so as to produce a smooth, regular watertight surface. Only enough water shall be added to provide plasticity in placing the grout. 4. Basin shall be suitable for soil loading to full depth and shall be suitable for AASHTO H-20 vehicle traffic. B. One pour monolithic base with 6” flange C. Manhole exterior joint waterproofing shall be an Esky-Wrap system as manufactured by Caddiloc External Pipe Joint, Inc. or a Miradri system as manufactured by Mirafi, Inc. including Miradri P-804 primer, Miradri 860 membrane and Miradri M-800 mastic, or approved equal that includes a membrane and adhesive system for positive water exclusion. Joint waterproofing shall extend a minimum of 6” above and 6” below the joint. D. Pre-molded gaskets for manhole construction shall be as manufactured by K. T. Snyder Company, Inc., Ram-Nek Gasket Division, 2100 Travis Street, Houston, Texas or equal. E. Provide with cast-in ladder rungs. 2.04 LIFT-OUT RAIL SYSTEM F. General: The lift-out rail system shall be of non-sparking design and shall be listed for explosion-proof service. G. Components: Each lift-out rail system shall consist of a ductile iron discharge base, brass faced pump attaching and sealing plate, brass pump guide plate, and cast iron elbow. All exposed nuts, bolts, and fasteners shall be of 300 series stainless steel. No fabricated steel parts shall be used. H. Elbow: Discharge elbow shall be 3 inch x 3 inch. Elbow shall bolt onto base and have standard 125 lb flanges. I. Sealing: A sealing plate shall be attached to the pump. A simple downward sliding motion of the pump and guide plate on the guide rails shall cause the unit to be automatically connected and sealed to the base. The mating faces of the sealing Blue Lake Expansion Project – Contract No. 9 15405-6 General Construction May 2012 plate and base shall be machined to provide a metal-to-metal, leak-proof seal at all operating pressures. J. Two rail pipes shall be used to guide each pump from the surface to the discharge base connection. The guide rails shall be 1½ inch Schedule 40 stainless steel pipe. The weight of the pump shall bear solely on the discharge base and not on the guide rails. Rail systems which require the pump to be supported by legs which might interfere with the flow of solids into the pump suction will not be considered equal. The guide rail shall be firmly attached to the access hatch frame. Systems deeper than 21 ft shall use an intermediate guide for each 21 ft of wetwell depth. K. Lifting Chain: An adequate length of stainless steel lifting chain shall be supplied for removing the pump. The chain shall be of sufficient length and shall include an adequate number of lifting rings for easy removal. 2.05 ACCESS COVER A. General 1. Furnish and install an aluminum access cover As Shown. The access cover shall be lockable, hinged and spring loaded for easy opening. Access opening shall be minimum 30 inch by 30 inch to allow for ease of pump installation/removal. 2. Cover shall be AASHTO H-20 vehicle rated. 3. The door leaf shall be a minimum thickness of ¼ inch reinforced. 4. The frame shall be extruded aluminum with an integral anchor flange and seat. 5. The access cover shall be equipped with a flush aluminum drop handle which does not protrude above the cover and an automatic hold open arm with a red vinyl grip on a release handle. 6. Hinges shall be all stainless steel with tamper proof stainless steel bolts and nuts, and shall be removable for maintenance after the access cover is cast in place. 7. For security, the access door shall be equipped with a staple for padlock (padlock by others). 8. The access cover shall be furnished with a factory standard finish. 2.06 PUMP DISCHARGE PIPING AND VALVES A. Pipe and fittings: Ductile iron per Section 15300. B. Check Valves: Swing type, capable of passing 3 inch spherical solid, flanged, cast iron body, bronze mounted, neoprene rubber faced disc facing, weighted level (assists closing), 175 psig working pressure to AWWA C-508. Check valve shall lift out with pumps. C. Plug Valves: Non-lubricated, tapered type design with resilient plug facing, capable of passing 3 inch spherical solid, cast iron body, bronze mounted, flanged, 175 psig working pressure, with square nut for operation with a valve wrench. Blue Lake Expansion Project – Contract No. 9 15405-7 General Construction May 2012 2.07 VENT PIPING A. Pipe and Fittings: Ductile iron per Section 15300. B. Route vent pipe up through and embedded in powerhouse foundation/wall. Extend to and discharge out of outside powerhouse wall at elevation 52.00 with a down turned 90° elbow. 2.08 PAINT A. Finish: 1. Factory applied finish. Finish shall be suitable for corrosion proof, submersible service. PART 3 EXECUTION 3.01 INSTALLATION A. Installation of the duplex pump package including controls and related appurtenances shall be performed in accordance with written instructions by the manufacturer. B. Contractor shall provide all supports necessary for proper installation of the pumping system including pipe fittings and valves. C. Precast manhole bases shall be set on a firm foundation of compacted gravel materials or rock. Continuous support under sewer pipes shall be required. Placement of manhole barrel sections and cones must be made in vertical alignment with watertight joints. Placement of cast iron frames and covers at proper elevations is required. Installation of pre-molded gasket materials for manhole construction shall be in accordance with manufacturer’s instructions. D. Use of, and installation of, pre-molded plastic gaskets for manhole construction shall be strictly in accordance with the manufacturer’s printed instructions. Gaskets shall be trimmed on the inside of the manhole to prevent the excess gasket material from entering the sanitary sewer lines. E. All penetrations through the wall of manholes for pipes shall be constructed with resilient EPDM rubber boots which are integral with the manhole wall. 3.02 START-UP SUPPORT A. Provide the services of a competent field service representative of the pump manufacturer for the following: 1. Inspect pump installations prior to startup. 2. Supervise initial startup of pumps. 3. Instruction of Operations Personnel. 4. Service. (Identify the closest local service facility that will be available 24 hours per day year round.) Blue Lake Expansion Project – Contract No. 9 15405-8 General Construction May 2012 3.03 FIELD QUALITY CONTROL A. Test pump system and high level alarm for proper operation at the specified liquid levels. 3.04 HEALTH AND SAFETY A. Contractor shall provide all health and safety related equipment and materials associated with the lift station work. END OF SECTION Blue Lake Expansion Project – Contract No. 9 15415-1 General Construction May 2012 SECTION 15415 BACKFLOW PREVENTERS PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and Install all backflow preventers. B. Furnish portable test kits, packaged in a substantially built, compartmented carrying case, containing hose, gauge, and fittings required for testing backflow preventer for proper operation, and printed procedure for conducting test. C. Supply special tools required for maintenance as recommended by supplier. D. Comply with all local, state federal permit requirements for cross connection control. Where conflicts occur between the permits, the most stringent requirements shall apply. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 15020: General Mechanical Provisions C. Section 15400: Plumbing Systems 1.03 REFERENCE STANDARDS A. Alaska Department of Environmental Conservation (ADEC) – 18 AAC 72, Wastewater Disposal, 2009. B. City and Borough of Sitka, Alaska Standard Specificaions for Streets-Parks- Utilities-Drainage, 2002 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Manufacturer’s catalog sheets, specifications, and installation and maintenance instructions for each type backflow preventer and test kit. C. Test Results: Submit the test results from the test kits for each backflow preventer. Blue Lake Expansion Project – Contract No. 9 15415-2 General Construction May 2012 PART 2 PRODUCTS 2.01 BACKFLOW PREVENTERS A. Reduced Pressure Zone Principle device, with atmospheric vent, conforming to ASSE Standard 1013, AWWA C-511, USC specifications manual for Cross Connection Control, and listed as acceptable in the State Department of Health, Environmental Health Manual. 1. Performance: 150 psig, and 130 degrees F maximum working conditions. 2. Assembly: Strainer and gate or ball valve on inlet side, gate or ball valve on outlet side, and four test cocks, all as furnished or recommended by the backflow preventer manufacturer. B. General: Cast iron, epoxy coated body with stainless steel trim. C. Supplier: Watts Series 909. D. Spare Parts: 1. Total rubber parts kit (provide sufficient quantities for both check valves). 2. Relieve valve rubber parts kit. 3. Spare strainer basket. PART 3 EXECUTION 3.01 INSTALLATION A. Install the Work of this backflow preventers in accordance with the manufacturer’s printed installation instructions. B. Atmospheric Vent: Pipe vent to spill over closest point of drainage, as directed, maintaining a minimum 12 inch air gap above the drain. 1. Install air gap fitting when shown, or if atmospheric vent must be connected to drainage line. 2. Route discharge of air gap fittings to nearest floor drain and terminate 6 inches above the floor. C. Maintain minimum clearances: 1. Above: 12 inches 2. Below: 18 inches 3. Front: 30 inches Blue Lake Expansion Project – Contract No. 9 15415-3 General Construction May 2012 3.02 SITE TESTS A. Operation Test: Test the device with the test kit in accordance with the supplier’s testing procedures. Backflow preventer shall be tested by certified tester. Submit the test report. B. Re-testing: Repair or replace any device failing the operation test, and repeat the test. END OF SECTION Blue Lake Expansion Project – Contract No. 9 15420-1 General Construction May 2012 SECTION 15420 EYE WASH STATION PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install the following: 1. Eye Wash Station 2. Thermostatic Mixing Valve 1.02 RELATED SECTIONS A. Section 01300 – Submittals 1.03 REFERENCE STANDARDS A. ANSI Z358.1 – Emergency Eye Wash and Shower Equipment. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Manufacturer's catalog sheets, specifications, and installation instructions. PART 2 PRODUCTS 2.01 EYE WASH A. Type: Pedestal mounted eye wash station with stainless steel bowl. 1. Complies with ANSI Z358.1. 2. Factory preassembled and tested. 3. All materials shall be corrosion resistant material. 4. Guardian Equipment Model G1825 or equal. B. Flow requirements: 1. 0.4 GPM at 30 psi flow pressure. C. Outlet Head Assembly: 1. Two self-regulating outlet flow heads. 2. Float off duct covers. Blue Lake Expansion Project – Contract No. 9 15420-2 General Construction May 2012 D. Valve: 1. 1/2 inch IPS stainless steel or chrome plated brass stay open ball valve. 2. Valve actuated by flag handle constructed of corrosion resistant material. E. Bowl: 1. 11.5 inch stainless steel. F. Mounting: 1. Free standing, pedestal mount, schedule 40 galvanized steel with orange or yellow polyethylene cover. G. Connections: 1. 1/2 inch NPT female water inlet. 2. 1-1/4 inch NPT waste outlet. H. Sign: 1. Supply one (1) ANSI compliant identification sign. 2.02 THERMOSTATIC MIXING VALVES A. Manufacturer: Watts, Model L111 or approved equal. B. Valve Body: 1. Cast brass. 2. Integral mounting holes to mount and support the unit. 3. Tamper resistant enclosure. C. Internal Components: 1. Metals: Brass, or stainless steel. 2. Non-Metals: Materials not adversely affected by contact with water, temperature changes, and normal wear. 3. Internals shall be maintainable without having to remove the valve from the piping. D. Finishes: Furnish polished, chrome plated brass, or No. 4 brush finished stainless steel on exposed to view surfaces installed in finished spaces. E. Standards: Comply with ASSE Standard 1016. F. Pressure and Temperature Ratings: 1. Minimum pressure: 15 psi. Blue Lake Expansion Project – Contract No. 9 15420-3 General Construction May 2012 2. Recommended inlet pressure: 30 to 60 psi. 3. Hot water inlet temperature range: 120ºF to 180ºF. 4. Cold water inlet temperature range: 33ºF to 85ºF. 5. Minimum temperature differential: 10ºF. 6. Mixed water temperature: Field adjustable between 60ºF and 120ºF. PART 3 EXECUTION 3.01 INSTALLATION A. Install the Work of this section in accordance with the manufacturer's printed installation instructions. B. Install the Work of this section in accordance with ANSI Z358.1, including, but not limited to the following: 1. Locate so that the valve actuator is easily accessible. 2. Locate so that the unit is highly visible. 3. Install at least 6 inches from wall and any obstruction. 4. Install between 33 inches and 45 inches above the floor. C. The water supply shall be tepid water provided by mixing cold and hot water with a thermostatic mixing valve (paragraph 2.02 above) set at 75 °F. 3.02 SITE TEST A. Testing: Test unit per ANSI Z358.1 and manufacturer’s recommendations. B. Training: Provide any training and maintenance information as recommended by ANSI Z358.1 and the manufacturer. END OF SECTION Blue Lake Expansion Project – Contract No. 9 15440-1 General Construction May 2012 SECTION 15440 PLUMBING EQUIPMENT AND FIXTURES PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install the following: 1. Water closets. 2. Lavatories. 3. Floor sink. 4. Shower. 5. Water heaters. 1.02 RELATED SECTIONS A. Section 01300 – Submittals B. Section 15300 – Piping C. Section 15400 – Plumbing Systems 1.03 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data for each plumbing fixture category and type specified. Include selected fixture, trim, fittings, accessories, appliances, appurtenances, equipment, and supports. Indicate materials and finishes, dimensions, construction details, and flow-control rates. C. Wiring diagrams from manufacturer for electrically operated units. D. O&M Manuals. 1.04 DEFINITIONS A. Accessible: Plumbing fixture, building, facility, or portion thereof that can be approached, entered, and used by physically handicapped, disabled, and elderly people. B. Fitting: Device that controls flow of water into or out of plumbing fixture. Fittings specified in this Section include supplies and stops, faucets and spouts, drains and tailpieces, traps and waste pipes. Pipe fittings, tube fittings, and general-duty valves are included where indicated. Blue Lake Expansion Project – Contract No. 9 15440-2 General Construction May 2012 1.05 QUALITY ASSURANCE A. Source Limitations: Obtain plumbing fixtures, faucets, and other components of each category from one source and by a single manufacturer. 1. Exception: Where fixtures, faucets, or other components are not available from a single manufacturer, obtain similar products from other manufacturers specified for this category. B. Regulatory Requirements: Comply with requirements of CABO A117.1, “Accessible and Useable Buildings and Facilities”; Public Law 90-480, “Architectural Barriers Act”; and Public Law 101-336, “Americans with Disabilities Act”; regarding plumbing fixtures for physically handicapped people. C. Environmental Conservation Law: Comply with requirements of International Plumbing Code regarding water consumption of plumbing fixtures. D. Select combinations of fixtures and trim, faucets, fittings, and other components that are compatible. E. Product Options: Drawings indicate size, profiles, dimensional requirements, and characteristics of plumbing fixtures and are based on specific types and models indicated. Other manufacturers’ fixtures with equal performance characteristics may be considered. 1.06 DELIVER, STORAGE AND HANDLING A. Deliver plumbing fixtures in manufacturer’s protective packing, crating, and covering. B. Store plumbing fixtures on elevated platforms in dry location. 1.07 PROJECT CONDITIONS A. Field Measurements: Coordinate roughing-in and final fixture locations and verify that plumbing fixtures can be installed to comply with original design and referenced standards. PART 2 PRODUCTS 2.01 FLUSH VALVE WATER CLOSETS (WC-1) A. Bowl: 1. Manufacturer: Eljer, Model Signature 111-2125. 2. Other acceptable manufacturers offering equivalent products: a) Crane. b) Elkay. c) Substitutions permitted under provisions of Division 1. Blue Lake Expansion Project – Contract No. 9 15440-3 General Construction May 2012 3. ASME A112.19.2: floor mounted, siphon jet vitreous china closet bowl, with elongated bowl, 1.6 gpm, 1½ inch top spud, china bolt caps. B. Exposed Flush Valve: 1. Manufacturer: Sloan, Royal Flushometer Model 111. 2. Other acceptable manufacturers offering equivalent products: a) Zurn Industries, Inc. b) Chicago. c) Substitutions permitted under provisions of Division 1. 3. ASME A112.18.1: exposed chrome plated, diaphragm type with oscillating handle, escutcheon, seat bumper, integral screwdriver stop and vacuum breaker; maximum 1.6 gallon flush volume. C. Seat: 1. Manufacturers: American Standard, Model Olsonite #95. 2. Other acceptable manufacturers offering equivalent products: a) Crane. b) Elkay. c) Substitutions permitted under provisions of Division 1. 3. Solid white plastic, open front, extended back, self-sustaining hinge, brass bolts, without cover. 2.02 ADA FLUSH VALVE WATER CLOSETS (WC-2) A. Bowl: 1. Manufacturer: Eljer, Model Signature 111-2145. 2. Other acceptable manufacturers offering equivalent products: a) Crane. b) Elkay. c) Substitutions permitted under provisions of Division 1. 3. ASME A112.19.2 and ANSI A117.1: floor mounted, siphon jet vitreous china closet bowl, with elongated bowl, 1.6 gpm, 1½ top spud, china bolt caps. Blue Lake Expansion Project – Contract No. 9 15440-4 General Construction May 2012 B. Exposed Flush Valve: 1. Manufacturer: Sloan, Royal Flushometer Model 111. 2. Other acceptable manufacturers offering equivalent products: a) Zurn Industries, Inc. b) Chicago. c) Substitutions permitted under provisions of Division 1. 3. ASME A112.18.1: exposed chrome plated, diaphragm type with oscillating handle, escutcheon, seat bumper, integral screwdriver stop and vacuum breaker; maximum 1.6 gallon flush volume. C. Seat: 1. Manufacturer: American Standard, Model Olsonite #95. 2. Other acceptable manufacturers offering equivalent products: a) Crane. b) Elkay. c) Substitutions permitted under provisions of Division 1. 3. Solid white plastic, open front, extended back, self-sustaining hinge, brass bolts, without cover. 2.03 WALL HUNG URINALS (UR-1) A. Urinal: 1. Manufacturer: American Standard, Model Washbrook 6501.010. 2. Other acceptable manufacturers offering equivalent products: a) Kohler. b) Elkay. 3. ASME A112.19.2; vitreous china, wall hung siphon jet urinal with shields, integral trap, removable stainless steel strainer, 1 inch top spud, steel supporting hanger. B. Exposed Flush Valve: 1. Manufacturer: Sloan, Royal Flushometer Model 180-1. 2. Other acceptable manufacturers offering equivalent products: a) Zurn Industries, Inc. b) Chicago. Blue Lake Expansion Project – Contract No. 9 15440-5 General Construction May 2012 3. ASME A112.18.1; exposed chrome plated, diaphragm type with oscillating handle, escutcheon, integral screwdriver stop, vacuum breaker, maximum 1 gallon flush volume. C. Wall Mounted Carrier: 1. Manufacturer: Zurn Industries, Inc., Model ZR-1222. 2. Other acceptable manufacturers offering equivalent products: a) Josam Company. 3. ASME A112.6.1; cast iron and steel frame with tubular legs, lugs for floor and wall attachment, threaded fixture studs for fixture hanger, bearing studs. 2.04 ADA WALL HUNG URINALS (UR-2) A. Urinal: 1. Manufacturer: American Standard, Model Allbrook 6541.132. 2. Other acceptable manufacturers offering equivalent products: a) Kohler. b) Elkay. 3. ASME A112.19.2 and ANSI 117.1; vitreous china, wall hung siphon jet urinal with extended shields and trap, removable stainless steel strainer, 1 gpm, 1 inch top spud, steel supporting hanger. B. Exposed Flush Valve: 1. Manufacturer: Sloan, Royal Flushometer Model 180-1. 2. Other acceptable manufacturers offering equivalent products: a) Zurn Industries, Inc. b) Chicago. 3. ASME A112.18.1; exposed chrome plated, diaphragm type with oscillating handle, escutcheon, integral screwdriver stop, vacuum breaker, maximum 1 gallon flush volume. C. Wall Mounted Carrier: 1. Manufacturer: Zurn Industries, Inc., Model ZR-1222. 2. Other acceptable manufacturers offering equivalent products: a) Josam Company Blue Lake Expansion Project – Contract No. 9 15440-6 General Construction May 2012 3. ASME A112.6.1; cast iron and steel frame with tubular legs, lugs for floor and wall attachment, threaded fixture studs for fixture hanger, bearing studs. 2.05 LAVATORIES A. Vitreous China Wall Hung Basin (LAV-1) 1. Manufacturer: Eljer, Model Mayburne 051-2248. 2. Other acceptable manufacturers offering equivalent products: a) Kohler. b) Elkay. 3. ASME A112.19.2: vitreous china wall hung lavatory, 20x18 inch nominal, drilling on 8-inch centers, back overflow. B. ADA Accessible Vitreous China Wall Hung Basin (LAV-2) 1. Manufacturer: Kohler, Model K-2035-8. 2. Other acceptable manufacturers offering equivalent products: a) Crane. b) Elkay. 3. ASME A112.19.2: Vitreous china wall hung lavatory 22x18 inch minimum, with drilling on 8 inch centers, with splash lip and front overflow. C. Lavatory Faucets (LAV-1) 1. Manufacturer: Chicago Faucets, Model 404-A369CP with 327A tailpiece and strainer. 2. Other acceptable manufacturers offering equivalent products: a) American Standard. b) Elkay. 3. ASME A112.18.1: chrome plated combination supply fitting with open grid strainer, 8 inch centers, quarter turn, 5-inch spout, lever handles, color indexed, water economy aerator with maximum 2.0 gpm flow. Water consumption shall not exceed the requirements of International Plumbing Code. D. ADA Lavatory Faucets (LAV-2) 1. Manufacturer: Chicago Faucets, Model 404-A317CP, with 337 offset tailpiece and strainer. 2. Other acceptable manufacturers offering equivalent products: a) American Standard. Blue Lake Expansion Project – Contract No. 9 15440-7 General Construction May 2012 b) Elkay. 3. ASME A112.18.1: chrome plated combination supply fitting with open grid strainer, 8 inch centers, 5-3/8 inch spout, 4 inch wrist blade handles, color indexed, water economy aerator with maximum 2.0 gpm flow, ADA compliant. Water consumption shall not exceed the requirements of NYSDEC Environmental Conservation Law, Section 15-0314. 4. Lavatory P-trap and angle valve assemblies shall be insulated with the fully molded insulation kit. TRUEBRO Handi Lav-Guard insulation kit, color white, Model #103 or approved equal. E. Accessories 1. Chrome plated 17 gage brass P-trap with cleanout plug and arm with escutcheon. 2. Stainless steel quarter-turn ball stop valves. 3. Stainless steel braided hose supply lines. 4. Chrome plated escutcheons. F. Wall Mounted Carrier: 1. Manufacturer: Zurn Industries, Inc., Model ZR-1231-E2. 2. Other acceptable manufacturers offering equivalent products: a) Josam Company. b) J.R. Smith Manufacturing Co. c) MIFAB. 3. ASME A112.6.1: cast iron and steel frame with tubular legs, lugs for floor and wall attachment, threaded studs for fixture hanger, bearing plate and studs. 2.06 SERVICE SINK (SS-1) A. Floor Mounted Service Sink 1. Manufacturer: Stern Williams, Inc. Elfin Model MTB-2424 (24 inch x 24 inch x 10 inch) with integral stainless steel cap on all exposed sides and with T-10-VB sink fitting and T-35-hose and wall hook. 2.07 BREAK ROOM SINK A. Break Room Sink (S-1) 1. Manufacturer: Elkay Model LR-2522. 2. Other acceptable manufacturers offering equivalent products: a) American Standard. Blue Lake Expansion Project – Contract No. 9 15440-8 General Construction May 2012 b) Crane. 3. Single compartment, 18 gage, Type 302 SS, self-rimming, 25x22 inch overall, underside protected by heavy duty sound guard undercoating, 4-hole faucet deck, strainer and tailpiece. B. Break Room Sink Faucets (KS-1) 1. Manufacturer: Chicago Faucets, Model 200A-GN8AE3-317. 2. Other acceptable manufacturers offering equivalent products: a) American Standard. b) Elkay. 3. ASME A112.18.1: chrome plated, 8 inch centers, 8 inch spout, 317 4-inch blade handles, color indexed, E3 aerator, vegetable spray. Maximum 2.5 gpm flow. C. Accessories 1. Brass P trap with bottom cleanout plug. 2. Stainless steel quarter-turn ball stop valves. 2.08 SHOWER (SHWR) A. Shower, 36 inch by 36 inch 1. One piece free standing shower unit, with built-in shelves. 2. Color: White 3. Finish: Gelcoat, reinforced with Fiberglass. 4. Manufacturer / Model: Hytec (Kohler) model 3620. 2.09 WATER HEATER, ELECTRIC, TANK TYPE (WH-1) A. Electric water heater, commercial grade complete with tank, controls and overpressure protection. 1. Manufacturer: Lochinvar Model LTA030HH. 2. 30 gallon tank. 3. 3 KW, 208 vac, single phase, 60 Hz. 2.10 WATER HEATER, ELECTRIC, TANK TYPE (WH-2) A. Electric water heater, commercial grade complete with tank, controls and overpressure protection. 1. Manufacturer: Lochinvar Model HS-X-018-120. Blue Lake Expansion Project – Contract No. 9 15440-9 General Construction May 2012 2. 120 gallon tank. 3. 18 KW, 480 vac, three phase, 60 Hz. PART 3 EXECUTION 3.01 EXAMINATION A. Examine roughing-in for potable, hot- and cold-water supply piping systems; soil, waste, and vent piping systems; and supports. Verify that locations and sizes of piping and locations and types of supports match those indicated, before installing and connecting fixtures. Use manufacturer’s roughing-in data when roughing-in data are not indicated. B. Examine walls, floors, and cabinets for suitable conditions where fixtures are to be installed. C. Do not proceed until unsatisfactory conditions have been corrected. 3.02 APPLICATIONS A. Include supports for plumbing fixtures according to the following: 1. Carriers: For wall-hanging fixtures supported from wall construction. 2. Chair Carriers: For wall-hanging lavatories, sinks, drinking fountains, and electric water coolers. 3. Reinforcement: For floor-mounted lavatories and sinks that require securing to wall and recessed, box-mounted, electrical water coolers. B. Include fitting insulation kits for accessible fixtures. 3.03 PLUMBING FIXTURE INSTALLATION A. Replace floor flanges on all floor mounted water closets. B. Assemble plumbing fixtures and trim, fittings, faucets, and other components according to manufacturers’ written instructions. C. Install fixtures level and plumb according to manufacturer’s written instructions, roughing-in drawings, and referenced standards. D. Install toilet seats on water closets. E. Install flushometer valves for accessible water closets and urinals with handle mounted on wide side of compartment. Install other actuators in locations that are easy for handicapped people to reach. F. Fasten wall-hanging plumbing fixtures securely to supports attached to building substrate when supports are specified, and to building wall construction where no support is indicated. Blue Lake Expansion Project – Contract No. 9 15440-10 General Construction May 2012 G. Fasten floor-mounted fixtures to substrate. Fasten fixtures having holes for securing fixture to wall construction, to reinforcement built into walls. H. Fasten recessed, wall-mounted fittings to reinforcement built into walls. I. Fasten wall-mounted fittings to reinforcement built into walls. J. Fasten counter-mounting plumbing fixtures to casework. K. Secure supplies to supports or substrate within pipe space behind fixture. L. Install individual stop valve in each water supply to fixture. Use gate or globe valve where specific stop valve is not specified. M. Install water-supply stop valves in accessible locations. N. Install traps on fixture outlets. O. Install escutcheons at wall, floor, and ceiling penetrations in exposed, finished locations and within cabinets and millwork. Use deep-pattern escutcheons where required to conceal protruding pipe fittings. P. Seal joints between fixtures and walls, floors, and counters using sanitary-type, 1- part, mildew-resistant, silicone sealant according to sealing requirements specified in Division 7 Section “Joint Sealants”. Match sealant color to fixture color. 3.04 CONNECTIONS A. Piping installation requirements are specified in other Division 15 Sections. Drawings indicate general arrangement of piping, fittings, and specialties. The following are specific connection requirements: 1. Install piping connections between plumbing fixtures and piping systems and plumbing equipment specified in other Division 15 Sections. B. Supply and Waste Connections to Plumbing Fixtures: Refer to plumbing fixture riser diagrams for fitting sizes and connection requirements for each plumbing fixture. C. Supply and Waste Connections to Equipment Specified in Other Sections: Connect equipment with supply inlets, supply stops, supply risers, and traps specified in this Section. Use fitting sizes required to match connected equipment. Connect fittings to plumbing piping. 3.05 FIELD QUALITY CONTROL A. Verify that installed fixtures are categories and types specified for locations where installed. B. Check that fixtures are complete with trim, faucets, fittings, and other specified components. C. Inspect installed fixtures for damage. Replace damaged fixtures and components. Blue Lake Expansion Project – Contract No. 9 15440-11 General Construction May 2012 D. Test installed fixtures after water systems are pressurized and demonstrate proper operation. Replace malfunctioning fixtures and components, then retest. Repeat procedure until units operate properly. 3.06 ADJUSTING AND CLEANING A. Operate and adjust faucets and controls. Replace damaged and malfunctioning fixtures, fittings, and controls. B. Operate and adjust disposers, hot-water dispensers, and controls. Replace damaged and malfunctioning units and controls. C. Adjust water pressure at drinking fountains, faucets, and flushometer valves having controls, to produce proper flow and stream. Water consumption shall not exceed the requirements of International Plumbing Code. D. Replace washers and seals of leaking and dripping faucets and stops. E. Clean fixtures, faucets, and other fittings with manufacturers’ recommended cleaning methods and materials. Include the following: 1. Remove faucet spouts and strainers, remove sediment and debris, and reinstall strainers and spouts. 2. Remove sediment and debris from drains. 3.07 PROTECTION A. Provide protective covering for installed fixtures and fittings. B. Do not allow use of fixtures for temporary facilities, except when approved by RPR. END OF SECTION Blue Lake Expansion Project – Contract No. 9 15480-1 General Construction May 2012 SECTION 15480 COMPRESSED AIR SYSTEMS PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install the following: 1. Pre-packaged Air Compressor 2. Coalescing / Particulate Filter 1.02 RELATED SECTIONS A. Section 01300 – Submittals B. Section 15020 – General Mechanical Provisions C. Section 15300 - Piping Systems 1.03 SUBMITTALS A. Submit under provisions of Section 01300. B. Submit product data for compressor package and miscellaneous components (if required). C. Submit operation, maintenance data and parts lists. D. Spare parts. 1.04 QUALITY ASSURANCE A. Manufacturers: Firms regularly engaged in manufacture of compressed air piping systems products, of types, materials, and sizes required, whose products have been in satisfactory use in similar service for not less than five years. PART 2 PRODUCTS 2.01 OIL-FREE COMPRESSOR (AC-1, AC-2, AC-1GH) A. Simplex, single stage oil-free reciprocating, air-cooled stationary compressor mounted on horizontal air receiver tank. Compressor to be heavy-duty cast iron construction, electric motor. ASME coded receiver with ASME coded safety valve pressure gauge, automatic drain, control panel, and vibration isolators. 1. Design conditions: a. AC-1, AC-2: 49.7 scfm at 100 psig, 125 psig maximum pressure Blue Lake Expansion Project – Contract No. 9 15480-2 General Construction May 2012 b. AC-1 GH: 69.0 scfm at 50 psig, 100 psig maximum pressure 2. Receiver: 120 gallon, horizontal, ASME rated. 3. Provide with safety relief valve. Relief valve shall be sized to relieve the full flow of compressor capacity at safety valve set pressure. 4. Provide with automatic drain valve on the receiver. 5. Provide with dry type inlet air filter. 6. Compressor and motor shall be mounted on a secondary sub-base with vibration isolators. B. Airend 1. Oil-free reciprocating compressor. 2. Rated for 100% continuous duty at design conditions. 3. Internal moving parts protected from wear without oil lubrication. Pistons move on alloyed heat-resistant filled PTFE guide and compression rings. C. Enclosure 1. Provide enclosure and/or guarding of all moving parts. 2. Enclosure shall be provided with access panels to access all internal components for maintenance. 3. Unit controls, gauges, indicators and all user interface points shall be accessible from the enclosure exterior. D. Motor Motor shall be 15 Hp, 460V, 3 phase, 60 Hz, TEFC with Class F insulation and a service factor of 1.15. E. Drive 1. Motor and airend shall be factory installed and aligned and shall be connected by a crank shaft or v-belt. 2. The complete drive system shall be contained within protective guarding. 3. Bearings shall be permanently lubricated by sealed, synthetic lubricants. F. Coolant System: 1. Integral fine tube air cooled heat exchanger to cool coolant and compressed air. Blue Lake Expansion Project – Contract No. 9 15480-3 General Construction May 2012 G. Controls 1. Standard duplex sequencing control panel, which provides starting, stopping, capacity and pressure control, together with operating and safety control for the package. a. AC-1GH will operate as a single compressor, with a second compressor potentially added in the future. 2. Integrally mounted, starter enclosure with full voltage starter and control transformer. Motor overload protection is designed and sized to match the specific characteristics of the motor. 3. Provide with over-pressure protection and high temperature shutdown/lag compressor alarm. H. Options: 1. Furnish with Service/Maintenance indicator consisting of Hour meter, Maintenance indicator, Indicator of Fault condition, Real time clock, Back light, Service due warning and Service overdue. 2. Furnish outputs for remote indication of the following compressor operating conditions: a. Compressor Available (On) b. Compressor Running c. Compressor Failure I. Manufacturer: 1. AC-1, AC-2: Ingersoll-Rand Model 10T3NLM, or approved equal. 2. AC-1GH: Gardner Denver Model 12T15VTS55, or approved equal. 2.02 MISCELLANEOUS MATERIALS A. Moisture Separator 1. In-line moisture separator, rated for full compressor flow at 175 psig, 200 degrees F. 2. Provide with automatic drain. B. Coalescing / Particulate Filter 1. In-line coalescing/particulate filter with automatic drain. 2. Filter shall remove bulk particles (1 micron and larger) and oil (0.5 mg per cubic meter) at design flow conditions. 3. Rated for full compressor flow at 175 psig, 200 degrees F. Blue Lake Expansion Project – Contract No. 9 15480-4 General Construction May 2012 4. Provide with automatic drain. C. Air hose fittings 1. Brass coupling/plug set quick disconnects for compressed air service. 2. Minimum pressure / temperature rating: 200 psig / 200 degrees F. 3. Fittings shall be Milton Series 700/1700/1800. Plug size/style to match Owner’s existing air lines. 2.03 SPARE PARTS A. Provide the following spare parts (as required) for each compressor: 1. One cleanable filter or strainer of each type. 2. Four disposable filters or strainers of each type. 3. One set of drive belts. 4. Oil sufficient for two complete oil changes. PART 3 EXECUTION 3.01 INSTALLATION OF COMPRESSOR SYSTEM A. Install in accordance with manufacturer’s instructions and requirements. B. Install compressor unit on concrete housekeeping pad. C. Route drains to nearest floor or trench drain. D. Provide valved drip connections at low points of piping system. E. Install take-offs to outlets from top of main, with shut-off valve after take-off. F. Provide moisture separators/filters where required by control valves or other devices. 3.02 SITE QUALITY CONTROL A. Refer to Division 1. 3.03 INSTALLATION A. Install air compressors in accordance with manufacturer’s instructions and requirements. B. Install compressor unit on concrete housekeeping pad and anchor. C. Connect condensate drains to nearest floor drain. D. Provide valved drip connections at low points of piping system. Blue Lake Expansion Project – Contract No. 9 15480-5 General Construction May 2012 E. Install take-offs to outlets from top of main, with shut-off valve after take-off. 3.04 TESTING A. Instrument Air Piping Leak Test: Prior to initial operation, clean and test air piping in accordance with ANSI B31.1 to a test pressure equal to 1-1/2 times the maximum working pressure of 150 psig. The test pressure shall be applied for a minimum 2-hour duration. B. Repair or replace instrument air piping as required to eliminate leaks, and retest to demonstrate compliance. C. Cap (seal) ends of piping when not connected to mechanical equipment. D. Verify electrical connections and direction of rotation. 3.05 COMMISSIONING A. Perform the following final checks before startup: 1. Verify that specified tests of piping are completed. 2. Check safety valves for correct setting. Ensure settings are greater than air- compressor discharge pressure, but no greater than rating of system components. B. Starting Procedures: Follow manufacturer’s written instructions. If no instructions are prescribed by manufacturer, proceed as follows: 1. Energize circuits. 2. Start and run equipment through complete sequence of operations. 3. Check for excessive vibration and noise. Correct problems. 4. Check air pressures. 5. Manually operate safety valves. 6. Adjust operating controls, including pressure settings. C. Operate and adjust operating and safety controls. Replace damaged and malfunctioning controls and equipment discovered by service representative. END OF SECTION Blue Lake Expansion Project – Contract No. 9 15600-1 General Construction May 2012 SECTION 15600 FIRE PROTECTION EQUIPMENT PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install the following: 1. Portable fire extinguishers 2. Range hood fire extinguisher 3. Hose stations 1.02 RELATED SECTIONS A. Section 01300 – Submittals B. Section 15300 – Piping C. Section 16721 – Fire Alarm Systems 1.03 REFERENCE STANDARDS A. The work of this section shall be in accordance with the following standards: 1. National Fire Protection Association Standard Number 10-88, Portable Fire Extinguishers. 2. National Fire Protection Association Standard Number 14, Standard for the Installation of Standpipe and Hose Systems. 3. National Fire Protection Association Standard Number 17A, Wet Chemical Fire Extinguishing Systems. 4. National Fire Protection Association Standard Number 851-87, Fire Protection for Hydroelectric Generation Plants. 5. Underwriters' Laboratories Standard Number 299-82, Dry Chemical Fire Extinguishers. 6. Underwriters' Laboratories Standard Number 711-79, Rating and Testing of Fire Extinguishers. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Catalog sheets, specifications and installation instructions for each item specified. Blue Lake Expansion Project – Contract No. 9 15600-2 General Construction May 2012 C. Hose Stations: Design calculations and drawings D. O&M Manuals PART 2 PRODUCTS 2.01 FIRE EXTINGUISHERS A. General 1. The portable fire protection equipment provided shall consist of portable dry chemical type fire extinguishers. Equipment selection shall be in accordance with the applicable codes of the National Fire Protection Association. 2. Wall-mounted extinguishers shall be provided with a wall mount from the same manufacturer as the extinguisher that allows fast, easy removal of the equipment. Wheeled fire extinguishers are also acceptable in locations next to or close to the generator. All extinguishers shall be capable of being handled by one person. 3. The extinguishers shall be of the classes tested and listed by the Underwriters' Laboratories and rated for A, B, and C class fires. 4. Extinguishers shall be rechargeable and have visual pressure gauges and safety handle discharge. B. Dry Chemical Fire Extinguishers (FE1, FE-2) 1. Contractor shall supply and install tri-class dry chemical fire extinguishers rated ABC. 2. Extinguishers shall be wall hung, complete with all required mounting hardware. 3. Manufacturer and models shall be as follows: a) FE-1: Amerex B456, 10 lb capacity, 4A:80B:C rated. b) FE-2: Amerex B402, 5 lb capacity, 2A:10B:C rated. C. Carbon Dioxide (CO2) Fire Extinguishers (FE3, FE-4) 1. Contractor shall supply and install carbon dioxide fire extinguishers rated BC. 2. Extinguishers shall be wall hung, complete with all required mounting hardware. 3. Manufacturer and models shall be as follows: a) FE-3: Amerex 330, 10 lb capacity, 10B:C rated. b) FE-4: Amerex 332, 20 lb capacity, 10B:C rated. D. Range Hood Automatic Fire Suppression System (FE-5) Blue Lake Expansion Project – Contract No. 9 15600-3 General Construction May 2012 1. General: Wet chemical automatic range fire extinguishing system, complete with enclosure, cylinder and valve, local detection and activation and remote activation. 2. Chemical Agent: Wet chemical as per NFPA 17A for Wet Chemical Fire Extinguishing Systems. 3. Controls: Integral control panel complete with temperature-activated sensor assembly, system operation light, audible alarm, auxiliary outputs, appliance shut-down device with manual reset. 4. Distribution Assembly: Provide in accordance with NFPA 17A and shall be UL listed, including Teflon-lined braided steel hoses and brass discharge nozzles. 5. Options: Provide with AC/DC wall plug in power supply and manual remote pull station. 6. Manufacturer: Guardian Safety Solutions International Model G300-B, or approved equal. 2.02 FIRE HOSE STATIONS A. Design, supply and installation of two (2) fire hose stations As Shown. 1. Hose stations shall be Class II per NFPA 14. 2. Hose stations shall be designed and installed in accordance with NFPA 14 by a firm with a minimum 5 years experience in design and installation of fire protection systems. PART 3 EXECUTION 3.01 INSTALLATION A. Provide the following quantities of fire extinguishers: 1. FE-1 (six total; five installed plus one spare) 2. FE-2 (two total; one installed plus one spare) 3. FE-3 (two total; one installed plus one spare) 4. FE-4 (three total; two installed plus one spare) 5. FE-5, one complete system 6. All spare extinguishers shall be provided with mounting hardware. B. The extinguishers shall be conveniently located, readily visible, and placed so as not to be unduly subject to accidental damage or overturning. Operating instructions for each extinguisher shall be clear, concise, and displayed in a readily visible location. C. Hose stations shall be installed and tested in accordance with NFPA 14. END OF SECTION Blue Lake Expansion Project – Contract No. 9 15700-1 General Construction May 2012 SECTION 15700 INSTRUMENTATION PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install instrumentation required for the mechanical systems As Shown. 1.02 RELATED SECTIONS A. Section 01300 – Submittals B. Section 15020 – General Mechanical Provisions C. Section 15300 – Piping D. Section 15800 – Heating and Ventilation Systems 1.03 SUBMITTALS A. Submit under provisions of Section 01300. B. Product Data: Catalog sheets, specifications and installation instructions for each item specified. C. Operation and Maintenance Manuals. PART 2 PRODUCTS 2.01 GENERAL A. Instrumentation shall be high quality, industrial grade. 2.02 PRESSURE GAUGES A. ASME B40.100 Grade 1A, stainless steel movement, front calibration, black scale on white background. Stainless steel case, tube, and socket, 3-1/2 inch dial, 1% full scale accuracy. Gage shall include pulsation damper and isolation valve. Ashcroft 1009, or equal. B. Pressure ranges As Shown. C. Provide ball valve for isolation to allow gauge to be removed for maintenance. 2.03 PRESSURE SWITCHES A. Watertight pressure switch for water service with some small solids, surface mount: 1. Ambient Temperature Limits: -20 to 150 deg F. Blue Lake Expansion Project – Contract No. 9 15700-2 General Construction May 2012 2. Adjustable Range: As Shown. 3. Deadband: Fixed. 4. Proof Pressure: 1000 psi. 5. Switch Output: 2 SPDT. 6. Set point Repeatability: +-1% of Range. 7. Electrical Rating: 15A: 125/250Vac. 8. Electrical Connection: ¾ inch NPT Female. 9. Process Connection: ¼ inch NPT. 10. Diaphragm: 316SS. 11. Enclosure: NEMA 12 minimum, Epoxy Coated. 12. Manufacturer: Dwyer. 13. Provide ball valve for isolation to allow switches to be removed for maintenance. 2.04 PRESSURE TRANSDUCER (LS-A, LS-B, LS-C, LS-1, LS-2) A. Submersible pressure transducer, titanium construction. 1. Output signal: Two wire, 4-20 mA. 2. Operating pressure range: a. LS-A, LS-B: 0 to 50 psig b. LS-C, LS-1, LS-2: 0 to 10 psig 3. Accuracy: Combined effects of Non-linearity, Hysteresis and Repeatability: ±0.25% FS BSL max. 4. Operating/Compensated Temperature Range: -5 to 140°F / 30 to 86°F. 5. Temperature Effects: ±2.0% FS Temperature Error Band (TEB). 6. Insulation: Greater than 100 MΩ at 50 VDC. 7. Cable: Vented polyurethane cable with integral Kevlar® strain relief cord. Cable shall be single length. 8. Provide with cable clamp and Sensro Termination Enclosure. 9. Manufacturer/Model: GE/Druck PTX1230. Blue Lake Expansion Project – Contract No. 9 15700-3 General Construction May 2012 2.05 SPARE PARTS A. Provide one spare for each type and pressure range of pressure gage, switch and transducer furnished. 2.06 INSULATED INSTRUMENTATION COVER A. Furnish and install insulated instrument cover for freeze protection As Shown. Cover shall be manufactured item, corrosion and UV resistant ABS body complete with 1” ABS/urethane insulation. B. Cover shall be hinged with secure stainless steel locking latches. C. Cover shall be sized so that all internal components can be inspected for routine maintenance or removed for replacement. The cover shall be sized for future addition (if required) of a heater (assume 400 W heater). Do not furnish heater. D. Provide with all required supports, mounting kits, entry kits and related appurtenances for a complete installation. E. Manufacturer: O’Brien VIPAK or approved equal. PART 3 EXECUTION 3.01 INSTALLATION A. Contractor shall verify that instrument-mounting locations and details are in accordance with the drawings. B. Contractor shall mount all instruments in accordance with the drawings and manufacturer’s instructions. C. Contractor shall adjust thermometers to ambient temperatures, set the trip and reset pressures of the pressure switches, and calibrate all pressure gauges. D. Contractor shall install all piping and tubing related to the instruments and the control panels. 3.02 TESTING A. As each section of the Work is completed, Contractor shall carry out checks to demonstrate that the instruments and controls are designed, manufactured and installed correctly, and operating properly. Submit test results to RPR. B. Any defects that become evident during the tests shall be immediately corrected and the tests continued until the Work is proved to be in working order. END OF SECTION Blue Lake Expansion Project – Contract No. 9 15800-1 General Construction May 2012 SECTION 15800 HEATING AND VENTILATION SYSTEMS PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install the following: 1. Ductwork. 2. Dampers. 3. Diffusers. 4. Registers/Grilles. 5. Fans. 6. Electric Unit Heaters. 7. Air Handling Units. 8. Louvers. 1.02 RELATED SECTIONS A. Section 01300 – Submittals B. Section 09900 - Painting and Protective Coatings C. Section 15020 – General Mechanical Provisions D. Section 15061 – Pipe Hangers and Supports E. Division 16: Electrical Work 1.03 REFERENCES A. ADC 1062 - Certification, Rating and Test Manual. B. AHRI 350 - Sound Rating of Non-Ducted Indoor Air-Conditioning Equipment. C. AHRI 840 - Unit Ventilators. D. AMCA 500 - Test Method for Louvers, Dampers and Shutters. E. ARI 650 - Air Outlets and Inlets. F. ASHRAE 70 - Method of Testing for Rating the Air Flow Performance of Outlets and Inlets. G. NFPA 70 - National Electrical Code. Blue Lake Expansion Project – Contract No. 9 15800-2 General Construction May 2012 H. NFPA 90A - Installation of Air Conditioning and Ventilating Systems. I. SMACNA - HVAC Duct Construction Standard - Metal and Flexible. J. SMACNA - Seismic Restraint Manual 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Provide data for equipment required for this project. Review outlets and inlets as to size, finish, and type of mounting prior to submission. Submit schedule of outlets and inlets showing type, size, location, application and noise level. C. Ventilation Fans: Provide manufacturer’s catalog sheets, performance charts, standard schematic drawings, specifications and installation drawings. D. Operation and Maintenance Manuals. E. Commissioning / balancing reports. 1.05 QUALITY ASSURANCE A. Air outlet and inlet performance shall be in accordance with ADC Equipment Test Code 1062 and ASHRAE 70. B. Louver performance shall be in accordance with AMCA 500. C. Ventilation Fan: 1. Fans shall be licensed to bear the AMCA seal. 2. Electrical components shall be UL listed. 1.06 QUALIFICATIONS A. Manufacturer: Companies specializing in manufacturing the products specified in this section with minimum five years documented experience. PART 2 PRODUCTS 2.01 DUCTWORK, FABRICATED (FOR OFFICE AND OCCUPIED SPACES) A. Construction: 2-inch pressure range for supply and return air ductwork for office and occupied spaces. Note that generator exhaust ducts are specified elsewhere. 1. Ducts shall be fabricated from lock forming quality galvanized sheet steel with 1-1/4 oz of zinc total per sq ft unless indicated otherwise. 2. Duct construction reinforcement, bracing and sealing shall be to the standards outlined in the latest edition of the ASHRAE “Guide” and the “Sheet Metal and Blue Lake Expansion Project – Contract No. 9 15800-3 General Construction May 2012 Air Conditioning Contractors National Association” (SMACNA). “HVAC Duct Construction Standards”, Latest Edition. 3. Duct metal gauges shall be to the standards listed above except where indicated otherwise on the Drawings. 4. Duct panels over 12 inches wide shall be cross-broken or beaded on 12-inch centers. 5. All duct panels shall be braced or reinforced as necessary, in addition to minimum requirements in the ASHRAE Guide, to eliminate vibration and noise and to prevent deflection from the indicated shapes and dimensions. 6. For ducts 24 inches in width and smaller cross sectional joints shall be standing “S” (SMACNA) type T-10. Above 24 inches, make cross sectional joints with duct mate system 35 include 20 gauge galvanized angles, corners with integral sealant, metal cleats, gaskets of extruded butyl and corners clips (SMACNA Standard T-24). Longitudinal seams shall be double corner seam (SMACNA Standard L-6). Seal all joints power SMACNA recommendations to make air tight. 7. Design ductwork for seismic requirements per SMACNA Seismic Restraint Manual. B. Elbows and Tees: Shall be as follows: 1. Long radius unvaned, except where indicated otherwise, with throat radius equal to the width of duct and full heel radius; or 2. Square with double thickness turning vanes, one nominal gauge heavier than duct elbow, size and spacing as per the “Duct Manual”. C. Transformations, Risers, and Drops: 1. Fabricate with a horizontal or vertical slope not exceeding one inch in seven inches. 2. Connections to equipment shall be straight on or at an angle not exceeding 30° from the air flow on the inlet side and 45° on the leaving side unless provided with vanes. D. Dampers: 1. Provide manually operated, opposed blade dampers where indicated and where required to balance the system. Damper blades shall be minimum 16 gauge thickness galvanized steel. 2. Provide gravity operated, backdraft dampers where indicated. Dampers shall be selected for horizontal or vertical installation to suit installation. Damper blades shall be minimum 16 gauge thickness. 3. Dampers shall be single or multiple blade type as required. 4. Maximum single blade size shall be 12 inches x 18 inches. Blue Lake Expansion Project – Contract No. 9 15800-4 General Construction May 2012 5. Manufacture: Greenheck Model VCD-15 for rectangular ductwork and VCDR- 50 for round ductwork. 6. Provide accessible self-locking quadrant type Ventlok No. 641 controls with handle on manual balancing dampers. Mark final balanced damper position permanently on duct or shaft. 7. Provide transitions for dampers larger than ducts. If smaller than duct, install a baffle plate to blank off the duct on one or two sides of the damper. If no size is indicated, damper shall be full duct size. E. Hangers: 1. Materials shall be of the following: a) Galvanized steel bands or galvanized steel rods. b) One-inch x 1/8-inch bands or approved alternate for ducts up to 60 inches wide, and trapeze type with rods for larger ducts. c) Galvanized black iron for vertical ducts to 24-inch maximum dimensions. 2. Space as required to adequately support the load and adjust as required to align ducts and eliminate sags. 3. Attach to the structure with one of the methods approved by the International Building Code. 4. Coordinate with the hangers for ceilings, light fixtures, etc. F. Fibrous Glass (Mineral Fiber) Insulation: Composed principally of fibers manufactured from rock, slag, or glass, with or without binders, and asbestos free. 1. Block or Board Insulation: Minimum density 3.0 pcf, Type IA or IB (Suitable for Temperatures Up to 450 degrees F): K of 0.26 at 75 degrees F. 2. Blanket Insulation: a) For Ductwork (Suitable for Temperatures Up to 450 Degrees F): Minimum density 1.0 pcf, K of 0.31 at 75 degrees F; ASTM C 553, Type II. 3. High Density Jacketed Insulation Inserts for Hangers and Supports: a) Ductwork: Fibrous glass board, minimum density 6 pcf, K of 0.26 at 75 degrees F, conforming to ASTM C 612, Type IA or IB. 4. Jackets: a) Laminated Vapor Barrier Jackets for Ductwork: Factory applied by insulation manufacturer, conforming to ASTM C 1136, Types I and II. i. Type I: Reinforced white kraft and aluminum foil laminate with kraft facing out. ii. Type II: Reinforced aluminum foil and kraft laminate with foil facing out. Blue Lake Expansion Project – Contract No. 9 15800-5 General Construction May 2012 iii. Aluminum: ASTM B 209, Alloys 1100, 30003, 3105 or 5005, Temper H14, 0.016 inch thick. b) Sheet Jacketing: Corrugated 1-1/4 inch x 1/4 inch deep with integral bonded laminated polyethylene film - kraft paper moisture barrier underside. c) Fastening Devices: i. Strapping: Type 18-8 stainless steel, 0.020 inch thick, 1/2 and 3/4 inch wide as specified. ii. Wing Seals: Type 18-8 stainless steel, 0.032 inch thick. iii. Sheet Metal Screws: Panhead, Type A, hardened aluminum, and stainless steel. 5. Cements: a) Fibrous Glass Thermal Insulating Cement: Asbestos free; ASTM C 195. b) Fibrous Glass Hydraulic Setting Thermal Insulating and Finishing Cement: ASTM C 449/C 449M. 6. Adhesives: a) Vapor Seal Adhesive: Childers’ CP-82, Epolux’s Cadoprene 400, Foster’s 85-75 or 85-20. b) Vapor Barrier Mastic/Joint Sealer: Childers’ CP-30, Epolux’s Cadalar 670, Foster’s 95-44 or 30-35. 7. Fasteners: a) Insulation Fasteners for Ductwork and Equipment: i. Acceptable Manufacturers: Duro-Dyne Corp.; Erico Fastening Systems, Inc. ii. Type: Weld pins, complete with self-locking insulation retaining washers. b) Pressure Sensitive Tape for Sealing Laminated Jackets: i. Acceptable Manufacturers: Alpha Associates, Childers, Ideal Tape, Morgan Adhesive. ii. Type: Same construction as jacket. c) Wire, Bands, and Wire Mesh: i. Binding and Lacing Wire: Nickel copper alloy or copper clad steel, gage as specified. ii. Bands: Galvanized steel, 1/2 inch wide x 0.015 inch thick, with 0.032 inch thick galvanized wing seals. Blue Lake Expansion Project – Contract No. 9 15800-6 General Construction May 2012 iii. Wire Mesh: Woven 20 gage steel wire with 1 inch hexagonal openings, galvanized after weaving. d) Metal Corner Angles: Galvanized steel, 2 x 2 inch 28 gage. e) Reinforcing Membrane: Glass or Polyester, 10 x 10 mesh. Alpha Associates Style 59, Childer’s Chil-Glas, Foster’s MAST-A-FAB. G. Flexible Ductwork Connections 1. Provide flexible duct connections as shown or at all equipment as recommended by manufacturer. a) Provide flexible connectors at all fan inlet and outlet connections. 2. Connectors shall consist of a 3 inch wide flexible fabric bonded to sheet metal on both sides. Fabric shall be suitable for continuous operation to 200 °F. 3. Manufacturer: DuroDyne MetalFab or equal H. Embedded ductwork 1. Provide sleeves or other suitable methods to protect embedded ductwork during concrete pours. 2.02 GENERATOR EXHAUST DUCT A. Construction: 1. Generator exhaust ducts shall be fabricated from ASTM A36 steel plate As Shown. 2.03 DUCTWORK, ROUND B. General: "Basic Round Diameter" as used in this article is the diameter of the size of round duct that has a circumference equal to the perimeter of a given sized of flat oval duct. Except where interrupted by fittings, provide round and flat oval ducts in lengths not less than 12 feet. C. Round Ducts: Fabricate round supply ducts with spiral lockseam construction. Comply with SMACNA "HVAC Duct Construction Standards," Table 3-2 for galvanized steel gages. C. Static Pressure Classifications: Except where otherwise indicated, construct round duct systems to the following pressure classifications: 1. Supply Ducts: 2 inches water gage. 2. Return Ducts; 2 inches water gage, negative pressure. 3. Exhaust Ducts: 2 inches water gage, negative pressure. D. Round Ducts: Fabricate round supply ducts using seam types identified in SMACNA "HVAC Duct Construction Standards," 1985 Edition, Figure 3-1, RL-1, RL-4, or RL-5. Seams Types RL-2 or RL-3 may be used if spot-welded on 1-inch intervals. Comply Blue Lake Expansion Project – Contract No. 9 15800-7 General Construction May 2012 with SMACNA "HVAC Duct Construction Standards," Table 3-2 for galvanized steel gages. 2.04 ROUND DUCT FITTINGS A. 90-Degree Tees and Laterals and Conical Tees: Fabricate to conform to SMACNA "HVAC Duct Construction Standards," 1985 Edition, Figures 3-4 and 3-5 and with metal thicknesses specified for longitudinal seam straight duct. B. Diverging-Flow Fittings: Fabricate with a reduced entrance to branch taps with no excess material projecting from the body onto branch tap entrance. C. Elbows: Fabricate in die-formed, gored, pleated, or mitered construction. Fabricate the bend radius of die-formed, gored, and pleated elbows 1.5 times the elbow diameter. Unless elbow construction type is indicated, provide elbows meeting the following requirements: 1. Mitered Elbows: Fabricate mitered elbows with welded construction in gages specified below. a) Mitered Elbows Radius and Number of Pieces: Unless otherwise indicated, construct elbow to comply with SMACNA "HVAC Duct Construction Standards," Table 3-1. b) Round Mitered Elbows: Solid welded and with metal thickness listed below for pressure classes from minus 2 inches to plus 2 inches: i) 3 to 26 inches: 24 gage. c) Round Mitered Elbows: Solid welded and with metal thickness listed below for pressure classes from 2 inches to 10 inches: i) 3 to 14 inches: 24 gage. ii) 15 to 26 inches: 22 gage. d) 90-Degree, 2-Piece, Mitered Elbows: Use only for supply systems, or exhaust systems for material handling classes A and B; and only where space restrictions do not permit the use of 1.5 bend radius elbows. Fabricate with a single-thickness turning vanes. 2. Round Elbows - 8 Inches and Smaller: Die-formed elbows for 45- and 90-degree elbows and pleated elbows for 30, 45, 60, and 90 degrees only. Fabricate nonstandard bend angle configurations or 1/2-inch-diameter (e.g. 3-1/2- and 4- 1/2-inch) elbows with gored construction. 3. Round Elbows - 9 Through 14 Inches: Gored or pleated elbows for 30, 45, 60, and 90 degrees, except where space restrictions require a mitered elbow. Fabricate nonstandard bend angle configurations or 1/2-inch-diameter (e.g. 9- 1/2- and 10-1/2-inch) elbows with gored construction. 4. Round Elbows - Larger Than 14 Inches and All Flat Oval Elbows: Gored elbows, except where space restrictions require a mitered elbow. Blue Lake Expansion Project – Contract No. 9 15800-8 General Construction May 2012 2.05 SUPPORTS A. Support ductwork in accordance with SMACNA HVAC Duct Construction Standards and Section 15061. B. Brace all ductwork for seismic per SMACNA Seismic Restraint Manual. Refer to Section 15020 for seismic design criteria. 2.06 SUPPLY DIFFUSERS (S-1A THROUGH S-4D) A. Type: Perforated face, adjustable pattern supply diffusers with four modular cores. B. Fabrication: Aluminum with factory white enamel finish. Backpan and pattern controllers shall be painted black. C. Damper: Integral volume control damper, gang operated, opposed blade type with removable key operator, operable from face. D. Face panel: Steel with spring clip latch arrangement for easy removal and adjustment of pattern controllers. E. Manufacturers/Models: 1. EH Price Model PDS, 24 inch x 24 inch face. a. S-1A/B, S-3A/B, S-4A/B/C/D: 10-inch neck b. S-2A: 14-inch neck c. S-2B/C/D/E: 12-inch diameter neck 2.07 RETURN GRILLES (R-1 & R-2A/R-2B) A. Type: Perforated plenum return grille. B. Fabrication: Aluminum with factory white enamel finish. C. Manufacturers/Models: 1. EH Price Model PDR, 24 inch x 24 inch module, maximum square neck for plenum return. 2.08 TRANSFER GRILLES (TG-3) A. Sightproof door transfer grille, aluminum construction. B. Provide grilles for each side of door. C. Manufacturers/Models: 1. EH Price Model ATG. 2.09 ACOUSTIC AIR TRANSFER SILENCER (TG-1 through TG-2D, TG-4A through TG-6) A. Noise reducing air transfer silencer, 22 gauge galvanized steel construction. Blue Lake Expansion Project – Contract No. 9 15800-9 General Construction May 2012 B. Provide with 24 gauge internal baffles filled with inorganic mineral wool type glass fiber absorbent material of sufficient density and packed under at least 5% compression to eliminate voids due to vibration and setting to obtain catalog ratings. C. Silencers shall not fail structurally when subjected to a differential pressure of 8 inch w.g. inside to outside of casing. D. Average noise reduction in the three speech-interference octave bands 4,5 and 6 (500, 1000 and 2000 Hz Center Frequencies, respectively): 49 dB. E. Grilles: Supply and install two (2) EH Price Model 60FH return grilles at each end of silencer. F. Manufacturers/Models: 1. Manufacturer: Commercial Acoustics 2. Models: Tags Model Rating TG-1, TG-2C TS-Z-307 750 cfm @ 0.1” W.C. TG-2A, TG-2B TS-Z-147 400 cfm @ 0.12” W.C. TG-2D, TG-4A, TG-4B TS-Z-427 1,075 cfm @ 0.1” W.C. TG-5, TG-6 TS-Z-143 200 cfm @ 0.13” W.C. 2.10 AIR HANDLING UNITS (AHU-1 THRU AH-4) A. General requirements 1. Unit shall be configured to provide outside air for cooling and heating through electric resistance elements. Refer to drawing 109-45-081 for a schematic and sequence of operation. 2. Units shall be complete and pre-assembled and pre-wired. 3. Units shall be provided without cooling coils. B. Product Requirements: 1. Performance Ratings: Design shall be in accordance with AHRI-480 2. Sound Ratings: Design shall be in accordance with AHRI-350 3. Performance Base: Sea level conditions. 4. Temperature Limit: Maximum 130 degrees F C. Performance: 1. AHU-1: 750 CFM, 5.85KW electric heat 2. AHU-2: 1880 CFM, 11.4 KW electric heat 3. AHU-3: 750 CFM, 10.0 KW electric heat Blue Lake Expansion Project – Contract No. 9 15800-10 General Construction May 2012 4. AHU-4: 1500 CFM, 10.0 KW electric heat D. Construction: 1. Heavy gauge steel cabinet powder coated exterior, galvanized steel interior. Cabinet shall be insulated and have removable access panels to access all interior components. 2. Horizontal units configured for rear access on outside air and return air, mounted in ceiling plenum with bottom of unit exposed and supply air duct connection. All connections are within the plenum. 3. Vertical units are floor mounted, have rear access for outside air, return air on the front and supply air ducted from the top of the unit. 4. Fans shall be double width / double inlet, forward curved centrifugal. Fans shall be factory installed, balanced and have speed taps for CFM adjustment. 5. Motor shall be permanent split capacitor with thermal overloads and have permanently lubricated bearings. 6. Electric heat coil shall have a resistive element mounted within and extended surface fin-tube bundle. Provide with disconnect and high temperature cut-out. 7. Outside / return air damper shall capable of modulating between 0 to 100% outside air. 8. Filters shall be low pressure drop, disposable type and mounted within the unit and provided with access panels for easy inspection and replacement. d. Provide four sets of spares for each unit. 9. Controls shall be as specified on the drawings. Controls shall be packaged integral to the unit, except for remote, wall mounted thermostat. If additional control logic is required above and beyond the capability of the unit, then Contractor shall provide individual discrete microprocessor controls and I/O as required to control the units As Shown. Controls shall be 24 VDC and control panel shall provide control power transformer. E. POWER 1. Power shall be 480 vac, three phase, 60 Hz. a. 120 vac power shall be provided for control power on AHU-3 and AHU-4. F. MANUFACTURER/MODEL: 1. Trane a. AHU-1: Model HUVC0752 (Horizontal) b. AHU-2: Model HUVC2002 (Horizontal) Blue Lake Expansion Project – Contract No. 9 15800-11 General Construction May 2012 2. Temspec a. AHU-3: Model VUD- 1200 b. AHU-4: Model VUD-1600 2.11 ELECTRIC UNIT HEATER (UH-1 THRU UH-11, UH-1GH, UH-2GH) A. Electric unit heater, self contained with heating element, blower, thermal cut-out. B. Construction: 1. Heavy-duty 18 gage sheet cabinet, painted with corrosion-resistant paint. 2. Adjustable front face louvers. 3. Fin tube heating elements, fabricated from corrosion-resistant materials. 4. Provide with all required mounting hardware. C. Fan: 1. Total enclosed fan motor, rated for continuous duty operation. 2. Dynamically balanced fan, mounted within the cabinet with vibration isolators. D. Controls: 1. AHU-1, AHU-2: a. Integral 120 VAC or 24 VDC control transformer. Provide control transformer integral to the unit. 2. AHU-3, AHU-4: a. Provide external 120 VAC power service for control power. 3. Provide pre-wired with heavy duty magnetic contractors. 4. Thermal cutouts to protect the heating elements from overheating. 5. Provide with remote, wall mounted programmablethermostat. E. Unit Specifics Tag (s) Capacity (kW) Electrical Manufacturer Model UH-1 4 208 VAC, 1PH, 60Hz Chromalox HVH-04-81-30-TL- D-FE-0-0-0 UH-2 thru UH-12 10 480 VAC, 3PH, 60Hz Chromalox HVH-07-43-30-TL- D-FE-0-0-0 UH-1GH, UH-2GH 10 480 VAC, 3 PH, 60Hz QMark IUH-1048 Blue Lake Expansion Project – Contract No. 9 15800-12 General Construction May 2012 2.12 LOUVERS (LV-1A, LV-1B, LV-2A, LV-2B, LV-3, LV-4, LV-5, LV-1GH) A. Provide 6-inch deep louvers with drainable blades on 37.5 degree slope, heavy channel frame and bird screen. 1. Bird screen shall be ½ inch x 0.063 inch aluminum square mesh, minimum 80% free area. B. Fabricate of minimum 0.081 inch thick aluminum with factory mill finish. Finish color and texture shall be as per RPR. C. Furnish with 1.5-inch exterior perimeter flange for installation. D. LV-3, LV-4, LV-5: Provide with optional perimeter clip angles. 1. Maximum spacing of clip angles shall be 24-inches around perimeter of louver. 2. Clips shall be 6-inches wide and shall extend 3-inches from the louver face. E. Louver to be designed to carry a lateral wind load of 40 PSF based on a wind load of 120 mph and an importance factor of 1.15. F. Louvers to have minimum free area of 54 percent. G. Manufacturer/Model: Greenheck Model ESD-635, size As Shown. 2.13 LOUVERS (LV-6 THRU LV-8, LV-10 THROUGH LV-15, LV-1FVU, LV-2FVU, LV- 3FVU) A. Provide 4-inch deep louvers with drainable blades on 37.5 degree slope, heavy channel frame and birds screen. 1. Bird screen shall be ½ inch x 0.063 inch aluminum square mesh, minimum 80% free area. B. Fabricate of minimum 0.081 inch thick aluminum with factory mill finish. Finish color and texture shall be as per RPR. C. Furnish with 1.5 inch exterior perimeter flange for installation. D. Louver to be designed to carry a lateral wind load of 40 PSF based on a wind load of 120 mph and an importance factor of 1.15. E. Louvers to have minimum free area of 52 percent (at 36 inch x 36 inch). F. Manufacturer/Model: Greenheck Model ESD-435, size As Shown. 2.14 COUNTER-BALANCED DAMPER (D-1A, D-1B, D-2A & D-2B) A. Heavy Duty / Industrial counter balanced backdraft dampers, lockable. B. Frame: 8 inch by 2 inch by 10 gage galvanized steel construction. Blue Lake Expansion Project – Contract No. 9 15800-13 General Construction May 2012 1. Frame shall be single panel. 2. Provide with 1½ inch flange width. C. Blades: 7 inch, air foil type, blades do not extend outside of frame, parallel blades. 1. Damper shall be constructed to allow for future installation by Owner of surface mounted framing to install air filter panels. Panels would be 2 feet square and would be supported by angles to cover entire extent of the damper on the powerhouse side of the damper. D. Axle: 3/4 inch plated steel. E. Bearing: Ball bearings, pressed to frame. F. Linkage: 3/16 inch thick by 3/4 inch plate steel bar with 16 gage linkage arms in airstream. G. Counter Balance: Internal counter balance. Counter balance shall not extend beyond the frame. H. Finish: Mill, galvanized. I. Seals: Provide with blade and jamb seals. J. Manufacturer/Model: Nailor Model 1905CB, size As Shown. 2.15 CONTROL DAMPERS (D-3A, D-3B, D-4A, D-4B, D-5A & D-5B) A. Frame: 8 inch by 2 inch by 12 gage galvanized steel. B. Blades: Parallel, air foil blades, 16 gage, not to extend beyond frame. C. Axle: 3/4 inch plated steel. D. Bearings: Teflon. E. Linkage: Side linkage outside of airstream. F. Finish: Mill, galvanized. G. Seals: Provide with silicone jamb and blade seals H. Flanges: As required for mounting. All flanges and mounting shall be external to the duct and shall not restrict the duct area. I. Manufacturer/Model: Nailor Model 1970 J. Provide with motorized actuator, Belimo or equal. Dampers controls to be configured as follows: 1. Damper pairs (D-3A/D-3B, D-4A/D-4B, D-5A/D-5B) shall be mechanically linked and shall be driven by, and operate in conjunction with the electric actuator. 2. Provide local control panel mounted at El. 17 near duct. Coordinate location with RPR. Panel shall have the following: Blue Lake Expansion Project – Contract No. 9 15800-14 General Construction May 2012 a. HOA switch b. 0 to 100% return air control knob c. Controls to move the dampers to 100% return air position when in “Auto” mode based on shut-down signal from the turbine/generator PLC. d. Controls to move the dampers to the return air set point when in “Auto” mode and based on permissive from the turbine/generator PLC. e. Controls to move the dampers to the return air set point when in “Hand”. f. Controls to move the dampers to 100% return air position when in “Off” mode. 2.16 SIDEWALL EXHAUST FAN (EF-1, EF-1FVU) A. General: Sidewall-mounted aluminum exhaust fan with direct-drive motor. B. Motor: Permanently lubricated, 1.15 service factor. C. Bearings: Permanently lubricated sealed bearings. D. Provide with ½ inch x 0.063 inch aluminum square mesh bird screen (minimum 80% free area) and gravity exhaust damper. 1. Fan EF-1, tag back-draft damper as “D-6”. E. Provide with wall collar and all required hardware to install and mount fan and damper. F. Provide with electronic, programmable thermostatic control and Fan-Off-Auto control switch. 1. Provide 2-stage thermostat for EF-1FVU G. Unit Specifics: Tag (s) Sizing Electrical Manufacturer / Model EF-1 9,500 cfm at 0.25”w.c. esp. 1.5HP, 480 VAC, 3PH, 60Hz Greenheck SCE3-36-307-B EF-1FVU 9,500 cfm at 1.0”w.c. esp. 2-speed (860/1725 rpm) 3HP, 480 VAC, 3PH, 60Hz Greenheck SBE-3H30 2.17 BATHROOM EXHAUST FANS (EF-2/D-8, EF-3/D-10) A. General: Bathroom exhaust fan. B. Motor: Permanently lubricated, 1.15 service factor. C. Bearings: Permanently lubricated, sealed bearings. Blue Lake Expansion Project – Contract No. 9 15800-15 General Construction May 2012 D. Wheel: Forward curved centrifugal type, constructed of calcium carbonate filled polypropylene and dynamically balanced. E. Unit shall be pre-assembled and pre-wired. F. Provide with aluminum duct-mounted back-draft damper and ceiling grille, white. 3. Tag back-draft dampers as follows: a. Fan EF-2: Back-draft damper “D-8” b. Fan EF-3: Back-draft damper “D-10” G. Electrical: 120vac, single phase, 60 Hz. Furnish with adjustable run timer, up to one hour, and on-off switch. H. Unit Specifics: 1. EF-2: 200 CFM at 0.5” w.c. esp., 7/30HP motor. Greenheck Model SP-B200. 2. EF-3: 75 CFM at 0.25” w.c. esp., 1/15HP motor. Greenheck Model SP-B90. 2.18 TRANSFER FAN (TF-1) A. Gerneral: Belt-drive inline cabinet fan, horizontal inline duct mounted. 1. Rectangular duct mounting collars. Inlet shall be in the back of the unit, outlet in the front. 2. Galvanized steel construction, hinged removal panels for bottom access of all internal components. 3. Fan wheel shall be of the galvanized steel, forward curved, centrifugal type. Wheels shall be dynamically and statically balanced. 4. Motors shall be of the heavy duty type with permanently sealed ball bearings. The wheel shaft shall be ground and polished steel mounted in permanently sealed pillow block bearings. Drives shall be sized for a minimum of 150% of driven horsepower. Pulleys shall be of the machined cast iron type, keyed and securely attached to the wheel and motor shafts. The motor pulleys shall be adjustable for final system balancing. B. Design Conditions: 800 CFM at 0.85” ESP C. Electrical: 120VAC, single phase, 60 Hz. Two winding ½ hp motor, 1725/1140 RPM. Provide with local starter, suitable for two stage operation. D. Provide with programmable 2 stage thermostat. First set point shall enable low speed operation of the first fan stage. The second set point shall enable operation of E. Options: Provide with slide-out filter box and 2” Merv-8 filters. F. Manufacturer/Model: Greenheck BCF-206 Blue Lake Expansion Project – Contract No. 9 15800-16 General Construction May 2012 2.19 ELECTRIC BASEBOARD HEATER (BH-1) A. Electric hydronic baseboard heater, designed for continuous operation, UL listed for installation over any surface. B. Enclosure: minimum 0.032 inch pre-painted steel with minimum .040 inch electrogalvanized steel control boxes. C. Heating element: Heating element wire shall consist of 80% nickel, 20% chromium, and shall be immersed in a heat-transfer liquid and sealed in a heater length copper tube. Aluminum fins shall be so designed as to block sheath radiation to front and back of heater body and pressure bonded to steel sheath. D. Operating Controls: Provide with wall-mounted thermostat. E. Safety Controls: Linear thermal cut-out shall be factory installed to automatically shut off heater in event of overheating and reactivate heater when temperatures return to normal. F. Electrical: 120VAC, single phase, 60 Hz. G. Manufacturer/Model: QMark HBB750 with wall-mounted thermostat. 2.20 THERMOSTATS A. Unless otherwise specified, thermostats shall be remote, wall mounted programmable. B. Provide thermostats suitable for all operating modes (heating, cooling, 2 stage cooling and/or ventilation) of equipment. C. Manufacturer: Honeywell, Johnson or equal. 2.21 DAMPERS A. General requirements. 1. Balancing dampers shall be provided for all HVAC ductwork at each outlet. 2. A vertical backdraft damper shall be provided at the outside connection of all ductwork serving fans. 3. All non backdraft type dampers shall have a means of operation. Unless otherwise specified, provide a manual operator. 2.22 SPARE PARTS A. Furnish one set of each type of all cleanable filters and strainers. B. Furnish four sets each of all disposable filters. C. Furnish one spare heating element of each type supplied. D. One thermostat of each type supplied. Blue Lake Expansion Project – Contract No. 9 15800-17 General Construction May 2012 E. One fan belt set and flexible shaft coupling, of each type provided. F. One relay, transducer, and switch of each type supplied. PART 3 EXECUTION 3.01 EQUIPMENT INSTALLATION A. Install all fans, air handlers and other equipment per manufacturer’s instructions. Review all instructions and provide any additional materials or labor as required for a complete and functioning system. B. Coordinate all work with related trades to facilitate installation and to avoid interferences. 1. Coordinate installation of Air Transfer Silencers into stud walls. C. Install fans as per manufacturer’s instructions: 1. Isolate fan from building construction. 2. Support fan independent from the ductwork. D. Attach all equipment to building structure. Do not support equipment from other piping, ductwork or equipment. 3.02 DUCTWORK INSTALLATION A. Install ductwork to allow maximum headroom. Properly seam, brace, stiffen, support and render ducts mechanically airtight. Adjust ducts to suit job conditions. Dimensions may be changed as approved, if cross sectional area is maintained. B. Provide necessary transformation pieces, and flexible fabric connections for ductwork connected to air handling equipment or air inlet and outlet devices. C. Check location of outlets and inlets and make necessary adjustments in position to conform with architectural features, symmetry, and lighting arrangement. D. Install diffusers to ductwork with airtight connection. E. Provide balancing dampers with diffusers. F. Check system flow rates and balance systems. Provide balancing reports as part of close-out submittal. G. Pitch horizontal ducts connected to hoods or louvers downward toward hood not less than 1 inch in 10 feet. H. Seal ductwork in accordance with the SMACNA Manual. I. Install and support ductwork as per SMACA Manual. Provide vertical supports and additional framing for the generator exhaust duct As Shown. Blue Lake Expansion Project – Contract No. 9 15800-18 General Construction May 2012 3.03 DUCTWORK UPPER HANGER ATTACHEMENTS A. Secure upper hanger attachments to structural steel wherever possible. B. Do not use drive-on beam clamps, flat bars or bent rods, as upper hanger attachments. C. Avoid damage to reinforcing members in concrete construction. D. Metallic fasteners installed with electrically operated or powder driven tools may be used as upper hanger attachments, in accordance with the SMACNA Manual, with the following exceptions: 1. Do not use powder driven drive pins or expansion nails. 2. Do not attach powder driven or welded studs to structural steel less than 3/16 inch thick. 3. Do not support a load, in excess of 250 lbs from any single welded or powder driven stud. 4. Do not use powder driven fasteners in precast concrete. E. Attachment to Steel Frame Construction: Provide intermediate structural steel members where required by ductwork support spacing. Select steel members for use as intermediate supports based on a minimum safety factor of 5. 1. Do not drill holes in main structural steel members without RPR approval. If possible, use mechanical connectors such as beam clamps. Where welding is required, provide a sketch and weld procedure for Engineer’s review and approval. F. Attachment to Hollow Block or Hollow Tile Filled Concrete Decks: 1. Hilti block fasteners. 3.04 BALANCING AND TESTING A. Thermostats 1. Coordinate thermostat locations with RPR. 2. Install thermostats per manufacturer’s instructions. 3. Verify proper operation of thermostat during equipment commissioning and testing to verify proper operation in all operating modes. END OF SECTION Blue Lake Expansion Project – Contract No. 9 15905-1 General Construction May 2012 SECTION 15905 AUTOMATIC BACKWASH STRAINER PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install automatic self-cleaning strainers, including accessories. 1.02 RELATED SECTIONS A. Section 01300 - Submittals. B. Section 15020 – General Mechanical Provisions 1.03 REFERENCE STANDARDS A. The following list of standards shall be referenced in the design and manufacture of the automatic self-cleaning strainer. 1. ANSI – American National Standards Institute 2. ASTM – American Society for Testing and Materials 3. NEMA – National Electrical Manufacturer’s Association: 250-91, Enclosures for Electrical Equipment 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Drawings containing the following information: 1. Manufacturer, model number, operating and shipping weights, certified outline dimensions and horsepower of the strainer. 2. Manufacturers catalog information and descriptive literature, specifications and identification of materials of construction. 3. External utility requirements such as air, water, power, drain, etc. 4. Functional description of internal and external instrumentation and controls to be supplied including a list of parameters monitored, controlled or alarmed. 5. Control panel elevation drawings showing construction and placement of operator interface devices and other elements. 6. Power and wiring diagrams, including terminals and numbers. 7. Shop and field painting systems proposed. C. Quality control documents to be submitted shall include: Blue Lake Expansion Project – Contract No. 9 15905-2 General Construction May 2012 1. Special shipping, storage and protection, and handling instructions. 2. Manufacturer’s written installation instructions. 3. Operation and maintenance manuals. 4. Spare parts. 1.05 QUALITY ASSURANCE A. Manufacturers: Firms regularly engaged in manufacture of automatic self-cleaning strainers of types, materials and sizes required, whose products have been in satisfactory use in similar service for not less than five years. PART 2 PRODUCTS 2.01 STRAINER (STR-1, STR-2, STR-1WTP, STR-2WTP) A. Pre-assembled, pre-wired automatic backflush strainer, complete with backflush mechanism and control panel. B. For fabricated steel construction, body and steel cover shall be designed, fabricated and tested per ASME Section VIII. C. Pressure Drop – Pressure drop at the design capacity should not exceed 2.0 psig, even when the strainer surface media is 75% clogged. The maximum pressure drop at the time of backwash should not exceed 4.0 psi. D. Design Conditions 1. STR-1, STR-2: 270 gpm at 167 psig, raw water between 32°F to 70°F. 2. STR-1WTP, STR-2WTP: 1,800 gpm at 175 psig, raw water between 32°F to 70°F. E. Design Pressure – Strainer shall be capable rated to an influent pressure of 225 psi. F. Strainer Media – Strainer media shall be slotted wedge wire or multi-tube element design that is capable of withstanding a differential pressure of 200 psig without bursting, distortion or being damaged. G. Backwash Mechanism – The backwash mechanism shall not come in contact with the strainer media to prevent damage to the media from large objects or high solids loadings. H. Backwash Flow – The average percentage of effluent required for backwashing the strainer should not exceed 5 percent of the strainer influent over a 24 hour period. I. Connections – Process connections shall be 150 psig ANSI raised faced flanged for all carbon steel units. 1. STR-1, STR-2: 4 inch Blue Lake Expansion Project – Contract No. 9 15905-3 General Construction May 2012 2. STR-1WTP, STR-2WTP: 12 inch. J. Inspection Port – An inspection opening in the body of the strainer is required to permit inspection of the strainer’s raw water chamber and to allow for removal of any oversize solids, which may have entered into the strainer. K. Materials of Construction – Materials of construction for the automatic self-cleaning strainer shall be as follows: Component Material of Construction Strainer Body Fabricated carbon steel with an internal epoxy lining Strainer Elements 304 stainless steel Backwash Assembly 304 stainless steel Tube sheet Ductile cast iron Wedge wire 304 stainless steel Seal Plate Bronze All Internal Fasteners Stainless steel L. Filtration Media Size: 1. STR-1, STR-2: 0.0625 inches. 2. STR-1WTP, STR-2WTP: 0.0625 inches. 2.02 DRIVE MECHANISM A. Electrical Characteristics – 120 vac, single phase, 60 HZ. B. The motor shall have a horsepower rating at least equal to the maximum horsepower requirements of the driven equipment without exceeding the continuous rating at a 1.0 Service Factor. The Service Factor shall be a minimum of 1.15. C. All AC motors shall be TEFC or squirrel cage induction type designed for starting across the full line voltage, continuous operation and constant speed. D. All motors shall meet the starting capability and performance requirements as specified for NEMA Type B as defined in NEMA Standard MG-1. 2.03 CONTROL SYSTEM A. The strainer shall be provided with a NEMA-4 Waterproof Backwash Control Panel mounted to the unit and pre-wired. B. Control functions to include ON/OFF/AUTO control of the strainer. In the AUTO mode, the automatic backwash shall be pressure differential controlled with adjustable timer override. In the ON mode, the strainer’s drive motor shall be energized and the backwash valve shall be open until the controls are returned to either the OFF or AUTO position. C. Panel power requirements shall be as specified on the drawings. Supply control power transformer if required, and pre-wire to provide a single point electrical connection for all power to the unit. Blue Lake Expansion Project – Contract No. 9 15905-4 General Construction May 2012 D. Provide adjustable differential pressure switch on an integral strainer instrument panel complete with connecting tubing. E. Provide backwash ball valve complete with piping connections to the strainer and a NEMA 4 electric actuator. F. Supply pressure gauges, plus or minus 1.5 percent accuracy, 0 to 300 psig range, for local indication of pressure at the inlet and outlet of the strainer. G. Provide dry contacts for remote activation of backwash and remote indication of failure to activate backflush. 2.04 ACCESSORIES A. Furnish, tag and box for shipment and storage the following spare parts (as applicable) for future maintenance: Item Quantity Cover Gasket(s) One set Inspection Opening Gasket One Spare Shear-Key One Seal-Plate O-Ring One set Drive Shaft Packing One set Gear Motor Seals (O-Rings) One Drive Shaft Gasket One Strainer Basket One Drive Motor and Gearbox One Pressure Switch and Timer One Disposable Filters/Strainers Four B. Provide quantity of spares indicated above for each strainer and for each type provided. C. Identification Plate – Stainless steel identification nameplate shall be securely mounted on the equipment in a readily visible location. 2.05 Manufacturer / Model: A. STR-1, STR-2: R.P. Adams 4"VWS-4 (225 PSIG Design, Non-code), or equal. B. STR-1WTP, STR-2WTP: SureFlow, 723 Series Eliminator, 225 PSIG rated, or equal. PART 3 EXECUTION 3.01 FACTORY INSPECTION AND TESTING A. Prior to shipment, the manufacturer shall perform a functional test to ensure that the strainer is in proper working order. B. Prior to shipment, the manufacturer shall perform a hydrostatic pressure test to ensure pressure vessel integrity. Blue Lake Expansion Project – Contract No. 9 15905-5 General Construction May 2012 C. Prior to plant startup, all equipment shall be inspected for proper alignment, quiet operation, proper connection and satisfactory performance. 3.02 PREPARATION FOR SHIPMENT A. Insofar as practical, the equipment specified herein shall be factory assembled. The parts and assemblies that are of necessity shipped unassembled shall be packaged and tagged in a manner that will protect the equipment from damage and facilitate the final assembly in the field. Generally machined and unpainted parts shall be protected from damage by the elements with the application of a strippable protective coating. 3.03 INSTALLATION A. The equipment specified herein shall be located As Shown and installed in conformance with the manufacturers recommended methods. B. Contractor to provide levelling shims and dry pack grout to result in a level and plumb installation without strain on the inlet and outlet piping. END OF SECTION Blue Lake Expansion Project – Contract No. 9 15915-1 General Construction May 2012 SECTION 15915 RAW WATER INTAKE SCREENS PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install the raw water inlet screen assembly. The raw water intake assembly shall consist of a flat panel wedge wire intake screen, a porosity plate to maintain uniform flow distribution and an air burst backwash assembly. Work also includes: 1. Sizing of screen, porosity plate and air burst manifold. 2. Structural design of assembly, including mounting requirements. 1.02 RELATED SECTIONS A. Section 01300 - Submittals B. Section 15020 - Mechanical General Provisions C. Section 15300 - Piping Systems D. Section 15480 - Compressed Air systems 1.03 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: 1. Provide flow distribution calculations including average flow rate, pressure drop and peak flows. Provide data from any physical flow distribution test of the actual, or similarly designed system. 2. Provide structural calculations. C. Shop Drawings Showing: 1. Drawing(s) showing screen general dimension, wire, slot, screen open area, porosity plate open area, and details of all connections to work by others. D. Warranties: Special warranties specified in this Section. E. Included in the intake screen submittals shall be all associated equipment catalog information, system sizing criteria, and drawings. All dimensional and operational information will be provided. All interconnecting wiring and piping information will be included. Blue Lake Expansion Project – Contract No. 9 15915-2 General Construction May 2012 F. Installation instructions including shipping support removal, mounting and support requirements, installation, start-up and commissioning. G. Operation and Maintenance Manuals. 1.04 DESIGN CRITERIA A. The following design conditions apply to the assembly: 1. Inclined flat plate design 2. Design flow: 9,000 gpm 3. Vertical wedgewire screen with 0.100 inch openings 4. Approach velocity: 0.365 fps (average face velocity, based on gross area) 5. Peak approach velocity: 0.44 fps 6. Top of screen: 2 ft below minimum water level 7. Design differential head: 10 ft 8. Design frequency of air backwash operation: Once per hour 9. System shall be designed for fixed installation: a) The assembly shall be bolted in place, and shall be removable. b) Assembly shall be supplied and installed as one complete, integral unit. c) Screen and/or porosity plate shall be provided with removable sections as required to access and maintain the air burst manifold. 10. System shall be manually operated: 1.05 QUALITY ASSURANCE A. The equipment specified herein shall be located As Shown and installed in conformance with the manufacturer’s suggested method as approved by the RPR. B. All welders must maintain certification to ASME Section IX. Copies of certificates shall be provided upon request. 1.06 WARRANTY A. Submit a written warranty, executed by manufacturer, agreeing to repair or replace any components, including screen components that fail in materials or workmanship within the specified warranty period. B. Warranty Period: One year from date of Substantial Completion. Blue Lake Expansion Project – Contract No. 9 15915-3 General Construction May 2012 PART 2 PRODUCTS 2.01 GENERAL A. Provide a complete inlet screen assembly, including inlet screen, air burst manifold, porosity plate, air receiver, fast-acting automatic air supply valve, piping, controls, panels, conduit and wiring. 1. Note: Air will be supplied by station compressed air system. B. Refer to Paragraph 1.04.A for design criteria 2.02 PASSIVE INTAKE SCREENS A. Intake Screens: 1. Screens shall be of stainless steel construction, ASTM A276, Type 304. Screen wire shall be Type 090. 2. The intake assembly shall be designed to withstand a differential hydrostatic collapse pressure as defined in paragraph 1.03.A. 3. Design stress used for determining strength of the assembly shall be no more than 90% of the published yield strength of the material used. Strength calculations verifying compliance with these criteria shall be provided. 4. The surface wire, support beam and stiffener structure shall be an all-welded matrix designed to provide the specific strength with minimal interference with the through screen flow pattern. 5. The screen shall contain an integral airburst diffuser and porosity plate B. Screen Slot Opening Size:. 1. The screen slot size shall be as defined in paragraph 1.04.A. 2. Slot size shall be controlled and continuously monitored during manufacture. 3. The mean slot size shall be within ±0.003 inch with a standard deviation no greater than 0.003 inch throughout the entire assembly. 2.03 AIR RECEIVER A. Size and furnish vertical air receiver based on the design criteria in Section 1.04. 1. Tank size shall not be less than 600 gal. 2. Maximum overall height of the receiver shall be 6 ft from base to top of tank. B. Receiver shall be carbon steel, coated with epoxy paint system or equivalent. C. Receiver shall be ASME rated to 200 psig, complete with automatic blowdown valve and pressure safety relief valve. Blue Lake Expansion Project – Contract No. 9 15915-4 General Construction May 2012 2.04 CONTROLS A. Provide system to allow manual start and stop of cleaning cycle based on differential pressure. Control system shall be a complete functional system, including, but not limited to control panel, all required electronic components, discrete microprocessor controllers (if required), alarms, valves, equipment, piping, conduit, wiring and supports. 1. The control system shall monitor differential pressure across the screen. The system shall be activated manually. 2. Controls shall be housed in a lockable NEMA 4 rated enclosure. 3. Control power shall be 120 vac, single phase, 60 HZ. If other voltages are required, provide transformers internal to the control panel. 4. Level sensors shall be Druck pressure transducer or equal (LS-2). Refer to Specification 15700, paragraph 2.04 and drawing 109-45-093. 5. Control panel shall be provided with visual and audible alarms with manual reset for fault indication or high differential pressure. 6. Activation of system shall be by manual operation from the control panel. Activation and deactivation shall be separate operations, and operator shall not be required to hold during operation. 7. Control panel shall provide the following measurements: a) Tailwater elevation; b) Elevation in sump; c) Differential across screen; and d) Air pressure. 2.05 MANUFACTURER A. Manufacturer shall have minimum of 5 years designing and supplying inlet screen systems. B. To the greatest extent possible, components shall be of manufacturer’s standard design and should be available as an off the shelf item. 1. Contractor shall provide a list of recommended spare parts. Supply of these materials is included in this contract. 2. Contractor shall identify components that may require long lead times to procure. 3. Use of proprietary equipment is to be avoided. 4. Contractor shall turn over copies of any required software, hardware, programming, and control logic required to program and operate the system. C. Fabricated components shall be from same manufacturer or shall be fully assembled, fit-up and tested in the Contractor’s manufacturing facility. Blue Lake Expansion Project – Contract No. 9 15915-5 General Construction May 2012 D. The complete assembly shall be fully assembled, fit-up and tested in the Contractor’s manufacturing facility prior to shipping. E. Contractor shall be directly responsible for design and integration of all components. F. Manufacturer: Cook Legacy, Johnson screens, or equal. PART 3 EXECUTION 3.01 EXAMINATION A. Review design drawings for compliance with requirements for installation tolerances and other conditions affecting installation performance of gates. 3.02 INSTALLATION, GENERAL A. General: Comply with manufacturer's detailed written instructions for installing screens and air burst system. B. Electrical Connections: In accordance with requirements in Division 16. 3.03 CLEANING AND PROTECTING A. Restore marred, abraded surfaces to their original condition. B. Provide final protection and maintain conditions, in a manner acceptable to manufacturer and Installer that ensure gate is without damage or deterioration at the time of Substantial Completion. END OF SECTION DIVISION 16 ELECTRICAL Blue Lake Expansion Project – Contract No. 9 16020-1 General Construction May 2012 SECTION 16020 ELECTRICAL GENERAL PROVISIONS PART 1 GENERAL 1.01 DESCRIPTION A. This Section covers the general electrical provisions and applies to all sections under Division 16. 1.02 APPLICABLE STANDARDS A. When this Specification requires material or equipment of better quality or larger size than required by governing codes, rules, regulations, and industry standards, the requirements of this Specification shall take precedence. B. When conditions are encountered that are not covered by Division 16, the requirements of the applicable standards referred to in the various sections shall govern the Work to the extent required. C. Devices located below elevation 13 in the Blue Lake Powerhouse, below elevation 428 in the gate house, or in any potentially wet area that could be subject to submergence, splash or spray, or mounted on the exterior of structures exposed to the elements, shall be suitable for the application and of corrosion resistant material. D. Interconnection wiring diagrams for the major pieces of owner furnished power production equipment and control apparatus will be prepared by the Engineer for use by the Contractor. 1.03 SUBMITTALS A. Materials: 1. Lists of material, equipment, apparatus, and accessories intended for use shall be submitted as outlined in Section 01300. 2. All physical and performance data shall be furnished, including materials, manufacturers’ names, model numbers, weights, sizes, capacities, temperatures, pressures, flow rates, performance curves, electrical ratings, finishes, colors, dimensions, and accessories, and all other data required to completely describe the equipment and to indicate complete compliance with the Contract. 3. All proposed deviations from specified requirements shall be clearly identified, with an explanation and the extent of the deviation. 4. RPR’s review of submittal data described above and drawings described below is to verify conformance with the design concept and specification of this project. Acceptance of a given item shall not indicate acceptance of an assembly in which the item functions nor will RPR’s acceptance relieve contractor from responsibility for errors or omissions in drawings or samples. B. Standard Compliance: Blue Lake Expansion Project – Contract No. 9 16020-2 General Construction May 2012 1. Where equipment or materials are specified to conform to requirements of the standards of organizations such as ANSI, ASME, ASTM, UL, and ASHRAE, submit evidence of such conformance to Owner for record purposes. 2. The label or listing of the specified agency will be acceptable evidence. 3. In lieu of the label or listing, Contractor may submit a written certificate from an approved, nationally recognized testing organization, adequately equipped and competent to perform such services, stating that the items have been tested and that the units conform to the specified standard. C. Operating and Maintenance (O&M) Manuals: 1. Contractor shall provide three (3) complete sets of the operating instructions, maintenance instructions, parts lists, and all other bulletins and brochures pertinent to the operation and maintenance of the mechanical equipment and systems that are part of the Work. 2. O&M Manuals shall be assembled into 3-ring binders, complete with table of contents and tabs. D. Certificates: 1. At the completion of construction, Contractor shall submit written certification that all electrical and mechanical systems have been tested and that the installation and performance of these systems conform to the requirements of this specification. 1.04 SEISMIC LOADINGS FOR ELECTRICAL AND MECHANICAL EQUIPMENT A. The base or feet for mounting or supporting equipment on concrete floors shall be designed so that none of the equipment parts are stressed beyond 67% of the equipment’s material yield point and to prevent shifting of the equipment during or following a seismic event. • Horizontal acceleration (minimum) .......................... 0.37 g • Vertical acceleration (minimum)............................... 0.25 g 1.05 SCOPE OF WORK A. Blue Lake Powerhouse Electrical Systems The new Blue Lake powerhouse will have three hydraulic turbine-driven generating units, associated protection and control, power distribution equipment and electrical equipment associated with the powerhouse auxiliary services. Two new main power transformers and associated accessories, will replace the existing transformers in the existing Blue Lake switchyard. A raw water pumping station will be located at the downstream side of the new powerhouse. The Blue Lake powerhouse electrical systems shall be As Shown and as specified in Division 16. B. Fish Valve Unit Powerhouse A new hydraulic turbine-driven generating unit and associated auxiliary equipment will replace the existing generating unit in the Fish Value Unit Powerhouse. A new feeder from the dam site junction pedestal will supply power to the new gate house Blue Lake Expansion Project – Contract No. 9 16020-3 General Construction May 2012 and dam. The Fish Valve Unit powerhouse electrical systems are As Shown and as specified in the balance of Division 16. PART 2 PRODUCTS 2.01 CONTRACTOR-FURNISHED EQUIPMENT AND MATERIALS A. All equipment and materials to be furnished by Contractor shall be new and unused and shall conform to the latest applicable standards. Materials and equipment used shall bear the label of the Underwriters' Laboratory (UL) and shall be listed by UL in their list of electrical materials, unless the materials and/or equipment are of a type that the UL does not list or provide label service for. Where no specific make of material or equipment is specified, a quality product of a reputable manufacturer may be used, provided it conforms to the requirements of these specifications. B. Contractor shall furnish the fittings, hangers, sleeves, chases, supports for fixtures, conduit, cable tray, anchors, switches, junction boxes, mounting brackets, cables and wires, cable supports, wire terminals, solderless lugs, connectors, identification tags, tape, insulating compounds, ground connections, nameplates and any other electrical accessories, hardware, or materials required to satisfactorily install and place into service Contractor furnished equipment and systems. PART 3 EXECUTION 3.01 INSTALLATION A. The electrical installation shall be in full compliance with applicable requirements of the local codes, and the National Electrical Safety Code (NESC). Contractor shall comply with the requirements of the National Electrical Code (NEC) as practical as it relates to services wiring, lighting, receptacles, low voltage (480 and 120/240 volt) equipment, motors, motor starters and similar type devices. B. All equipment supplied and installed by Contractor shall be in accordance with the manufacturers' recommendations. Contractor shall be responsible for and shall correct by repair or replacement, at his own expense, damage to or failure of any part of any of the items of the equipment which has been caused by faulty mechanical or electrical assembly by Contractor. Necessary tests to demonstrate that the electrical and mechanical operations of the equipment are satisfactory and meet the requirements of these Specifications shall be made by the Supplier. C. Minor changes in location of equipment may be required during the course of the Work. D. Contractor shall preserve technical data, instructions, spare parts lists, and manuals furnished with electrical equipment. At the completion of the Work, this material, along with any duplicate copies, shall be neatly organized and bound, and shall be delivered to RPR. E. Equipment shall not be set in place without proper protection from surrounding construction activities, and it shall be protected by means of tarpaulins as long as painting or overhead work is being done in the area where the equipment is located. Touch-up painting shall be performed, if required, following construction work. Blue Lake Expansion Project – Contract No. 9 16020-4 General Construction May 2012 3.02 PREPARATION A. Electrical equipment shall be properly installed, adjusted, connected, and tested by Contractor prior to Substantial Completion, unless Contractor is specifically relieved from performing part of the work in writing by RPR. B. All circuits shall be checked for continuity and proper insulation before Substantial Completion. C. All shipping blocking of instruments, relays and mechanisms shall be removed. D. All equipment shall be thoroughly cleansed inside and outside of all dirt, grease, grit, cable and conductor strippings, metal filings, or any other foreign matter. All items shall be properly cleaned and finish painted or touch-up painted, as required by the Specifications. Protective relay cases and associated auxiliaries shall be thoroughly blown out with an aerosol duster and checked for proper operation of jack contacts, shorting bars, and built-in switches. E. Identification markers and nameplates shall be properly and accurately installed. F. All connections shall be accurately torqued. G. Insulator assemblies and all insulator materials for bushings, bus supports, and lightning arrestors shall be thoroughly inspected and cleaned immediately prior to energizing. H. Insulating oil shall be properly filtered and purified, checked for proper level, and tested for insulating quality prior to energizing the equipment with which it is used. I. The alignment of all working parts shall be checked; all adjustable devices calibrated and set at their proper operating value; all artificial load tests completed; and all preliminary functional and operational tests required for satisfactory line operation completed. 3.03 TESTS A. General: All tests required to ensure the satisfactory installation, adjustment, operation, and performance of all equipment and materials erected and installed under and in accordance with this Specification shall be performed by Contractor as outlined herein and hereinafter in other Specification sections: 1. Testing of turbine and generator equipment provided by Others is specified in Section 20100. 2. Testing by Contractor: Contractor shall furnish all other electrical test equipment and all other meters, instruments, and miscellaneous equipment and shall perform all work required to make ground system resistance tests, insulation resistance (megohmmeter), and high potential tests, on all power and control cables, motors, heaters, ac and dc auxiliary power systems, lighting system, miscellaneous electrical equipment, and all other equipment installed by him. Contractor shall also complete all equipment checks, lubrication checks, bearing temperature tests, and all artificial loading of starters and circuit breakers furnished as miscellaneous equipment. Contractor shall furnish RPR with three copies of all test data taken for tests performed by Blue Lake Expansion Project – Contract No. 9 16020-5 General Construction May 2012 Contractor. The test data shall be properly signed by an authorized Contractor's representative. B. Low-Voltage Equipment Insulation Tests: After installation but prior to making external wiring connections, Contractor shall measure and record the insulation resistance to ground and phase-to-phase of all equipment installed by him. C. Operational Tests of Station Auxiliary Systems by Contractor: 1. Prior to placing the station auxiliary systems in service, the component equipment and devices shall be tested for satisfactory operation under normal operating conditions. 2. Station auxiliary systems include lighting, power distribution, heating, and ventilating, fire alarm, raw water pumping, drainage pumping and sewage lift station. 3. Each system shall be operated through sufficient cycles and for a sufficient length of time to establish that the system operates properly and is ready to be placed in service. 3.04 DEMONSTRATION OF COMPLETE ELECTRICAL SYSTEMS A. After the electrical installation has been completed and the various components contained therein have been checked and tested for satisfactory installation and proper operation, the various systems shall be operated a sufficient number of times to demonstrate to RPR that all equipment, components, and materials for each such completed system have been properly installed and will perform the desired operation. Such demonstration of all power and control circuitry, lighting system, grounding system, protective relaying, fire detection system, and other similar complete systems shall be considered an integral part of the Work of the Contract. B. If test results show improper adjustment, operation, or performance of any equipment and such deficiencies are due to negligence or unsatisfactory installation by Contractor, Contractor shall furnish all labor, equipment and materials necessary for correction and adjustment. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16071-1 General Construction May 2012 SECTION 16071 FASTENERS, ATTACHMENTS AND SUPPORTING DEVICES PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install fasteners, attachments and supporting devices. 1.02 RELATED SECTIONS A. Section 01300: Submittals 1.03 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Shop Drawings: Show support details if different from methods specified or shown on the drawings. C. Product Data: Catalog cut sheets, specifications and installation instructions. 1.04 CORROSION RESISTANT FASTENERS, ATTACHMENTS AND SUPPORT DEVICES A. All fasteners, attachments and support devices located below elevation 13.0 in the Blue Lake Powerhouse, below elevation 428 in the gate house, or in any wet location subject to water submergence, splash or spray or mounted on the exterior of structures shall be stainless steel or other corrosion resistant material. PART 2 PRODUCTS 2.01 ANCHORING DEVICES A. Sleeve Anchors (FS FF-S-325 Group II, Type 3, Class 3): Molly/Emhart's Parasleeve Series, Phillips' Red Head AN, HN, FS Series, or Ramset's Dynabolt Series, HILTI. B. Wedge Anchors (FS FF-S-325 Group II, Type 4, Class 1): Hilti's Kwik Bolt Series, Molly/Emhart's Parabolt Series, Phillips' Red Head WS, or Ramset's Trubolt Series, HILTI. C. Self-Drilling Anchors (FS FF-S-325 Group III, Type 1): Phillips' Red Head Series S or Ramset's Ram Drill Series, HILTI. D. Non-Drilling Anchors (FS FF-S-325 Group VIII, Type 1): Hilti's Drop-In Anchor Series, Phillips' Red Head J Series, or Ramset's Dynaset Series, HILTI. E. Stud Anchors (FS FF-S-325 Group VIII, Type 2): Phillips' Red Head JS Series, HILTI. 2.02 CONCRETE INSERTS Blue Lake Expansion Project – Contract No. 9 16071-2 General Construction May 2012 A. Continuous Slotted Type Concrete Insert, Galvanized: 1. Load Rating 1300 lbs/ft.: Kindorf's D-986. 2. Load Rating 2400 lbs/ft.: Kindorf's D-980. 3. Load Rating 3000 lbs/ft.: Hohmann & Barnard Inc.'s Type CS-H. 4. Load Rating 4500 lbs/ft.: Hohmann & Barnard Inc.'s Type CS-HD. B. Threaded Type Concrete Insert: Galvanized ferrous castings, internally threaded. C. Wedge Type Concrete Insert: Galvanized box-type ferrous castings, designed to accept bolts having special wedge shaped heads. 2.03 MISCELLANEOUS FASTENERS A. Except where shown otherwise on the Drawings, furnish type, size, and grade required for proper installation of the work, selected from the following: Furnish galvanized fasteners for exterior use, or for items anchored to exterior walls, except where stainless steel is indicated. 1. Standard Bolts and Nuts: ASTM A 307, Grade A, regular hexagon head. 2. Lag Bolts: FS FF-B-561, square head type. 3. Machine Screws: FS FF-S-92, cadmium plated steel 4. Machine Bolts: FS FF-B-584 heads; FF-N-836 nuts. 5. Wood Screws: FS FF-S-111 flat head carbon steel. 6. Plain Washers: FS FF-W-92, round, general assembly grade carbon steel. 7. Lock Washers: FS FF-W-84, helical spring type carbon steel. 8. Toggle Bolts: Tumble-wing type; FS FF-B-588, type, class and style as required to sustain load. B. Stainless Steel Fasteners: Type 302 for interior work; Type 316 for exterior work; Phillips head screws and bolts for exposed work unless otherwise specified. 2.04 TPR (THE PEEL RIVET) FASTENERS A. 1/4 inch diameter, threadless fasteners distributed by Subcon Products, 315 Fairfield Road, Fairfield, NJ 07004 (800) 634-5979. 2.05 POWDER DRIVEN FASTENER SYSTEMS A. Olin Corp.'s Ramset Fastening Systems, or Phillips Drill Company Inc.'s Red Head Powder Actuated Systems. 2.06 HANGER RODS Blue Lake Expansion Project – Contract No. 9 16071-3 General Construction May 2012 A. Mild low carbon steel, unless otherwise specified; fully threaded or threaded each end, with nuts as required to position and lock rod in place. Unless galvanized or cadmium plated, provide a shop coat of red lead or zinc chromate primer paint. 2.07 “C” BEAM CLAMPS A. With Conduit Hangers: 1. For 1 Inch Conduit Maximum: B-Line Systems Inc.'s BG-8, BP-8 Series, Caddy/Erico Products Inc.'s BC-8P and BC-8PSM Series, or GB Electrical Inc.'s HIT 110-412 Series. 2. For 3 Inch Conduit Maximum: Appleton Electric Co.'s BH-500 Series beam clamp with H50W/B Series hangers, Kindorf's 500 Series beam clamp with 6HO- B Series hanger, or OZ/Gedney Co.'s IS-500 Series beam clamp with H-OWB Series hanger. 3. For 4 Inch Conduit Maximum: Kindorf's E-231 beam clamp and E-234 anchor clip and C-149 series lay-in hanger; Unistrut Corp.'s P2676 beam clamp and P- 1659A Series anchor clip with J1205 Series lay in hanger. B. For Hanger Rods: 1. For 1/4 Inch Hanger Rods: B-Line Systems Inc.'s BC, Caddy/Erico Products Inc.'s BC, GB Electrical Inc.'s HIT 110, Kindorf's 500, 510, or Unistrut Corp.'s P1648S, P2398S, P2675, P2676. 2. For 3/8 Inch Hanger Rods: Caddy/Erico Products Inc.'s BC, Kindorf's 231-3/8, 502, or Unistrut Corp.'s P1649AS, P2401S, P2675, P2676. 3. For 1/2 Inch Rods: Appleton Electric Co. BH-500 Series, Kindorf's 500 Series, 231-1/2, OZ/Gedney Co.'s IS-500 Series, or Unistrut Corp.'s P1650AS, P2403S, P2676. 4. For 5/8 Inch Rods: Unistrut Corp.'s P1651AS beam clamp and P1656A Series anchor clip. 5. For 3/4 Inch Rods: Unistrut Corp.'s P1653S beam clamp and P1656A Series anchor clip. 2.08 CHANNEL SUPPORT SYSTEM A. Channel Material: 12 gauge steel. B. Finishes: 1. Phosphate and baked green enamel/epoxy. 2. Pre-galvanized. 3. Electro-galvanized. 4. Hot dipped galvanized. 5. Polyvinyl chloride (PVC), minimum 15 mils thick. Blue Lake Expansion Project – Contract No. 9 16071-4 General Construction May 2012 C. Fittings: Same material and finish as channel. D. UL Listed Systems: 1. B-Line Systems Inc.'s B-22 (1-5/8 x 1-5/8 inches), B-12 (1-5/8 x 2-7/16 inches), B-11 (1-5/8 x 3-1/4 inches). 2. Grinell Corp.'s Allied Power-Strut PS 200 (1-5/8 x 1-5/8 inches), PS 150 (1-5/8 x 2-7/16 inches), PS 100 (1-5/8 x 3-1/4 inches). 3. Kindorf's B-900 (1-1/2 x 1-1/2 inches), B-901 (1-1/2 x 1-7/8 inches), B-902 (1-1/2 x 3 inches). 4. Unistrut Corp.'s P-3000 (1-3/8 x 1-5/8 inches), P-5500 (1-5/8 x 2-7/16 inches), P- 5000 (1-5/8 x 3-1/4 inches). 5. Versabar Corp.'s VA-1 (1-5/8 x 1-5/8 inches), VA-3 (1-5/8 x 2-1/2 inches). 2.09 MISCELLANEOUS FITTINGS A. Side Beam Brackets: B-Line Systems Inc.'s B102, B103, B371-2, Kindorf's B-915, or Versabar Corp.'s VF-2305, VF-2507. B. Pipe Straps: 1. Two Hole Steel Conduit Straps: B-Line Systems Inc.'s B-2100 Series, Kindorf's C-144 Series, or Unistrut Corp.'s P-2558 Series. 2. One Hole Malleable Iron Clamps: Kindorf's HS-400 Series, or OZ/ Gedney Co.'s 14-G Series, 15-G Series (EMT). C. Deck Clamps: Caddy/Erico Products Inc.'s DH-4-T1 Series. D. Fixture Stud and Strap: OZ/Gedney Co.'s SL-134, or Steel City's FE-431. E. Supporting Fittings for Pendent Mounted Industrial Type Fluorescent Fixtures on Exposed Conduit System: 1. Ball Hanger: Appleton Electric Co.'s AL Series, or Crouse-Hinds Co.'s AL Series. 2. Flexible Fixture Hanger: Appleton Electric Co.'s UNJ-50, UNJ-75, or Crouse- Hinds Co.'s UNJ115. 3. Flexible (Hook Type) Fixture Hanger: Appleton Electric Co.'s FHHF, or Crouse- Hinds Co.'s UNH-1. 4. Eyelet: Unistrut Corp.'s M2250. 5. Eyelet with Stud: Kindorf's H262, or Unistrut Corp.'s M2350. 6. Conduit Hook: Appleton Electric Co.'s FHSN, or Crouse-Hinds Co.'s UNH-13. F. Supporting Fasteners (Metal Stud Construction): Metal stud supports, clips and accessories as produced by Caddy/Erico Products Inc. Blue Lake Expansion Project – Contract No. 9 16071-5 General Construction May 2012 G. All fasteners, attachments and support devices located below elevation 13.0 in the Blue Lake Powerhouse, below elevation 428 in the gate house, or in any wet location subject to water submergence, splash or spray or mounted on the exterior of structures shall be stainless steel or other corrosion resistant material. PART 3 EXECUTION 3.01 INSTALLATION A. Where specific fasteners are not specified or indicated for securing items to in-place construction, provide appropriate type, size, and number of fasteners for a secure, rigid installation. B. Install anchoring devices and other fasteners in accordance with manufacturer's printed instructions. C. Make attachments to structural steel wherever possible. 3.02 FASTENER SCHEDULE A. Material: 1. Use cadmium or zinc coated anchors and fasteners in dry locations. 2. Use hot dipped galvanized or stainless steel anchors and fasteners in damp and wet locations. 3. For corrosive atmospheres or other extreme environmental conditions, use fasteners made of materials suitable for the conditions. B. Types and Use: Unless otherwise specified or indicated use: 1. Cast-in-place concrete inserts in fresh concrete construction for direct pull-out loads such as shelf angles or fabricated metal items and supports attached to concrete slab ceilings. Epoxy anchors may also be used as appropriate. 2. Anchoring devices to fasten items to solid masonry and concrete when the anchor is not subjected to pull out loads, or vibration in shear loads. 3. Hilti epoxy anchors shall be used to fasten items to hollow masonry and stud partitions. 4. TPR fasteners to fasten items to plywood backed gypsum board ceilings. 5. Metallic fasteners installed with electrically operated or powder driven tools for approved applications, except: a. Do not use powder driven drive pins or expansion nails. b. Do not attach powder driven or welded studs to structural steel less than 3/16 inch thick. c. Do not support a load, in excess of 250 lbs from any single welded or powder driven stud. Blue Lake Expansion Project – Contract No. 9 16071-6 General Construction May 2012 d. Do not use powder driven fasteners in precast concrete. 3.03 ATTACHMENT SCHEDULE A. General: Make attachments to structural steel or steel bar joists wherever possible. Provide intermediate structural steel members where required by support spacing. Select steel members for use as intermediate supports based on a minimum safety factor of 5. 1. Make attachments to steel bar joists at panel points of joists. 2. Holes may be drilled in main structural members provided that they are drilled on the neutral axis and are less than 25% of the depth of the web (“T” dimension). Before drilling holes, contractor shall obtain the approval for such work from RPR. 3. Use "C" beam clamps for attachment to steel beams. B. Where it is not possible to make attachments to structural steel or steel bar joists, use the following methods of attachment to suit type of construction unless otherwise specified or indicated on the drawings: 1. Attachment to Steel Roof Decking (No Concrete Fill): a. Decking With Hanger Tabs: Use deck clamps. b. Decking Without Hanger Tabs: • Before Roofing Has Been Applied: Use 3/8 inch threaded steel rod welded to a 4 x 4 x 1/4 inch steel plate and installed through 1/2 inch hole in roof deck. • After Roofing Has Been Applied: Use welding studs, or self - drilling/tapping fasteners. Exercise extreme care when installing fasteners to avoid damage to roofing. 2. Attachment to Concrete Filled Steel Decks (Total thickness, 2-1/2 inches or more): a. Before Fill Has Been Placed: • Use thru-bolts and fish plates. • Use welded studs. Do not support a load in excess of 250 pounds from a single welded stud. b. After Fill Has Been Placed: Use welded studs. Do not support a load in excess of 250 lbs from a single welded stud. 3. Attachment to Cast-In-Place Concrete: a. Fresh Concrete: Use cast-in-place concrete inserts. b. Existing Concrete: Use anchoring devices. 4. Attachment to Cored Precast Concrete Decks: Blue Lake Expansion Project – Contract No. 9 16071-7 General Construction May 2012 a. New Construction: Use thru-bolts and fish plates before Construction Work Contractor has placed concrete fill over decks. b. Existing Construction: Toggle bolts may be installed in cells for a maximum load of 100 lbs. 5. Attachment to Hollow Block or Tile Filled Concrete Deck: a. New Construction: Use cast-in-place concrete inserts by having Construction Work Contractor omitting blocks and pouring solid blocks with insert where required. 6. Attachment to Waffle Type Concrete Decks: a. New Construction: • Use cast-in-place concrete inserts in fresh concrete. • If concrete fill has been applied over deck, thru-bolts and fish plates may be used where additional concrete or roofing is to be placed over the deck. 7. Attachment to Precast Concrete Planks: Use Hilti HCI-WF or HCI-MD as applicable anchoring devices, except do not make attachments to precast concrete planks less than 2-3/4 inches thick. 8. Attachment to Precast Concrete Construction: a. New Construction: • Use tee hanger inserts between adjacent flanges. • Use thru-bolts and fish plates, except at roof deck without concrete fill. b. Existing Construction: • Use anchoring devices installed in webs of tees. Install anchoring devices as high as possible in the webs. c. Do not use powder driven fasteners. d. Exercise extreme care in drilling holes to avoid damage to reinforcement. 9. Attachment to Wood Construction: Use side beam brackets fastened to the sides of wood members to make attachments for hangers. a. Under 15 lbs Load: Attach side beam brackets to wood members with 2 No. 18 x 1-1/2 inch long wood screws, or 2 No. 16 x 1-1/2 inch long drive screws. b. Over 15 lbs Load: Attach side beam brackets to wood members with bolts and nuts or lag bolts. Do not use lag bolts in wooden members having a nominal thickness (beam face) less than 2 inches in size. Install bolts and nuts or lag bolts in the side of wood members at the mid-point or slightly above. Install plain washers under all nuts. Load Lag Bolt Size Bolt Dia. Blue Lake Expansion Project – Contract No. 9 16071-8 General Construction May 2012 15 lbs to 30 lbs 3/8 x 1-3/4 inches 3/8 inch 31 lbs to 50 lbs 1/2 x 2 inches 1/2 inch Over 50 lbs to load limit of structure Use bolt & nut 5/8 inch c. Bottom chord of wood trusses may be utilized as structural support, but method of attachment must be specifically approved. d. Do not make attachments to the diagonal or vertical members of wood trusses. e. Do not make attachments to the nailing strips on top of steel beams. 10. Attachment to Metal Stud Construction: Use supporting fasteners manufactured specifically for the attachment of raceways and boxes to metal stud construction. a. Support and attach outlet boxes so that they cannot torque/twist. Either: • Use bar hanger assembly, or: • In addition to attachment to the stud, also provide far side box support. 3.04 CONDUIT SUPPORT SCHEDULE A. Provide number of supports as required by National Electrical Code. Exception: Maximum support spacing allowed is 4'-0" for conduit sizes 3 inches and larger supported from wood trusses. B. Use pipe straps and specified method of attachment where conduit is installed proximate to surface of wood or masonry construction. 1. Use hangers secured to surface with specified method of attachment where conduit is suspended from the surface. C. Use "C" beam clamps and hangers where conduit is supported from steel beams. D. Use deck clamps and hangers where conduit is supported from steel decking having hanger tabs. 1. Where conduit is supported from steel decking which does not have hanger tabs, use clamps and hangers secured to decking, utilizing specified method of attachment. E. Use channel support system supported from structural steel for multiple parallel conduit runs. F. Where conduits are installed above ceiling, do not rest conduit directly on runner bars, T-Bars, etc. 1. Conduit Sizes 2-1/2 Inches and Smaller: Support conduit from ceiling supports or from construction above ceiling. 2. Conduit Sizes Over 2-1/2 Inches: Support conduit from beams, joists, or trusses above ceiling. 3.05 CHANNEL SUPPORT SYSTEM SCHEDULE Blue Lake Expansion Project – Contract No. 9 16071-9 General Construction May 2012 A. Use channel support system where specified or As Shown. B. Channel supports may be used, as approved, to accommodate mounting of equipment. C. Material and Finish: 1. Dry Locations: Use 12 gauge steel channel support system having any one of the specified finishes. 2. Damp Locations: Use 12 gauge steel channel support system having any one of the specified finishes except green epoxy/enamel. 3. Wet Locations: Use 12 gauge steel channel support system having hot dipped galvanized, or PVC finish. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16110-1 General Construction May 2012 SECTION 16110 RACEWAYS PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install raceways such as conduits and cable trays As Shown and as specified herein. 1.02 RELATED SECTIONS A. Section 01300: Submittals 1.03 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submit shop drawings and catalogue cuts of raceways. 1.04 CODES, SPECIFICATIONS AND STANDARDS A. American National Standards Institute (ANSI) 1. ANSI C80.3 "Specifications for Electrical Metallic Tubing, Zinc Coated" 2. ANSI C80.5 "Specification for Aluminum Conduit" B. National Electrical Manufacturer's Association (NEMA) 1. NEMA VE 1 "Metallic Cable Tray Systems" 2. NEMA TC 2 "Electrical Plastic Tubing (EPT) and Conduit (EPC-40 and EPC-80)" 3. NEMA TC 3 "PVC Fittings for Use with Rigid PVC Conduit and Tubing" 4. NEMA TC 6 "PVC and ABS Plastic Utilities Duct for Underground Installation" 5. NEMA TC 9 "Fittings for ABS and PVC Plastic Utilities Duct for Underground Installation" C. National Electrical Code (NEC) D. National Electrical Safety Code (NESC) E. Underwriters' Laboratories (UL) 1. UL 6 "Rigid Metal Conduit" 2. UL 360 "Liquid-Tight Flexible Steel Conduit" 3. UL 651 "Rigid PVC Conduit, Schedule 40 and 80" Blue Lake Expansion Project – Contract No. 9 16110-2 General Construction May 2012 4. UL 797 "Electrical Metallic Tubing" 1.05 PRODUCT DELIVERY, STORAGE AND HANDLING A. All materials shall be delivered, handled, and stored at the site in a manner that will protect them from damage of any type. B. All packaged products shall be clearly identified on the exterior of the container by name, catalog number and name of manufacturer. C. Any damaged or defective items shall be rejected and removed from the site. Damaged or defective materials shall be replaced by Contractor at no additional cost to Owner. PART 2 MATERIALS 2.01 CABLE TRAYS A. Cable trays shall conform to NEMA VE-1. B. Cable trays shall be aluminum and shall be the size and type indicated on the drawings. 2.02 CONDUIT A. The sizes of conduit to be installed at various locations inside buildings and outside buildings both above and below grade is shown on the drawings and can include ¾” 1”, 1 ½”, 2 ½”, 3”, 4”, 5” and 6” Rigid galvanized Steel (RGS). For power circuits outside the substation fence, 6” Polyvinyl Chloride (PVC), encased in concrete, conduit may be used if shown on the drawings. B. The type of conduit to be installed at various locations shall be in accordance with the drawings as follows: Location Conduit Type Outdoor or in concrete RGS Outdoor outside fence PVC Within Buildings (services) Electrical metallic tubing or liquid-tight flexible steel PART 3 EXECUTION 3.01 CABLE TRAY A. A complete cable tray system including all fasteners, hangers, expansion anchors, supports, clamps, and accessories shall be provided and installed As Shown. B. Cable tray to be class designation NEMA 20C (100 lbs working load per linear foot). The span between cable tray supports shall not exceed the manufacturer recommendation or 20' whichever is greater. Supports shall be located within 2' of cable tray dropouts. Blue Lake Expansion Project – Contract No. 9 16110-3 General Construction May 2012 C. The inside of the cable tray system shall be free of burrs, sharp edges, or projections, which could damage the cable insulation. D. The interconnection of sections, fittings and other components shall provide a rigid mechanical assembly with splice plates adequately installed to avoid structural weakness. E. Cable trays shall be supported from building structural steel, concrete floor, concrete ceiling, inserts or support columns As Shown. All miscellaneous steel necessary to provide adequate support of cable trays shall be provided by Contractor. F. Cable trays shall have a continuous ground conductor As Shown. G. No drilling, modifications to, or welding of building steel members will be permitted without written approval of RPR. Overstressing of building steel members will not be allowed. H. Contractor shall furnish and apply one coat of Galvanox or Subox paint on all tray support steel around holes or cuts where corrective work has been done. I. Contractor shall perform all necessary work to penetrate the floor below new control panels As Shown. J. Contractor shall provide adequate means for crossing the existing cable tray As Shown. 3.02 CONDUIT A. When not shown in detail on the drawings, the exact locations and routing of conduit and the location and sizing of conduit sleeves passing through floors, walls, etc., shall be determined by Contractor subject to approval of Engineer. B. Conduit, which is run exposed, shall be run at right angles to or parallel to building structural members. Diagonal runs will be permitted only in concrete slabs or in special cases with prior approval of Engineer. C. Conduit shall be cut square with an approved conduit cutter and threaded with an approved conduit threader. The ends shall be reamed of burrs, and all metal shavings and cutting lubricants shall be removed before the conduit is connected to the conduit system. D. Bends, offsets, and bevels shall be avoided where practical; but where they are necessary, they shall be made with an approved bending device. Any conduit crushed or deformed in bending will be rejected, and the use of heat in bending conduit shall be restricted to PVC conduit only. Where a number of conduits are run together, the radii of any required bends shall be such that the installation will be neat in appearance. E. Unless noted otherwise on the drawings, the minimum conduit bending radii shall be as follows: Location Bending Radius Below Grade or in concrete See Table Below Above Grade-Switchyard NEC Building/Enclosure (Inside) NEC Blue Lake Expansion Project – Contract No. 9 16110-4 General Construction May 2012 Below Grade Bending Radius Conduit Size Minimum Radius ¾” 4” 1” 6” 1 ½” 10” 2 ½” 15” 3” 18” 4” 24” 5” 30” 6” 36” F. No conduit runs shall have more bends than that permitted by the NEC. No wires shall be pulled until the conduit system is complete. G. Damage to galvanized surfaces shall be repaired by painting the damaged surface with Galvanox or Subox corrosion protection coating. Extensively damaged galvanized steel conduit shall be replaced. H. A minimum of five threads of the conduits shall connect to the various fittings. The conduit ends shall be reamed after cutting and threading. I. All conduits below and above grade shall be rodded and swabbed by Contractor. Plugs shall be installed at all conduit openings to prevent the entrance of foreign material prior to cable pulling. Plugs shall remain in unused conduits except where necessary to drain duct banks. J. Conduit shall terminate in boxes with double lock nuts and bushings, box connectors, or otherwise as noted, for protection of cables during pulling. K. Field cutting of conduit holes in sheet metal shall be made with hole saws or Greenlee Punches. L. Conduit clamp supports shall be spaced to provide a neat and orderly appearance. All field drilled holes for the conduit clamp support shall be coated with Galvanox or Subox paint. M. All threads shall be coated with a suitable joint/sealant compound. N. Bushings shall be the nonmetallic, insulating type. O. Conduits shall be run such that water does not accumulate in the conduit, a minimum slope of 0.25 percent shall be maintained in horizontal runs. Contractor may put drain holes in low spots prior to pulling of cable. P. Galvanized conduit shall be secured to steel structures, walls, building framing, etc., by the use of malleable-iron, galvanized U-bolts; beam clamps; conduit straps; or "Unistrut" fittings where "Unistrut" racks or supports are used. Q. Rigid metal conduit shall be securely fastened to all outlet boxes, pull boxes, cabinets, and switch boxes with double lock nuts and insulating bushings unless boxes with hubs are provided. Blue Lake Expansion Project – Contract No. 9 16110-5 General Construction May 2012 R. EMT shall be terminated with rain-tight, compression-type connectors with insulated throats. Couplings used with EMT shall be rain-tight, compression, type. Set screw-type connectors and couplings are unacceptable. S. All conduit connectors shall be made with appropriate fittings and securely tightened. Improperly made connections or terminations, as well as any which have not been adequately tightened, will be rejected. T. Conduit openings into which dirt, plaster, mortar mix, or debris may fall shall be closed with caps or tight-fitting plugs during the construction period. All conduits shall be thoroughly cleaned by pulling a mandrel through the conduit. With the mandrel shall be a pulling cord which shall be left in each conduit (both used and spare). Where such accumulations cannot be readily removed, the conduit shall be replaced. U. Conduits to be sealed for the purpose of preventing airflow and rodent and insect access shall be sealed where specified on the drawings with a pliable duct-sealing compound, such as John-Manville "Duxseal." V. All conduits shall be installed with a minimum cover as follows: Conduit Size Minimum Cover ¾” 12” 1” 12” 1 ½” 18” 2 ½” 24” 3” 30” 4” 36” 5” 48” 6” 48” 3.03 JUNCTION, TERMINAL AND PULL BOXES A. Junction and pull boxes shall be sized as indicated on the drawings. Where not specifically sized on the drawings, all boxes shall be sized in accordance with Article 370 of the NEC. B. Junction and pull boxes located indoors in non-hazardous areas shall be code- gage, galvanized sheet steel; welded construction; with conduit knockouts or raceways openings; and hinged or screwed covers as noted on the drawings. Boxes located outdoors shall be aluminum with screwed, gasketed covers and watertight hubs. See construction drawings for cabinets that require painting. The cabinet front door shall be painted with two coats of safety yellow and have fuse nomenclature affixed to the out side surface of the door. C. Terminal boxes shall be provided with a removable panel for mounting relays, wiring devices, and terminal blocks. Terminal boxes shall be Hoffman NEMA 3R aluminum enclosures for outdoor applications, and NEMA 12 enclosures for indoor applications. D. Contractor shall install all conduits for a bottom entry into boxes. No conduits shall enter boxes on the sides or top. Blue Lake Expansion Project – Contract No. 9 16110-6 General Construction May 2012 3.04 DEVICE AND OUTLET BOXES A. Surface-mounted outlet boxes for receptacles, switches, etc., shall be the cast type. Outdoor boxes shall be aluminum. 3.05 TESTS AND INSPECTIONS (PROVIDED BY CONTRACTOR) A. Contractor shall not backfill over any conduit or duct banks until Owner/Owner’s Representative has verified that the conduit or duct banks are installed according to the drawings. B. No conduit shall be considered complete until the mandrel is pulled and the pulling cord is left in the conduit. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16111-1 General Construction May 2012 SECTION 16111 EMBEDDED CONDUIT PART 1 GENERAL 1.01 SCOPE A. Furnish and install embedded conduit and fittings As Shown and as specified herein. 1.02 RELATED SECTIONS A. Section 03300: Cast-in-Place Concrete 1.03 REFERENCE A. All conduits, fittings and accessories shall comply to: 1. American Society for Testing and Materials (ASTM) 2. American National Standards Institute (ANSI) 3. National Electrical Manufacturer’s Association (NEMA) 4. National Electrical Code (NEC) 5. Underwriter’s Laboratories (UL) PART 2 PRODUCTS 2.01 MATERIALS A. Rigid Metal: Rigid metal conduit, conduit fittings and accessories shall be galvanized conforming to ANSI, NEMA and NEC Standards. B. PVC: PVC conduit, conduit fittings and accessories shall be rigid, heavy wall, DB2, and shall conform to ASTM 1785 or ASTM 2241 as applicable, ANSI, NEMA and NEC Standards. These shall be UL listed for direct earth burial and concrete encasement. PART 3 EXECUTION 3.01 INSTALLATION A. The conduit and fittings shall be handled and installed to prevent damage to them and to prevent dirt, water, oil and grease from contaminating their surfaces inside and out. Any damage or contamination shall be corrected by cleaning, repairing or replacing the material. B. Installation of the embedded conduit system shall be in accordance with the NEC. For rigid steel, it shall consist of cutting to the correct length; bending, threading Blue Lake Expansion Project – Contract No. 9 16111-2 General Construction May 2012 and reaming ends; installation of expansion joints; and general assembly of the conduit and fittings. Bending shall be done in an approved manner, and there shall be no flattening of the section or cracking of the conduit. The ends of the cut conduit shall be carefully reamed to provide a smooth interior surface when assembled. All joints shall be threaded. Welding of the conduit will not be permitted, except for waterstop plates, as indicated on the Construction Drawings. The ends of the conduit shall be protected and closed with threaded caps or bushings, and steel or fiber pennies. For PVC conduit, similar precautions shall be taken, using appropriate fittings and installation methods. C. The size, location, alignment and details of all embedded conduit and fittings shall be as indicated on the Construction Drawings. Conduit and fittings shall be placed accurately in the forms and shall be securely fastened in place to prevent displacement either at the terminals or along the run. Care shall be taken to prevent any damage during concrete placement or other Work, and any damage or displacement so caused shall be corrected. D. All rigid steel conduit and fittings shall form an electrically continuous path. All joints or connections shall be watertight with thick red conductive primer applied to threaded couplings before assembly and allowed to dry before being embedded. Where embedded conduit crosses a contraction or expansion joint, expansion/contraction fittings with bonding jumpers shall be provided. E. Each run of conduit shall be tested to ensure that it is free of obstructions as soon as assembled and shall be capped immediately. Each run shall again be tested immediately after concrete has been placed so that the conduit may be cleaned before any concrete found inside can harden. Any concrete or other substance in the run shall be immediately and thoroughly removed. Conduit shall be recapped immediately. Contractor shall be responsible for keeping the conduit capped and free from debris until such time as electrical wires are placed therein. Wooden pegs or makeshift caps will not be permitted. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16114-1 General Construction May 2012 SECTION 16114 CABLE TRAY PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install cable tray systems. PART 2 PRODUCTS 2.01 MATERIALS A. Cable tray shall be in accordance with NEMA Standard VE-1. The tray and fittings shall be fabricated from hot-rolled carbon steel, 14-gauge minimum thickness, hot-dip galvanized after fabrication or extruded from Aluminum Association Alloy 6063 with fittings made from Aluminum Association Alloy 5052. The tray shall be free of sharp burrs, projections, and exposed sharp edges that might be injurious to the cables. B. The tray shall be ladder-type with rungs and side rails and shall have a minimum depth of 4 in. Maximum overall depth shall be 6 in. Tray width shall be as required by final design, with a maximum rung spacing of 9 in. on centers, The tray shall be designed and constructed to support a uniformly distributed load of 100 lbs/ft with a maximum deflection of 1/2-in. when tested as a single 20 ft span, free beam. C. The tray components shall be fabricated to 1/16-in. tolerance to ensure straight and true alignment of the system at the time of installation. The rung connections to the side rail shall be by a positive mechanical joint to ensure lateral and longitudinal stability. D. The fittings, including barriers and covers, shall be of the same or equivalent material, finish, and construction as the straight tray. The minimum radii of the side rails on the horizontal elbows, vertical risers, tees, and crosses shall be 12 in. E. Cable tray supports and hangers shall consist of continuous slotted channels, hot-dip galvanized after fabrication. All supports and hangers shall be equipped with end caps and shall be assembled with matching spring clamp nuts and cap screws. F. Contractor shall furnish and install metal inserts (Unistrut P-3200 Series, Power-Strt PS-349 Series, or equal) and all mounting brackets, hanger supports, and miscellaneous fittings as required to complete the cable tray installation. Where inserts are not required, supports shall be installed with cap screws and expansion anchors. G. Cable trays made of aluminum that meet the structural and physical requirements of this section will be acceptable. Blue Lake Expansion Project – Contract No. 9 16114-2 General Construction May 2012 PART 3 EXECUTION 3.01 INSTALLATION A. The cable tray system and supports shall be installed rigid, level, and straight. No part of the tray system shall have a rise, buckle, sag, twist, or any other deflection of more than 1/8-in. when installed. The tray sections shall join together to provide a smooth joint. B. All necessary accessories shall be assembled on the tray system, including galvanized lockwashers for the tray support bracket bolts. All tray sections, fittings, connectors, fasteners, and bolts shall be installed so that there will be no sharp burrs to damage the cables. C. Expansion joint splice plates shall be used to allow 1.5 in. of free movement between adjacent trays when crossing an expansion joint. D. The trays shall be supported at intervals not exceeding 20 ft. The corners shall be supported by two supports installed as close as possible to the corner, with one support on each side of the corner. All cable tray joints to be supported. E. A minimum clearance of 3/4-in. shall be maintained between the bottom of trays and concrete surfaces; and a minimum clearance of 12 in. shall be maintained between trays measured from the top of the upper tray to the top of the lower tray. F. Power cables should have dedicated cable trays. If communication, instrument and control circuits have to be placed together with power circuits then barriers shall be installed to isolate communication, instrument, and control circuits from power circuits. Covers of the solid or louvered type shall be as required. G. Metal inserts shall be securely held in place to prevent displacement during placement of concrete. Cardboard closer strips shall be used to prevent the entry of concrete into the inserts. After forms are removed, slots and exposed surfaces shall be cleaned of concrete and other foreign material. Aluminum supports shall not be embedded in concrete. Galvanized supports shall not be tied to reinforcing steel with metal or placed in contact with reinforcing steel. H. Raceway grounding shall be ensured by a continuous No. 2 AWG copper grounding conductor, properly attached to the cable tray. I. All cable trays shall be identified by stencils or approved self-adhesive markings at each end and at intervals not exceeding 20 ft. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16120-1 General Construction May 2012 SECTION 16120 WIRE AND CABLE PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install wire and cable as required to complete the installation of equipment As Shown. 1.02 RELATED SECTIONS A. Section 01300: Submittals 1.03 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Contractor shall show the manufacturer's name and the following information on each cable on the cable and conduit schedule: 1. Technical description of insulation, shields, conductor, and jacket. 2. Provide catalog cut sheets 1.04 APPLICABLE STANDARDS A. Cables shall be manufactured and tested in strict accordance with applicable standards issued by ICEA, NEMA, UL, and ASTM. Any specific reference to standards in the ensuing paragraphs shall not release the manufacturer of compliance with the above standards. 1.05 AMPACITIES A. Cables shall be sized by the following criterion: 1. Cable shall be capable of carrying the maximum current in the circuit without exceeding its rated conductor temperature at the maximum ambient or at 40ºC, whichever is higher. 2. Cable and cable shields shall be able to withstand the maximum short circuit currents encountered in the system for sufficient time to allow the primary and backup protective devices to operate and the circuit breaker to open. 3. Voltage loss in the primary feeder runs shall not exceed two percent. PART 2 PRODUCTS 2.01 MATERIALS A. Medium-Voltage Power Cable: Medium-voltage power cable shall be single-conductor, stranded copper, ASTM Class B, manufactured in accordance Blue Lake Expansion Project – Contract No. 9 16120-2 General Construction May 2012 with NEMA WC-8, ASTM B8, UL 1072, and ICEA S-93-639 with the following characteristics: 1. Voltage: 15 kV, 133% insulation level. 2. Conductor Shield: Extruded, semiconducting, thermosetting compound. 3. Insulation: Ethylene-propylene based compound. 4. Insulation Shield: Extruded semiconducting compound. 5. Metallic Shield: Copper tape applied with a minimum 12.5 percent overlap. 6. Jacket: Overall cable assemblies shall be covered with flame-retardant, low smoke, zero halogen, thermoplastic. 7. Use: Installation in conduit, tray, ducts, and directly buried. 8. Flame Retardance: In accordance with IEEE Standard 383. B. Power Cable: Cable for 480-V power and lighting feeders shall be XLPE RW -90 insulated and shall be in accordance with ICEA S-66-516/WC-7. Cable shall be UL certified Type XHHW for continuous operation at 90ºC dry and 75ºC wet locations, for installation in cable tray and conduit. Power cable shall have the following characteristics: 1. Voltage: 600/1000 V depending upon cable size. 2. Conductors: Annealed copper, tin or lead-alloy coated, with sizes and number of conductors as required. 3. Conductor Strandings: Conductor shall have concentric Class B stranding. 4. Insulation: The conductors shall be insulated with XLPE. 5. Jacket: Overall cable assemblies shall be covered with flame-retardant, low smoke, zero halogen, thermoplastic. C. Control Cable: Control cables shall be XLPE insulated and shall be in accordance with ICEA S-66-516/NEMA WC-7. They shall be UL certified Type XHHW for continuous operation at 90ºC in wet and dry locations, for installation in cable tray and conduit. Control cable shall have the following characteristics: 1. Voltage: 600 V. 2. Conductors: Annealed copper, tin or lead-alloy coated, multiconductor, with sizes and number of conductors as required. 3. Conductor Strandings: Concentric Class B. 4. Insulation: The conductors shall be insulated with XLPE. 5. Jacket: Overall cable assemblies shall be covered with flame-retardant, low smoke, zero halogen, thermoplastic. Blue Lake Expansion Project – Contract No. 9 16120-3 General Construction May 2012 6. Color Coding and Identification: Individual conductors shall be permanently color coded in accordance with Section 5.6.3.1.1, Method 3, of NEMA WC-8. D. Instrumentation Cable: Instrumentation cable shall be XLPE insulated, or equal; size not less than 18 AWG shielded, and have a flame-resistant outer jacket. Cable shall be UL certified for 90ºC and shall be suitable for installation in cable tray and conduit. Instrumentation cables shall have the following characteristics: 1. Voltage: 300 V. 2. Conductors: Annealed copper, single or multiple twisted pairs or triads, and conductor sizes as required. 3. Insulation: XLPE. 4. Shield: Aluminum-coated mylar tape with tinned copper drain wire over each pair or triad. 5. Overall Shield: Aluminum-coated mylar tape with tinned-copper drain wire. 6. Jacket: Flame-retardant, low smoke, zero halogen, thermoplastic. 7. Conductor Identification: Pigmented black and white in pairs, black, white, and red in triads; white conductor numerically printed for group identification. E. Lighting Wire: Lighting wire shall be single-conductor copper, No. 12 AWG, in accordance with NEMA WC-5, and shall conform to the National Electrical Code for Type XHHW insulation. Lighting wire shall be color coded as follows: black, blue, red for phase wires, white for neutral wire. F. Identification of Cable Reels: Reels of cable shall be identified with permanently attached tags showing the manufacturer's name and catalog number, number of conductors, stranding, insulation type, length of cable, net weight of cable, and gross weight of reel. All markings shall be permanent and waterproof. 2.02 UNACCEPTABLE MATERIALS A. Materials such as the following but not limited to these are not acceptable for use in the construction of the cables as fillers ; insulators or jackets, etc., Polyvinyl Chloride (PVC) Asbestos Butyl Rubber Styrene Butadiene Rubber PART 3 EXECUTION 3.01 INSTALLATION A. Wire and cable shall not be installed in conduit or cable tray until the raceway system had been completed and cleaned. The equipment and methods for the installation of wire and cable shall ensure that no cuts or abrasions in the insulation or protective covering or kinks in the conductors occur. Blue Lake Expansion Project – Contract No. 9 16120-4 General Construction May 2012 B. Contractor shall pull wire and cable into the conduit and tray with sufficient length remaining at the ends to conveniently make connections to all equipment or devices. C. Where practicable, the minimum radius to which an insulated conductor shall be bent, whether permanently or temporarily during installation, shall be ten times the diameter over the outer covering for rubber and thermoplastic insulated cables and 12 times the outer diameter for medium-voltage shielded cables. Manufacturers' recommendations requiring larger bending radii shall prevail. D. Where a lubricant is needed as an aid in pulling wire or cable, a nonconducting lubricant or cable-pulling compound that is not injurious to the sheath or insulation shall be used. Oil or grease shall not be used for lubrication. Excessive pulling stresses will not be permitted. Lubricant shall be Polywater Yellow 77, or equal. E. Contractor shall install the wire connectors used for connecting conductors to terminal blocks. They shall be solderless, pressure-type, Hylug YAV ring type, unless otherwise noted. Terminals shall be put on with a full-compression pressure tool approved by the manufacturer of the terminals. Conductor ends shall be carefully stripped of insulation to avoid nicking the metal conductor. F. Power, Instrument and control cable shall be continuous, with no splice permitted, except As Shown. Shipping length of power cable shall be equal to a circuit length or summation of various circuit lengths to minimize excess cable. Wire for the lighting and receptacle circuits may be spliced in outlet boxes and junction boxes by the use of approved pressure fittings. Splices will not be permitted in conduit bodies. Wire in pull boxes shall be tied and neatly racked on the sides of the boxes in an approved manner. Supports shall be installed as required. G. Cable in the tray system shall be installed in accordance with the requirements of the National Electrical Code, Article 318. Where possible, cable shall be lifted into place on the tray rather than pulled into the tray. Where pulling is necessary, suitable rollers designed for the purpose shall be used. Pulling tension shall not exceed the recommended pulling tension of the manufacturer. H. After being placed in the tray, cable shall be neatly straightened to present an orderly appearance and to aid in tracing runs. Nylon cable ties of an approved type located at 4 ft o.c., shall be used to secure cable installed in vertical trays. I. Whenever cable leaves a tray or conduit, a cable support shall be furnished and installed to prevent stress being placed on the terminals to which the cable is connected. J. 15-kV Shielded Power Cable: Medium-voltage cable shall be installed in accordance with the cable manufacturer's instructions. All medium-voltage cable shall be terminated by stress relief cones or special termination fitting, which shall be installed strictly in accordance with the instructions of the cable or termination manufacturer. Where heat-shrink terminations are used, care shall be taken not to heat the cable insulation above the recommended temperature. Care shall be taken in constructing stress cones to eliminate all moisture from the taping, to build the cone to the specified dimensions, and to properly terminate and ground the outer shield conductor. Only one end of the shield wire shall be connected to the grounding system. K. Wire connectors used for joining conductors shall be solderless pressure type. They shall be installed by Contractor, as required for all splices, joints, and Blue Lake Expansion Project – Contract No. 9 16120-5 General Construction May 2012 connections, to render the connections mechanically and electrically secure and shall be covered with an insulating material equal to that of the conductor insulation. L. All power, control, instrument, and lighting cable shall be identified by nonmetallic tags, furnished by Contractor, shall be subject to the approval of RPR Engineer, machine-stamped with identification symbols (see Cable Schedule), and securely fastened to the cable at points where they are clearly visible. Tags shall be attached to each cable at intermediate pulling points in junction boxes, pull boxes, points of entering or leaving cable tray or conduit, and as required at other points of access. Each conductor shall be tagged at splices, devices, terminal blocks, and panels. Heat shrink tags shall be used for smaller conductors, tags shall be secured to larger conductors using type wraps. M. Cable on reels shall be stored and protected from damage. Proper precaution shall be taken in handling reels to prevent damage to the cable. N. Wire or cable damaged during installation shall be removed and replaced at Contractor's expense. O. Direct buried cable will be installed at a depth not less than 36 inches from finished grade. It will be laid on a 6-in. thick bed of soft sand, covered with an additional 6 in. of sand, and backfilled as required to maintain cable depth. A yellow caution tape will be provided all along the cable routing to warn excavators. Cable burial depth shall be increased as required to ensure that it is located below the frost line. 3.02 TESTS ON COMPLETED CABLES A. Insulated Wire and Cable Dielectric Tests: After the wiring is installed and all taps and splices are completed, but before making connections to equipment terminals, the cable shall be given insulation tests in accordance with these Specifications and NEMA and ICEA Standards. B. Voltage Tests and Insulation Tests: 1. Voltage tests shall be conducted in accordance with ICEA. Medium voltage cables and terminations shall be tested utilizing a DC HyPot tester. 15 kV class cables and terminations shall be tested for 15 minutes at 55 kV. Leakage shall be measured and recorded at one minute intervals. The 600 volt cables shall be tested using a 1000 VDC Megger. 300 volt cables shall be testing using a 500 VDC Megger. Communications and instrumentation cable shall be continuity tested only. C. Continuity Tests: 1. Before wiring connections to equipment and devices have been made, Contractor shall be responsible for continuity tests by measuring conductor resistance. 2. If a failure is detected, Contractor shall locate and determine the trouble, make necessary corrections to the installation, and retest. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16131-1 General Construction May 2012 SECTION 16131 EXPOSED CONDUIT – WET LOCATIONS PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install exposed conduit in wet locations. Wet areas are defined as below elevation 13 in the powerhouse, below elevation 428 in the gate house, and any place subject to submergence, spray, rainfall, or periodic splashing. 1.02 RELATED SECTIONS A. Section 01300: Submittals 1.03 REFERENCES A. NEMA, ANSI and UL Standard. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Catalog sheets, specifications and installation instructions. PART 2 PRODUCTS 2.01 RACEWAYS A. Rigid Ferrous Metal Conduit: Steel, hot dipped galvanized on the outside and inside UL categorized as Rigid Ferrous Metal Conduit (identified on UL Listing Mark as Rigid Metal Conduit - Steel, or Rigid Steel Conduit), by Allied Tube & Conduit Corp., LTV Copperweld, or Wheatland Tube Co. B. Liquid-tight Flexible Metal Conduit: UL categorized as liquid-tight flexible metal conduit (identified on UL Listing Mark as Liquid-Tight Flexible Metal Conduit, also specifically marked with temperature and environment application data), by AFC Cable Systems Inc., Anamet Electrical Inc., Electri-Flex Co., or Universal Metal Hose Co. 2.02 FITTINGS AND ACCESSORIES A. Connectors and Couplings: 1. Couplings (For Rigid Metal Conduit): Standard threaded couplings as furnished by conduit manufacturer. 2. Watertight Conduit Hubs: Cooper/Crouse Hinds’ Myers Hubs (stainless steel), OZ/Gedney Co.’s Type CH-T (hot dipped galvanized finish). 3. Liquid-tight Flexible Metal Conduit Connectors: OZ/Gedney Co.’s 4Q-TG Series (hot-dip/mechanically galvanized), or Thomas & Betts Corp.’s 3322 Series (PVC coated). Blue Lake Expansion Project – Contract No. 9 16131-2 General Construction May 2012 B. Conduit Bodies (Threaded): Malleable iron or cast iron alloy bodies and covers with hot dipped galvanized or other specified corrosion resistant finish; Cooper/Crouse-Hinds’ Condulets (Corro-free epoxy powder coat), Thomas & Betts Corp.’s Conduit Bodies (hot dipped galvanized), or OZ/Gedney Co.’s Conduit Bodies (hot dipped galvanized). Stainless steel cover screws, covers gasketed to suit application. C. Expansion Fittings: Cooper/Crouse-Hinds XJG (Corro-free epoxy powder coat), OZ Gedney Co.’s AX, EXE (end type, hot dipped galvanized), or Thomas & Betts Corp.’s XJG (hot dipped galvanized). D. Deflection Fittings: Ductile iron couplings with hot dipped galvanized finish, neoprene sleeve, and stainless steel bands, Appleton Electric Co.’s CF; or bronze couplings, neoprene sleeve, and stainless steel bands, OZ/Gedney Co.’s Type DX. E. Sealing Fittings: Malleable iron body with hot dipped/mechanically galvanized finish, neoprene sleeve, and stainless steel bands, Appleton electric Co.’s CF; or bronze couplings, neoprene sleeve, and stainless steel bands, OZ/Gedney Co.’s Type DX. 1. Horizontal: Cooper/Crouse-Hinds’ EYS with Chico A sealing compound and Chico X filler, OZ/Gedney Co.’s EYD with EYC sealing compound and EYF damming fiber, or Thomas & Betts Corp.’s. EYS w/Chico A sealing compound and Chico X filler. 2. Vertical (with Drain): Cooper/Crouse-Hinds with Chico A sealing compound and Chico X filler, OZ/Gedney Co.’s EY, EYA with EYC sealing compound and EYF damming fiber, or Thomas & Betts Corp.’s. w/Chico A sealing compound and Chico X filler. 3. Other Type Fittings. As required to suit installation requirements, by Cooper/Crouse-Hinds, OZ/Gedney Co., or Thomas & Betts Corp. with hot dipped/mechanically galvanized finish or epoxy powder coat. F. Service Entrance Caps/Heads: Hot dipped/mechanically galvanized finish; OZ/Gedney Co.’s 17-50G Series. G. Vertical Conductor Supports: Kellems/Hubbell Inc.’s Conduit Riser Grips (stainless steel or tin coated bronze), or OZ/Gedney Co.’s hot dipped galvanized finish Type CMT or Type W H. Conduit Clamps and Back Spacers: Malleable iron, hot dipped/mechanically galvanized finish; Cooper/Crouse-Hinds’ 510 and CB1 Series, OZ/Gedney Co.’s 14-G and 141G Series, or Thomas & Betts Corp.’s 1275 and 1350 Series. I. Drains and Breathers: Stainless steel; Appleton Electric Co.’s ECBD, Cooper/Crouse-Hinds’ ECD, OZ/Gedney Co.’s Type DB, or Thomas & Betts Corp.’s Type ECD. PART 3 EXECUTION 3.01 RACEWAY INSTALLATION - GENERAL A. Number of Raceways: Do not change number of raceways to less than the number indicated on the drawings. Blue Lake Expansion Project – Contract No. 9 16131-3 General Construction May 2012 1. Each raceway shall enclose one circuit unless otherwise indicated on the drawings. B. Conduit Size: Not smaller than 1/2 inch electrical trade size. The minimum allowable conduit size shall be based on Type THW conductors. C. Conduit Bends: For 3/4 inch conduits, bends may be made with manual benders. For all conduit sizes larger than 3/4 inch, manufactured or field fabricated offsets or bends may be used. Make field fabricated offsets or bends with an approved hydraulic bender. D. Conduit Exposed In Indoor Wet Locations: Install entire wiring system including conduit, boxes, and fittings so that there is a 1/4 inch air space between it and the wall or supporting surface. 3.02 RACEWAY SCHEDULE - TYPES & USE A. Rigid Ferrous Metal Conduit: Install in all wet locations unless otherwise specified or indicated on the drawings. B. Liquid-tight Flexible Metal Conduit: Install equipment grounding conductor in liquid- tight flexible metal conduit and bond at each box or equipment to which conduit is connected: 1. Use 1 to 3 feet of liquid-tight flexible metal conduit (UL listed and marked for the installation’s temperature and environmental conditions) for final conduit connection to: a. Motors with weather-protected or totally enclosed housings. b. Equipment subject to vibration. c. Equipment requiring flexible connection for adjustment or alignment. 3.03 FITTINGS AND ACCESSORIES SCHEDULE A. General: 1. Use malleable iron or cast iron alloy fittings and accessories having hot dipped/mechanically galvanized finish or other specified corrosion resistant finish in conjunction with ferrous raceways unless otherwise specified or indicated on the drawings. 2. Use caps or plugs to seal ends of conduits until wiring is installed (to exclude foreign material). 3. Use expansion fittings: a. Where raceways cross expansion joints. b. At intervals not exceeding 75 feet in straight runs (outside installations). c. Between fixed equipment (outside installations). Blue Lake Expansion Project – Contract No. 9 16131-4 General Construction May 2012 4. Use deflection fittings where raceways cross expansion joints that move in more than one plane 5. Use watertight hub on end of each conduit entering cabinets or boxes that are not constructed with integral threaded hubs. 6. Use back spacers behind each conduit clamp to keep raceway off surface to which it is attached and arranged to allow raceway to move due to expansion and contraction (outside installations). 7. Use drains in low points of the system to drain condensation, keeping interior of raceway system free of moisture. Also use breather at high point of the system for outside installations. B. For Rigid Metal Conduit: Use threaded fittings. C. For Liquid-tight Flexible Metal Conduit: Use liquid-tight connectors. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16132-1 General Construction May 2012 SECTION 16132 INTERIOR RACEWAYS, FITTINGS AND ACCESSORIES PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install interior raceways, fittings and accessories. 1.02 RELATED SECTIONS A. Section 01300 – Submittals 1.03 REFERENCES A. NEMA, ANSI, and UL. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Catalog sheets, specifications and installation instructions. 1.05 MAINTENANCE A. Spare Parts: Furnish the following items in the manufacturer’s original containers labelled with the names of the items and locations where the items would be used. Store them at the site where directed: 1. Touch up coating compound for plastic coated rigid metal conduit (one spray type can and one non-spray can with brush top). PART 2 PRODUCTS 2.01 RACEWAYS A. Rigid Ferrous Metal Conduit: Steel, hot dipped galvanized on the outside and inside, UL categorized as Rigid Ferrous Metal Conduit (identified on UL Listing Mark as Rigid Metal Conduit - Steel or Rigid Steel Conduit), by Allied Tube & Conduit Corp., LTV Copperweld, or Wheatland Tube Co. B. Liquid-tight Flexible Metal Conduit: UL categorized as liquid-tight flexible metal conduit (identified on UL Listing Mark as Liquid-Tight Flexible Metal Conduit, also specifically marked with temperature and environment application data), by AFC Cable Systems Inc., Anamet Electrical Inc., Electri-Flex Co., or Universal Metal Hose Co. C. Wireways, Fittings and Accessories: 1. NEMA 1 (Without Knockouts): Hoffman Enclosures Inc. Bulletin F-40, Hubbell/Wegmann’s HSK, Lee Products Co.’s S Series, Rittal/Electromate’s Blue Lake Expansion Project – Contract No. 9 16132-2 General Construction May 2012 EW & EWHC Lay-In Wireway System, or Square D Co.’s Square-Duct Class 5100. 2.02 FITTINGS AND ACCESSORIES A. Insulated Bushings: 1. Threaded, malleable iron/zinc electroplate with 105°C minimum plastic insulated throat; Appleton Electric Co.’s BU50I Series, Cooper/Crouse-Hinds’ 1031 Series, OZ/Gedney Co.’s IBC-50 Series, Raco Inc.’s 1132 Series, Steel City/T & B Corp.’s BI-901 Series, or Thomas & Betts Corp.’s 1222 Series. 2. Threaded malleable iron with 150°C plastic throat; Appleton Electric Co.’s BU501 Series, Cooper/Crouse-Hinds’ H1031 Series, or OZ/Gedney Co.’s IBC- 50 Series. B. Insulated Grounding Bushings: 1. Threaded, malleable iron/zinc electroplate with 105°C minimum plastic insulated liner, and ground lug; Appleton Electric Co.’s GIB-50 Series, Cooper/Crouse-Hinds’ GLL Series, OZ/Gedney Co.’s IBC-50L Series, Raco Inc.’s 1212 Series, Steel City/T & B Corp.’s BG-801 (1/2 to 2”) Series, or Thomas & Betts Corp.’s 3870. 2. Threaded malleable iron/zinc electroplate with 150°C plastic insulated liner, and ground lug; Appleton Electric Co.’s GIB Series, Cooper/Crouse-Hinds’ HGLL Series, or OZ/Gedney Co.’s IBC-50L Series, or Thomas & Betts Corp.’s 3870. C. Connectors and Couplings: 1. Locknuts: UL, steel/zinc electroplate; Appleton Electric Co.’s BL-50 Series, Cooper/Crouse-Hinds’ 11 Series, OZ/Gedney Co.’s 1-50S Series, Raco Inc.’s 1002 Series, Steel City/T&B Corp.’s LN-101 Series, or Thomas & Betts Corp.’s 141 Series. 2. Grounding Wedge: Thomas & Betts Corp.’s 3650 Series. 3. Couplings for Rigid Metal and IMC Conduit: Standard galvanized threaded couplings as furnished by conduit manufacturer, Allied Tube & Conduit Corp.’s Kwik-Couple, or Thomas & Betts Corp.’s Shamrock. 4. Three Piece Conduit Coupling For Rigid Metal and IMC Conduit: Steel, malleable iron, zinc electroplate; Allied Tube & Conduit Corp.’s Kwik-Couple, Appleton Electric Co.’s EC-50 Series, Cooper/Crouse-Hinds’ 190M Series, OZ/Gedney Co.’s 4-50 Series, Raco Inc.’s 1502 Series, Steel City/T & B Corp.’s EK-401 Series, or Thomas & Betts Corp.’s 675 Series. 5. Liquid-tight Flexible Metal Conduit Connectors: Steel, malleable iron, zinc electroplate, insulated throat; Appleton Electric Co.’s STB Series, Cooper/Crouse-Hinds’ LTB Series, OZ/Gedney Co.’s 4Q-50T Series, Raco Inc.’s 3512 Series, Steel City/T & B Corp.’s LT-701 Series, or Thomas & Betts Corp.’s 5332 Series. D. Conduit Bodies (Threaded): Blue Lake Expansion Project – Contract No. 9 16132-3 General Construction May 2012 1. Malleable Iron/Zinc Electroplate: Zinc electroplate malleable iron or cast iron alloy bodies with zinc electroplate steel covers; Appleton Electric Co.’s Unilets, Cooper/Crouse-Hinds’ Condulets, OZ/Gedney Co.’s Conduit Bodies, or Thomas & Betts Corp.’s Conduit Bodies. E. Expansion Fittings: 1. Malleable Iron, Zinc Electroplate Finish: Appleton Electric Co.’s XJ or OZ/Gedney Co.’s AX (TX for EMT), with external bonding jumper. 2. Electrogalvanized Steel: Cooper/Crouse-Hinds’ XJG (XJG-EMT for EMT), or Thomas & Betts Corp.’s XJG, with internal grounding. F. Deflection Fittings: Appleton Electric Co.’s DF, Cooper/Crouse-Hinds’ XD, or OZ/Gedney Co.’s Type DX. G. Vertical Conductor Supports: Kellems/Hubbell Inc.’s Conduit Riser Grips, or OZ/Gedney Co.’s Type M, Type R. H. Pulling-In-Line for Installation in Spare and Empty Raceways: Polypropylene monofilament utility line; Greenlee Textron Inc.’s Poly Line 430, 431, or Ideal Industries Powr-Fish Pull-Line 31-340 Series. PART 3 EXECUTION 3.01 RACEWAY INSTALLATION - GENERAL A. Number of Raceways: Do not change number of raceways to less than the number indicated on the drawings. 1. Each raceway shall enclose one circuit unless otherwise indicated on the drawings. B. Raceways for Future Use (Spare Raceways and Empty Raceways): Draw fish tape through raceways in the presence of Owner’s Representative to show that the raceway is clear of obstructions. 1. Leave a pulling-in line in each spare and empty raceway. C. Conduit Installed Concealed: 1. Install conduit concealed where indicated on the drawings. 2. Install conduit in concrete slabs, under slabs on grade, or under slabs where indicated on the drawings. a. Conduit in Slab: Run 1/2 and 3/4 inch conduit in the slab where placement of reinforcement and slab thickness is sufficient to allow 1-1/2 inches of concrete cover over conduit, otherwise run conduit under slab. Run conduit one inch and larger in the slab in the specific location(s) where it is indicated on the drawing to be run in the slab, otherwise run conduit under slab. • Run conduit under reinforcement where reinforcement is in upper portion or middle of slab. Blue Lake Expansion Project – Contract No. 9 16132-4 General Construction May 2012 • Run conduit over reinforcement where reinforcement is in lower portion of slab. • Run conduit between reinforcement where reinforcement is in upper and lower portions of slab. • Separate parallel conduits minimum of 2 inches so that each conduit will be enveloped in concrete. • Pass conduit over steel beams, if any, parallel with the reinforcement. • Tie down conduit to avoid movement during placement of concrete. • Demonstrate to Owner’s Representative that conduit has been placed to allow minimum of 1-1/2 inches of concrete cover. 3. Conduit Under Slab on Grade: a. Run conduit under vapor barrier, if any. b. Install equipment grounding conductor in each conduit. Bond at boxes and equipment to which conduit is connected. D. Conduits Penetrating Concrete Floor Slabs (Concrete slabs that are both ceilings and floors shall be treated as floor slabs): 1. Provide a minimum of 2 inches between conduits that vertically penetrate elevated concrete slabs. 2. Provide fire stopping and spray on fireproofing at locations where conduits penetrate surface of floor slab and slab is part of fire rating required for construction. E. Conduit Installed Exposed: 1. Install conduit exposed where indicated on the drawings. 2. Install conduit tight to the surface of the building construction unless otherwise indicated or directed. 3. Install vertical runs perpendicular to the floor. 4. Install runs on the ceiling perpendicular or parallel to the walls. 5. Install horizontal runs parallel to the floor. 6. Do not run conduits near heating pipes. 7. Installation of conduit directly on the floor will not be permitted. F. Conduit Size: Not smaller than 3/4 inch electrical trade size. The minimum allowable conduit size for new Work shall be based on Type THW conductors. G. Conduit Bends: For 3/4 inch conduits, bends may be made with manual benders. For all conduit sizes larger than 3/4 inch, manufactured or field fabricated offsets or Blue Lake Expansion Project – Contract No. 9 16132-5 General Construction May 2012 bends may be used. Make field fabricated offsets or bends with an approved hydraulic bender. 3.02 RACEWAY SCHEDULE A. Rigid Ferrous Metal Conduit (RMC) or Intermediate Metal Conduit (IMC): Install in all locations permitted by code unless otherwise specified or indicated on the drawings. B. Liquid-tight Flexible Metal Conduit: Install equipment grounding conductor in liquid- tight flexible metal conduit and bond at each box or equipment to which conduit is connected: 1. Use 1 to 3 feet of liquid-tight flexible metal conduit (UL listed and marked suitable for the installation’s temperature and environmental conditions) for final conduit connection to: a. Motors with weather-protected or totally enclosed housings. b. Equipment subject to vibration (damp and wet locations). c. Equipment requiring flexible connection for adjustment or alignment (damp and wet locations). C. Wireways: May be used indoors in dry locations for exposed raceway between grouped, wall mounted equipment. 3.03 FITTINGS AND ACCESSORIES SCHEDULE A. General: 1. Use fittings and accessories that have a temperature rating equal to, or higher than the temperature rating of the conductors to be installed within the raceway. 2. Use zinc electroplate or hot dipped galvanized steel/malleable iron or cast iron alloy fittings and accessories in conjunction with ferrous raceways in dry and damp locations unless otherwise specified or indicated on the drawings. 3. Use insulated grounding bushings or grounding wedges on ends of conduit for terminating and bonding equipment grounding conductors, when required, if cabinet or boxes are not equipped with grounding/bonding screws or lugs. 4. Use caps or plugs to seal ends of conduits until wiring is installed to exclude foreign material. 5. Use insulated grounding bushings on the ends of conduits that are not directly connected to the enclosure, such as stub-ups under equipment, etc., and bond between bushings and enclosure with equipment grounding conductor. 6. Use expansion fittings where raceways cross expansion joints (exposed, concealed, and buried). 7. Use deflection fittings where raceways cross expansion joints that move in more than one plane. 8. Use 2 locknuts and an insulated bushing on end of each conduit entering sheet metal cabinet or box in dry or damp locations. Blue Lake Expansion Project – Contract No. 9 16132-6 General Construction May 2012 a. Plastic bushing may be used on 1/2 and 3/4 inch conduit in lieu of insulated bushing. b. Terminate conduit ends within cabinet/box at the same level. B. For Rigid and Intermediate Metal Conduit: Use threaded fittings and accessories. Use 3 piece conduit coupling where neither piece of conduit can be rotated. C. For Liquid-tight Flexible Metal Conduit: Use liquid-tight connectors. D. For Wireways: Use wireway manufacturer’s standard fittings and accessories. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16133-1 General Construction May 2012 SECTION 16133 EXPOSED CONDUIT PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install exposed conduit As Shown and as specified herein. 1.02 RELATED SECTIONS A. Section 16111: Embedded Conduit B. Section 16120: Wire and Cable C. Section 16200: Electrical Trenches 1.03 APPLICABLE STANDARDS A. All conduits, fittings, and accessories shall comply with: 1. American Society for Testing and Materials (ASTM) 2. American National Standards Institute (ANSI) 3. National Electrical Manufacturer’s Association (NEMA) 4. National Electrical Code (NEC) 5. Underwriters Laboratories (UL) PART 2 PRODUCTS 2.01 MATERIALS A. The following exposed conduits shall be used on this project: 1. Rigid galvanized steel (RGS) threaded conduit, hot dipped galvanized for all 480 V wiring systems and in areas where the wiring system may be subject to mechanical damage. 2. Electrical metallic tubing (EMT) for all 120/208 V or less building services wiring systems, in areas where the wiring system is not subject to mechanical damage such as wiring contained within ceilings, walls, or other structures. 3. Liquid-tight flexible metal conduit where final connections to devices require flexible connections. B. Conduit Fastenings: 1. One-hole steel straps to secure surface conduits of 2 in. trade size or smaller. Two-hole steel straps for conduits larger than 2 in. Blue Lake Expansion Project – Contract No. 9 16133-2 General Construction May 2012 2. Beam clamps to secure conduits to exposed steel work. 3. Channel type supports for two or more conduits. 4. 3/8 in. diameter threaded rods to support suspended channels. C. Conduit Fittings: 1. Fittings: Manufactured for use with conduits specified, coating to be the same as conduit. 2. Factory “els” where 90º bends are required for 1 in. trade size or larger conduits. 3. Compression type connectors and couplings for EMT. PART 3 EXECUTION 3.01 INSTALLATION A. Conduits – General: 1. Install conduits to conserve headroom in exposed locations and cause minimum interference in spaces through which they pass. 2. Mechanically bend steel conduit over 3/4 in. diameter. Bend conduits cold. Conduits over 1¼ in. trade size and larger to be bend using a hydraulic bender or use factory bends. Conduits found to be bent using methods or other than indicated above will be removed. Replace conduits if kinked or flattened more than 1/10th of its original diameter. 3. Field threads on rigid conduit must be of sufficient length to draw conduits up tight. 4. Install fish cord in empty conduits. 5. Coordinate all conduit routings with the mechanical trades. Do not run conduits at elevations which may interfere with equipment removals, ventilation, louvers, ductwork, piping, cable trays, or other trades. B. Exposed Conduits: 1. Run parallel or perpendicular to building lines. 2. Run conduits in flanged portion of structural steel. 3. Group conduits wherever possible on surface channels. 4. Do not pass conduits through structural members. 5. Do not locate conduits less than 3 in. parallel to hot water lines with a minimum of 1 in. separation at crossovers. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16134-1 General Construction May 2012 SECTION 16134 OUTLET, JUNCTION AND PULL BOXES PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install of outlet boxes, junction boxes and pull boxes. 1.02 RELATED SECTIONS A. Section 01300: Submittals 1.03 REFERENCES A. NEMA and UL Standard. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Catalog sheets, specifications and installation instructions. C. For fire rated construction, demonstrate that materials and installation methods proposed for use are in accordance with the listing requirements of the classified construction. PART 2 PRODUCTS 2.01 GALVANIZED STEEL JUNCTION AND PULL BOXES A. Code gage, galvanized steel screw cover boxes by Delta Metal Products Inc., Hoffman Enclosures Inc., Hubbell Wiegmann, Lee Products Co., or Rittal/Electromate. 2.02 THREADED TYPE BOXES A. Outlet Boxes: 1. For Dry, Damp Locations: Zinc electroplate malleable iron or cast iron alloy boxes by Appleton Electric Co., Cooper/Crouse-Hinds Co., or OZ/ Gedney Co., with zinc electroplate steel covers to suit application. 2. For Wet Locations: Malleable iron or cast iron alloy boxes with hot dipped galvanized or other specified corrosion resistant finish as produced by Cooper/Crouse-Hinds (hot dipped galvanized or Corro-free epoxy powder coat), or OZ/Gedney Co. (hot dipped galvanized), with stainless steel cover screws, and malleable iron covers gasketed to suit application. B. Junction and Pull Boxes: Blue Lake Expansion Project – Contract No. 9 16134-2 General Construction May 2012 1. For Dry, Damp Locations: Zinc electroplate cast iron boxes by Appleton Electric Co., Cooper/Crouse-Hinds, or OZ/Gedney Co., with zinc electroplate steel or cast iron cover. 2. For Wet Locations: Cast iron boxes by Cooper/Crouse-Hinds’ (hot dipped galvanized or Corro-free epoxy powder coat), or OZ/Gedney Co. (hot dipped galvanized), with stainless steel cover screws and cast iron cover gasketed to suit application. C. Conduit Bodies, Threaded (Provided with a Volume Marking): 1. For Dry, Damp Location: Zinc electroplate malleable iron or cast iron alloy bodies with zinc electroplate steel covers; Appleton Electric Co.’s Unilets, Cooper/Crouse-Hinds’ Condulets, or OZ/Gedney Co.’s Conduit Bodies. 2. For Wet Locations: Malleable iron or cast iron alloy bodies with hot dipped galvanized or other specified corrosion resistant finish; Cooper/Crouse-Hinds’ Condulets (hot dipped galvanized or Corro-free epoxy power coat), or OZ/Gedney Co.’s Conduit Bodies (hot dipped galvanized) with stainless steel cover screws and malleable iron covers gasketed to suit application. 2.03 SPECIFIC PURPOSE OUTLET BOXES A. As fabricated by manufacturers for mounting their equipment. PART 3 EXECUTION 3.01 PREPARATION A. Before proceeding with the installation of junction and pull boxes, check the locations with the Owner’s Representative and have same approved. 3.02 INSTALLATION A. Mounting Position of Wall Outlets for Wiring Devices: Unless otherwise indicated, install boxes so that the long axis of each wiring device will be vertical. B. Height of Wall Outlets: Unless otherwise indicated, locate outlet boxes with their center lines at the following elevations above finished floor: Lighting Fixtures 6’-0” Exit Lights 8’-0” where ceiling height allows a minimum of 6 inch clearance between ceiling and top of exit light. Otherwise mount exit light so that its top is 6 inches below finished ceiling. Adjust height and clearances as required to suit installation over doors. Switches 4’-0” Single & Duplex Receptacles 1’-6”* Special Purpose Receptacles 4’-0” Thermostats 5’-0” Manual Fire Alarm Boxes 4’-0” Blue Lake Expansion Project – Contract No. 9 16134-3 General Construction May 2012 Audible Notification Appliances 8’-0” where ceiling height allows a minimum of 6 inch clearance between ceiling and top of appliance. Otherwise mount appliance so that its top is 6 inches below finished ceiling. Visible Notification Appliances Install outlet so that the bottom of the visible lens will be 6’-8” AFF. Combination Audible/Visible Notification Appliances Install outlet so that the bottom of the visual lens will be 6’-8” AFF, and the audible section will be above the visible section. Telecommunications 2’-0” Telephone 2’-0” Telephone Marked W.T. Install outlet so that the highest operable part of the wall mounted telephone will not be more than 4’-0” AFF. * In areas containing heating convectors, install outlets above convectors at height indicated on drawings. C. Supplementary Junction and Pull Boxes: In addition to junction and pull boxes indicated on the drawings and required by NFPA 70, provide supplementary junction and pull boxes as follows: 1. When required to facilitate installation of wiring. 2. At every third 90° turn in conjunction with raceway sizes over 1 inch. 3. At intervals not exceeding 100 feet in conjunction with raceway sizes over 1 inch. 3.03 OUTLET, JUNCTION, AND PULL BOX SCHEDULE A. Boxes for Exposed Conduit System: 1. Dry and Damp Locations: Use zinc electroplate or hot dipped galvanized threaded type malleable iron or cast iron alloy outlet, junction, and pull boxes or conduit bodies provided with a volume marking in conjunction with ferrous raceways unless otherwise specified or indicated on the drawings. a. Galvanized steel boxes may be used in conjunction with conduit sizes over 1 inch in non-hazardous dry and damp locations. 2. Wet Locations: Use threaded type malleable iron or cast iron alloy outlet junction, and pull boxes or conduit bodies (provided with a volume marking) with hot dipped galvanized or other specified corrosion resistant coating in conjunction with ferrous raceways unless otherwise specified or indicated on the drawings. a. Use corrosion resistant boxes in conjunction with plastic coated rigid ferrous metal conduit. 3. Finishing Collar or Combination Finishing Collar/Outlet Box (Surface Mounted Equipment Used With Exposed Raceway): a. Use finishing collar where surface mounted equipment is installed on an exposed raceway outlet box and the equipment base is larger than the outlet box. Blue Lake Expansion Project – Contract No. 9 16134-4 General Construction May 2012 b. Use combination finishing collar/outlet box where surface mounted equipment is not indicated to be installed on an exposed raceway outlet box, but raceway cannot be run directly into equipment body due to equipment design. B. Specific Purpose Outlet Boxes: Use to mount equipment when available and suitable for job conditions. Unless otherwise specified, use threaded type boxes with finish as specified for exposed conduit system, steel (painted) for surface metal raceway system and galvanized steel for recessed installations. C. Stencil cover of pullboxes used on systems over 600V, in white lettering minimum 1/2 inches high, the words “DANGER HIGH VOLTAGE - KEEP OUT”. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16138-1 General Construction May 2012 SECTION 16138 ELECTRIC MANHOLES PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and installation of all electric manholes. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 02300: Earthwork C. Section 03050: Cast-In-Place Concrete 1.03 DEFINITIONS A. The words manhole, handhole, and pullbox are synonymous. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Catalog sheets, specifications and installation instructions. C. Shop Drawings: Show dimensions, reinforcing and construction details for manholes. PART 2 PRODUCTS 2.01 MANHOLES A. Manholes may be precast or field constructed: 1. Field Constructed Manholes: Furnish manholes of dimensions As Shown. 2. Precast Manholes: As manufactured by Utility Vault, The Fort Miller Co., or Lakelands Pre-cast, Inc., having: a. Reinforcing meeting American Association State Highway Officials’ requirements for H-20 loading. b. Minimum interior dimensions As Shown for field-constructed manholes. c. Walls minimum 6 inches thick reinforced concrete. Exception: • Walls minimum 4½ inches thick reinforced concrete for 30x30 inch manholes. d. Top slab minimum 7 inches thick reinforced concrete. Exceptions: Blue Lake Expansion Project – Contract No. 9 16138-2 General Construction May 2012 • Top slab minimum 6 inches thick reinforced concrete for 4x4 ft manholes. • Top slab not required for 30x30 inch manholes. e. Bottom slab minimum 6 inches thick reinforced concrete. Exception: • Bottom slab minimum 4 inches thick reinforced concrete for 30x30 inch manholes. f. Sealed joints. B. Equip manholes with a pulling hook opposite each conduit entrance. Construct hook of 3/4 inch galvanized stock with 3 inch diameter eye and 8 inches for anchoring in manhole wall, or use Pennsylvania Pulling Iron as manufactured by Pennsylvania Insert Corporation. Each pulling hook shall be suitable for a minimum load rating of 2000 lbs. C. Manholes shall be well drained. 2.02 WATERTIGHT MANHOLE FRAMES AND COVERS A. Design of each shall be the same throughout the project unless otherwise specified or indicated on the drawings. B. Units shall meet AASHTO H20 wheel loading requirements. Manufacture, workmanship and certified proof-load tests shall conform to ASASHTO M306-89. 1. Material: a. Cast iron: ASTM A48, Class 30B or 35B. b. Delivered to the site free of any coatings, unless otherwise specified. 2. Frames: a. Round, 6½ inches high with a minimum 27-inch clear opening. b. Minimum bearing area of the flange on the masonry: 645 sq. inches. c. Minimum weight: 156 lbs. 3. Outer Lids: a. Round, approximately 1½ inches thick at the perimeter bearing surface. b. Minimum 1 inch wide perimeter bearing surface. c. Non-perforated checkered surface design. d. Concealed type pick holes. e. The letter “P” 6 inches high cast in the outer lid for power manholes; the letter “S” 6 inches high for signal manholes. Blue Lake Expansion Project – Contract No. 9 16138-3 General Construction May 2012 f. Minimum weight: 215 lbs. 4. Inner Lids: a. Each equipped with two lift handles, a neoprene seating gasket, and a lock bar with a hasp or other means suitable for padlocking. b. Minimum total weight of lid and lock bar: 165 lbs. C. Acceptable Frames and Covers: Pattern R1755-G1 by Neenah Foundry Company, P. O. Box 729, Neenah, WI 54957, (414) 729-3661; Pattern 6553 by Syracuse Casting Sales Corp., P. O. Box 190, South Bay Rd., Cicero, NY 13039, (315) 699- 2601. 2.03 CABLE SUPPORT ASSEMBLIES A. Cable Support Assemblies (Steel): A.B. Chance Co.'s 1225 rack, 1231 Series support arms, 1121 porcelain insulators, or McGraw-Edison's DU10B Series rack, DU9S Series support arms, DE12U porcelain insulators. B. Cable Support Assemblies (Nonmetallic): Underground Devices Inc.'s CR36 rack, RA Series support arms. 2.04 GROUNDING AND BONDING A. Rod Electrodes: Copper clad (min. 010 jacket) ground rods minimum 5/8 inch diameter by 8 ft, 0 inches long. B. Exothermic Type Weld: Erico Products Inc.’s Cadweld Process. C. Compression Connectors: Amp Special Industries' Ampact Grounding System, Burndy Corp.'s Hyground System, or Thomas & Betts Corp.'s Grid and Ground Rod System. D. Grounding Electrode Conductors and Bonding Conductors: Bare copper conductors. E. Hardware: Silicon-bronze bolts, nuts, flat and lock washers, etc. as manufactured by Burndy Corp., Dossert Corp., or OZ/Gedney Co. PART 3 EXECUTION 3.01 PREPARATION A. Dewater and remove debris from existing manholes used for the Work. B. Provide heavy blankets, plywood or other devices to protect existing cables and equipment from physical damage. 3.02 INSTALLATION A. Depth: Install manholes at depth required to bring top of manhole covers 2 inches above finished grade in lawns, and flush with paved surfaces of walks, roads, or parking spaces. Blue Lake Expansion Project – Contract No. 9 16138-4 General Construction May 2012 B. Mortar any used openings. Set manhole frame with mortar. Waterproof exterior of throat with minimum thickness of 3/32 inch elastic bituminous plastic cement coating. C. Cable Supports: Install racks, support arms and insulators of size and number to provide one insulator (or equivalent space on nonmetallic support arms) on each cable support assembly for each conduit entering the manhole: 1. New Manholes: Equip manholes with number of cable support assemblies indicated on the drawings. Route cables around periphery of manholes. Secure cables with waxed lacing twine. 2. Existing Manholes: Where indicated on the drawings, equip existing manholes with cable support assemblies (or support arms and porcelain insulators if manhole is equipped with racks). Route new cables around periphery of manhole. Set existing unracked cables on cable support assemblies where indicated on the drawings. Secure cables with waxed lacing twine. 3. Signal Manholes: In addition to cable support assemblies, provide across and spanning the support arms, troughs for support of each signal cable. Troughs shall consist of lengths of 4 inch diameter Schedule 40 plastic conduit split lengthwise into halves. Route cable around periphery of manhole. Set trough on the support arms, lay in cable and lash with waxed lacing twine. D. Grounding and Bonding: 1. New Manholes Containing Feeder Circuits over 600 volts: a. Install rod electrode in each manhole near a wall. Install rod electrode through floor into earth below manhole with 4 inches protruding for ground connection. b. Bond manhole cover frame, steel cable support assemblies and splices (lead sheath of splice or cable shields for non-lead type cables) to rod electrode with No. 6 AWG bare copper ground conductor. c. Make connection to rod electrode with exothermic type weld or compression connectors. 2. Existing Manholes Containing New Splices over 600 volts: a. Install a rod electrode in each manhole where new cable splices are required (existing rod electrodes may be utilized if available). Install rod electrode through floor into earth below manhole with 4 inches protruding for ground connection. b. Bond existing manhole cover frame, new and existing steel cable support assemblies and new splices (lead sheath of splice or cable shields for non- lead type cables) to rod electrode with No. 6 AWG bare copper ground conductor. c. Make connection to rod electrode with exothermic type weld or compression connectors. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16221-1 General Construction May 2012 SECTION 16221 MOTOR AND MOTOR CONTROLLERS PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install motor and motor controls As Shown. 1.02 RELATED SECTIONS A. Section 01300 – Submittals 1.03 REFERENCES A. NEMA MG -1 - Motors and Generators. B. NEMA ICS - General Standards for Industrial Control and Systems. C. UL508 - Electric Industrial Control Equipment. D. IEEE 519 - Recommended Practices and Requirements for Harmonic Control in Electric Power Systems. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submit the product data, and quality control submittals specified below at the same time as a package. C. Product Data: Motor Controllers: Catalog sheets, specifications, and installation instructions. Submit product data for motor controllers simultaneously with product data required for motors. 1. Identify each controller for use with corresponding motor. a. Identify each controller for use with corresponding motor. b. Describe overload devices being supplied with each motor controller (include equipment manufacturer’s recommendations). c. Enumerate and describe all accessories being supplied with each motor controller. 2. All Motors: a. Catalog sheets, specifications and installation instructions. b. Data proving that voltage rating of each motor is in accordance with specified NEMA standard motor voltage. Blue Lake Expansion Project – Contract No. 9 16221-2 General Construction May 2012 c. Data proving that the service factor and temperature rise for the motor’s insulation system conforms to NEMA standards for each motor’s specific application. d. Data proving that the motor efficiency rating conforms to NEMA testing and marking standards MG1-12.54 and 12.55. 3. Additional Data for Motors Controlled by Solid State or Adjustable Speed Motor Controllers: a. Data proving that the motor has been designed for use with associated controller. b. Data proving that the motor has been designed for use with DC injection braking (if required). 4. Additional Data for Motors 50 HP and Larger: Certified report of manufacturer’s routine tests for each motor (NEMA MG 1-12.54). PART 2 PRODUCTS 2.01 MOTORS A. Classification: 1. Classification According to Application: Comply with NEMA standards for general-purpose alternating-current squirrel-cage induction motors, except: a. Furnish NEMA definite-purpose or special-purpose motors when required to suit the application. b. Furnish NEMA type other than squirrel-cage construction when required to suit the application. 2. Classification According to Environmental Protection and Methods of Cooling: Comply with NEMA requirements for a drip-proof machine unless otherwise specified or indicated on the Drawings, or required to suit the application. B. Efficiency: Motors shall be stamped with a NEMA nominal efficiency rating in accordance with NEMA testing and marking standards MG1-12.54 and 12.55. 1. Nominal full-load three phase motor efficiency: Open Motors RPM 1200 1800 3600 HP 1.0 80.0 82.5 1.5 84.0 84.0 82.5 2.0 86.5 84.0 84.0 3.0 86.5 86.5 84.0 5.0 88.5 87.5 85.5 7.5 89.5 88.5 87.5 10 90.2 89.5 88.5 Blue Lake Expansion Project – Contract No. 9 16221-3 General Construction May 2012 15 91.0 90.2 89.5 20 90.2 91.0 90.2 25 91.7 92.4 91.0 30 92.4 93.0 92.4 40 93.0 93.0 92.4 50 92.4 94.1 92.4 60 93.0 93.6 93.0 75 93.6 94.1 93.6 100 93.6 94.1 93.6 125 94.1 94.1 93.6 150 94.5 94.5 94.5 200 94.5 95.0 95.4 Closed Motors RPM 1200 1800 3600 HP 1.0 81.5 84.0 1.5 85.5 85.0 84.0 2.0 86.5 84.0 85.5 3.0 88.5 88.5 86.5 5.0 88.5 88.5 87.5 7.5 89.5 91.0 88.5 10 89.5 91.0 89.5 15 90.2 91.0 89.5 20 91.0 91.7 90.2 25 91.7 92.4 90.2 30 92.4 93.6 91.0 40 93.0 93.0 91.0 50 93.6 93.6 92.4 60 93.6 94.1 94.1 75 94.1 94.5 94.1 100 94.1 95.0 94.1 125 94.1 95.0 94.1 150 95.0 95.0 94.1 200 95.0 95.8 95.01 C. Motor (Nameplate) Voltage: 1. 480 V, Three Phase, 3W, Premises Wiring Systems: a. Motors Less Than 1/2 hp: NEMA standard motor voltage 115 V, single phase, 60 Hz. b. Motors 1/2 hp and Larger: NEMA standard motor voltage 460 V, three phase, 60 Hz. 440 V motors are not acceptable. c. At the fish valve unit, motors rated for operation at 208 volts, three phase may be utilized. The use of 230 volt motors shall not be permitted. D. Horsepower Capacity: Blue Lake Expansion Project – Contract No. 9 16221-4 General Construction May 2012 1. Each motor shall not be overloaded by the apparatus it operates under every condition of operation. 2. The horsepower capacity shall be the continuous rating based on the nameplate horsepower rating. (The motor may not be overloaded up to the horsepower obtained by multiplying the rated horsepower by the service factor shown on the nameplate). 3. Where a minimum horsepower capacity is listed, furnish a motor larger than the minimum, if required in a particular case. E. Bearings: Equip motors 1/2 hp and larger with ball or roller bearings unless otherwise specified or indicated on the Drawings F. Speed: As required and approved to meet the requirements of the service for which motors are intended. G. Space Heaters: Where indicated, equip motors with space heaters and accessories to prevent condensation in the motor windings when motor is not operating. H. Motor Winding Protection: Where indicated, equip motors with imbedded temperature measuring detectors in the windings (thermocouples or resistance thermometers) with control unit and accessories for direct reading of stator temperatures. Alarm shall sound and motor controller trip at temperature recommended by motor manufacturer. I. Additional requirements for motors used with solid state motor starters and adjustable speed motor controllers (VSD): 1. Designed specifically for use with type of variable speed drive where high harmonic content is anticipated. 2. Designed for DC injection braking. J. Brake: Where indicated, equip motors with electro/mechanical brake system. K. Motors shall be Baldor, Reliance, US Motors or other approved vendor supply. 2.02 MANUAL AND MAGNETIC MOTOR CONTROLLERS A. Manufacturer: Allen Bradley or Squared-D are acceptable manufacturers. Starters should include water tight or oil tight as applicable, pilot lights and switches. B. Minimum Size: The minimum allowable size of single or three phase magnetic motor controller is NEMA size 0. C. Voltage Rating: To suit system voltage. 1. For single phase motor controllers which are not produced to suit the system voltage and phases, furnish properly rated 3 phase motor controllers and utilize required number of poles for the single phase circuit. D. Enclosures: Blue Lake Expansion Project – Contract No. 9 16221-5 General Construction May 2012 1. NEMA Type: In powerhouse areas subject to periodic water exposure or inadvertent water spray, NEMA 4, in machine areas subject to oil and dust exposure furnish NEMA 12 enclosures, in dry non-hazardous areas, NEMA 3. 2. Material: Steel construction unless otherwise indicated. 3. Type A, A1 and A2 Controllers Indicated To Be Flush Mounted: Furnish stainless steel face plates and galvanized steel recessed mounting boxes. E. Control Power: Furnish fused secondary control power transformer (maximum control voltage 120 volts) mounted within each magnetic motor controller enclosure. F. Local Control Devices: 1. Manual Motor Controllers: a. Type A1 Controller: In addition to the on/off switch function, furnish where indicated, a hand/auto switch or 3 position hand-off-auto switch mounted in the enclosure cover. 2. Magnetic Motor Controllers: Equip controllers with push buttons, or 3 position hand-off-auto selector switch, (to suit operation) mounted in the enclosure cover. a. For NEMA 3 enclosures furnish standard duty devices. b. For other NEMA enclosures furnish heavy duty devices to suit the requirements of the NEMA enclosure. G. Pilot Lights: 1. Manual Motor Controllers: Equip controllers with pilot lights (LED type) mounted in the enclosure cover. 2. Magnetic Motor Controllers: Equip controllers with pilot lights of the LED lamp type or transformer type, mounted in the enclosure cover. H. Space Heaters: Equip magnetic motor controllers which are installed outdoors and indoors in unheated locations, with space heaters and humidistat to prevent condensation within the housing. I. Overload Devices: Equip motor controllers with manual reset melting type (eutectic), or manual reset bi-metallic type standard trip overload devices (NEMA Class 20, trips in 20 seconds or less when carrying a current equal to 600 percent of its current rating). Exceptions: 1. Equip motor controllers with automatic reset overload devices only where indicated. 2. Equip motor controllers with fast trip overload devices when recommended by equipment manufacturer (NEMA Class 10, trips in 10 seconds or less when carrying a current equal to 600 percent of its current rating). Blue Lake Expansion Project – Contract No. 9 16221-6 General Construction May 2012 3. Equip motor controllers with slow trip overload devices when recommended by equipment manufacturer (NEMA Class 30, trips in 30 seconds or less when carrying a current equal to 600 percent of its current rating). 4. Equip motor controllers with ambient compensated overload protection where motor and relay are not in the same ambient. 5. Equip motor controllers with solid state overload relays where indicated. J. Manual Motor Controller Types: 1. Type A (Full Voltage, Non-Magnetic): Allen-Bradley Co.’s Bulletin 609, Cutler- Hammer Products’ File A/B300-9115, Furnas Electric Co.’s Class 11, General Electric Co.’s CR-1062, Square D Co.’s Class 2510, Type M, or Westinghouse Electric Corp.’s Type B100. 2. Type A1 (Full Voltage, Non-Magnetic Single Phase): Allen-Bradley Co.’s Bulletin 600, Cutler-Hammer Products’ File B200-9101, Furnas Electric Co.’s class 10, General Electric Co.’s CR-101, Square D Co.’s Class 2510, Type F, or Westinghouse Electric Corp.’s Type MS. 3. Bradley Co.’s Bulletin 609TS, Cutler-Hammer Products’ File A700, General Electric Co.’s CR-1062, or Square D Co.’s Class 2512, Type M. 4. Type A3 (2 Speed, 2 Winding, Full Voltage, Non-Magnetic, Single Phase): Allen-Bradley Co.’s Bulletin 600, Cutler-Hammer Products’ File B200-9106, General Electric Co.’s CR-101, or Square D Co.’s Class 2512, Type F. K. Magnetic Motor Controller Types: 1. Type B (Full Voltage Magnetic): Allen-Bradley Co.’s Bulletin 509, Cutler- Hammer Products’ File A10-9586, Furnas Electric Co.’s Class 14, General Electric Co.’s CR-306, Square D Co.’s Class 8536, or Westinghouse Electric Corp.’s Class A200. 2. Type B-COM (Combination Full Voltage, Magnetic/Safety Switch): Allen- Bradley Co.’s Bulletin 512, Cutler-Hammer Products’ File A30-9589, Furnas Electric Co.’s Class 17, General Electric Co.’s, CR-308, Square D Co.’s Class 8538, or Westinghouse Electric Corp.’s Class A203. 3. Type B2 (2 Speed, 2 Winding, Full Voltage, Magnetic): Allen-Bradley Co.’s Bulletin 530, Cutler-Hammer Products’ File A700, Furnas Electric Co.’s Class 30, General Electric Co.’s CR-309, Square D Co.’s Class 8810, or Westinghouse Electric Corp.’s Class A900. 4. Type C (Automatic, Reduced Voltage Autotransformer, Magnetic): Allen- Bradley Co.’s Bulletin 570, Cutler-Hammer Products’ File A400-9621, Furnas Electric Co.’s Class 36, General Electric Co.’s CR-331, Square D Co.’s, Class 8606, or Westinghouse Electric Corp.’s Class A600. 5. Type C-Com (Combination Automatic, Reduced Voltage Autotransformer, Magnetic/Safety Switch): Allen-Bradley Co.’s Bulletin 572, Cutler-Hammer Products’ File A400-9621, Furnas Electric Co.’s Class 37, Square D Co.’s Class 8606, or Westinghouse Electric Corp.’s Class A603. Blue Lake Expansion Project – Contract No. 9 16221-7 General Construction May 2012 6. Type D (Part Winding, Magnetic): Allen-Bradley Co.’s Bulletin 530, Cutler- Hammer Products’ File A460-9612, Furnas Electric Co.’s Class 36, General Electric Co.’s CR-330, Square D Co.’s Class 8640, or Westinghouse Electric Corp’s Class A700. L. Remote Control Stations: 1. Normal Duty in dry non-hazardous locations: Start-Stop with pilot light unless otherwise indicated, in NEMA 3 enclosure; Allen-Bradley Co.’s Bulletin 800S, Cutler-Hammer Products’ Bulletin 10250, Furnas Electric Co.’s Class 50, General Electric Co.’s CR-2943, Square D Co.’s Class 9001, or Westinghouse Electric Corp.’s Type PB1/PB2. 2. Heavy Duty: Start-Stop with pilot light unless otherwise indicated, in NEMA 4 or 12 enclosure to suit conditions; Allen-Bradley Co.’s Bulletin 800T, Cutler- Hammer Products’ 10250T, Furnas Electric Co.’s Class 52, General Electric Co.’s CR104P, Square D Co.’s Class 9001, or Westinghouse Electric Corp.’s Type PB1/PB2. 2.03 NAMEPLATES A. General: Precision engrave letters and numbers with uniform margins, character size minimum 3/16 inch high. 1. Phenolic: Two color laminated engraver’s stock, 1/16 inch minimum thickness, machine engraved to expose inner core color (white). 2. Aluminum: Standard aluminum alloy plate stock, minimum .032 inches thick, engraved areas enamel filled or background enamelled with natural aluminum engraved characters. 3. Materials for Outdoor Applications: As recommended by nameplate manufacturer to suit environmental conditions. PART 3 EXECUTION 3.01 INSTALLATION A. Install the Work of this Section in accordance with the manufacturer’s printed instructions. B. Nameplates: Identify each remote control station, indicating motor controlled. Identify each interlock switch, indicating purpose of switch: 1. NEMA 3 Enclosures: Rivet or bolt nameplate to the cover. 2. NEMA 12 Enclosures: Rivet or bolt and gasket nameplate to the cover. 3. NEMA 3R, 4, 4X, 7, or 9 Enclosures: Attach nameplates to the cover using adhesive specifically designed for the purpose, or mount nameplate on wall or other conspicuous location adjacent to switch. Do not penetrate enclosure with fasteners. 3.02 REMOTE CONTROL STATION SCHEDULE Blue Lake Expansion Project – Contract No. 9 16221-8 General Construction May 2012 A. Use normal duty remote control stations in dry non-hazardous locations. Use heavy duty NEMA 4 or 12 remote control stations in all other locations. 3.03 FIELD QUALITY CONTROL A. Preliminary System Test: 1. Preparation: Have the Company Field Advisor program and adjust the completed solid state and adjustable speed motor controllers and then operate them long enough to assure that they are performing properly. 2. Run a preliminary test for the purpose of: a. Determining whether motor controllers are in a suitable condition to conduct an acceptance test. b. Checking instruments and equipment. c. Training facility personnel. B. System Acceptance Test: 1. Preparation: Notify the Director’s Representative at least 3 working days prior to the test so arrangements can be made prior to the test to have a Facility Representative witness the test. 2. Submit written report of test results signed by the Company Field Advisor and the Director’s Representative. Mount a copy of the final report in a plexiglass enclosed frame assembly in a conspicuous location on or adjacent to each motor controller. 3.04 MOTOR CONTROLLER SCHEDULE A. Types of Motor Controllers Required For Single Speed Motors, unless indicated otherwise on Drawings: 1. 480 V, Three Phase, 3W , Premises Wiring System: a. Single Phase Motors Less than l/2 hp - Manually Operated: Type A or Type A1. b. Single Phase Motors Less Than 1/2 hp - Automatically Operated: Type B. Exception: Type A or Type A1 may be used when the automatic auxiliary controlling device (thermostat, pressure switch, etc.) is rated for the voltage and current requirements of the motor. c. Three Phase Squirrel Cage Motors Less than 15 hp - Manually or Automatically Operated: Type B-COM (B when indicated on Drawings) or Type SS. d. Three Phase Squirrel Cage Motors 15 hp and Larger - Manually or Automatically Operated: Type C-COM (C when indicated on Drawings) or Type SS. e. Three Phase Hermetically Sealed Compressor Motors Less than 15 hp - Automatically Operated: Type B or Type SS. Blue Lake Expansion Project – Contract No. 9 16221-9 General Construction May 2012 f. Three Phase Hermetically Sealed Compressor Motors 15 hp and Larger - Automatically Operated: Type D or Type SS. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16223 General Construction May 2012 SECTION 16223 LOW VOLTAGE STATION SERVICE SWITCHGEAR PART 1 GENERAL 1.01 WORK INCLUDED A. The Owner will furnish the following described switchgear to the Contractor for installation. B. The work herein described is to furnish a lineup of 277/480 volt switchgear for distribution of Station Service Power as shown in Drawing 109-45-107 and 109-45- 108. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 16414: Automatic Transfer Switch C. Drawing 109-45-107 Powerhouse 480 Volt Station Service Switchgear SSB1 & SSB2 One Line Diagram D. Drawing 109-45-108 Powerhouse 480 Volt Station Service Switchgear SSB1 & SSB2 Arrangement E. Reference Documents, Contract 2, Low Voltage Station Service Switchgear - Eaton 1.03 CODES AND STANDARDS A. The switchgear shall conform to the requirements of: 1. UL 1558/UL1066 2. ANSI C37.20.1, C37.13, C37.51 3. ANSI C37.20.7 4. CSA C22.2 No. 31-04 5. NFPA 70E 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Manufacturer’s information and catalog cuts. C. Control panel shop drawings. 1.05 ACCEPTABLE MANUFACTURERS Cutler-Hammer/Eaton Blue Lake Expansion Project – Contract No. 9 16223 General Construction May 2012 PART 2 PRODUCTS 2.01 PRODUCTS A. The Switchgear and its components will be Eaton/Cutler Hammer DS Magnum type, narrow front accessible configuration. B. Circuit Breakers: 1. DS Magnum Type MDN408 800 Amp frame 42,000 Amp Fault Clearing 2. Trip Unit - Digitrip 520M LSIG-4W 3. Operations Counter – Option OC 4. Motor Operated Charging 120 Vac 5. Shunt Trip 120 Vdc 6. Spring Release (close) 120 Vdc. 7. Auxiliary Switches 4A-4B 8. No Cell Position Aux. Sw. 9. Bell Alarm 2C C. Enclosure: The Switchgear will be supplied completely assembled in two sections, UL Type 1 enclosures, as shown on manufacturer’s submittal. D. Switchgear Options: 1. Breaker Lifter, switchgear mounted on top. 2. Maintenance Free Torque and Forget bus hardware. 3. Electronic Remote Control Device to allow operator to open and close the breaker at a distance. 3.01 TESTS AND CERTIFICATION A. The complete Switchgear shall be factory tested to ensure proper operation of the individual components. This will not include testing of the two SEL meters and the generator protection relay, except to demonstrate that they will power up. 3.02 SERVICE REPRESENTATION No factory representation is required on site. 3.03 INSTALLATION Blue Lake Expansion Project – Contract No. 9 16223 General Construction May 2012 The Switchgear will be installed by the General Contractor in accordance with the Manufacturer’s recommended practice and other sections of this specification. 3.04 SITE QUALITY CONTROL A. Preliminary Switch/System Test: 1. Preparation: Control power and bus power is provided. 2. Each circuit breaker will be tested by opening, closing in fully engaged position and in test position. Motor charging will be tested, shut trip, and spring release. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16232-1 General Construction May 2012 SECTION 16232 125V DC BATTERY AND CHARGING SYSTEM PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install the 125V DC system with batteries, battery rack, dual battery changers, disconnect switches, DC distribution panel board, and emergency eyewash station. The battery shall be a minimum size of 300 A-Hr. 1.02 RELATED SECTIONS A. Section 01300 – Submittals 1.03 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submit the shop drawings, product data, and quality control submittals specified below at the same time as a package. C. Shop Drawings: 1. Wiring and/or schematic diagram of the complete system as proposed to be installed. D. Product Data: 1. Catalog sheets, specifications and installation instructions. 2. Company's data indicating amp hour (AH) rating with proof that the system will meet the final system test. E. Contract Closeout Submittals: 1. Test Report: System acceptance test report. 2. Certificate: Affidavit, signed by the Company Field Advisor and notarized, certifying that the system meets the contract requirements and is operating properly. 3. Battery Manufacture Certified Date: Upon battery purchase, submit certified data from the battery manufacturer indicating date batteries were manufactured. 4. Operation and Maintenance Data: Deliver 2 copies, covering the installed products, to Owner. 1.04 QUALITY ASSURANCE A. Source Quality Control: The company producing the system shall have test facilities available which can demonstrate that the proposed system meet contract requirements. Blue Lake Expansion Project – Contract No. 9 16232-2 General Construction May 2012 PART 2 PRODUCTS 2.01 BATTERIES A. A lead selenium (60) cell battery system nominally rated at 125VDC shall be provided. The battery system shall be furnished with all required accessories and mounting hardware include inter-cell connectors, connecting bolts, end lugs, terminal connectors, flame arrester vent caps and hydrometer with holder. The battery system shall have a minimum useful life expectancy of 20 years. B. The battery rack shall be listed for Seismic Site Class E. A stainless steel or acid resistance polymer pan shall be installed underneath the battery rack to protect the floor surface from battery acid. C. Acceptable Manufacturers: 1. Alcad, Cell types ; SD, SHD 2. C&D Power, Cell types: JC, KAR 3. GBN Incorporated. Cell types: MAT, MAX 4. EnerSys, Cell type: CA 2.02 BATTERY CHARGERS A. Two battery changers will be provided. The changers will be installed as shown on the project drawings. B. Each battery charger shall be capable of recharging a fully depleted battery (from 1.67 volts per cell) to a full charge within 12 Hours, in addition to supplying the continuous DC load. The continuous load is anticipated to be 12.2 amperes. As a minimum, the charger shall be sized with an output of 37.5 amperes. C. The battery charger shall be a constant potential, silicon controlled rectifier type. The changer shall operate from a three phase, 208 V, 4 wire power source. The charger output shall be filtered so that is may be operated as a battery eliminator with the battery disconnected. AC ripple shall not exceed 30mV. D. The charger shall be provided with the following options: 1. Float/Equalize mode Switching 2. Surge Protection 3. Adjustable current-limiting 4. 0-72 hour equalize timer 5. Output ammeter and voltmeter with isolation fuses 6. Input and output thermal magnetic circuit breakers 7. AC input and DC output power failure alarm relays Blue Lake Expansion Project – Contract No. 9 16232-3 General Construction May 2012 8. DC high and low voltage alarm relays 9. DC battery discharging alarm relay 10. DC ground detection indication and alarm 11. DC battery low voltage alarm relay 12. DC changer common alarm relay with audible alarm Items 7 to 12 shall have auxiliary contacts, one normally open and one normally closed, wired to a common alarm terminal strip to facilitate connection to the owner’s SCADA system. E. Acceptable Manufacturers: Owner presently uses Exide EnerSys chargers model SCRF 130-3-XX-E at their existing plants. While this is the preferred charger, if not compatible with the cells provided, owner will consider chargers from: 1. La Marche Manufacturing Co. 2. Alcad Incorporated PART 3 EXECUTION 3.01 INSTALLATION A. Battery rack shall be mounted on a full-length dielectric rubber mat. Rubber mat shall extend a minimum of one foot beyond the front of the battery rack. B. A safety barrier shall be provided to prevent incidental contact with battery terminals. Barrier shall be non-conductive material and sized to prevent contact over the entire exposed battery area. Typical height is 36 inches. C. All connections shall be protected by an appropriate corrosion inhibitor. D. Rack shall be installed 6 inches minimum from wall. No equipment shall be mounted on the wall behind the battery. E. Aisle-way in front of battery rack shall be a minimum of 3’ for personnel use. F. The battery rack shall be grounded accordance with Standard C33.45 Grounding Battery Rack. G. The battery rack shall be connected to the station ground grid only once. This will prevent the battery rack from becoming a through path for ground fault current. H. Cable connections to the DC disconnecting device shall be a minimum of #2/0 copper 600V insulation welding type cable. Connections to the battery shall be made using tin plated connectors. The connectors must have a full load current carrying capability and rated for 600 Volts. I. The entire DC system shall be checked and tested per the Manufacturers’ instructions. Blue Lake Expansion Project – Contract No. 9 16232-4 General Construction May 2012 J. Chargers shall be wall mounted or installed on a raised floor stand, in a manner and elevation off the floor (minimum of 18”) such that maintenance and internal diagnostic work and repairs can be readily carried out. K. DC and AC disconnect switches shall be mounted in close proximity to the equipment they isolate, per NEC and applicable State Building Codes. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16233-1 General Construction May 2012 SECTION 16233 UNINTERRUPTIBLE POWER SUPPLY SYSTEM (DUAL INVERTERS AND STATIC TRANSFER SWITCH) PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install of an uninterruptable power supply system with dual inverters and static transfer switch as per drawing 109-45-109. B. The uninterruptible power supply shall provide continuous high quality regulated sine wave power to the generator air duct actuator, exhaust fan EF-4, protective relaying, SCADA, computers and HMI devices. Normal power supply to the inverters shall be from the AC station service, back up supply shall be from the station 125 VDC battery bank. C. There shall be two uninterruptable power supply systems, each energizing a static transfer switch. The static transfer switch provides power to the uninterruptable power distribution panel DP-3. Upon failure of one of the uninterruptable power supply systems, the transfer switch shall automatically switch the supply to the 120 VAC essential services panel to the second uninterruptable power supply system. 1.02 RELATED SECTIONS A. Section 01300: Submittals 1.03 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submit the shop drawings, product data, and quality control submittals specified below at the same time as a package. C. Shop Drawings: 1. Wiring and/or schematic diagram of the complete system as proposed to be installed (standard diagrams will not be accepted). D. Product Data: 1. Catalog sheets, specifications and installation instructions. 2. Company's data indicating volt-amp rating with proof that the unit will meet the final system test. E. Quality Control Submittals: 1. Provide certified factory acceptance test results. F. Contract Closeout Submittals: 1. Test Report: System acceptance test report. Blue Lake Expansion Project – Contract No. 9 16233-2 General Construction May 2012 2. Operation and Maintenance Data: Deliver 2 copies, covering the installed products, to the Owner’s Representative. PART 2 PRODUCTS 2.01 Uninterruptable Power Supply A. UPS Power Electronics 1. 5 kVA output minimum 2. Normal input- 120/240 VAC 3. Back up input- 125 VDC nominal input voltage 4. 120 volt, single phase, 60 Hz output voltage 5. AC load circuit breaker 6. Utility failure alarm (source on DC power) B. Static Transfer Switch 1. Automatically switch from one inverter source to the alternate upon inverter failure. 2. Provision for manual transfer between inverters while both powered. 3. Provide bumpless transfer between UPS systems 4. Facility to select either inverter as “lead” or “lag”. C. Uninterruptible Power AC Distribution Panel 1. Provide QOD type breakers as shown on the project drawings. PART 3 EXECUTION 3.01 INSTALLATION A. General: Install inverter complete and ready for service. B. Identification: 1. Stencil on front of unit or above with white paint in 1 inch high lettering "UNINTERRUPTIBLE POWER SUPPLY". 2. Label function of each branch circuit. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16272-1 General Construction May 2012 SECTION 16272 TRANSFORMERS – DRY TYPE, UNDER 600 V PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install dry type transformers with a voltage less than 600 V. 1.02 RELATED SECTIONS A. Section 01300: Submittals 1.03 REFERENCE STANDARDS A. Comply with the applicable requirements of NEMA, ANSI, and UL. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Product Data: Catalog sheets, specifications and installation instructions. C. Quality Control Submittals: 1. Transformers Rated 75KVA and Above: Submit certified report of the Company's routine commercial NEMA tests for each type transformer. Test report format shall be NEMA "Transformer Test Report for Dry-Type Transformers". D. Contract Closeout Submittals: 1. Operation and Maintenance Data. 1.05 DELIVERY, STORAGE AND HANDLING A. Storage of Transformers: Provide supplemental heating devices, such as incandescent lamps or low wattage heaters within the enclosure or under a protective covering to control dampness. Maintain this protection from the time equipment is delivered to the site until it is installed. PART 2 PRODUCTS 2.01 DRY TYPE TRANSFORMERS A. As produced by Square D, General Electric Co., Hevi-Duty Electric, Niagara Transformer Corp., Sorgel Electric Corp., or Westinghouse Electric Corp., having: 1. General purpose 2 winding insulating type construction. Blue Lake Expansion Project – Contract No. 9 16272-2 General Construction May 2012 2. Average winding temperature rise of 150 degrees C over 40 degrees C. Maximum ambient temperature with transformer utilizing a Class 220 insulation system. 3. Ventilated enclosure for transformers rated over 10 KVA. Enclosures for transformers rated 10KVA and under may be ventilated or non-ventilated. 4. Primary Taps: Capacity 3 to15KVA 2 of 5% FCBN, Capacity over 15 KVA 4 of 21/2% FCBN and 2 of 21/2% FCAN. 5. Mounting accessories. PART 3 EXECUTION 3.01 INSTALLATION A. Install dry type transformers As Shown. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16273-1 General Construction May 2012 SECTION 16273 TRANSFORMERS – OIL FILLED TYPE, OVER 600 V PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install Dam site, and Water treatment plant oil filled type transformers with a voltage greater than 600 V. B. Install oil filled type transformers with voltage greater than 600V. 1.02 RELATED SECTIONS A. Section 01300 – Submittals 1.03 REFERENCE STANDARDS A. Comply with the applicable requirements of NEMA and ANSI including: 1. ANSI/IEEE C57.12.00 Distribution, Power and Regulating Transformers General Requirements for Liquid-immersed. 2. ANSI/IEEE C57.12.10 Test Code for Liquid-immersed Distribution, Power and Regulating Transformers and Guide for Short-Circuit Testing of Distribution and Power Transformers. 3. ANSI/NFPA 70, National Electrical Code. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submittals Package: 1. For Transformers Rated 75 KVA and Below: Submit the product data and quality control submittals specified below at the same time as a package. 2. For Transformers Rated Over 75 KVA: Submit the product data, and quality control submittals preliminary data specified below at the same time as a package. C. Product Data: Catalog sheets, specifications and installation instructions. D. Quality Control Submittals: 1. Submit documentation that demonstrates transformers are suitable for installation outside, in a diluted salt spray marine type environment. 2. Transformers Rated 75 KVA and Below: Submit report of the Company’s routine commercial NEMA tests for each type transformer. 3. Transformers Rated over 75 KVA: Blue Lake Expansion Project – Contract No. 9 16273-2 General Construction May 2012 a. Preliminary Data: Submit certified report of the Company’s standard tests for each type transformer. Provide nameplate data. b. Final Approval: After approval of preliminary data and after construction of transformers, make routine commercial NEMA tests at the factory on the actual transformers and submit certified test reports. E. Operation and Maintenance Manuals 1.05 DELIVERY, STORAGE AND HANDLING A. Storage of Transformers: Provide supplemental heating devices, such as incandescent lamps or low wattage heaters with the enclosure or under a protective covering to control dampness. Maintain this protection from the time equipment is delivered to the site until it is installed. PART 2 PRODUCTS 2.01 OIL FILLED TYPE TRANSFORMERS A. Oil Filled Type Transformers 1. The transformers shall be of the low profile, dead front pad mounted design, supplied with a 304 stainless steel sill, doors, hardware of captive stainless steel penta head door locking bolts, anti-corrosion coating system such that they are suitable for installation outside, in a marine type environment. Note that occasionally, a dilute salt spray from the ocean may be present. 2. Self-cooled, (ONAN) ratings as indicated on the drawings. The cooling media shall be mineral oil. 3. Copper windings, primary and secondary winding configurations and voltages as indicated on drawings. Core shall be grain orientated low loss steel. High voltage compartment shall have provisions for a bayonet type expulsion fuse. The high voltage bushing shall be a well type suitable for a load break insert. , Secondary connections shall be threaded studs with a 6-hole silver plated spade, NEMA 9/16” diameter 1 ¾ spacing NEMA drilling pattern. 4. Impedance shall be manufacturer’s standard. Tank color shall be manufacturer’s standard. 5. Average self cooled winding temperature rise of 65 degrees C over 40 degrees C maximum ambient temperature at full rated output at lowest FCBN tap. 6. Minimum of two 2-1/2 percent FCAN and two 2-1/2 percent FCBN primary taps. Taps shall be adjustable from outside of the enclosure and a locking device provided on the tap changer switch. 7. Insulation Class Requirements- 15 kV class, 95 KV BIL 8. The transformers shall be complete with the following auxiliary equipment: a. Automatic pressure relief valve Blue Lake Expansion Project – Contract No. 9 16273-3 General Construction May 2012 b. Drain plugs c. Tank grounding provisions d. Ground strap form X0 to tank e. Oil level gage 9. The preferred supplier is ABB. PART 3 EXECUTION 3.01 INSTALLATION A. Install and connect oil filled type transformers As Shown. B. Test transformers in accordance with the NETA Testing Specifications, provide signed results of tests to RPR. C. Take oil samples, supply test results including moisture analysis, di-electric break down strength and acidity to RPR. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16275-1 General Construction May 2012 SECTION 16275 MAIN SUBSTATION TRANSFORMER INSTALLATION PART 1 GENERAL 1.01 WORK INCLUDED A. Install the following electrical equipment furnished by Owner for the Blue Lake powerhouse including startup, testing and commissioning and completion of Work such that the equipment can be utilized as intended: 1. Two 69 kV step-up transformers complete with auxiliary devices, each rated at 12/16 MVA OA/FA. B. The Work also includes: 1. Receipt of Owner furnished equipment at Point of Destination, including unloading. 2. Transport to storage, storage and transport of equipment to the location of installation. 3. Before transporting transformers, note reading on impact recorders. After placing transformers on pad, record reading on impact recorders, remove impact recorders and turn over to Owner. C. Owner furnished equipment may arrive at the Point of Destination in multiple shipments. D. Details of Owner furnished equipment are described in the Contract 5 specifications included in the reference documents. E. The contractor is cautioned that this work may be conducted in a live substation. During critical periods of the installation and testing work, as identified by Owner in consultation with contractor, liaison with owner for periodic shutdowns may be required. F. Contractor shall furnish: 1. All supplies, temporary equipment, tools, material and labor for transportation to site, placing on pad and other items necessary for the installing, aligning, assembly, oil filling, LV control and protection cable interconnections, site testing, commissioning and placing into service the Owner supplied Substation transformers and associated auxiliary equipment in accordance with the requirements of this specification and as shown on the drawings. The Owner will handle high voltage switching, make the high voltage jumper connections to the bushings, and will energize the transformer. The transformers may come with oil in the tank or oil shipped separately. Assume for bid purposes that the oil is shipped separately. The Owner has a filter press system that he would make available to the Contractor. Blue Lake Expansion Project – Contract No. 9 16275-2 General Construction May 2012 2. Necessary consumables such as wire markers, wire/cable connectors and terminals, stress cones, cable termination accessories, shims, welding rod, grout, rags, cleaning solutions and other consumables necessary for installing the Work and placing the Work into operation. 3. Touch-up paint shall be furnished by the transformer manufacturer G. The installation Work shall include provision of necessary standard tools and lifting slings, as required to accomplish the Work. Torque wrenches shall have been previously calibrated against a national standard before use. H. Contractor shall also furnish all test equipment as necessary for the installation, testing and commissioning Work, including oil conditioning and di-electric testing equipment. I. The Contractor shall provide the dry nitrogen to purge the transformers and leave the transformers with a full nitrogen tank at the end of the installation. The transformers will be provided with a nitrogen make up cabinet including valves, gauges, and pressure regulator. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 01550: Co-ordination with Owner Performed Work C. Section 09900: Painting D. Section 16020: Wiring 1.03 REFERENCE STANDARDS A. American National Standards Institute (ANSI)/IEEE 1. C57.12.00 - General Requirements for Liquid Immersed Distribution, Power, and Regulating Transformers 2. C57.12.90 - Test Code for Liquid Immersed Distribution, Power, and Regulating Transformers 3. C57.19.00 - Standard General Requirements and Test Procedure for Outdoor Power Apparatus Bushings 4. C57.98 - Guide for Transformer Impulse Tests 5. C57.106 - IEEE Guide for Acceptance and Maintenance of Insulating Oil in Equipment B. National Electrical Code (NFPA 70) C. National Electrical Manufacturers’ Association (NEMA) D. NETA (National Electrical Testing Association) Acceptance Testing Specifications for Electric Power Distribution Equipment and Systems Blue Lake Expansion Project – Contract No. 9 16275-3 General Construction May 2012 E. State of Alaska OSHA Standards 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submit the following: 1. Installation plan. The plan shall provide for continuous operation of the switchyard and existing powerhouse generation during installation of the first transformer followed by continuous operation of the new Blue Lake powerhouse during installation of the second transformer. 2. Report for each unit on installation, testing and commissioning. 1.05 INTERFACE POINTS WITH OWNER FURNISHED EQUIPMENT A. Interface points between Owner furnished equipment and Contractor furnished conduit wiring and cable and shall be as defined in Section 01550: 1. Contactor shall furnish all exposed conduit, control cable and wiring between Owner furnished transformer and owner furnished protection and control system as indicated on the drawings and cable schedules. 2. Owner will terminate all control and power cabling. 1.06 INSTALLATION PROCEDURES A. Installation and testing procedures for the Owner furnished transformers and switchgear will be provided by Owner. Contractor shall review the Owner firnished documentation. Intended deviations from these procedures must be brought to the attention of and accepted by RPR before the start of any testing. PART 2 PRODUCTS Not Used PART 3 EXECUTION 3.01 RESPONSIBILITY FOR INSTALLATION A. Owner, at its discretion, will have one or more equipment supplier’s Site Representatives at Site during specific periods of the installation and testing Work. The Site Representative(s) will provide technical advice on the installation and testing of the equipment. The requirement for Site Representative(s) will be reviewed with Contractor prior to start of the installation Work. B. Contractor shall have overall responsibility for satisfactory installation and testing of the Owner furnished equipment. Contractor shall immediately advise Owner in writing of any dispute or misunderstanding between Contractor and equipment supplier’s Site Representative. Blue Lake Expansion Project – Contract No. 9 16275-4 General Construction May 2012 3.02 EQUIPMENT INSTALLATION A. Contractor shall submit to RPR an overall installation and test plan for the W ork that supplements and augments Owner furnished installation and test procedures. Contractor’s plan shall identify key stages at which the Work should be inspected by RPR. B. When installation of Owner supplied equipment is complete, contractor shall remove all tools, debris, and other items from the work area. Touch up painting shall be in accordance with the Supplied Equipment recommendations. The work area around the switchyard shall be kept clean by contractor during installation and testing. 3.03 SITE TESTING A. Site tests shall be performed to demonstrate to the satisfaction of RPR that Owner furnished transformers are installed and operating in accordance with procedures and equipment supplier’s requirements. B. The tests shall be performed under the general direction of equipment supplier’s Site Representative(s) using Owner furnished testing and commissioning plan and procedures. Contractor shall be satisfied that each step of the tests is being conducted in a prudent and proper sequence and manner. Any defects related to equipment installation that become evident during the tests shall be immediately corrected and the tests continued until the Work is proved to be in working order to the satisfaction of RPR and the equipment supplier’s Site Representative. Any defects related to Owner furnished equipment design or manufacture will be corrected by the respective equipment supplier in accordance with Owner’s contract with the equipment supplier. Manufacturer’s Representative will be provided by the Owner under the Transformer Equipment Contract. C. Site tests shall include, but not be limited to: 1. Insulation tests with a megger, HV and LV windings in accordance with Manufacturer’s recommended test levels.. 2. Doble Test, also know as power factor test. 3. Turns ratio tests on all tap positions to verify that the tap switch has not been damaged 4. CT polaritytests. This can be done with turns around the CT, a dry cell battery, and a multimeter. 5. Continuity of wiring (ring out), megger testing, phasing of power conductors. 6. Take periodic oil samples during filling, note and record breakdown level, condition oil to acceptable levels during filling. 7. Take oil samples after initial operation of at least 48 hours- perform standard laboratory tests on condition of oil including moisture content, breakdown, color, acidity, presence of carbon, Furans, PCB content, metallic particles, etc. D. At the completion of the installation and testing Work, Contractor shall provide a complete report for each of the transformers and the switchgear package including Blue Lake Expansion Project – Contract No. 9 16275-5 General Construction May 2012 signed copies of all installation and testing measurements, records and documentation. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16335-1 General Construction May 2012 SECTION 16335 MEDIUM VOLTAGE SWITCHGEAR INSTALLATION PART 1 GENERAL 1.01 WORK INCLUDED A. Install the following electrical equipment furnished by Owner for the Blue Lake powerhouse including assembly, startup, testing and commissioning and completion of Work such that the equipment can be utilized as intended: 1. 12.47 kV switchgear As Shown. 2. Switchgear remote operations/test panel. B. The Work also includes: 1. Receipt of Owner furnished equipment at Point of Destination, including unloading. 2. Transport to storage, storage and transport of equipment to the location of installation. C. Owner furnished equipment may arrive at the Point of Destination in multiple shipments. D. Details of Owner furnished equipment are described in the Contract 2 specifications included in the reference documents. E. Contractor shall furnish: 1. All supplies, temporary equipment, tools, material and labor, for removal from storage and transportation to site, putting into place, incremental assembly of switchgear sections, and other items necessary for the installation, site testing, commissioning and placing into service the owner supplied switchgear and auxiliary equipment in accordance with the requirements of this Specification and As Shown on the drawings. 2. Necessary consumables such as wire markers, wire/cable connectors and terminals, stress cones, cable termination accessories, shims, welding rod, grout, rags, cleaning solutions and other consumables necessary for installing the Work and placing the Work into operation. 3. Touch-up paint will be applied by Contractor but paint will be furnished by the Switchgear manufacturer F. The installation Work shall include provision of necessary standard tools and lifting slings, as required to accomplish the Work. Torque wrenches shall have been previously calibrated against a national standard before use. G. Contractor shall also furnish all test equipment as necessary for the installation, testing and commissioning Work, including MV di-electric test set. Blue Lake Expansion Project – Contract No. 9 16335-2 General Construction May 2012 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 01550: Co-ordination with Owner Performed Work C. Section 09900: Painting D. Section 16020: Wiring E. Reference Documents: Square D Arc Flash Resistant Switchgear-Passive 1.03 REFERENCE STANDARDS A. American National Standards Institute (ANSI)/IEEE 1. C37.20.7 IEEE Guide for Testing of Metal Clad Switchgear Rated up to 38 kV for Internal Arcing Fault 2. C37.09 Standard Test Procedure for High Voltage AC Circuit Breakers B. National Electrical Code (NFPA 70) C. National Electrical Manufacturers’ Association (NEMA) D. NETA (National Electrical Testing Association) Acceptance Testing Specifications for Electric Power Distribution Equipment and Systems E. State of Alaska OSHA Standards 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submit the following: 1. Report for each unit on installation, testing and commissioning. 1.05 INTERFACE POINTS WITH OWNER FURNISHED EQUIPMENT A. Interface points between Owner furnished equipment and Contractor furnished conduit wiring and cable and shall be as follows: 1. Contractor shall furnish and install all exposed conduit, cable tray, cable and control wiring between the switchgear cubicles and the SCADA junction cubicle. 2. Owner will furnish wiring between the Owner furnished switchgear SCADA junction box and Owner furnished SCADA equipment. 1.06 INSTALLATION PROCEDURES A. Installation and testing procedures for the Owner furnished switchgear will be provided by Owner. Contractor shall review the Owner furnished documentation. Intended deviations from these procedures must be brought to the attention of and accepted by Owner before the start of any testing. Blue Lake Expansion Project – Contract No. 9 16335-3 General Construction May 2012 PART 2 PRODUCTS Square D Medium Voltage Arc Resistant Switchgear – Passive- See Reference Section. PART 3 EXECUTION 3.01 RESPONSIBILITY FOR INSTALLATION A. Owner, at its discretion, will have one or more equipment supplier’s Site Representatives at Site during specific periods of the installation and testing Work. The Site Representative(s) will provide technical advice on the installation and testing of the equipment. The requirement for Site Representative(s) will be reviewed with Contractor prior to start of the installation Work. B. Contractor shall have overall responsibility for satisfactory installation and testing of the Owner furnished equipment. Contractor shall immediately advise RPR in writing of any dispute or misunderstanding between Contractor and equipment supplier’s Site Representative. 3.02 EQUIPMENT INSTALLATION A. Contractor shall submit to RPR an overall installation and test plan for the W ork that supplements and augments Owner furnished installation and test procedures. Contractor’s plan shall identify key stages at which the Work should be inspected by RPR. B. When installation of Owner supplied equipment is complete, Contractor shall remove all tools, debris, and other items from the work area. Touch up painting shall be in accordance with the supplied equipment recommendations. Work are around the switchgear shall be kept clean by Contractor during installation and testing. 3.03 SITE TESTING A. Site tests shall be performed to demonstrate to the satisfaction of RPR that Owner furnished switchgear is installed and operating in accordance with procedures and equipment supplier’s requirements. B. The tests shall be performed under the general direction of equipment supplier’s Site Representative(s) using Owner furnished testing and commissioning plan and procedures. Contractor shall be satisfied that each step of the tests is being conducted in a prudent and proper sequence and manner. Any defects related to equipment installation that become evident during the tests shall be immediately corrected and the tests continued until the Work is proved to be in working order to the satisfaction of RPR and the equipment supplier’s Site Representative. Any defects related to Owner furnished equipment design or manufacture will be corrected by the respective equipment supplier in accordance with Owner’s contract with the equipment supplier. C. Site tests shall include, but not be limited to: Blue Lake Expansion Project – Contract No. 9 16335-4 General Construction May 2012 1. Megger Insulation testing of the switchgear live MV parts, 5 kV minimum (bus, breaker stabs, with breakers fully installed, but open before connection of MV cable) insulation level tests in accordance with manufacturer’s recommended . 2. Interconnection MV cable insulation megger tests, 5 kV minimum. 3. CT and VT polaritytests. 4. Phasing of power and instrumentation conductors, continuity of control wiring (ring out) and megger testing. 5. Setting and verification of settings on all protective relays, functional testing of all protective relay devices by current and voltage injection will be done by the RPR 6. Confirmation of all breaker closing and tripping circuits by activation through the remote operations/test panel will be done by the RPR. D. At the completion of the installation and testing Work, Contractor shall provide a complete report for the switchgear package including signed copies of all installation and testing measurements, records and documentation with the exeption of work done by the RPR. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16414-1 General Construction May 2012 SECTION 16414 AUTOMATIC TRANSFER SYSTEM PART 1 GENERAL 1.01 WORK INCLUDED The Automatic Transfer function is not a typical integrated automatic transfer switch, but rather a combination of an Owner Furnished PLC Based Control System combined with a standby generator package, and the Low Voltage Station Service Switchgear. The generator is furnished and installed by the Contractor. The Low Voltage Switchgear is furnished by the Owner and installed by the Contractor. The overall control system is furnished by the Owner and installed by the Owner. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 16622: Standby Generator C. Section 16223: Low Voltage Station Service Switchgear 1.03 CODES AND STANDARDS The Contractor is furnishing no equipment for this system outside of the two sections listed in 1.02, the Standby Generator. 1.04 SUBMITTALS The Contractor is furnishing no equipment for this system outside of the two sections listed in 1.02, so will provide submittals only for the Standby Generator. 1.05 ACCEPTABLE MANUFACTURERS See Standby Generator Section. 1.06 OPERATION A. Voltage and Frequency Sensing – This equipment is part of the Owner furnished Low Voltage Switchgear. 1. Voltage monitors will be provided within the Station Service Switchgear. Each 3 phase bus or feeder shall be monitored for rotation, high voltage and low voltage, with pickups adjustable. Such voltage sensing devices will be provided to monitor Bus 1, Bus 2, transformers feeding the main circuit breakers, and output of Standby Generator. 2. Frequency shall be monitored, high and low, on the Standby Generator Output. 3. Circuit Breaker positions will be monitored with breaker auxiliary contacts. Blue Lake Expansion Project – Contract No. 9 16414-2 General Construction May 2012 B. Time Delays: 1. A time delay shall be provided on transfer to emergency, adjustable from 0 to 5 minutes for controlled timing of transfer of loads to emergency. (PLC function) 2. A time delay shall be provided on retransfer to normal, adjustable from 0 to 30 minutes (PLC function). Time delay shall be automatically bypassed if emergency source fails and normal source is acceptable. 3. All time delays shall be incorporated into the PLC based hardware and software provided and installed by the Owner. PART 2 PRODUCTS 2.01 MECHANICALLY HELD CIRCUIT BREAKERS A. The circuit breakers used to affect all the transfer functions shall be electrically charged, mechanically held, tripped open and tripped closed with solenoids. B. These circuit breakers are all furnished within the Low Voltage Station Service Switchgear furnished by the Owner. 2.02 CONTROL PANEL A. The Owner furnished and installed control panel shall direct the operation of the transfer switch function as follows. a. Loss of proper power is detected on both buses and closed tie breaker is verified. b. Station Service transfer main breakers are tripped open. c. Electric space heat loads tripped open at proper subpanels. These must later be closed back in manually. d. Signal is sent to Emergency Generator to start and come to speed and excitation. e. When voltage sensor on Generator Breaker input verifies proper voltage and rotation, generator breaker is closed, energizing bus and connected loads. f. When either transformer input to main breaker is sensed to be good, the generator breaker is tripped open after a time delay. g. The main breaker first detected to have valid power is closed. h. Tie Breaker closure is verified, both buses are verified to be good. i. Power input from the other station service transformer is verified to be good. j. Second Main is closed. Blue Lake Expansion Project – Contract No. 9 16414-3 General Construction May 2012 k. Operator would manually close back in space heater circuit breakers at his convenience. PART 3 EXECUTION 3.01 INSTALLATION A. Install switch function components as outlined above. B. Control cable tray, and conduits have been provided within the Contractor’s responsibilities, but running and terminating the control wiring for the Transfer System will be the responsibility of the Owner. It is possible this work would be awarded to the Contractor as a Change Order. 3.02 SITE QUALITY CONTROL A. Switch/System Acceptance Test: 1. Make the following tests: a. Test each switch function step by step. This will be done by the Owner as he installs and tests the control system. b. The Contractor will be responsible to promptly repair any interfacing equipment which does not work properly. 2. Submit signed written report of test results. This will be done by the Owner’s Representative and Contractor, jointly. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16442-1 General Construction May 2012 SECTION 16442 PANELBOARDS PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install all panelboards As Shown. 1.02 RELATED SECTIONS A. Section 01300: Submittals 1.03 REFERENCES A. NEMA, UL50, UL67. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submittal Packages: Submit the shop drawings, and the product data specified below at the same time as a package. C. Shop Drawings; include the following for each panelboard: 1. Cabinet and gutter size. 2. Voltage and current rating. 3. Panelboard short circuit rating. 4. Circuit breaker enumeration (frame, ATE, poles, I.C.). 5. Accessories. D. Product Data: 1. Catalog sheets, specifications and installation instruction. 2. Bill of materials. E. Contract Closeout Submittals: 1. Operation and Maintenance Data. PART 2 PRODUCTS 2.01 PANELBOARDS A. 120/208 Volt AC Panelboards - As produced by Square D Co., type NQ with bolt in breakers type QOB. Blue Lake Expansion Project – Contract No. 9 16442-2 General Construction May 2012 B. 277/480 Volt AC Panelboards - As produced by Square D Co., type I Line with bolt in breakers type as appropriate, such as FA. C. 125 Volt DC Panelboards - As produced by Square D Co., type I Line with bolt in breakers type as appropriate for I Line and rated for DC. D. All Panelboards shall be furnished with the following features. 1. Flush or surface type cabinets, NEMA 3 R or 4X As Shown. 2. Increased gutter space for gutter taps, sub-feed wiring, through-feed wiring, oversize lugs. 3. UL label "SUITABLE FOR USE AS SERVICE EQUIPMENT" where used as service equipment. 4. Door and one piece trim. Door fastened to trim with butt or piano hinges. Trim fastened to cabinet with devices having provision for trim adjustment. 5. Solid copper bus bars. Ampere rating of bus bars not less than frame size of main circuit breaker. 6. Full capacity copper neutral bus in panelboards where neutrals are required. 7. Copper equipment grounding bus in panelboards where equipment grounding conductors are required. 8. Sections designated "space" or "provision for future breaker" equipped to accept future circuit breakers. 9. Lock on devices for exit light, fire alarm and other circuits as indicated on the drawings. 10. Handle padlock devices for locking-out circuits as indicated on the drawings. 11. Directory. 12. Short circuit rating not less than indicated on panelboard schedule. 13. Molded case, bolt-on circuit breakers: a. Mounting: Individually mounted main circuit breaker (when MCB is required), and group mounted branch/feeder circuit breakers to accommodate the circuit breaker style and panelboard construction. b. Single pole 15 ATE and 20 ATE circuit breakers marked SWD where used as switches. c. Single pole and two pole 15 and 20 ATE circuit breakers rated for high intensity discharge lighting loads when applicable. 2.02 NAMEPLATES A. General: Precision engrave letters and numbers with uniform margins, character size minimum 3/16 inch high. Blue Lake Expansion Project – Contract No. 9 16442-3 General Construction May 2012 1. Phenolic: Two color laminated engravers stock, 1/16 inch minimum thickness, machine engraved to expose inner core color (white). PART 3 EXECUTION 3.01 INSTALLATION A. Install panelboards in accordance with NEMA Publication No. PB1.1 "General Instructions for Proper Installation, Operation and Maintenance of Panelboards Rated 600 Volts or Less". B. Directory: Indicate on typewritten directory the equipment controlled by each circuit breaker, and size of feeder servicing panelboard. For power panelboards also include ATE rating and feeder size for each breaker. C. Identification: 1. Use nameplates, "LP-l, PP-l, etc." in 1/2 inch lettering corresponding to panelboard designations on the drawings, and electrical parameters (phase, wire, voltage). END OF SECTION Blue Lake Expansion Project – Contract No. 9 16450-1 General Construction May 2012 SECTION 16450 GROUNDING PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install embedded and exposed parts of the grounding systems As Shown. Included are test stations, ground rods, fittings, cables, connectors, and all material, equipment, and accessories required to complete the grounding in accordance with the design. PART 2 PRODUCTS 2.01 MATERIALS A. Ground cable shall be annealed, concentric stranded, bare copper cable of required size and in accordance with ASTM B8. B. Above-grade ground connectors shall be high copper alloy as manufactured by Burndy or AMP. Bolted compression type connectors may be used for ground cables No. 4 AWG and larger, crimp connectors are acceptable for smaller size ground cables only. Exothermic connectors such as Cadweld may be used for connections to flat steel surfaces. C. Below-grade grounding cable connections shall be made by exothermic or compression-type ground connectors made for the purpose. Compression-type cable connectors shall be the U-shaped barrel type, compressed by precision dies to form a wrap-around connector. Tooling shall be made by the same manufacturer as the connectors. Connectors shall be AMPOWER ground grid connectors manufactured by Amp Special Industries, TELEDYNE PENN-UNION, or equal. D. Ground rods shall be copper-clad steel, 3/4-in. in diameter and not less than 8 ft long, ITT-Blackburn, or equal. PART 3 EXECUTION 3.01 INSTALLATION A. All exposed grounding connections between ground conductors and from ground conductors to equipment shall be made by bolted-type connectors of an approved type as per grounding layout drawings. No solder shall be used in any part of the ground circuit. B. Contractor shall provide a ground system for the powerhouse which will provide a maximum ground potential rise (GPR) in accordance with local state requirements. The maximum measured ground resistance shall not more than 1.0 ohms. Contractor shall perform ground resistance tests and shall submit the results to Owner prior to the start-up date. Blue Lake Expansion Project – Contract No. 9 16450-2 General Construction May 2012 C. All electrical equipment enclosures and equipment and all metallic parts of the installation, including structures, pipes, conduits, cable trays, wireways, air ducts, frames, handrails, ladders, platforms, water and air liners, and metalwork, shall be grounded and connected to the nearest ground cable. D. The electrical continuity of cable trays, wireways, pipes, air ducts, rails, enclosures, and handrails shall be maintained by bonding. Bonding of electrical raceway and enclosures shall ensure electrical continuity and the capacity to conduct safely any fault current that could be imposed. Bonding shall comply fully with Article 250 of the NEC. E. Grounding connections shall be made as specified herein. Paint, scale, rust, corrosion, or other foreign matter shall be removed from the points of contact on metal surfaces before ground connections are made. F. Embedded ground cables and fittings shall be securely attached to concrete reinforcing steel with tie wires to prevent displacement during concrete placement. Precautions shall be taken to ensure that no damage is done to grounding conductors or connections during backfilling, compacting, or concreting operations. The Work shall be arranged in such a manner that each part of the grounding system that is laid below finished grade shall be completed and inspected before backfilling is done. G. All grounding conductors that are to be extended beyond the concrete surface shall have a free pigtail of sufficient length to reach the point where they are to be connected without splicing. Minimum extension shall be 5 ft. Grounding conductors that project from a concrete surface where they may be subject to mechanical damage shall be protected by being located as close as possible to a corner; otherwise they shall be protected by a section of conduit or terminated in a flush grounding plate. Exposed grounding conductors shall be supported on surfaces of the building and on equipment with non-corrosive hardware, such as Everdur or equal, at not more than 4-ft intervals. Ground bus risers shall be visible for inspection whenever practicable. H. Ground tap connections to equipment shall be made at the points provided on the equipment for grounding, in accordance with the equipment manufacturer's recommendations. Connections from ground conductors to the ground buses of switchgear, switchboards, motor control centers, and other cabinet-mounted equipment shall be made by means of an acceptable bolted fitting. I. All electrical power apparatus shall be provided with a ground-fault-current return path. Motors and power receptacles shall utilize a grounded, identified fourth grounding conductor in the feeder or branch circuit raceway that connects the motor frame or receptacle to the motor control ground bus. Metallic conduits shall not be utilized to ground lighting circuits and fixtures. A separate grounding conductor shall be provided to ground lighting circuits and fixtures. J. The grounding conductor shall in no case be a system neutral or a current-carrying conductor. Where a circuit consists of two or more power conductors in a conduit or wiring channel, the grounding conductor may be one standard wire size smaller than the power conductor, but in no case smaller than No. 14 nor larger than No. 4/0, and shall be stranded and covered by green insulation. In all cases, the white insulated wire shall be used for the current-carrying neutral only. K. The ground end of each surge arrestor shall be connected to the station ground. Blue Lake Expansion Project – Contract No. 9 16450-3 General Construction May 2012 L. Metallic sheaths or shields of shielded cable or power and control cable shall be terminated by a copper grounding strip provided with a connector for connection to the station ground. The manufacturer of the cable shall furnish instructions for ground termination of shielded cable. Cable shields shall be grounded at one end only. M. Communication and instrumentation cable with special requirements for shield or conductor grounding shall be grounded strictly in accordance with the manufacturer's instructions. N. Generally the ground cable inside the powerhouse shall be installed within the concrete wherever feasible, embedded approximately 2 in. below the finished surfaces. Where circumstances make embedment of the grounding conductor impractical, it may be installed upon the surfaces. 3.02 TESTS A. All ground resistance test measurements shall be made using the "Fall- of-Potential" or "Three-Terminal" test method described in James Biddle Bulletin 25T. Ground resistance shall not exceed the values specified in 3.01B. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16480-1 General Construction May 2012 SECTION 16480 RAW WATER PUMP ELECTRICAL SYSTEM PART 1 GENERAL 1.01 WORK INCLUDED A. Install the Owner furnished electrical power and control system for two duplex pump/motor sets for the raw water pumps. The duplex pump sets shall provide the following services: 1. Industrial water supply: these two pumps (Pumps P-3A and P-3B) will provide raw water to the existing industrial water supply system. These pumps will serve as the primary source and will operate the two pump motors with variable frequency drive (VFD) controls to maintain a user definable pressure set point. 2. Potable water supply: these two pumps (Pumps P-4A and P-4B) will provide raw water to the City’s water treatment facility as a backup. These pumps will operate using the City’s water treatment facility pressure control valve and pressure switch to maintain a pressure set point. B. Furnish and Install all equipment required to form complete, functional systems including conduit, cable, junction boxes, cable tray, supports, fasteners, consumables, etc. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 15700: Instrumentation C. Section 15132: Vertical Turbine Pumps 1.03 DESIGN AND PERFORMANCE REQUIREMENTS A. Note this section is provided for information purposes only. The equipment described will be provided by the Owner. B. Industrial water supply (“NSRAA”) pumps shall be designed to operate continuously providing flows from 600 GPM to 4600 GPM to a local hatchery. Operation of the pumps shall be to maintain a user definable pressure set point. Pumps shall be operated using VFD to provide a high efficiency operation. Pumps shall be controlled as follows: 1. Utilize VFDs to vary pump speed to supply water over a range from 600 GPM to 4600 GPM. 2. Provide a pressure transducer and pressure switch to monitor pressure downstream of the pumps discharge. Pressure switch shall be set up for backup operation in the event of transducer failure. C. Potable water supply pump system shall be designed only to occasionally operate as a backup for the City. The pumps shall utilize the water treatment facility Blue Lake Expansion Project – Contract No. 9 16480-2 General Construction May 2012 pressure control valves and control system to regulate the pressure. Control system will operate as follows: 1. The water treatment facility control system will start and stop pumps to provide flow over the range of the pumps (2 to 5 MDG) (1,400-3,500 GPM). 2. The City’s water treatment facility control system will monitor pressure and provide start/stop commands to the pump starters in automatic mode. PART 2 PRODUCTS Note that this section is provided for information purposes only. The equipment described will be provided by the owner. 2.01 MOTOR CONTROL CENTER A. An integrated motor control center complete with circuit breakers, variable speed drives, soft starters, line reactors and sine wave filters, current and potential transformers, metering sockets, PLC controller and all associated auxiliaries shall be installed. B. The motor control center shall contain moulded case, manually operated circuit breakers mounted in draw out wrappers, with frame sizes and trip ratings as indicated on the drawings. The breakers shall be in the top compartment of each associated drive/soft start vertical section. C. The variable speed drives/soft starters and associated filter equipment shall be installed in vertical sections of the MCC. 2.02 LOCAL CONTROL PANELS A. Pump local control panels shall be designed for bolting to concrete pad or wall- mounting. B. Each control panel shall include internal space heaters and thermostat. 2.03 VARIABLE FREQUENCY DRIVE A. Variable frequency drives (VFDs) shall be suitable for the requirement of operating pump/motor over its range of allowable speeds and for the pump and motor’s characteristics. B. Each VFD shall have a manual bypass switch to allow pump to run if the controller becomes disabled. C. Line Conditioner and Filter: Line and EMC line filers suitable for each VFD as recommended by the VFD manufacturer. 2.04 SINE WAVE FILTER A. Sine wave filter shall be a passive L-R-C low-pass filter designed for removing carrier frequency distortions from output voltage waveform. The filter shall be connected in series with the motor leads and shall be compatible with the VFD specified above. The filter shall be designed to reduce the effects of reflected wave phenomenon in the motor leads and stray high frequency audible noises. Blue Lake Expansion Project – Contract No. 9 16480-3 General Construction May 2012 2.05 SOFT STARTER (supplied by Owner) A. Soft starters shall be microprocessor-based and in modular construction for ease of maintenance. Soft starters shall be suitable for operation of squirrel-cage motors and have programmable parameters. 2.06 PROGRAMMABLE LOGIC CONTROLLER (PLC) (supplied by Owner) A. PLCs shall be provided to control industrial pumps, interface with VFDs, and allow means for the user to enter control setpoint. 2.07 MISCELLANEOUS CONTROL DEVICES A. Contractor shall provide all instrumentation to be mounted on piping and control valves, including: 1. Pressure switches for operation and control of the potable water system. 2. Limit switch requirements for pressure regulating valve for the potable water system. 3. Control valve requirements for the potable water system pumps. 4. Pressure transducer and switches for the control and monitoring of industrial water supply pumps. PART 3 EXECUTION 3.01 INSTALLATION AND TESTING A. Install equipment as directed by Supplier’s representative. Furnish and install all equipment such as conduit, cables, consumables required to complete the installation of the Owner furnished equipment to form a functional system. B. Test equipment as outlined in other sections of this document and as directed by Supplier’s representative. Tests shall include, but not be limited to: 1. Megger of all power wiring external to the Owner supplied equipment 2. Continuity test of wiring to external devices. 3. Verify appropriately rated fuses and overloads are installed. 4. Insulation tests of motors. 5. “Bump” test of motors to confirm direction of rotation. 6. Functional testing of all external devices. 7. Provide assistance with adjustment and commissioning of Owner supplied equipment as directed by the Supplier’s representative. C. Submit three copies of field test report. Blue Lake Expansion Project – Contract No. 9 16480-4 General Construction May 2012 END OF SECTION Blue Lake Expansion Project – Contract No. 9 16500-1 General Construction May 2012 SECTION 16500 LIGHTING AND RECEPTACLES PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install lighting fixtures and equipment for the complete indoor and outdoor lighting and receptacle system. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 16111: Embedded Conduit C. Section 16120: Wire and Cable D. Section 16134: Outlet Junction and Pull Boxes E. Section 16450: Grounding 1.03 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Manufacturer’s information and catalog cuts. 1.04 DESCRIPTION A. Fixtures shall be as shown on drawings and as specified below. B. The power plant lighting system shall operate from a 208Y\120-V, three-phase, 4-wire, 60-Hertz system, except high bay lighting. It shall be 480 volt, 3 phase, 3 wire controlled via the 2TS contactor. Metal halide luminaires shall be installed for general inside lighting above the operating floor of the main powerhouse floor. Fluorescent lighting fixtures shall be installed in office areas and control rooms. Metal halide luminaires, complete with ballasts, photocells, and lighting poles, shall be installed outdoors. Metal halide outdoor street lighting shall be furnished where shown. In conjunction with the 208Y\120-V lighting system, 120-V receptacle outlets shall be installed throughout the powerhouse. C. The emergency lighting for the powerhouse shall be from fixtures with self- contained batteries and a charger to provide illumination for up to 1.5 hours. D. Lighting power shall be derived from the ac switchboard, with lighting panels energized from the station service transformer. E. Fixtures, outlets, receptacles, switches, and all other applicable lighting system components and details shall be as specified. Contractor shall supply all lighting fixtures, outlets, boxes, raceways, and other applicable details as required. F. Lighting levels shall be As Shown. Blue Lake Expansion Project – Contract No. 9 16500-2 General Construction May 2012 PART 2 PRODUCTS 2.01 MATERIALS A. Lighting Fixtures: Lighting fixtures (luminaires) shall be complete with photoelectric controls (where required), ballasts (where required), mounting brackets and hardware, lamps, fixture wire, and all required accessories as specified in the Fixture Schedule and as required by the NEC. B. Ballasts: Ballasts for fluorescent fixtures shall be CBM certified, high power factor (90 percent or better) and shall be Class P thermally protected. Lighting fixtures shall be designed to keep the operating temperature as low as possible, and the maximum temperature of the hot spot on the ballast case shall not exceed 90ºC during normal operation. Ballasts shall be designed for Rapid-Start lamps. Metal halide lamp ballasts shall be the voltage stabilized or lead type, HPF. Outdoor ballasts shall be suitable for use at -10ºC ambient temperature C. Refractors and Reflectors: All glassware and plastic shall be uniform, free from defects, and photometrically tested for distribution by an independent testing laboratory. Plastic diffusers shall be of new virgin acrylic plastic material. D. Lamps: Lamps shall be supplied by Contractor in accordance with the design requirements. E. Conduit: Conduit, including hangers and fittings, shall be as described in these Specifications. F. Receptacles and Switches: Receptacles and switches shall be as follows: 1. 120-V, single-phase, 20-ampere duplex receptacles shall be Hubbell 5362, or approved equal. Color shall be ivory. 2. 120-V, single-phase, 20-ampere GFCI duplex receptacles shall be Hubbell GF53521A or approved equal. Color shall be ivory. 3. 120-V, single-pole switches shall be rated 20 amperes, Hubbell 1221, or approved equal. Color shall be ivory. 4. 120-V, single-pole, three-way switches shall be rated 20 amperes, Hubbell 1223, or approved equal. Color shall be ivory. 5. 120-V wiring device plates shall be Hubbell Type 302 stainless steel, satin finish, with a minimum thickness of 0.04-in. for use with steel or cast iron boxes. Receptacles exposed to weather shall be provided with spring loaded, gasketed lift covers. 6. Receptacles and switches installed in a powerhouse “wet location” as outlined in section 16134 or out of doors shall be weatherproof as required. G. Fixture Wire: Fixture wire for fluorescent and incandescent fixtures shall be single-conductor, solid copper, No.12 AWG; shall have a heat-resistant silicone Blue Lake Expansion Project – Contract No. 9 16500-3 General Construction May 2012 insulation for 300 V; and shall conform to the US National Electric Code for Type SF-2 insulation. H. Power Outlets: The 480-V ac, three-phase power receptacle outlets shall be rated 60 amperes. Each outlet assembly shall consist of a three-wire, four-pole circuit breaker receptacle, aluminum enclosure, angle adapter, and threaded captive cap. Each power outlet shall be furnished with a matching plug of proper size for the cable sizes dictated by the design. 2.02 FIXTURE TYPES A. Fixture types shall be As Shown. PART 3 EXECUTION 3.01 INSTALLATION A. Contractor shall install all lighting fixtures, lamps, and associated supports, fittings, panelboards, switches, control devices, conduit, boxes, wiring, and grounding conductors As Shown as described in this Specifications, in accordance with the manufacturer's instructions and recommendations. B. Contractor shall thoroughly clean the fixtures, lamps, and accessories and shall replace all lamps that were used for a period equivalent to 50 percent or more of their rated life. C. All fixtures shall be aligned and directed as shown or so as to illuminate the desired area properly. Fixtures shall be directly and rigidly mounted on their supporting structures. The conduit system shall not be used to support fixtures. Where brackets or supports for lighting fixtures are welded to steel members, the welded area shall be treated with rust-resistant primer and finish paint. D. Light switches and boxes shall be surface mounted, unless otherwise specified. E. All lighting fixtures shall be directly grounded to the equipment grounding system by means of a conductor of a size not less than that required by the National Electrical Code. If insulated, the ground conductor insulation shall be colored green. F. Photoelectric controls shall be furnished to automatically turn on outdoor lighting fixtures As Shown. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16622-1 General Construction May 2012 SECTION 16622 STANDBY DIESEL-GENERATOR PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install one standby diesel-generator system. The system is required to provide a source of emergency and standby power for the essential services at the powerhouse. B. The intent is to procure a standard engine generator package, with no unusual or special requirements. If any of the specification seems contrary to this intent, the contractor should ask the RPR for clarification. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 16414: Automatic Standby Generator Transfer Function C. Section 15500: Ancillary Equipment 1.03 SYSTEM DESCRIPTION A. The system shall be a packaged, self contained, engine generator unit in a high quality enclosure suitable for installation outside, in a mild marine, coastal environment. The system shall consist of the following items and components integrated into the package: 1. Engine-generator 2. Generator Circuit Breaker 3. Engine/Generator Control Module containing voltage and current metering, engine temperature and oil level monitoring, protective circuits to shut down engine generator and/or trip generator circuit breaker, voltage regulator. 4. Exhaust silencer, piping, and fittings, complete. 5. Fuel fittings and day tank in the base. 6. Containment for fuel, coolant, and engine oil. 7. Battery and charger. B. Engine generator system will provide source of emergency and standby power. The nominal voltage and frequency is 480 volts, 60 Hz three phase grounded wye configuration. C. System Capacity: 250 kW minimum continuous rating at elevation of approximately 30 feet above sea level, and ambient temperature between 10οF and 90οF [-12οC Blue Lake Expansion Project – Contract No. 9 16622-2 General Construction May 2012 and 32οC; continuous rating using engine-mounted radiator. Set is to have a standby rating of 300 kW minimum. 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Provide documentation indicating that the packaged unit is suitable, meeting all requirements of Section 1.03. C. All components of the standby diesel-generator power supply system shall be indicated on shop drawings. D. Include instructions for normal operation, routine maintenance requirements, service manuals for engine and day tank, oil sampling and analysis for engine wear, and emergency maintenance procedures. 1.05 DELIVERY, STORAGE AND HANDLING A. Deliver products to site under provisions of Division 1, Section 01600. B. Store and protect products under provisions of Division 1, Section 01600. C. Accept packaged engine-generator set and accessories on Site, inspect. Verify any damage noted, and document any new damage. D. Protect equipment from dirt and moisture by securely wrapping in heavy plastic, if required, in addition to shipping packaging. 1.06 WARRANTY A. Provide two-year warranty. 1.07 MAINTENANCE SERVICE A. Provide contact information of the nearest representative capable of advising service and maintenance of engine-generator system. 1.08 ADDITIONAL MATERIALS AND SPARE PARTS A. Furnish one set of tools required for preventative maintenance of engine-generator system. Package tools in adequately sized, high quality, metal tool box. B. Provide two additional sets of fuel, oil and air filter elements required for engine- generator system. C. Provide one complete spare set of all belts. D. Two complete set of spare fuses, and two sets of indicating lamps. 1.09 MANUFACTURERS: A. Caterpillar, Cummins, Onsite Energy Blue Lake Expansion Project – Contract No. 9 16622-3 General Construction May 2012 PART 2 PRODUCTS 2.01 General: Three engine generator packages have been determined acceptable for the Project as listed below. Consideration primarily centered around service availability and quality of equipment. This is a highly competitive market and we find that prices are very close. It is expected the Contractor will choose one of the packages specified below. No other packages will be approved. Specifications and sales information is included in the bid reference materials. These materials do not exactly define what is required. Many items are shown in the “quotations” for consideration but are not required by this specification. For instance, no emergency transfer switch is required since this function is handled within the plant. The pricing shown was for rough estimate and should not be used by the bidder. 2.02 Caterpillar – NC Machinery Engine Generator Set - Caterpillar C9 480V 60 HZ PKG GEN SET Control Panel – EMCP 4.2 Controls Standard Options: 300 EKW w/Engine Driven Fan 500 Amp min UL 3 Pole 100% Circuit Breaker with 24 vdc shunt trip. IDW Fuel Tank BS-400 Gal - double wall containment, acts as gen set base. Coolant Level Sensor Fuel Rupture Basin Alarm Permanent Magnet Excitation 24 Volt Battery Set Dry 950 CCA Battery Charger 10 Amp Manual Sump Pump for containment Neutral Grounding Connection Turret Group Addition 800 Amp (for breaker) Non Standard Options: Block Heater, freeze plug type, 500 watts @ 120 Vac, with thermostat. Overall Packaging – this shall be in reasonable conformance to Caterpillar Drawing # 080545-GD1 pages 1 through 7, dated 11-17-08. Sales Contact Information: Steve Rude Anchorage NC Machinery 800-478-7000 Email: SGRude@NCPowerSystems.com 2.03 Cummins – Cummins Northwest Engine Generator Set – C300 DQHAB 480V 60 HZ PKG GEN SET Control Panel – PCC 2100 Controls Standard Options: Blue Lake Expansion Project – Contract No. 9 16622-4 General Construction May 2012 300 EKW w/Engine Driven Fan- 270 EKW prime 500 Amp min UL 3 Pole 100% Circuit Breaker with 24 vdc shunt trip. IDW Fuel Tank BS-400 Gal - double wall containment, acts as gen set base. Coolant Level Sensor Fuel Rupture Basin Alarm Permanent Magnet Excitation 24 Volt Battery Set Dry 950 CCA Battery Charger 10 Amp Manual Sump Pump for containment Neutral Grounding Connection Turret Group Addition 800 Amp (for breaker) Non Standard Options: Block Heater, freeze plug type, 500 watts @ 120 Vac, with thermostat. Overall Packaging – this shall be in reasonable conformance to Cummins weather protective enclosure with integral fuel storage tanks and containment as described in Cummins Brochure “Enclosures and Tanks 250-1000kW gensets” dated 2009. Fuel tank capacity shall be 400 gallons. Sales Contact Information: Brant Smith Phone: 907-748-3601 Fax: 907-276-6340 Email: brant.c.smith@cummins.com 2.04 On Site Energy – On Site Energy Engine Generator Set – OnSite DS300D6SRA C9 480V 60 HZ PKG GEN SET Control Panel – DGC2020 Control Standard Options: 300 EKW w/Engine Driven Fan 500 Amp min UL 3 Pole 100% Circuit Breaker with 24 vdc shunt trip. IDW Fuel Tank BS-400 Gal - double wall containment, acts as gen set base. Coolant Level Sensor Fuel Rupture Basin Alarm Permanent Magnet Excitation 24 Volt Battery Set Dry 950 CCA Battery Charger 10 Amp Manual Sump Pump for containment Neutral Grounding Connection Fuel Tank shall be “24” hr rated 525 gallon. Non Standard Options: Block Heater, freeze plug type, 500 watts @ 120 Vac, with thermostat. Overall Packaging – this shall be in reasonable conformance to On Site Drawing # XZ57200000051 pages 1 through 5, dated 08-31-2011. Sales Contact Information: Blue Lake Expansion Project – Contract No. 9 16622-5 General Construction May 2012 Bob Bruner Pacific Power Products/Power System Sales Direct Phone 503-649-1573 Cell Phone 503-308-0063 Fax 503-308-0063 Email: bbruner@pac-power.com 2.05 ENGINE A. Type: Water-cooled, four cycle, compression ignition diesel, internal combustion engine. B. Rating: Sufficient to operate at 10% overload for one hour at specified elevation and ambient limits. C. Fuel System: Appropriate for use of No. 2 fuel oil. D. Engine Speed: 1,800 rpm. E. Governor: Isochronous type to maintain engine speed within 0.5%, steady state, and 3%, no load to full load, with recovery to steady state within two seconds following sudden load changes. Equip governor with means for manual operation and adjustment. F. Safety Devices: Engine shutdown on high water temperature, low oil pressure, over speed and engine over crank. G. Engine Jacket Heater: Freeze plug type heater, 500 watts, thermostatically controlled. H. Radiator: Radiator using inhibited glycol coolant, with engine drive fan, sized to maintain safe engine temperature in ambient temperature of 90οF (32οC). I. Engine Accessories: Fuel filter, lube oil filter, intake air filter, lube oil cooler, fuel primary pump, gear-driven water pump. Include water temperature gage and lube oil pressure gage on engine-generator control panel. J. Mounting: Provide unit with suitable spring-type vibration isolators and mount on structural steel base, integral with enclosure. K. Entire assembly should be seismic rated for Horizontal Acceleration of 0.379 G and Vertical Acceleration of 0.259 G 2.06 GENERATOR A. Generator: ANSI/NEMA MG 1; three phase, six pole, grounded-star synchronous generator with brushless excitation. B. Rating: As required at 0.8 power factor, 480 volts, 60 Hz. C. Insulation: ANSI/NEMA MG 1, Class F. D. Temperature Rise: 105°C continuous, 130°C standby. Blue Lake Expansion Project – Contract No. 9 16622-6 General Construction May 2012 E. Enclosure: suitable for use in an outdoor marine environment. F. Voltage Regulation: Include generator-mounted volts per Hertz exciter-regulator to match engine and generator characteristics, with voltage regulation ±1% from no load to full load. Include manual controls to adjust voltage level to ±5%. 2.07 ACCESSORIES A. Fuel Tank: The fuel tank shall have a capacity of at least 300 USG, sized to operate the unit at full load for 24 hours. The tank shall be of double wall spill containment type. Include flexible fuel line connections, fuel gage, check valve, high and low fuel level alarm contact, and indicating light. B. Exhaust Silencer: The silencer shall be incorporated into the overall enclosure. The Silencer shall be Residential grade if available. C. Battery: Heavy duty, diesel starting type lead-acid storage battery. Match battery voltage and amp hour capacity to starting system. Include necessary cables and clamps. D. Battery Tray: Plastic coated metal or wooden tray treated for electrolyte resistance, constructed to contain spillage of electrolyte. E. Battery Charger: Current limiting type designed to float at 2.17 volts per cell and equalize at 2.33 volts per cell. Include overload protection, full wave rectifier, DC voltmeter and ammeter, and 120 volts, 1 phase AC fused input. During diesel run conditions, the battery should be re-charged from the engine mounted alternator. F. Engine Instrument Panel: An engine instrument panel shall be furnished, shock mounted on the unit and completely factory wired and tested. It may be incorporated into the Engine Control Panel if this is the vendor’s standard practice. It shall include the following instruments: lubricating oil pressure gage, low oil pressure cut off, cylinder water temperature gauge, high water temperature cut off, over speed shutdown and running time meter. The panel shall also include engine alarm lights for low oil pressure, high water temperature, over speed and over crank. G. Engine-Generator Control Panel: Panel shall be furnished complete with a manually operated, moulded case, main circuit breaker with shunt trip, manual start/stop switch, manual reset overload protection, current and potential transformers, voltmeter and ammeter with three phase selector switch. The controls and metering section of the generator control panel shall be completely isolated from the feeder circuit breaker section of the control panel. The panel shall be designed for power cables bottom entry. Provide controls, push-to-test indication lights and alarm horn as required by the manufacturer. H. Additional Accessories: 1. All rotating assemblies, hot (145°F or more) pipes and other hot surface (up to 7 ft elevation) shall have OSHA safety guards. 2. Contractor shall furnish any additional equipment or accessories not specifically stated as being furnished by others which are required to achieve operation as described herein. Blue Lake Expansion Project – Contract No. 9 16622-7 General Construction May 2012 3. All nameplate, data plates and information plates on engines, generators, and control panels shall be stainless steel or other highly durable and readable material. 2.08 SHOP INSPECTION AND TEST A. The unit shall be assembled in the factory and fully tested before shipping. Factory tests shall include, but not be limited to: 1. Visual inspection of mechanical components, wiring, mounting of control and protection devices, point to point continuity checks, and insulation testing of power cables. 2. Start engine, check for any abnormalities such as excessive vibration, perform verification that the engine protection and control system operates as designed by simulating each of the malfunctions. Verify that gauges and other indicating devices are fully functional. 3. Verify adjustment of frequency and voltage over the specified ranges, record voltage and frequency at no load and at the fully loaded condition. PART 3 EXECUTION 3.01 EXAMINATION A. Verify that surfaces are ready to receive work and field dimensions are As Shown. B. Verify that required utilities are available in proper location and ready for use. C. Beginning of installation means Contractor accepts existing conditions. 3.02 INSTALLATION A. Install in accordance with manufacturer’s instructions. B. At the completion of all installation and testing work, fill the generator fuel tank with 200 gallons of diesel fuel. 3.03 FIELD QUALITY CONTROL A. Field inspection and testing shall be performed under provisions of Section 01400. B. Provide full load test, if required, for 4 hours minimum. Simulate power failure including operation of transfer switch, automatic starting cycle and automatic shutdown, and return to normal. C. During testing, record the following at 20 minute intervals: 1. Kilowatts. 2. Amperes. 3. Voltage. 4. Coolant temperature. Blue Lake Expansion Project – Contract No. 9 16622-8 General Construction May 2012 5. Ambient temperature. 6. Frequency. 7. Oil pressure. D. Test alarm and shutdown circuits by simulating conditions. 3.04 MANUFACTURER’S FIELD SERVICES A. Provide a manufacturer’s site representative to check the installation and supervise the testing of the system. Manufacturer’s site representative shall confirm in writing their acceptance of the equipment installation. Site representative shall prepare, start, test, and adjust the system as required. 3.05 ADJUSTING A. Adjust generator output voltage and engine speed. 3.06 CLEANING A. Clean work under provisions of Division 1, Section 01700. B. Clean engine and generator surfaces. Replace oil and fuel filters. 3.07 DEMONSTRATION A. Simulate power outage by interrupting normal source, and demonstrate that system operates to provide standby power. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16721-1 General Construction May 2012 SECTION 16721 FIRE ALARM SYSTEMS PART 1 GENERAL 1.01 WORK INCLUDED A. Furnish and install the following: 1. Fire alarm control panel. 2. Manual fire alarm pull stations. 3. Automatic smoke, heat and flame detectors. 4. Fire Alarm signalling appliances. 5. Auxiliary fire alarm equipment 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 16010: Electrical General Provisions 1.03 REFERENCES A. NFPA 70 – National Electrical Code. B. NFPA 72 – Installation, Maintenance and Use of Protective Signalling Systems. C. NFPA 72E – Automatic Fire Detectors. D. NFPA 72G – Notification Appliances for Protective Signalling Systems. E. NFPA 72H – Guide for Test Procedures for Protective Signalling Systems. F. NFPA 101 – Life Safety Code. 1.04 SYSTEM DESCRIPTION A. Fire Alarm System: NFPA 72, fully addressable fire alarm system. B. Furnish and install fire detection and alarm system As Shown (refer to Drawing 109-45-127) consisting of the following: 1. Smoke detectors in occupied spaces, including lavatory, washroom, SCADA closet, control room, break room, senior operator’s office and common areas. 2. Smoke detectors in operating area, including one under the mezzanine and three in the roof peak. 3. Manual pull box at each exterior mandoor exit Blue Lake Expansion Project – Contract No. 9 16721-2 General Construction May 2012 4. Audible/visual (horn/strobes) alarms within the powerhouse 5. Audible Alarm (bell) at each exit door on the exterior of the powerhouse 6. An acknowledge/alarm silence pushbutton station 7. Fire alarm control panel complete with input modules and multiplying relay panel. 1.05 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Shop Drawings: Provide ladder diagram, annunciator layout and system wiring diagram showing each device and wiring connection required. C. Product Data: Provide detailed description of operation, electrical characteristics and connection requirements, device catalogue cut sheets. D. Test Reports: Indicate satisfactory completion of required tests and inspections. E. Manufacturer’s Installation Instructions: Indicate application conditions and limitations of use stipulated by product testing agency. Include instructions for storage, handling, protection, examination, preparation, installation and starting of products. 1.06 PROJECT RECORD DOCUMENTS A. Record actual locations of initiating devices, signalling appliances, and end-of-line devices. 1.07 OPERATION AND MAINTENANCE DATA A. Operation Data: Operating instructions. B. Maintenance Data: Maintenance and repair procedures. 1.08 QUALIFICATIONS A. Manufacturer: Company specializing in manufacturing the products specified in this section with minimum five years documented experience. B. Installer: Company specializing in installing the products specified in this section with minimum five years documented experience, and certified by State of Alaska as fire alarm installer. 1.09 REGULATORY REQUIREMENTS A. Conform to requirements of NFPA 70, NFPA 72, and NFPA 101 and Factory Mutual (FM). B. Furnish products listed and classified by testing firm acceptable to authority having jurisdiction as suitable for purpose specified and indicated. 1.10 MAINTENANCE SERVICE Blue Lake Expansion Project – Contract No. 9 16721-3 General Construction May 2012 A. Furnish service and maintenance of fire alarm system for one year from Date of Substantial Completion. 1.11 EXTRA MATERIALS A. Provide one manual pull station B. Provide 6 break-glass rods for manual pull stations. C. Provide two keys of each type. D. Provide two of each type of automatic detector without base. E. Provide one spare input module of each type. F. Provide one spare auxiliary relay. PART 2 PRODUCTS 2.01 FIRE ALARM AND SMOKE DETECTION CONTROL PANEL A. Control Panel: Modular construction with surface wall-mounted enclosure. B. Power Supply: Adequate to serve control panel modules, remote detectors, smoke dampers, relays, and alarm signalling devices. Include battery-operated emergency power supply with capacity for operating system in standby mode for 24 hours followed by alarm mode for 5 minutes. C. System Supervision: Component or power supply failure places system in trouble mode. D. Remote Station Signal Transmitter: Electrically supervised digital alarm communicator transmitter, capable of transmitting alarm and trouble signals over telephone lines to central station receiver. E. Auxiliary Relays: Provide sufficient SPDT auxiliary relay contacts for each detection zone to provide accessory functions specified. F. Provide TROUBLE ACKNOWLEDGE, DRILL, and ALARM SILENCE switch. G. Trouble Sequence of Operation: System or circuit trouble places system in trouble mode, which causes the following system operations: 1. Visual and audible trouble alarm indicated at fire alarm control panel. 2. Trouble signal transmitted to central station. 3. Manual acknowledge function at fire alarm control panel silences audible trouble alarm; visual alarm is displayed until initiating failure or circuit trouble is cleared. H. Alarm Sequence of Operation: Actuation of initiating device places circuit in alarm mode, which causes the following system operations: Blue Lake Expansion Project – Contract No. 9 16721-4 General Construction May 2012 1. Upon detection of an alarm condition the annunciator devices shall be activated, and the zone causing the alarm indicted on the fire alarm control panel. An auxiliary contact indicating that a zone has operated shall be provided to interface with the station SCADA system. If the alarm is acknowledged by the station operator by depressing an acknowledge/silence push button mounted in the control room, the annunciation devices shall silence, however, the zone causing the alarm shall continue to indicate activation until the system is reset. If the alarm is not acknowledged within 30 seconds, the alarm shall continue to annunciate until the fire alarm control panel is reset. 2. If a manual pull station is activated, the annunciation devices shall be activated, and the auxiliary relays shall shut down the powerhouse ventilation system. An auxiliary relay contact shall be provided to interface with the station SCADA system. If a manual pull station is activated, the operator cannot cancel the alarm using the acknowledge/silence push button. If a fire is detected in the standby generator area, only the annunciation device in the operator’s control room will be activated. The zone shall be indicated, and an auxiliary relay shall shutdown the standby generator. The alarm silence/acknowledge push button shall silence the annunciation device, however, the zone shall continue to annunciate activation until reset. An auxiliary relay contact shall be provided to interface with the station SCADA system. I. Alarm Rest: System remains in alarm mode until manually reset with key- accessible reset function; system resets only if initiating circuits are out of alarm mode. J. Lamp Test: Manual lamp test function causes alarm indication at each zone at fire alarm control panel. K. Drill Sequence of Operation: Manual drill function causes alarm mode operation as described above. L. Zoning: Provide separate zones for each area as indicated on the drawings. M. SCADA Interface: The system shall communicate alarm conditions through the power plant SCADA system via an interface with the power plant PLC. 2.02 INITIATING DEVICES A. Manual Station: Surface mounted, non-coded type, single action manual station with break-glass rod. Provide manufacturer’s standard backbox. B. Ceiling Mounted Smoke Detector: NFPA 72E photoelectric type with adjustable sensitivity, plug-in base, integral thermal element rated 135 degrees F (57 degrees C), and visual indication of detector actuation, suitable for mounting on 4 inch (102 mm) outlet box. Provide two-wire detector with common power supply and signal circuits. 2.03 SIGNALING APPLIANCES A. Alarm Horn: NFPA 72G, surface type fire alarm horn. Sound Rating: 87 dB at 10 ft (3 m). Provide integral strobe lamp and flasher with red lettered “FIRE” on white lens. Blue Lake Expansion Project – Contract No. 9 16721-5 General Construction May 2012 B. Alarm Bell: 6 inch, vibrating bell, fire red finish, 92 dba at 10 feet, complete with weatherproof box for outside mounting. 2.04 AUXILIARY DEVICES A. Provide and install electrical components to annunciate to SCADA and shut down the components as indicated above. 2.05 FIRE ALARM WIRE AND CABLE A. Fire Alarm Power Branch Circuits: Building wire as specified in Section 16050. B. Initiating Device and Indicating Appliance Circuits: Power limited fire-protective signalling cable, copper conductor, 300 volts insulation rated 105 degrees C. PART 3 EXECUTION 3.01 INSTALLATION A. Install products in accordance with manufacturer’s instructions. B. Install manual pull stations with operating handle 4 ft 6 inches (1.4 m) above floor. Install audible and visual signal devices 7 ft 6 inches (21.3 m) above floor. C. Use 14 AWG minimum size conductors for fire alarm detection and signal circuit conductors. Install wiring in conduit. D. Mount end-of-line device in box with last device or separate box adjacent to last device in circuit. E. Make conduit and wiring connections to detectors, annunciation devices, fire alarm control panel, SCADA interface and shutdown devices. 3.02 FIELD QUALITY CONTROL A. Test in accordance with NFPA 72H and local fire department requirements. 3.03 MANUFACTURER’S FIELD SERVICES A. Provide services of certified technician to supervise installation, adjustments, final connections and system testing. 3.04 FIRE ALARM WIRE AND CABLE COLOR CODE A. Provide fire alarm circuit conductors with insulation color coded as follows, or using colored tape at each conductor termination and in each junction box. B. Power Branch Circuit Conductors: Black, red, white. C. Initiating Device Circuit: Black, red. D. Detector Power Supply: Violet, brown. E. Signal Device Circuit: Blue (positive), white (negative). Blue Lake Expansion Project – Contract No. 9 16721-6 General Construction May 2012 3.05 DEMONSTRATION A. Demonstrate all modes of operation, and required responses to each. END OF SECTION Blue Lake Expansion Project – Contract No. 9 16723-1 General Construction May 2012 SECTION 16723 FIBER OPTIC CABLE SYSTEM PART 1 GENERAL 1.01 WORK INCLUDED Install a single-mode fiber optic cable furnished by the Owner. The Contractor will have installed the necessary conduit as shown. The Owner will terminate the optic fiber. A. Definition: Fiber optic cable is defined as composite overhead optical ground wire glass fiber cable, operating in the single-mode wave lengths, to be installed on pole structures supporting power conductors, and in conduit. 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 16010: Electrical General Provisions 1.03 DELIVERY, STORAGE AND HANDLING A. Delivery of Cable: 1. Owner will deliver optic fiber cable to the Contractor at the job site. 2. Cable ends shall be sealed when delivered to prevent ingress of moisture. B. Storage of Cable and Equipment: During any storage of cable and equipment, Contractor shall ensure that it is suitably protected from damage or corrosion. C. Handling of Materials and Equipment: Cable and cable reels shall be lifted and otherwise handled in such a manner as to avoid damage or distortion to cable or cable reels. Suitable lifting gear and slings shall be used by Contractor at all times. D. Repair of Minor Defects and Damage: Fiber optic cable and equipment shall be free from defects or damage. Any such defects or damage that, in the opinion of RPR, compromise the performance of the cable or equipment may be cause for rejection. PART 2 PRODUCTS 2.01 CABLE CONSTRUCTION A. The fiber optic cable shall be an overhead optical cable described as follows: 1. A cable made up of multiple strands of single-mode glass fibers grouped in buffer tubes that are loosely arranged in a concentric configuration around a dielectric central member, the whole of which is encased in a thick walled plastic jacket. Blue Lake Expansion Project – Contract No. 9 16723-2 General Construction May 2012 2. The optic fiber cable to be furnished by the Owner is AFL Telecommunications Specification DNA-28146 AFL-ADSS Fiber Optic Cable. Although this cable is used primarily for overhead lines, use in underground conduit is acceptable to the manufacturer. PART 3 EXECUTION 3.01 INSTALLATION A. Contractor shall use cable manufacturer’s recommended installation practices. This particularly concerns limiting bending radius and tensions on the cable. B. Contractor shall use common materials and methods compatible with the materials utilized at all locations. C. All cable installed in trays, trenches, wireways, racks or otherwise exposed shall be installed in orange-colored plenum-rated HDPE innerduct. D. All cables shall be clearly marked at each end, wireway transition (e.g., conduit to tray), pedestal, handhole and pullbox with a permanent, weather resistant tag. E. Install at least three meters of extra cable coiled near each termination or splice point. Coil extra cable within pedestals and pullboxes, and in trays or trenches near racks and wall-mount panels. F. Seal the ends of the cable to prevent moisture intrusion. 3.02 SPLICING, TERMINATION AND TESTING A. Owner shall arrange for certified expert services for fiber splicing, termination, and testing. 3.03 SURPLUS MATERIAL A. Contractor shall deliver to RPR any surplus material on Site. END OF SECTION DIVISION 20 TURBINE AND GENERATOR EQUIPMENT Blue Lake Expansion Project – Contract No. 9 20100-1 General Construction May 2012 SECTION 20100 TURBINE AND GENERATOR EQUIPMENT INSTALLATION PART 1 GENERAL 1.01 WORK INCLUDED A. Install turbine and generator equipment furnished by Owner for the Blue Lake powerhouse and the Fish Valve Unit powerhouse, including startup, testing and commissioning and completion of Work such that the equipment can be utilized as intended. B. The Work also includes: 1. Receipt of Owner furnished equipment at Point of Destination, including unloading. 2. Transport to storage, storage and transport of equipment to the location of installation. C. Owner furnished equipment may arrive at the Point of Destination in multiple shipments. D. Owner furnished turbine and generator equipment will include: 1. Three main units (BLU), including: a) Three horizontal shaft Francis turbines, each with a full load output of 7.0 MW at 356 ft rated net head. b) Three butterfly type turbine inlet valves with connecting pipe segments. c) Three hydraulic pressure units for operation of the turbine wicket gate servomotors, turbine inlet valves, turbine inlet valve bypass and generator brakes. d) Three governors. e) Three horizontal shaft synchronous generators, each with a rated output of 9.1 MVA. f) A brushless exciter with permanent magnet generator for each of the three generators. g) A turbine generator control panel for each of the three generating units. h) Cooling water system for generator bearings, turbine shaft seal and runner seals. 2. One Fish Valve Unit (FVU), including: Blue Lake Expansion Project – Contract No. 9 20100-2 General Construction May 2012 a) Horizontal shaft Francis turbine, with full load discharge of 73 cfs at 186 ft net head. b) Butterfly type turbine inlet valve and hydraulic actuator. c) Wicket gate controller for turbine. d) Horizontal shaft synchronous generator rated at 1,650 kVA. e) Brushless exciter for generator. f) Cooling water system for the generator bearings and turbine shaft seal. 3. Special tools for turbine and generator equipment installation. E. Details of Owner furnished equipment are described in the Contract 1 specifications included in the Reference Documents, and on the equipment supplier’s shop drawings included in the Reference Documents. F. Contractor shall provide: 1. Necessary consumables such as wire markers, wire/cable connectors and terminals, stress cones, cable termination accessories, shims, welding rod, grout, rags, cleaning solutions and other consumables necessary for installing the Owner furnished equipment and placing the equipment into operation. 2. Additional supports for embedded parts required by Contractor’s method of concreting. 3. Flushing fluids, lubricants and hydraulic oil necessary testing, start-up and commissioning and placing the equipment in continuous operation. 4. Interconnecting piping and valves As Shown. 5. Interconnecting wiring and cabling. 6. Touch-up paint. G. The installation Work shall include provision of necessary standard tools and lifting slings, as required to accomplish the Work. H. Contractor shall also furnish mechanical and electrical test equipment for checking instrumentation calibration, pressure level, alignment, vibration, temperature, spiral case pressure, generator assembly and interconnection wiring, as necessary for the installation, testing and commissioning Work as described herein. For commissioning Work this shall include data logging or equivalent instrumentation for real time data collection and display. Instrumentation shall be calibrated to a recognized national standard 1.02 RELATED SECTIONS A. Section 01300: Submittals B. Section 01550: Co-ordination with Owner Performed Work C. Section 09900: Painting Blue Lake Expansion Project – Contract No. 9 20100-3 General Construction May 2012 D. Section 15300: Piping E. Section 16020: Wiring 1.03 REFERENCE STANDARDS A. ASTM PTC-18 – Hydraulic Turbines and Pump-Turbines B. IEC 60545 – Guide for Commissioning, Operation and Maintenance of Hydraulic Turbines. C. IEC 60994 – Guide for Field Measurement of Vibrations and Pulsations in Hydraulic Machines (Turbines, Storage Pumps and Pump-Turbines) D. IEEE 125 – Speed Governing Systems for Hydraulic Turbine Generating Units E. ISO 1940 – Balancing F. ISO 10815-5 – Evaluation of Machine Vibration by Measurement of Non-Rotating Parts G. NEMA MG 5.1 – Large Hydraulic Turbine Driven Synchronous Generators H. NETA (National Electrical Testing Authority) Acceptance Testing Specifications for Electric Power Distribution Equipment and Systems. I. NFPA 70 – National Electric Code J. State of Alaska OSHA Standards 1.04 SUBMITTALS A. Submit under provisions of Section 01300 for review. B. Submit the following: 1. Comments on Owner furnished installation and test procedures. 2. Contractor’s installation and test plan that supplements/augments Owner furnished procedures. 3. Documentation on installation and alignment checks. 4. Report for each unit on installation, testing and commissioning. 1.05 INTERFACE POINTS WITH OWNER FURNISHED EQUIPMENT A. Interface points between Owner furnished equipment and piping and wiring provided by Contractor shall be as follows: 1. Owner furnished BLU cooling water piping, valves and equipment will extend from the turbines and generators to and including the shutoff valves on the upstream side of the cooling water filters. Contractor shall provide piping to the valves on the upstream side of the filters as part of the service water system. Blue Lake Expansion Project – Contract No. 9 20100-4 General Construction May 2012 Contractor shall also provide cooling water drain piping from the generator bearing cooling water return lines to the floor drain. 2. Owner will furnish the hydraulic operated spiral case drain line for the BLU turbines. Contractor shall provide all piping to and from the valve, including the piping to the drain line flange on the spiral case. 3. Owner will furnish hydraulic piping and tubing between terminal points on the BLU hydraulic power units and the devices on the turbines, turbine inlet valves and the generators. 4. Owner will furnish valves for the BLU penstock pressure tap connections upstream of the turbine inlet valve, As Shown. 5. Contractor shall provide all wiring and conduit between the junction boxes on the turbine, generator, turbine inlet valve, HPU, governor and turbine generator control panel. 6. Contractor shall provide power, instrumentation, control cables, fiber optic and conduit between the BLU generator, turbine-generator control panel, AC and DC station services, SCADA interface and the Owner furnished 12.47 kV switchgear. 1.06 INSTALLATION PROCEDURES A. Installation procedures for the turbine and generator equipment will be furnished by Owner. The procedures furnished by Owner will include alignment tolerances for the various equipment components and rotational tests to be carried out on the assembled unit. The procedures will include record sheets on which the various alignment checks and tests shall be recorded by Contractor and accepted by RPR as the Work at Site progresses. Deviations from these procedures must be accepted by RPR. B. Contractor shall review installation procedures furnished by Owner and submit comments and concerns to RPR, for address by the equipment supplier. PART 2 PRODUCTS 2.01 LUBRICANTS AND HYDRAULIC OILS A. Hydraulic and bearing oil shall be Panolin HYP SYNTH oil. PART 3 EXECUTION 3.01 RESPONSIBILITY FOR INSTALLATION A. RPR, at its discretion, will have one or more equipment supplier’s Site Representatives at Site during specific periods of the installation and testing Work. The Site Representative(s) will provide technical advice on the installation and testing of the equipment. The requirement for Site Representative(s) will be reviewed with Contractor prior to start of the installation Work. B. Contractor shall have overall responsibility for satisfactory installation and testing of the Owner furnished equipment. Contractor shall immediately advise RPR in Blue Lake Expansion Project – Contract No. 9 20100-5 General Construction May 2012 writing of any dispute or misunderstanding between Contractor and equipment supplier’s Site Representative(s). 3.02 EQUIPMENT INSTALLATION A. Contractor shall submit to RPR an overall installation and test plan for the Work that supplements and augments Owner furnished installation and test procedures. Contractor’s plan shall identify key stages at which the Work should be inspected by RPR. B. Before installation of embedded parts, Contractor shall remove all loose scale and foreign material from all surfaces in contact with concrete. C. Contractor shall install all embedded anchors and shall erect and align the turbine and generator embedded parts to tolerances specified in the equipment supplier’s installation procedure. Alignment checks shall be made before and during concreting of embedded parts. D. Upon completion of concreting operations, the embedded parts shall be cleaned and checked for level and alignment by Contractor. Corrective measures shall be taken to obtain the specified tolerances and clearances before proceeding with the installation of the remaining parts. E. Owner furnished equipment shall be installed as specified in the equipment supplier’s installation procedure. Care shall be taken to ensure all specified tolerances are achieved. F. Contractor shall clean and flush all hydraulic lines and cooling water lines. All hydraulic and bearing oil shall be filtered. G. Contractor shall complete at Site the records sheets contained in equipment supplier’s installation procedures as well as record sheets in Contractor prepared supplementary procedures. As information in each sheet is recorded, dated and approved by Contractor, a copy shall be submitted to RPR for review and for final records. H. When installation of Owner furnished equipment is complete, Contractor shall remove all tools, debris, and other items from the work area and complete the application of paint and protective coatings as specified in Division 9. The work area around the turbine and generator equipment shall be kept clean by Contractor during installation and testing. 3.03 SITE TESTING A. Site tests of individual machinery components and completed units shall be performed to demonstrate to the satisfaction of RPR that Owner furnished turbine and generator equipment is installed and operating in accordance with procedures and equipment supplier’s requirements. B. The tests shall be performed under the general direction of equipment supplier’s Site Representative(s) using Owner furnished testing and commissioning plan and procedures. Contractor shall be satisfied that each step of the tests is being conducted in a prudent and proper sequence and manner. Any defects related to equipment installation that become evident during the tests shall be immediately corrected and the tests continued until the Owner furnished turbine and generator equipment is proved to be in working order to the satisfaction of RPR and the Blue Lake Expansion Project – Contract No. 9 20100-6 General Construction May 2012 turbine and generator equipment supplier’s Site Representative(s). Any defects related to Owner furnished equipment design or manufacture will be corrected by the respective equipment supplier in accordance with Owner’s contract with the equipment supplier. C. Site tests shall include but not be limited to those listed below. These tests shall be conducted on each of the three BLU units, and on the FVU except for equipment that is not installed by Contractor. 1. Tests on turbine inlet valves dry operation, all control functions, and closure against flow. 2. Rotation, shaft runout, and air gap check. 3. Tests of all shutdown devices and protective relays. 4. Insulation tests, wiring checks, and functional tests of all electrical equipment. 5. Operational tests for governor system. 6. Operational tests of the excitation system. 7. Test of control, metering and protection system, including: a) Visual inspection and mechanical tests relating to complete and correct assembly. b) Electrical tests of continuity of wiring, meggar insulation testing of installed wiring. c) Calibration and setting of relay and protective devices, temperature indicators, instrumentation devices, alarm and shutdown sensors and similar devices. d) Functional testing of all control, metering and protection associated with the unit start/stop sequences and all unit and station general services equipment controlled from the turbine generator control panel and the HPU local control panel to ensure no cables, instrumentation device, protection relay or controls have been overlooked. 8. Tests of automatic startup and synchronization equipment. 9. Load rejection tests. 10. Generator characteristic tests: a) High potential test on stator and rotor windings. b) Open circuit saturation. c) Short circuit saturation. d) Rated current, zero power factor saturation. Blue Lake Expansion Project – Contract No. 9 20100-7 General Construction May 2012 e) Temperature rise and heat run. 11. Turbine index test. D. At the completion of the installation and testing Work, Contractor shall provide a complete report for each of the BLU units and the FVU, presenting all installation and testing measurements, records and documentation. END OF SECTION ATTACHMENT A MILESTONE SCHEDULE IDTask NameDurationStartFinish12013 Lake Level Window (below El 330)148 daysWed 1/26/11Fri 8/19/1122014 Lake Level Window (below El 302)113 daysFri 3/14/14Fri 7/4/1432013 Spill Window93 daysSun 9/1/13Mon 12/2/134Generation Outage62 daysMon 9/1/14Sat 11/1/145Powerhouse Tailwater Window (below El 160) - Season 1269 daysSat 12/15/12Mon 9/9/136Powerhouse Tailwater Window (below El 160) - Season 2395 daysMon 12/2/13Wed 12/31/147Notice to Proceed1 dayThu 11/1/12Thu 11/1/128Intake Tunnel & Portal Excavation - Season 1125 daysTue 4/16/13Sun 8/18/139Intake Tunnel Completion and Structure - Season 2154 daysSat 2/1/14Fri 7/4/1410Drainage Tunnel92 daysTue 4/16/13Tue 7/16/1311Install FVU92 daysMon 9/1/14Mon 12/1/1412Drainage Tunnel Complete (Milestone # 1)0 daysMon 7/1/13Mon 7/1/1313Initial Intake Tunnel Complete (Milestone # 2)0 daysMon 8/19/13Mon 8/19/1314Intake Structure Complete (Milestone # 3)0 daysFri 7/4/14Fri 7/4/1415Sufficiently Complete to Allow Generation Outage (Milestone # 4)0 daysSun 8/24/14Sun 8/24/1416Substantially Complete First BLU (Milestone # 5)0 daysSat 11/1/14Sat 11/1/1417Substantially Complete Second BLU (Milestone # 6)0 daysMon 12/1/14Mon 12/1/1418Substantially Complete FVU (Milestone # 7)0 daysFri 12/5/14Fri 12/5/1419Existing Bulkhead Refurbishment (Low Lake Level)5 daysThu 5/1/14Mon 5/5/1420MS - Set Transformer # 10 daysSun 6/1/14Sun 6/1/1421MS - Set Transformer # 20 daysSat 12/27/14Sat 12/27/1422Install Temporary Log Boom for Intake10 daysTue 7/1/14Thu 7/10/1423Reservoir Debris Management (Contract 8)762 daysTue 7/1/14Tue 10/25/162425Delivery of Owner Furnished Equipment591 daysSat 5/12/12Mon 12/23/1326Bulkhead Gate and Guides (Contract 3)33 daysThu 1/17/13Mon 2/18/1327Fixed Wheel Gate, Guides & Hoist (Contract 3)31 daysWed 4/17/13Fri 5/17/1328Bridge Crane (latest delivery) (Contract 6)124 daysSat 5/12/12Wed 9/12/1229Turbines & Generator Equipment Embedded Parts (Contract 1)96 daysMon 1/21/13Fri 4/26/1330Turbines & Generator Equipment Remaining Parts (Contract 1)96 daysMon 1/21/13Fri 4/26/1331Turbine Inlet Valves (Contract 1)96 daysMon 1/21/13Fri 4/26/1332Manifold (Contract 4)92 daysFri 1/4/13Fri 4/5/1333Penstock (Contract 4)92 daysFri 1/4/13Fri 4/5/133469 kV Transformers (Contract 5)84 daysTue 10/1/13Mon 12/23/133512.47 kV Switchgear (Contract 2)71 daysWed 9/18/13Wed 11/27/1336Steel Building (Contract 7)92 daysTue 1/15/13Tue 4/16/1337Turbine Generator Control Panel (Contract 1)43 daysMon 1/21/13Mon 3/4/132014 Lake L2013 Spill GenerPowerhouse Tailwater Window (Powerhouse Tailwater Window (below El 160) - 11/1Intake Tunnel Intake Tunnel CoDrainage Install FV7/18/197/48/2411/112/112/56/112/27Reservoir Debris Management (ContraBuFi Turbines Turbines Turbine InlManifold (Penstock 69 kV Tra12.47 kSteel BuilTurSepNovJanMarMayJulSepNovJanMarMayJulSepNovJanMar201320142015TaskSplitProgressMilestoneSummaryProject SummaryExternal TasksExternal MileTaskSplitConstruction Schedule Milestones and ConstraintsConstruction Schedule Milestones and ConstraintsPage 1* Durations represent calender daysProject: Blue LakeDate: Mon 4/30/12 ATTACHMENT B GEOTECHNICAL BASELINE REPORT FOR TUNNEL AND ADIT CONSTRUCTION City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page i © Hatch 2012/04 City and Borough of Sitka Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction DATE REV. STATUS PREPARED BY CHECKED BY APPROVED APPROVED BY January 30, 2012 3 Draft Sam Sisodraker DJ, PF Jan 30, 2012 Steve Hart January 13, 2012 2 Draft Sam Sisodraker DJ, PF Jan.13 2012 Steve Hart October 11, 2011 1 Draft Maria Mammoliti DJ,PF Oct.18 2011 Steve Hart City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page ii © Hatch 2012/04 Geotechnical Baseline Report (GBR) Purposes and Limits This Geotechnical Baseline Report (GBR) has been prepared by Hatch Associates Consultants, Inc. (“Hatch”) for the sole and exclusive use of City and Borough of Sitka (the “Client” or “CBS”). The document has been prepared in accordance with the ASCE suggested guidelines for “Geotechnical Baseline Report for Construction” (Essex 2007). This GBR covers the design and construction of the surface and underground excavations for the Blue Lake Hydroelectric Expansion Project (Project). This GBR is a Contract Document and is intended to assist bidders in evaluating the requirements for excavating and supporting the ground, and in preparing their tenders. Risks associated with subsurface conditions consistent with, or less adverse than, the baseline conditions represented in the Contract Documents are allocated to the Contractor. Those risks associated with subsurface conditions more adverse than the baseline conditions are accepted by the Owner. The provisions of baseline conditions in the Contract is not a warranty that the baseline conditions will be encountered. The baseline conditions represent a contractual standard that the Owner and the Contractor will agree to use when interpreting and applying the General Conditions and the Supplementary Conditions. The GBR should be read in conjunction with the Geotechnical Data Report (GDR), also included in the Contract Documents. The GDR contains factual geotechnical data resulting from the explorations and testing completed for this Project. In the event of apparent conflicts, discrepancies, or inconsistencies with any other geotechnical data made available to the Contractor, the GBR takes precedence in reconciliation of the conflict. Precedence of Contract Documents is given in the Supplemental Conditions of the Contract. Supporting documents such as the 1954 report by the United States Bureau of Reclamation (USBR) are also available for reference. City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page iii © Hatch 2012/04 Table of Contents Geotechnical Baseline Report (GBR) Purposes and Limits ............................................................................. ii 1. Introduction ............................................................................................................................................ 1 2. Project Description ................................................................................................................................. 1 2.1 Blue Lake Dam Extension and Plunge Pool (Features 20 and 22)................................................... 2 2.2 Drainage Tunnel (Feature 23) ......................................................................................................... 2 2.3 Intake Tunnel (Feature 24) ............................................................................................................. 2 2.4 Gate Shaft and Intake Structure (Features 25 and 26) ...................................................................... 2 2.5 Tunnel Modifications and Surge Chamber (Feature 30) .................................................................. 3 2.6 Penstock and Penstock Drain (Features 31 and 32) ........................................................................ 3 2.7 Powerhouse and Switchyard (Features 45 and 55) .......................................................................... 3 3. Sources of Geological and Geotechnical Information ............................................................................. 4 4. Project Geological Setting ....................................................................................................................... 5 4.1 Overview of Site Exploration and Investigation Programs ............................................................... 5 4.2 Overview of Geologic Settings ....................................................................................................... 5 4.3 Ground Characterization and Baselines ......................................................................................... 7 4.3.1 Site Tectonics ....................................................................................................................... 7 4.3.2 Overburden.......................................................................................................................... 7 4.3.3 Rock Types ........................................................................................................................... 9 4.3.4 Rock Mass Discontinuities .................................................................................................... 9 4.3.5 Rock Mass Classification ...................................................................................................... 9 4.3.6 Groundwater Levels, Water Inflow and Hydraulic Conductivity ......................................... 10 4.3.7 Intact Rock Strength ........................................................................................................... 12 5. Construction Considerations ................................................................................................................. 13 5.1 Drilling and Blasting .................................................................................................................... 13 5.2 Tunnels and Shafts Rock Support Design ..................................................................................... 13 5.3 Dam Excavation ........................................................................................................................... 13 5.4 Installation of Pressure Relief Wells & Scour Wall ....................................................................... 14 5.5 Penstock and Powerhouse Excavation .......................................................................................... 14 5.6 Geotechnical Mapping ................................................................................................................. 14 5.7 Geotechnical Measurements ........................................................................................................ 14 5.8 Groundwater Control and Treatment ........................................................................................... 14 6. Principal Project Features ..................................................................................................................... 15 References ................................................................................................................................................... 21 City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 1 © Hatch 2012/04 1. Introduction The Blue Lake Hydroelectric Project, owned and operated by the City and Borough of Sitka (Owner), was commissioned in 1961 and is located on Baranof Island, about five miles east of the community of Sitka in the City and Borough of Sitka, Alaska. The current facility consists of a 149-ft high, 256-ft wide concrete arch dam on Sawmill Creek impounding the 1,255-acre Blue Lake reservoir. The arch dam is equipped with a release valve and a 140-ft long spillway with the crest at el. 342. The project also includes two tunnel segments, two penstock segments, and three powerhouses. The powerhouses include the 2x3 MW Blue Lake powerhouse, the 0.67 MW Fish Valve Unit (FVU) and the 0.87 MW Pulp Mill Feeder Unit (PMFU). Water from the Blue Lake reservoir is used for hydroelectric generation, in-stream flow needs, municipal water use and bulk water sales. The general arrangement of the site is shown in Figure 1 of the TM-07 Geotechnical Data Report (GDR). The Blue Lake Hydroelectric Expansion Project (Project) is comprised of the following elements: • A dam raise by 83 ft, increasing the overall maximum gross head on the plant from 329 ft to 413 ft, a 25% increase; • Three new 5.3-MW generating units (the existing units must operate at a higher head and will likely be decommissioned rather than upgraded); • A new powerhouse, housing the new generating units; • A modification to the existing intake (e.g. a new intake tunnel and gate shaft located South of the existing Upper Tunnel alignment); • A new downstream surface penstock segment from the Lower Tunnel; • A new surge chamber; and • A new switchyard. The purpose of this report is to provide a geotechnical baseline for bidding and construction called for in Contract No. 9, which involves both underground and surface rock excavation. This Geotechnical Baseline Report (GBR) is the sole location for geotechnical interpretations of the available data and information upon which the Contractor may rely. The City and Borough of Sitka (Owner) owns and operates the project. The design team for the project consists of Hatch Ltd. and the Owner. The entire scope of the project is under regulation by the Federal Energy Regulatory Commision (FERC No. 2230). The Owner has retained a Board of Consultants as per FERC requirements, comprised of Eric Kollgard, Kim de Rubertis, and James Cowley. 2. Project Description The major structures and improvements to be constructed in this contract are described in the sections below. Excavations are all expected to be carried out by the drill and blast method. Section 6 describes the contract excavation requirements of each feature. City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 2 © Hatch 2012/04 2.1 Blue Lake Dam Extension and Plunge Pool (Features 20 and 22) The arch dam structure will be raised 83 ft above the current 160 ft height. A new concrete gravity thrust block and cutoff wall will be constructed on the left abutment. The abutment areas will be cleared of overburden to expose the rock foundation prior to construction. Scaling, excavation, and installation of rock support will be required for both abutments. The foundation rock at the abutments and at the toe will be systematically grouted (curtain, consolidation, and contact grouting) to reduce the seepage under and around the dam. These dam extension features and thrust block will have adequate drainage (open and buried drains) to reduce water pressure uplift. The dam extension also includes construction of a left abutment drainage tunnel system (Feature 23, described in more detail in Section 2.2), rock anchors, and slope drains. The top concrete surface of the existing dam will be prepared , and the new extended structure with new spillway, left abutment thrust block cut- off wall, and parapet wall will be constructed. The work also incudes installation of dam instrumentation, piezometer monitoring wells, and a sluice gate operating system. Pressure relief wells will be constructed at the base of the dam in the plunge pool area and a plunge pool scour wall (Feature 22) will be constructed at the toe of the dam to protect the toe from further errosion. 2.2 Drainage Tunnel (Feature 23) A 140-ft long, 13-ft high by 10-ft wide, D-shape drainage tunnel will be constructed in the left abutment. This work will include creating temporary staging and work areas and access roads, and site restoration. This work will also include installing erosion and sediment control measures in the river, tunnel and portal excavation and support, spoil removal and disposal, and drilling of geotechnical exploratory percussion and cored holes in the tunnel and installation of a drainage measurement weir. 2.3 Intake Tunnel (Feature 24) A new 829-ft long, 12-ft high by 10-ft wide, D-shape intake tunnel will connect the reservoir to the existing intake tunnel. Some sections of the new tunnel will be higher and wider as ahown on the drawings. An alternate modified horseshoe design shape has been included. The tunnel will be declined at 17% maximum grade. This work will include excavating a reservoir access road, a portal, and the intake tunnel, and installing rock support. 2.4 Gate Shaft and Intake Structure (Features 25 and 26) The new headworks system consists of an intake structure which includes a trashrack structure at the tunnel portal, a bulkhead gate slot, and a gate shaft. The 109-ft deep, 11.5-ft diameter, circular gate shaft fitted with a fixed wheel gate will connect to the power tunnel approximately 55 ft downstream from the tunnel portal. An intake gate house will be constructed atop of the shaft and will be an access point for tunnel inspections and maintenance of the gates. City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 3 © Hatch 2012/04 A trashrack system will be constructed at the tunnel portal for the purpose of preventing debris from entering the intake power tunnel. A single bulkhead gate is adjacent to the trashrack intake system at the tunnel portal. The gate will be used to isolate and unwater the tunnel for inspection and maintenance on the tunnel and/or the intake gate guides. This work will include a temporary rock cofferdam at the new intake, permanent closure and sealing of existing gate structures, foundation preparation for the new intake structure, and removal of the rock cofferdam. The overburden rock slope encompassing the trashrack and bulkhead gate system will be entirely excavated prior to construction of the intake system. This work will also include construction of the gatehouse access road and crane access area adjacent to the gatehouse. 2.5 Tunnel Modifications and Surge Chamber (Feature 30) This work will include constructing the intake tunnel tie-in to the existing upper tunnel comprised of excavation of the rock plug between new and existing tunnel, spoil disposal, and construction of a concrete plug in the existing tunnel immediately upstream of the tunnel tie-in to isolate the abandoned existing intake from the modified tunnel. In addition, the work will include construction of a 355-ft deep, circular surge shaft composed of two sections of different diameters. The upper section, 207 ft deep, is 20 ft in diameter while the lower 148 ft deep section is 8 ft in diameter. At the base of the vertical shaft, a 332-ft long, 12 ft high by 10 ft wide, D-shape construction access adit will connect to the existing tunnel. Steel liners to be installed in the tunnel will be transported through the north river, south river, and lower tunnel portals. This work will also include restoring the filter plant access road from Sawmill Creek road to the Pulp Mill Feeder Unit (PMFU) and site restoration. 2.6 Penstock and Penstock Drain (Features 31 and 32) Penstock modifications include the demolition of a portion of the existing lower penstock (Sta 2+56 to Sta. 4+12), timber crib wall modifications, and construction of an approximate 380 ft of new 9-ft diameter penstock section including anchor blocks, penstock drain, and associated features. 2.7 Powerhouse and Switchyard (Features 45 and 55) Clearing and foundation excavation and preparation are required at the new powerhouse and afterbay. Also required is the excavation of the 3-tier manifold that leads into the powerhouse. This work will also include the construction of an access road from the Sawmill Creek Road to the powerhouse. The switchyard work will include construction of new transformer support pads and a containment basin and installation for new transformers. City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 4 © Hatch 2012/04 3. Sources of Geological and Geotechnical Information Geotechnical work completed by Hatch in 2009 and 2010 to support the design of the principal project features included field reconnaissance, literature review, field exploration, laboratory testing, tunnel inspection, and geotechnical evaluation. The Geotechnical Data Report (GDR) prepared by Hatch is factual geotechnical data resulting from the explorations and testing completed for this Project. The GDR is not a Contract Document, but is available for review by the bidders. This GBR was prepared based on an interpretation of the following available geotechnical information: • Surface geological mapping; • Logs of cored boreholes, including down-hole discontinuity data; • Permeability testing in overburden and bedrock; • Laboratory testing of core samples; and • Previous geological reports by other consultants. All of the above-listed geotechnical data is presented in the following document, prepared by Hatch (2011): • Technical Memorandum No. 7 – Geotechnical Data Report. Prepared for the City and Borough of Sitka. In addition, other information and data from previous studies documents prepared by Hatch include: • Technical Memorandum No. 23 – Plunge Pool Analysis; and • Technical Memornadum No. 24 - Seepage Analysis. Some information and data from previous studies on specific issues for this project by other consultants are also available for review and include the following documents: 1. United States Department of the Interior Bureau of Reclamation. 1954. Preliminary Report on the Blue Lake Project, Sitka, Alaska. Alaska District Office, Juneau Alaska. 2. R & M Consultants Inc. 2009. Boundary Rim Stability. Blue Lake Hydroelectric Project. 3. R & M Consultsnts Inc. 2010. Geotechnical Memorandum. Historic PHGAs – Blue Lake Hydroelectric Project. 4. Bowes, D.E., 1994. Periodic Safety Inspection Report. Blue Lake Hydroelectric Project. FERC Project No. 2230 AK. Prepared for City and Borough of Sitka. 5. de Rubertis, K. 2004 Review of Safety. Blue Lake Dam FERC No. 2230. Prepared for City and Borough of Sitka, Alaska. 6. de Rubertis, K. and McArthur, M. Report on Investigations. April 25 – 27, 2009. Prepared for City and Borough of Sitka, Alaska. City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 5 © Hatch 2012/04 7. Duke Engineering and Services. 1999 Review of Safety. FERC NO. 2230 AK. Prepared for City and Borough of Sitka. 8. Duke Engineering and Services. 1997 Spillway Plunge Pool Inspection Report. FERC NO. 2230 AK. Prepared for City and Borough of Sitka. 9. R. W. Beck and Associates. 1989. Blue Lake Hydroelectric Project FERC Project 2230. Periodic Safety Inspection Report. Prepared for the City and Borough of Sitka. 10. R. W. Beck and Associates. 1984. Blue Lake Hydroelectric Project FERC Project 2230. Periodic Safety Inspection Report. Prepared for the City and Borough of Sitka. 11. R. W. Beck and Associates. 1983. Blue Lake Hydroelectric Project FERC Project 2230. Supplemental Safety Inspection Report. Spillway Plunge Pool. Prepared for the City and Borough of Sitka. 12. R. W. Beck and Associates. 1974. Blue Lake Hydroelectric Project FERC Project 2230. Periodic Safety Inspection Report. Prepared for the City and Borough of Sitka. In addition, photographs of the existing features and the construction drawings, and other reference documents for the project are also available for review. 4. Project Geological Setting 4.1 Overview of Site Exploration and Investigation Programs Studies of the area for a hydroelectric project were started with geological mapping and drilling of 17 boreholes in 1952-53 in support of the design and construction of the existing project components. The location of all the boreholes is shown in the GDR or on the Drawings. Additional studies include Periodic and Part 12 Safety Inspections (de Rubertis 2004; Duke Engineering and Services 1999; Bowes 1994; R.W. Beck and Associates 1989, 1984, 1974) as per the requirements of the Federal Regulatory Energy Commission (FERC); Plunge Pool Surveys were carried out in 1968, 1983 and 1997 (Duke Engineering and Services 1997; R.W. Beck and Associates 1983); and a geotechnical reconnaissance was carried out in 2006 to examine the feasibility of connecting the water conveyance structure to a new powerhouse (de Rubertis and McArthur 2006). Further geotechnical investigations were conducted in 2009 and 2010 by Hatch in conjunction with the Design Development Study. These investigations included an inspection of the Lower and Upper Tunnels. The findings of all of these investigations are included in the GDR. 4.2 Overview of Geologic Settings Blue Lake occupies the west end of a broad, glacial, U-shaped valley. The lower end of the lake is bounded by bedrock cliffs up to 300 ft in height. The valley slopes are mantled with colluvium and talus deposits with bedrock outcrops exposed on the steeper slopes; there are also remnants of glacial till in the areas, in particular in the buried valley underlying the the Blue Lake access road. City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 6 © Hatch 2012/04 There are two distinct bedrock lithologies within the Project area belonging to the Kelp Bay group. The first is described by multiple sources as a combination of greywacke, phyllite, argillite, greenstone, greenschist, and metachert. This unit will be referred to as “greywacke”. Underlying the greywacke is a unit described as a “greenstone”, however, it is anticipated that all of the underground and surface excavations will occur entirely within the greywacke unit. City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 7 © Hatch 2012/04 4.3 Ground Characterization and Baselines 4.3.1 Site Tectonics Major faulting has occurred throughout the area, and the faults can be divided into two main groups; one northwest-trending, and the other east-west trending (USBR, 1954). The USBR mapped three major potential faults in the vicinity of the project area; one parallel to the upper channel of Sawmill Creek at the dam site, another thought to pass through the Beaver Lakes, and a third parallel to the shoreline at Herring Cove. None of these faults are considered active, nor are they associated with the dam, tunnel, adit, or other project excavation areas. The known earthquake history for the Sitka area is described by R&M (2011). Catalogs of historic earthquakes in southeast Alaska list at least 12 ≥ M6 earthquakes (excluding aftershocks) since the late 18th century that were reportedly felt strongly or resulted in some damage at Sitka; including at least eight earthquakes documented by seismographic measurements since 1898. Strong ground motion records available from the USGS and the Pacific Engineering Research Center (PEER) include data from one earthquake measured at the USGS observatory in Sitka: a M7.68 earthquake in 1972 along the offshore segment of the Fairweather fault, which produced a maximum PHGA of 0.0941g at Sitka, about 35 km west of the fault. Considering the Blue Lake project is about 6 km east of the Sitka observatory (i.e., about 41 km from the Fairweather fault), and neglecting topographic site effects, it is likely the PHGA experienced at the dam during the 1972 earthquake was reasonably close to the value recorded at Sitka. During the geotechnical investigations carried out in 1952-53, a narrow debris-filled stream channel was identified under the center of the arch dam, approximately 45 ft deep and 30 – 45 ft wide. This feature is thought to be associated with the fault parallel to upper Sawmill Creek mapped by the USBR (1954). The inactive Beaver Lake and Herring Cove faults are not near the tunnel, adit or surface excavation areas and are not discussed further in this report or in the GDR. Based on surface mapping and other observations, narrow faulted or shear zones, or zones with closely jointed rock, will be encountered during tunnel excavation, and specifically in the intake tunnel excavation area. These zones were inferred to correlate with concrete-lined sections of the existing intake tunnel. The approximate surface locations of all geological features are shown on the Drawings and on the Figures in the GDR. 4.3.2 Overburden Overburden test pits and exploratory boreholes were completed at the surface construction areas. Overburden depths in the construction areas are shown in Table 4-1. The 2009 borehole and test pit logs are included in Appendix D of the GDR. City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 8 © Hatch 2012/04 Table 4-1: Overburden Depths at Excavation Areas Feature Location Depth of Overburden (ft) Data Source(s) 20, 22 23, 26 Dam abutments, plunge pool, left abutment drainage tunnel 0.0 – 21.2 DH09-01 – DH09-04, DH09-07, DH09-08, DH-11 24, 25, 26, Intake, intake gate shaft, new intake tunnel alignment 0.0 – 41.4 DH09-05, DH09-06 , DH09-09, DH09-10, DH09-12 30 Surge chamber 2.0 DH09-14 31, 32, 55 Powerhouse, penstock, WTP, Existing access roads 1.1 – to over 16.0 DH09-15; TP-1, TP-2, TP-11, TP-15, TP-16, TP-3, TP-12, TP-17 45 Access road excavation areas 5.1 – 6.1 TP-6, TP-13, TP-18 NA Existing filter plant 4.0 – to over 18.0 TP-4, TP-5, TP-14A The overburden throughout most of the site is comprised of a wide range of materials, including: organic matter, angular rock fragments, boulders, gravel, sand, silt and clay. Grain size distributions of overburden material samples are found in Appendix G of the GDR and are described in the borehole and test pit logs provided in Appendix D of the GDR. Overburden will also be anticipated at the plunge pool area where the scour wall will be constructed. Fill material in this area is comprised of boulders, cobbles, and fragmented rock of various size infilled with alluvial material. The geotechnical investigations of 1952-53 identified a narrow debris-filled stream channel under the center of the arch dam that extends downstream of the dam in the plunge pool area. During dam construction, the debris was removed from this channel and a concrete base plug was cast from el. 140 to el. 210. The base plug was shored up by a temporary timber crib constructed at the downstream side. Construction photos indicate that the base plug was placed directly on alluvial material assumed to be up to 20 feet thick. The material in the channel was interpreted by the USBR (1954) to be comprised of talus and alluvium and is described as primarily sand and gravel, with some layers of silt and fine sand. The overburden material along the penstock alignment consists unstratified rockfill composed of gravel and boulders in a silty sand matrix. There are portions of the alignment where bedrock is required to be excavated. There are also portions of the alignment where sandy silt was encountered. City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 9 © Hatch 2012/04 The overburden around the powerhouse area consists of sand and gravel, with boulders up to 3 ft in diameter overlain by engineered fill (up to 6 ft in depth) composed of sand and gravel. The depth of overburden at construction site is inferred based on the data presented in the GDR. For baseline purposes, the bedrock profile is as shown by the neat lines on the Drawings. 4.3.3 Rock Types The two rock types present in the project area, the Triassic-Jurassic-aged greywacke, and the Permian-Triassic-aged greenstone, are described below. The Triassic–Jurassic greywacke is generally strong to very strong but locally contains abundant, typically discontinuous, and moderately weak to moderately strong, quartz-carbonate and calcite veinlets that will reduce the rock-mass strength. Also present are phyllitic zones and argillite lenses inter-bedded within the greywacke, which could adversely affect rock-mass strength. Most of the existing lower tunnel was excavated in the Permian-Triassic greenstone. This rock unit is typically strong to very strong but also contains weak to moderately weak calcite veinlets that will reduce rock mass strength. The downstream contact between the greywacke and the greenstone is gradational. The surface excavations and underground structures are expected to be constructed entirely within the greywacke unit. Baseline conditions and behavior of the greywacke are described in Sections 3.5 to 3.8, herein. None of the underground and surface excavations will occur within the greentstone unit. 4.3.4 Rock Mass Discontinuities The jointing in the Triassic – Jurassic greywacke is presented in stereo-plots and summarized in the GDR. These joint sets were measured on rock outcrops throughout the project area, as well as from data obtained using a down-hole optical televiewer. As with all naturally-occurring discontinuities, the orientations of these joint sets vary with depth and location. For the tunnels and shafts, wedge analyses of combinations of the joints resulted in the design of pattern rock bolts and spot bolting ground support as shown on the Drawings and described in the Specifications. For the surface excavations, such as the powerhouse and dam excavations, the joint set information was used in toppling, planar sliding, and wedge failure analyses and resulted in the design of rock support measures, including scaling, installing rock bolts, and rock anchors and drains, as shown on the Drawings and described in the Specifications. 4.3.5 Rock Mass Classification The rock mass has been assessed from cores from the 2009 boreholes DH09-09, 10, 12, 13 and 14, using the Rock Mass Rating (RMR) (Bieniawski, 1989). The assessment indicates predominantly good to very good (RMR values of 60 to 70) conditions in the greywacke. Figure 4-1 displays the RMR values obtained from these boreholes. City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 10 © Hatch 2012/04 Figure 4-1: Histogram of RMR for Greywacke The RMR-based tunnel and shaft rock support classes shown on the Drawings represent baseline classifications for all underground excavations. Surface excavation support is not determined using RMR data. 4.3.6 Groundwater Levels, Water Inflow and Hydraulic Conductivity The static groundwater levels could not be reliably measured in the boreholes during site geotechnical investigations and most of the water observed in the boreholes was residual drilling water. Piezometers have been installed in two locations and water levels were monitored between September 2009 and April 2011. One piezometer (DH09-08) is located in the plunge pool and recorded water levels between el. 185 and 200 ft in borehole DH09-13 and recorded water levels in the left abutment between el. 285 and 295 ft. The water levels were observed to be lower during late spring, with some fluctuations in late winter. There has been no evidence of significant seepage through the dam foundations during periodic dam safety inspections, dewaterings, and surveys of the plunge pool. Less than 40 gpm of groundwater seepage and surface runoff will flow into the dewatered plunge pool area during construction. 0 50 100 150 200 250 300 350 400 450 500 0-10 10-20 20-30 30-40 40-50 50-60 60-70 70-80 80-90 90-100 Total Length for All Boreholes (ft) RMR Range City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 11 © Hatch 2012/04 Water levels were monitored in the test pit excavations, but, as shown in Table 4-2, only 3 pits had groundwater inflows. Table 4-2: Water Levels in Test Pits Test Pit No. Location Water Level Elevation (ft) Comments TP-1 Powerhouse 12.2 Seepage at river level TP-3 Filter Plant road 75.4 Seepage below rock-fill and wood debris TP-15 Water Treatment Plant 70.4 Seepage at roadfill - native overburden material interface Water pressure testing and observations in the existing Upper Tunnel and right abutment adit indicate that the bedrock in the Project area is of low permeability - most of the joints in the boreholes were tight and groundwater did not seep into the boreholes at a sufficient rate to be measured during drilling. Water pressure testing in other boreholes drilled in the area also exhibited low rock permeability. Upper and Lower Tunnel and right abutment adit inspections were carried out in 2009. The Upper Tunnel and right abutment adit were generally “wet” to “dripping” with minor “dry” areas and no significant inflows (less than 1 gpm per 100 ft of tunnel). Portions of the existing Lower Tunnel exhibited “damp” to “dry” conditions with minor dripping areas and no significant inflow (less than 1 gpm per 100 ft of tunnel). Cumulative discharge at the portals will not exceed 40 gallons per minute. Slope drains were installed in both abutments of the dam during the 1952-53 dam construction, but their current effectiveness is unknown. Based on observations made during the 2009 geotechnical investigations, there is very little water seeping into the right abutment adit. Based on water testing in the 2009 boreholes, the ranges of hydraulic conductivity in the greywacke are expected to be as shown in Figure 4.2. City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 12 © Hatch 2012/04 Figure 4-2: Histogram of Hydraulic Conductivities in 2009 Boreholes Hydraulic conductivity will be less than 1x10-6 feet/second for 85% of the all underground excavations, and 1x10-5 ft/sec for the remaining 15% of the underground excavations and will be associated with fault(s), shears, and zones of close spaced joints. Hydraulic conductivity at the powerhouse location will be less than 4x10-7 feet/second and excavation inflow is anticipated to be less than 40 gpm. 4.3.7 Intact Rock Strength The UCS of intact rock is estimated from Point Load and Uniaxial Load tests on rock samples taken from boreholes in the left abutment of the dam, as well as boreholes along the alignments of the new intake tunnel, surge shaft, and existing Lower Tunnel. From lithologic descriptions of UCS test samples and documentation of the mode of failure of the test samples, it is concluded that the Unconfined Compressive Strength (UCS) of the bedrock is impacted by the presence of discontinuities and veinlets. Baseline UCS values are given in Table 4-3. 700.23 (55.6%) 107.36 (8.5%) 250.23 (19.9%) 148.12 (11.8%) 53.2 (4.2%) 0 (0.0%) 0 100 200 300 400 500 600 700 800 < 1e-8 1e-8 - 1e-7 1e-7 - 1e-6 1e-6 - 1e-5 1e-5 - 1e-4 > 1e-4 Total Length for All Boreholes (ft) Hydraulic Conductivity Range (ft/s) City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 13 © Hatch 2012/04 Table 4-3: Baseline of Intact Rock Strength for Greywacke Rock Type Min. and Max. UCS (ksi) Average UCS (ksi) Greywacke (Point load testing) 6.0 – 34.0 17.5 Greywacke (Uniaxial Compression testing) 10.0 – 28.7 17.0 The detailed laboratory test results can be found in the GDR. 5. Construction Considerations 5.1 Drilling and Blasting The Contractor is expected to carry out best practice for drilling and blasting and mechanical breaking to achieve as close as possible the design profile (neat line), minimize overbreak and eliminate underbreak. Overbreak and underbreak are defined in the Specifications. 5.2 Tunnels and Shafts Rock Support Design Rock support classes for the tunnels and shafts are presented on the Drawings for implementation during construction. The baseline aggregate quantities for each support class represent the Engineer’s interpretation of the distribution of rock quality and are not based on a specific data set of RMR estimated from borings. Preliminary relationships between rock mass quality and rock support are presented and may be adjusted during construction by the RPR in consultation with the Engineer. The selection of rock support will be determined after each blast round by the Resident Project Representative (RPR) and instructed to the Contractor. Stand-up time for all rock support classes will be adequate to install rock bolts, mesh, and steel sets. It is not anticipated that groundwater will be encountered in sufficient quantities to interrupt or significantly delay the excavation and construction activities. See Section 4.3.7 for groundwater inflow baseline conditions. Feeler holes, as described in the Specifications, are required in advance of every round to probe for unexpected water inflows, fault zones, and other difficult ground. Feeler holes can be used for drainage or grouting if greater than anticipated groundwater inflows are encountered. 5.3 Dam Excavation Dam and thrust block excavation designs are shown on the Drawings. The slope and bench designs are based on the Engineer’s interpretation of the rock quality data collected within the excavation City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 14 © Hatch 2012/04 area that included laboratory testing and field observations. Preliminary relationships between rock mass quality and excavation design are presented and may be adjusted during construction by the RPR in consultation with the Engineer. 5.4 Installation of Pressure Relief Wells & Scour Wall Pressure relief wells are to be installed in the plunge pool area at the base of the dam as shown on the Drawings. The orientations of the pressure relief wells are based on the Engineer’s interpretation of data and observations from the original dam construction and the 2009 investigations; these orientations may be adjusted as required during construction by the RPR in consultation with the Engineer. A scour wall will be constructed As Shown and include fill material placed behind it consisting of graded filter material (possibly from excavated tunnel rock) and overlain by rip-rap. The scour wall consist of a combination of a vertical micro-pile wall system and a reinforced concrete beam. 5.5 Penstock and Powerhouse Excavation Penstock and Powerhouse excavation designs are as shown on the Drawings. The slope designs shown are based on the Engineer’s interpretation of the rock and overburden conditions within the excavation area. The designs also take into account the locations of existing buried utilities and tie- ins that will be incorporated into the new water, sewer, and electrical systems. Interpreted relationships between rock mass quality and excavation and support design are presented and may be adjusted during construction by the RPR. 5.6 Geotechnical Mapping Geotechnical mapping will be performed regularly and continuously by the Engineer for each advance of the face during underground excavation and for each lift of slope excavations. 5.7 Geotechnical Measurements Geotechnical instrumentation, including blast monitoring, will be required for the assessment and monitoring of ground deformations during and after excavation. The various types of geotechnical instrumentation, locations, and installation and monitoring procedures are detailed in the Specifications and shown on the Drawings. Geotechnical measurements will be compiled into graphical form and compared with expected deformations and be examined by the Engineer for trends. This process, together with visual observations, is essential for the decision making, determination of final ground support, and adjustment of designed rock support. 5.8 Groundwater Control and Treatment Groundwater within the underground and surface excavations will be collected and treated as per the Specifications. The expected groundwater inflows are based on on the Engineer’s interpretation City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 15 © Hatch 2012/04 of the groundwater conditions and permeability of the rock and overburden materials in the vicinity of the surface and subsurface excavations. 6. Principal Project Features As noted above, most of the work specified in this contract involves both surface and underground rock excavations and foundation preparation. Table 6-1 lists the expected conditions, Drawings, and data available for each principal project featurein this contract (exploration boreholes described as DH09-x are from Hatch’s 2009 investigations and ‘DH-x’ are from the 1954 USBR report). City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 16 © Hatch 2012/04 Table 6-1: Principal Project Features Feature No. Description Explorations Expected Soil/Rock Conditions Expected Construction Methods Support Drawings Blue Lake Dam Structure Work 20 A) Right abutment rock support DH09-07, DH09- 11, DH-1, DH-7 Exposed bedrock only Scaling required prior to bolting (see scaling limits). Up to 30 rock bolts, with an average length of 20 ft will be installed on the right abutment. 109-20-020, 109-20-017 20 B) Left abutment rock support DH09-01, DH09- 02, DH09-03, DH09-04, DH09- 11, DH-7 Exposed bedrock only Scaling required prior to bolting (see scaling limits). Fully grouted, tensioned rock anchors will be installed as per design criteria. Up to 30 rock bolts, with an average length of 20 ft will be installed on the left abutment. 109-20-020, 109-20-017 20, 23 C) Left abutment drainage tunnel DH09-01, DH09- 02, DH09-03, DH09-04, DH09- 11 Bedrock 140-ft long, 13 ft high by 10 ft wide, D-shape drainage tunnel will be excavated. Scale loose rock on portal face and provide rock support, along with drainage, as indicated. 109-23-001, 109-23-002, 109-23-003, 109-23-004, 109-23-006 City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 17 © Hatch 2012/04 Feature No. Description Explorations Expected Soil/Rock Conditions Expected Construction Methods Support Drawings 20 D) Abutments, cutoff wall, and thrust block excavation/ foundation preparation, grout curtain DH09-07, DH09- 01, DH09-02, DH09-03, DH09- 04, DH09-11 Bedrock and loose rubble See excavation details 109-20-014, 109-20-015, 109-20-016, 109-20-017, 109-20-018, 109-20-019, 109-20-020 22 E) Plunge Pool Scour Wall and Pressure Relief Wells DH09-08, DH-2 - DH-6, DH10 – DH-13 Overburden comprised of sand, gravel cobbles and boulders, bedrock See excavation details 109-22-001 Dam Staging Area and Intake Work 20, 24, 25, 26 A) Re-grading of Blue Lake Access Road from the highway to the dam site and construction of Reservoir Access Road DH09-05 – DH09- 07, DH09-09 – DH09-12, DH14 – DH17 Rock slope excavation cuts will be required in some areas Areas of the new road will be concrete paved and other areas will be overlain by gravel. Road width decreases beyond the public access ramp from 15’-0” to 10’-0”. 109-05-005, 109-05-017, 109-05-018, 109-05-019 City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 18 © Hatch 2012/04 Feature No. Description Explorations Expected Soil/Rock Conditions Expected Construction Methods Support Drawings 24, 25, 26 B) Excavation (e.g. removal) of the rock cofferdam used for construction of the new intake tunnel DH09-10, DH09- 12 Bedrock Construct rock cofferdam between Blue Lake and the intake portal. Portal access road and cofferdam design as shown is optional. Contractor may develop alternate means of cofferdam protection. Rock bolt support will be required along the intake portal face. 109-05-017, 109-24-003, 109-90-005, 109-25-001, 109-25-002, 109-25-005 24, 25, 26 C) Foundation preparation for new intake DH09-10 , DH09- 12 Bedrock Excavate intake area to elevation as shown. 109-25-001, 109-25-002, 109-25-005, 109-25-006 25, 26 D) Excavation of the gate shaft DH09-10, DH09- 12 Bedrock and overburden A 109 ft deep, 11.5 ft diameter, circular intake gate shaft to be excavated. Rock support measures as shown. 109-26-001, 109-26-002, 109-26-003, 109-90-004, 109-24-003 24 E) Intake tunnel excavation and support, existing tunnel tie-in DH09-09, DH09- 10, DH09-12 Bedrock An 829-ft long, 12 ft high by 10 ft wide, D shape intake tunnel will connect to an existing intake tunnel. Tunnel dimensions vary in parts of the alignment. Rock support measures as indicated. 109-24-001, 109-24-002, 109-90-004, 24 F) Intake tunnel rock trap DH09-10, DH09- 12 Bedrock 4 ft deep rock trap to be excavated in the downstream side of the new intake tunnel. 109-24-002, 109-24-005, 109-24-006 City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 19 © Hatch 2012/04 Feature No. Description Explorations Expected Soil/Rock Conditions Expected Construction Methods Support Drawings 30 G) Surge shaft excavation DH09-14 Bedrock The 355-ft deep, circular surge shaft, composed of an upper section, 207 ft deep, 20 feet in diameter and a lower 148 ft deep section, 8 ft in diameter. 109-30-060, 109-30-040, 109-90-004 30 H) Construction adit excavation DH09-14 Bedrock 332-ft long, 12 ft high by 10 ft wide, D-shape construction access adit will be excavated to connect the base of the surge shaft and the existing lower tunnel. Support requirements as indicated. 109-30-040, 109-30-042, 109-90-004, 109-90-005, 109-30-060 New Powerhouse Work 45 A) Excavation and construction of access roads leading to powerhouse, filter plant, and water treatment plant. TP-1,TP-2, TP-3,TP- 4, TP-5, TP-6, TP- 11, TP-12, TP-13, TP-14, TP-15, TP- 16, TP-17, TP-18, DH09-15 Rock slope excavation cuts will be required in some areas. Filter plant access road will have concrete barriers on powerhouse side. Water Treatment Plant access road will be supported by pre-cast concrete gravity wall in selected area. 109-45-010 45 B) Excavation of penstock, powerhouse and afterbay area for the new powerhouse and penstock including penstock manifold TP-1,TP-2, TP-3,TP- 4, TP-5, TP-6, TP- 11, TP-12, TP-13, TP-14, TP-15, TP- 16, TP-17, TP-18, DH09-15 Sand and gravel rockfill (depth varies-see dwg), bedrock Penstock will be partially exposed above bedrock depth upstream of the powerhouse (as shown). 109-31-005, 109-31-006, 109-31-007 City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 20 © Hatch 2012/04 Feature No. Description Explorations Expected Soil/Rock Conditions Expected Construction Methods Support Drawings 45 C) Foundation preparation for new powerhouse TP-1,TP-2, TP-3,TP- 4, TP-5, TP-6, TP- 11, TP-12, TP-13, TP-14, TP-15, TP- 16, TP-17,TP-18, DH09-15 Sand and gravel rockfill (depth varies-see dwg), bedrock Powerhouse foundation will be on bedrock (as shown). 109-45-006, 109-45-007, 109-45-008, 109-45-009 45 D) Underground Utilities plan TP-1,TP-2, TP-3,TP- 4, TP-5, TP-6, TP- 11, TP-12, TP-13, TP-14, TP-15, TP- 16, TP-17, TP-18, DH09-15 Sand and gravel rockfill (depth varies-see dwg), bedrock Site utilities plan consists of two phases as described in the drawings 109-45-002, 109-45-003, 109-45-004, 109-45-005 31 E) Timber Crib Wall NA Sand and gravel rockfill Demolition of existing timber crib wall, removal of existing rockfill material and resurface to finishing grade 109-31-002, 109-31-003, 109-31-004 City and Borough of Sitka - Blue Lake Hydroelectric Expansion Project Geotechnical Baseline Report for Tunnel and Adit Construction – March 23, 2012 Rev. 3, Page 21 © Hatch 2012/04 References Barton, N.R., Lien, R. and Lunde, J. 1974. Engineering Classification of rock Masses for the Design of Tunnel Support. Rock Mechanics and Rock Engineering (Springer), Volume 6, No. 4, pp 189– 236. Bieniawski, Z.T. 1989. Engineering Rock Mass Classifications. New York: Wiley. Essex, R. J. et al. 2007. Suggested Guidelines, Geotechnical Baseline Reports for Construction. American Society of Civil Engineers: Reston, Virginia. Hatch Associates. 2011. Blue Lake Expansion Project: Contract No. 9 – General Construction Drawings. Prepared for City and Borough of Sitka. Hatch Associates. 2011. Blue Lake Expansion Project: Contract No. 9 – General Construction Specifications. Prepared for City and Borough of Sitka. Hatch Associates. 2011. Blue Lake Expansion Project: Geotechnical Design Report. Prepared for City and Borough of Sitka. Hoek, E. 2007. Practical Rock Engineering. Found on the Rocscience website at: http://www.rocscience.com/hoek/corner/Practical_Rock_Engineering.pdf United States Department of the Interior Bureau of Reclamation. 1954. Preliminary Report on the Blue Lake Project. Sitka, Alaska. Alaska District Office, Juneau Alaska.