01_Eisenhower_Lock_13.8KV_Cable_Specifications.pdf

Eisenhower Lock 13.8KV Cable Replacement Specifications Page 1 of 7

Eisenhower Lock 13.8KV Cable Replacement Specifications

1. Scope of Work

A. Two buried medium voltage cables at Eisenhower Lock have been damaged and need replacement. The contractor shall replace both damaged cables named Seaway 1 and Seaway 2.

The existing buried cables cross two drainage ditches, a road, and three fence lines. To eliminate the ditch where the cables cross near the North side of the road crossing, the contractor shall extend the storm and sanitary lines to daylight downhill over the new cables. The contractor shall perform the following work:

1. Remove the damaged cables this includes all excavation required to expose the cables for removal.

2. Remove existing road crossing, ditch crossings, fence crossings and install new according to the drawings.

3. Install new sections of cables including all trenching, backfill, restoration, terminations, testing, and reconnecting both ends of both cables.

4. Test each cable to verify functionality/integrity before installation, after installation but before terminations, and after installation and terminations but prior to final connections and energizing.

5. Extend the existing storm and sanitary lines approximately 6 feet downhill of new cables.

Maintain slope of the drainpipes.

6. Install buried cable markings over entire length of cable runs.

B. Major job materials will include six heat shrink terminations (three per cable) on one end and six dead break terminations on the other (three per cable) and approximately 1500’ of 15kv armored cable (750’ per cable).

2. Quality Assurance

A. Qualification for electrical contractor installer: contractor shall utilize journeyman electrician with previous medium voltage, armored cable installation and termination experience.

B. Testing Agency Qualifications: Contractor shall engage the services of a third-party testing agency.

Accredited member of NETA or an NRTL. Testing Agency's Field Supervisor: Certified by NETA to supervise on-site testing. Third-party testing agency shall be the following or preapproved equal:

RESA Power Field Services and Testing, 6268 State Route 31, Cicero, NY 13039. Contact Person:

Neil Wicks - office (315) 699-5563, cell (315) 401-1535.

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3. Products

A. Armored Cable - Armored cable shall match existing Okonite 15kv Okoguard Shielded Power Cable Aluminum Sheath, cable C-L-X Type MV-105. Catalog number 571-23-3524. Refer to attached cut-sheets. The primary wiring to each 13.8 KV switch shall be two independent feeds (Seaway 1 & Seaway 2) of aluminum jacketed armored cable UL type MV-105/MC shielded, 105deg C, 15 KV, 133% insulation level, three conductor #4/0 AWG with #3 AWG ground. The conductors shall be class B compressed soft or annealed concentric stranded bare copper. The conductors shall be shielded with an extruded semi-conducting thermosetting polymeric layer over the conductor applied in tandem with and firmly bonded to the insulation. The insulation shall be EPR (ethylene propylene rubber), 133% insulation level, with an average thickness of 0.220” and a minimum spot thickness not less than 90% of the average. The insulation shall be shielded with an extruded layer of semi-conducting thermosetting material. Over this layer shall be a helically applied, lapped, 5 mil bare copper tape. A suitable binder tape may be applied over the shielding. The insulated and shielded power conductors shall be round with fillers and with a grounding conductor in one outer interstice and covered with a binder tape. The cable shall be encased by an interlocked aluminum jacketed armor. The armor shall be covered with an overall red PVC (polyvinyl chloride) jacket that is flame and sunlight resistant. The average thickness shall be in accordance with ICEA and the minimum spot thickness not less than 80% of the average. The cable shall be identified by surface printing on the jacket. It shall meet or exceed the following standards:

1. UL 1072

2. IEEE 1202, CSA/FT4

3. ICEA T-29-520

4. IEEE 383

5. ICEA S-93-639/NEMA WC-74

B. Heat Shrink Terminations – Tyco Electronics’ Raychem. Contractor shall utilize Raychem heat shrink terminations MOD-3A-HVT for the Seaway 1 and Seaway 2 connections to the bottom of the NYPA fused switches.

C. Deadbreak Terminations – Cooper Power Systems. Contractor shall use Cooper Power Systems 600A, 15KV Class BOL-T Deadbreak Connectors model# BT625DD16A1T for the Seaway 1 and Seaway 2 connections to the existing Cooper Deadbreak junction.

D. Carsonite Line Marker CLM-72-04-24-04 or approved equal. Contractor shall submit enhancer wording for approval. See attached cut-sheets.

E. Compression Lugs and Grounding. Contractor shall use Burndy Hyground compression system for all connections for terminations or grounding system connections and repair.

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4. TESTING

A. The contractor shall perform, at a minimum, an insulation resistance acceptance test on all new cable pieces prior to installation in the ground. The contractor shall submit both the certified factory test results and his own onsite testing results to GLS COR for approval before installing them. If they are not deemed acceptable, the contractor shall replace the cables with new cable at no additional cost to GLS.

B. The contractor’s approved third-party testing agency shall perform “Installation” testing of both Seaway 1 and Seaway 2 cables after they have been completely installed in the ground but prior to any terminations being made. The testing shall conform to IEEE Standard 400.2-2013 as shown below in Table 3. The testing results will be submitted to GLS COR for approval before performing terminations. If they are not deemed acceptable, the contractor shall either identify the reason for failure, correct it and perform additional testing to show compliance or replace the cables with new cable at no additional cost to GLS.

C. The contractor’s approved third-party testing agency shall perform “Acceptance” testing of both Seaway 1 and Seaway 2 cables after they have been completely installed in the ground and all terminations have made but prior to energizing. The testing shall conform to IEEE Standard 400.2-2013 as shown below in Table 3 with a duration of no less than 60 minutes. The testing results will be submitted to GLS COR for approval before completing connections and energizing. If they are not deemed acceptable, the contractor shall either identify the reason for failure, correct it and perform additional testing to show compliance or replace the cables with new cable and terminations at no additional cost to GLS.

Background

When performing a VLF Withstand test on shielded power cable, it’s recommended to follow the guidelines as set forth by the IEEE 400.2-2013 standard. The test voltage and time duration are critical for each test described within the standard and are the result of many years of VLF field use and 3rd party research. A VLF Withstand test performed as per IEEE 400.2-2013 will trigger a partial discharge event within any defect large enough to be excited by the test voltage applied and drive this defect toward failure during the test. If the test duration is not long enough, the test may only severely weaken the defect resulting in an in-service failure sometime after the now insulation compromised cable has been put back into service. Lesser defects are not affected, as they are not large enough to be excited into PD by the applied test voltage. They remain dormant and are not aggravated by the test voltage since it is below the PD inception voltage level of the defect.

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VLF AC Withstand Testing of Cable The purpose of a withstand test is to verify the integrity of the cable under test. If the test cable has a defect severe enough at the withstand test voltage, an electrical tree will initiate and grow in the insulation. Inception of an electrical tree and channel growth time are functions of several factors including test voltage, source frequency and amplitude, and the geometry of the defect. For an electrical tree from the tip of a needle in PE insulation in laboratory conditions to completely penetrate the insulation during the test duration, VLF ac voltage test levels and testing time durations have been established for the two most commonly used test voltage sources, the cosine-rectangular and the sinusoidal wave shapes. However, the time to failure will vary according to the type of insulation such as PE, paper, and rubber. Thus, the electrical tree growth rate is not the same for all materials and defects.

IEEE Std. 400.2-2013 IEEE Guide for Field Testing of Shielded Power Cable Systems Using Very Low Frequency (VLF) (less than 1 Hz)

Table 3 - VLF withstand test voltages for sinusoidal and cosine-rectangular waveforms (see note 1)

Waveform Cable System Testing

(phase to phase) kV

Installation

(phase to ground)

Acceptance

(phase to ground)

Maintenance2 (phase to ground)

See Note 2 kV rms kV peak kV rms kV peak kV rms kV peak

Sinusoidal 5 9 13 10 14 7 10

8 11 16 13 18 10 14

15 19 27 21 30 16 22

(Note 3)

(Note 3)

26 37 20 28

(Note 3)

(Note 3)

32 45

(Note 3)

(Note 3)

28 32 45

(Note 3)

(Note 3

27 38

30 34 48 38 54

(Note 3)

(Note 3)

35 39 55 44 62 33 47

46 51 72 57 81 43 61

69 75 106 84 119 63 89

NOTE 1 - If the operating voltage is a voltage class lower than the rated voltage of the cable, it is recommended that the maintenance test voltages should be those corresponding to the operating voltage class.

NOTE 2 - The maintenance voltage is about 75% of the acceptance test voltage magnitude.

NOTE 3 - Some existing test sets have a maximum voltage that is up to 5% below the values listed in the table. These test sets are not acceptable to be used. There is a risk that the cable may be “undertested” due to a combination of lower test voltage and allowed uncertainty of the measuring circuit.

VLF ac voltage testing methods utilize ac signals at frequencies in the range of 0.01 Hz to 1 Hz. The most commonly used, commercially available VLF ac voltage test frequency is 0.1 Hz. VLF ac test voltages with cosine-rectangular and the sinusoidal wave shapes are most commonly used.

Eisenhower Lock 13.8KV Cable Replacement Specifications Page 5 of 7

The voltage levels (installation and acceptance) are based on the most used, worldwide practices of from less than 2 U0 to 3U0, where U0 is the rated rms phase to ground voltage, for cables rated between 5 kV and 69 kV. The maintenance test level is about 75% of the acceptance test level. One can reduce the test voltage by another 20% if the voltage is applied for longer times (Bach [B2]; Baur, Mohaupt, and Schlick, [B6]; Krefter [B27]). Evidence (Hernandez-Mejía, et al. [B21]) indicates that increasing the voltage above 3U0 to compensate for reduced test cycles (time) does not replicate performance either on test or in service as compared to the lower voltage, longer time tests.

Table 3 lists voltage levels for VLF withstand testing of shielded power cable systems using cosine-rectangular and sinusoidal waveforms (Bach [B2]; Eager, et al. [B9]; Krefter [B27]; Moh [B28]). For a sinusoidal waveform the rms is

0.707 of the peak value, assuming less than 5% harmonic distortion. The rms and peak values of the cosine-rectangular waveform are assumed to be equal. It should be noted that terminations may need to be added to avoid flashover for installation tests on cables rated above 35 kV.

The recommended minimum testing time for a simple withstand test on aged cable circuits is 30 min at 0.1 Hz (Goodwin, Oetjen, and Peschel [B13]). If a circuit is considered as important, e.g., feeder circuits, then consideration should be given to extending the testing time to 60 min at 0.1 Hz (Hampton, et al. [B19].

The recommended minimum testing time for an installation and/or acceptance withstand test on new cable circuits is 60 minutes.

A test time within the range 15–30 min may be considered if the monitored characteristic remains stable for at least 15 min and no failure occurs. It should be noted that the recommended test time for a withstand test is 30 min.

If the circuit fails during the test, it should be repaired or replaced and then retested using a complete 30-minute test, preferably a monitored withstand test. It is recommended to retest each section with VLF-TD, VLF-DTD, VLF-TDTS, or VLF-PD before the repair to get an assessment of the cable before repair. It is also recommended to retest with VLF-TD, VLF-DTD, VLF-TDTS, or VLF-PD after repair to assess the workmanship of the repair. Monitoring cannot be used to reduce the tests as the cable system has already been shown to be potentially weak by the prior failure.

Summary The above information describes VLF Withstand testing, where the intent of the test is to apply a sufficient test voltage for a long enough time to permit any severe defects driven into partial discharge to fail within the test duration. If a defect can’t withstand the test voltage, let it fail and make the repair or replacement. If the cable holds, the operator has a high assurance that the cable should not fail in service for many years.

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5. Execution

A. Utilize some type of weatherproof enclosure or structure, such as a tent, to totally encase the entire outdoor termination work area while performing the terminations’ work. Keep area clean of dirt, debris, and water. All cable ends shall be encased in weatherproof seals to prevent moisture and other contaminates from entering unless they are actively being tested or terminated.

B. Underground Ducts Crossing under paved roads and ditches shall be schedule 80 PVC encased in reinforced concrete. Refer to drawing for details of trench and road work.

C. Concrete-Encased Ducts and Duct Bank:

1. Excavate trench bottom to provide firm and uniform support for duct.

2. Width: Excavate trench a minimum of 6 inches wider than the duct on each side.

3. Depth: Install so top of duct envelope is at least 48 inches below finished grade.

4. Support duct on duct spacers.

5. Spacer Installation: Place spacers close enough to prevent sagging and deforming of duct, with not less than five spacers per 10 feet of duct. Place spacers within a maximum of 12 inches from duct ends. Secure spacers to earth and to duct to prevent floating during concreting. Tie entire assembly together using fabric straps; do not use tie wires or reinforcing steel that may form conductive or magnetic loops around ducts or duct groups.

6. Reinforcement: Arrange reinforcing rods and ties without forming conductive or magnetic loops around ducts or duct groups.

7. Forms: Use walls of trench to form side walls of duct bank where soil is self-supporting and concrete envelope can be poured without soil inclusions; otherwise, use forms.

8. Concrete Cover: Install a minimum of 6 inches of concrete cover between edge of duct to exterior envelope wall. Concrete duct shall be a minimum of 4 inches thick above the top of each PVC pipe.

9. Pouring Concrete: Place concrete carefully during pours to prevent voids under and between duct and at exterior surface of envelope. Do not allow a heavy mass of concrete to fall directly onto ducts. Allow concrete to flow around duct and rise up in the middle, uniformly filling all open spaces. Do not use power-driven agitating equipment unless specifically designed for duct-installation application.

10. Mix into concrete compatible red coloring covering the entire surface of the duct bank.

11. Install a high voltage buried electric/danger tape horizontally and parallel to each cable 12 inches above the top of the concrete duct bank and 12 inches above each cable where direct buried.

12. Repair or replace in kind any guard rails and fencing that was removed or disturbed because of work whether necessary for trenching or access or other. If the original location of posts or other support structures must be relocated, the contractor shall use an approved GLS method for placement as approved by the COR. All equipment and hardware shall match the existing in size, strength, and other pertinent properties.

D. Contractor shall provide and install new GLS approved high voltage buried cable markings a minimum of every 50 feet for the entire length of both cables approximately in the center of the

Eisenhower Lock 13.8KV Cable Replacement Specifications Page 7 of 7 cable trench. Contractor shall install each marker 24 inches in the ground according to manufacturer’s recommendations.

E. All concrete work shall be as described above or shown on the drawings and conform with attached specification named “C.24 Concrete”. If there are any conflicts in the requirements, the most stringent shall apply and be resolved by the COR.

F. All sitework and restoration shall be as described above or shown on the drawings and conform with attached specification named “C.23 Sitework”. If there are any conflicts in the requirements, the most stringent shall apply and be resolved by the COR.

G. All Fencing and guardrail repair or replacement shall be as described above or shown on the drawings and conform with attached specifications named “C.18 Fencing” and “C.20 Fence Post and Guardrail Foundations”. If there are any conflicts in the requirements, the most stringent shall apply and be resolved by the COR.

H. Contractor shall comply with attached specification “260500 Common Work Results For Electrical”. If there are any conflicts in the requirements, the most stringent shall apply and be resolved by the COR.

C.24. CONCRETE

a. General. The scope of this item includes all cast-in-place concrete for fence or guardrail posts, and trench work as shown on the contract drawings or disturbed through the contractors’ work. Work performed under this section shall include the installation of insulation, construction and removal of formwork, installation of reinforcing steel, anchor bolts and utility penetration sleeves, placement and curing of concrete and installation of control joints as required. Where standards or codes are cited or referenced, the latest editions of these shall govern the project. The following definitions apply: “Concrete” is a mixture of Portland cement, fine aggregate, coarse aggregate, water, and admixtures, that is mixed completely in full accordance with these specifications and the applicable provisions of ASTM C94. The use of a particular supplier of concrete is subject to the Corporation’s acceptance of the supplier and the supplier’s plant and equipment. “Cement” is Portland cement meeting ASTM C-150. No other cementitious materials will be permitted.

“Compressive strength” is the average result of two standard 6 in. x 12 in. cylinders fabricated and tested in accordance with ASTM C-31 and ASTM C-39. “Sack” is equivalent to 94 lbs. of cement. The following American Concrete Institute (ACI) standards shall apply to the materials, proportioning, measuring, mixing, placing, curing and inspection of the concrete:

● Selecting Proportions for Concrete ACI-211

● Guide for Use of Admixtures in Concrete ACI-212

● Specifications for Structural Concrete in Buildings ACI-301

● Measuring, Mixing, and Placing Concrete ACI-304

● Hot Weather Concreting ACI-305

● Cold Weather Concreting ACI-306

● Curing Concrete ACI-308

● Recommended Practice of Consolidation of Concrete ACI-309

● Recommended Practice for Concrete Inspection ACI-311

● Building Code Requirements ACI-318

● Concrete Formwork ACI-347

b. Submittals. The following are to be submitted to the COR prior to the start of work.

1. Materials List. The materials list shall be comprised of the following:

● Complete list of materials to be furnished under this item with sufficient data to indicate conformance with specified requirements.

● Cement data; source of supply, physical and chemical properties, mill certificates, handling procedures, cube strengths, etc.

● Aggregate data; sources, procurement, processing, storage, conformance with required properties.

● Admixture data; type of admixture, manufacturer, properties, etc.

● List of materials for formwork, including details of forming system, accessories and form release agents.

2. Shop Drawings. Detailed working drawings and schedules showing reinforcing steel designations (shop marks), bends, quantities, sizes and incorporated locations accompanied by the steel producer’s certificates of mill analysis and physical (bend and tensile) testing shall be submitted to the COR for review. No fabricating or placement of reinforcing steel will be permitted until such drawings, schedules and reports have been reviewed by the COR.

3. Cement Test Certificates. Certificates presenting the results of the testing of three representative cement samples for fitness, soundness, time of setting and three (3) day and seven (7) day compressive strengths shall be provided for each shipment of cement to be used in the work. In lieu of the above, current certificates of acceptance by the NYSDOT will be accepted by the COR.

4. Mix Designs. A mix design shall be prepared and tested for each concrete mix proposed for the project. Certified reports from the supplier for the same mix used in other applications will be accepted if they are no more than six (6) months old and use the same materials and proportions as proposed for the project. If these reports are not available, a new mix design shall be prepared and tested by a testing laboratory retained by the Contractor or supplier. The mix design report shall contain the following information:

● Complete listing of all ingredients, sources and proportions used in each mix proposed.

● The three (3) and seven (7) day compressive cube strengths for the actual cement used in the design mix and proposed for use in the work.

● The actual water-cement ratio, slump, temperature, air content, and unit weight of each mixed batch.

● Aggregate moisture contents, as-batched, with the appropriate corrections for the actual water-cement ratios.

● Gradation of each aggregate and the computed gradation of the entire mix, excluding the cement, in both tabular and graphic forms.

● Seven (7) and twenty-eight (28) day compressive strength data.

● Graphical plots of compressive strength versus water-cement ratio.

Compressive strengths shall be determined by the testing of standard 6 in. x 12 in. test cylinders in accordance with ASTM C-31 and C-39. A minimum of four cylinders shall be tested, two at seven (7) days and two at twenty-eight

(28) days. The test results for specimens less than twenty eight (28) days old shall be used in conjunction with the age-strength data published by the Portland Cement Association (PCA) as a guide to the anticipated twenty-eight

(28) day strength of the mix. Until the twenty-eight (28) day strength data become available, this value shall be considered evidence of non-compliance with the strength requirements if the twenty-eight (28) day strength obtained by such a projection of early strength data is less than the specified twenty-eight (28) day strength. The range of water-cement ratios reported in the design mixes shall be such that it completely defines the water-cement ratio versus compressive strength relationship for the compressive strength specified and for the conditions under which the concrete will be placed.

5. Samples. If requested by the COR, samples of all products required to complete work under this item shall be submitted.

c. Materials.

1. Cement. Cement shall be a standard domestic Portland cement meeting the requirements of ASTM C-150, Type II. The cement shall be currently certified acceptable by the NYSDOT or in lieu of this certification; it shall have been tested within the last two (2) months by an independent testing laboratory for the following parameters: fitness, soundness, time of setting, and three (3) day and seven (7) day compressive strength. If requested by the COR, three samples of cement from each shipment shall be tested for the above parameters. The cement shall be delivered to the plant in airtight tankers and be accompanied by shipping certificates plainly marked with the brand, manufacturer, type of cement, place of manufacture, batch number and the net weight. It should be stored in airtight silos, for a period of no longer than sixty (60) days. Cement stored more than sixty (60) days shall be subject to acceptance based on the testing described above. Any such testing shall be at the expense of the Contractor. Cement that deteriorates or hardens during storage will not be acceptable.

2. Aggregates.

● Fine aggregate shall consist solely of clean, natural sand produced by screening and washing and shall be free from dust, soft or flaky particles, mica, loam, clay, organic matter or frozen material and shall conform to ASTM C-33. Sand exhibiting a color darker than the reference color when tested for impurities in accordance with ASTM C-40 shall not be used. The fine aggregate gradation shall conform to the requirements of ASTM C-33. The sand particles shall be rounded or subrounded in shape as defined by ASTM D-2488.

● Coarse aggregate shall consist of crushed gravel or crushed stone which is comprised of hard, durable pieces and is free from adherent coatings and deleterious substances. Coarse aggregate shall meet the requirements of ASTM C-33 and shall be graded in accordance with the requirements of Table II in ASTM C-33 with a designated particle size of 1 in. to 3/8 in. (Size No. 56).

● The combined fine and coarse aggregate shall be of such size that when separated on a No. 4 Standard Sieve, no more than 50% or less than 30% of the total weight passes the sieve.

● Aggregate sampling and testing shall be performed in accordance with ASTM C-33 and ASTM C-40. Certified test reports no more than six (6) months old may be accepted from suppliers in lieu of performing the aggregate testing as noted above.

● The aggregate moisture content shall be determined on a daily basis and as necessary. This test result shall be used to adjust the quantity of water added to the concrete mixture.

3. Water. The water used in mixing concrete shall be clean, potable water free from any acid, alkali, organic matter or other deleterious materials.

4. Admixtures. Admixtures other than the standard air-entraining and water-reducing admixtures shall be used only upon approval of the COR. All admixtures shall conform to ASTM C-260, C-494 and/or C-1017.

5. Fly Ash. The fly ash, if used, shall conform to ASTM C 618.

6. Reinforcing Steel. Reinforcing bars shall consist of billet steel meeting the requirements of ASTM A-615, Grade 60 with a yield strength of 60,000 psi. The reinforcing steel bars shall be clean and free of defects, kinks, bends, rust, scale, oil or other coatings. Reinforcing in slabs shall be supported using wire bar type supports (chairs) in accordance with Concrete Reinforcing Steel Institute (CRSI) recommendations.

7. Formwork. Formwork for wall surfaces shall be constructed of smooth-faced, undamaged plywood or other panel-type materials, to provide continuous, smooth surfaces. Form ties shall be of such type that after removal of that portion external to the concrete face, no metal will be closer than 1 inch from the surface.

Form coatings shall be commercially formulated compounds that will not bond with or stain concrete, nor adversely affect concrete surfaces that require bond or adhesion, nor impede the wetting of surfaces to be cured with water.

8. Curing Materials. All slabs shall be moist-cured using curing blankets, or other means approved by the COR. Blankets shall be “Transguard 4000” as manufactured by Reef Industries, Houston, Texas, or approved equivalent. All walls, piers, footings, and similar items shall be moist cured using soaked burlap covered with polyethylene sheeting at least 6 mils thick.

9. Concrete Mixtures. The concrete mixture shall conform to the following:

● Minimum 28-day Compressive Strength (psi) 4000

● Entrained Air Content (%) 5 to 7

● Maximum Water–Cement Ratio 0.45

● Minimum Cement Factor (sacks per cubic yard) 6

● Maximum Slump (inches) 3

● Maximum Temperature as mixed (°F) 80

● Minimum Temperature as placed and maintained (°F) 55

● Time limit between charging cement to the mixer and completing discharge of the load (min.) 90

d. Installation/Placement.

1. Mixing.

i. Truck-Mixed Concrete. Truck mixers shall be of the inclined, rotating drum type, conforming to the “Truck Mixer and Agitator” standards of the Truck Mixers Manufacturer’s Bureau (TMMB). The mixer must have a water metering device accurate to plus or minus 2%. The mixer shall be cleaned after each load and shall have no more than 2 gals. of wash water remaining before charging the next load. The mixer may be charged with the complete load, including up to 60% of the total batch water, at the batch plant provided the time interval between batching and completion of discharge at the site does not exceed ninety (90) minutes. If this time limit cannot be met, the cement must be charged to the mixer at such a location as to meet the time limit.

Mixing may be done en route to the site and must be performed in accordance with ASTM C-94. Seventy (70) to 100 revolutions of the drum at mixing speed (6 to 18 RPM) shall be used, and after 100 revolutions, the drum should be rotated at no more than 2 to 6 rpm agitating speed. The mix shall be discharged within no more than ninety (90) minutes or 300 drum revolutions after the cement has been added to the mix. The mixer shall be operated within the volume and rotation speed limitations of the manufacturer. The slump may be adjusted at the site by no more than two (2) additions of water followed by complete mixing, and no water may be added to the mix after discharge of more than 2 cu. yds. or 25% of the mixer’s capacity.

ii. Site-Mixed Concrete. For small placements (2 cu. yds. or less) in miscellaneous work and if approved by the COR, site-mixed concrete may be used. Site-mixed concrete shall be mixed in a powered rotary batch-type mixer, at a minimum mixing time of one (1) minute per cu. yd. or less increased by fifteen (15) seconds for each additional 1/2 cu. yd. or fraction thereof. The minimum drum speed shall be 200 peripheral ft. per min. The mixer shall allow for ready and accurate control of ingredient weights, with positive shut-off, and otherwise meet the approval of the COR.

2. Formwork.

Forms shall conform to the applicable provisions of ACI-347 and to the shape, lines and dimensions of the cast-in-place concrete members shown on the drawings.

The forms shall be sufficiently tight as to prevent leakage of mortar, grout or paste and shall be designed and constructed sufficiently stable and rigid to maintain proper position, shape and dimensions of the cast-in-place member, before, during and after concrete placement and until removal. The forms shall be built and maintained such that when removed, the concrete surfaces will be left with a smooth surface free of offsets, ridges, fins and other defects. The formwork shall provide for all openings, chamfers, offsets, inserts and penetrations for other trades (pipe sleeves for utility lines) as required and the locations and dimensions of these features shall conform to those shown on the drawings or as designated by the COR. The aboveground exterior wall corners shall be chamfered by placing suitable moldings in the formwork corners at these locations. Form ties shall be spaced in accordance with the manufacturer’s recommendations. The removable portions of the form ties shall be withdrawn from the concrete within four (4) hours of removal of the forms (the four (4) hour time limit applies to exposed concrete), and the remaining holes shall be filled with grout and made smooth and flush with the wall. Footings may be cast against earth walls provided the earth contact surfaces are straight, smooth, and stable, the minimum dimensions as shown on the drawings are met and that one additional inch of concrete on all sides is provided. The forms shall be constructed so as to allow for removal without damage to the concrete. Prior to any concrete placement, the forms shall be clean and free of any foreign matter, ice, snow or other deleterious items. The Contractor shall be responsible for the adequacy and safety of the forms.

3. Reinforcing.

Steel reinforcing shall be supplied, fabricated and installed in accordance with the designated locations and dimensions, and in accordance with the applicable recommendations of the current edition of the CRSI Manual of Standard Practice.

Reinforcing steel shall be securely held so that it will be in the correct position after the concrete is in place. Bars shall not be bent in the field using heat. The placement of reinforcement shall be completed prior to the placing of any concrete and is subject to the inspection and approval of the COR prior to concrete placement. Reinforcing steel shall be adequately secured in position by suitable tie wires, spacers, chairs or other related accessories. Bars shall be fastened together with annealed steel wire of not less than 18 gauge or another approved method. Twisted ends of wire shall face away from exposed surfaces. Reinforcing shall not be used to support runways for construction equipment. Splices for reinforcing shall be lapped no less than 40 diameters for tension bars and 20 diameters for compression bars. The minimum clearances for concrete cover over the reinforcing bar shall be 2 in. At the time concrete is placed, the reinforcing shall be free from loose rust, scale, loose mill scale, oil, paint or other materials which would reduce the bond between the steel and the concrete. If necessary, the reinforcing shall be cleaned.

4. Embedded Items.

The Contractor shall be responsible for installation of anchor bolts furnished by the pre-engineered building manufacturer at the locations as shown on drawings furnished by that manufacturer. If the concrete floor option (Basic Requirement Contract Item No. 4b) is awarded, the Contractor shall also install anchors for the collector trench grating frame as shown on the contract drawings.

5. Concrete Placement.

Concrete shall be placed in accordance with the provisions of ACI-304. Discharge of concrete shall be through an unrestricted gate or opening, into acceptable bottom dump buckets, buggies, hoppers, conveyors or other devices or into chutes attached to the truck. Pumping is acceptable provided the equipment, mix design and procedures are approved by the COR. All conveying equipment shall be clean and free of foreign material, frost, ice, free water or other unsuitable materials. The delivery end of the chute shall be as close as possible to the point of deposit and the free fall shall not exceed 4 ft. Concrete shall be conveyed and deposited in such a way as to prevent segregation and should be deposited as close as possible to its final location. Concrete being placed in wall forms shall be deposited using an “elephant trunk” with a free fall not to exceed 3 ft. Concrete shall be adequately consolidated and the consolidation shall be supplemented by shoveling as necessary to evenly distribute the concrete throughout the area to be placed. The vibrator shall not be used to transport concrete laterally. Once the placement has started, it shall be carried out in a smooth continuous manner until the entire formed section is completed. Concrete that has partially set, been re-tempered, contaminated with foreign materials, exceeded the ninety (90) minute time limit from the time the cement was batched or rejected due to excessive temperature, slump, or nonconforming air content will not be accepted.

6. Consolidation.

All concrete shall be properly consolidated in accordance with ACI recommended procedures using suitable mechanical vibrators. The vibrator shall be inserted vertically and the vibration stopped when the first sheen of mortar appears on the surface. Two vibrators shall be used on all placements of any significant size, unless otherwise approved by the COR.

7. Hot Weather Concreting.

If temperatures exceeding 75oF and/or excessively dry conditions prevail during the batching, mixing, placement or curing period, special precautions shall be taken in preparing, mixing, delivering, placing, finishing and curing the concrete.

Hot weather concreting procedures shall be followed in accordance with ACI-305.

8. Cold Weather Concreting.

All reinforcing and formwork shall be free of frost and ice and shall be at a temperature of at least 45°F prior to concrete placement. If temperatures less than 40°F prevail during the batching, mixing, placement and curing period, special precautions shall be taken in preparing, mixing, delivering, placing, finishing and curing the concrete. Frost, ice or snow shall not be permitted in the concrete mix. The concrete shall be adequately heated or insulated, depending on the ambient temperature, to prevent freezing and to promote timely curing. Cold weather concreting procedures shall be followed in accordance with ACI-306.

9. Form Removal.

Forms shall not be removed until the concrete has gained sufficient strength to support live and dead loads that will be imposed on it during the construction period. Forms shall remain in place for at least three (3) days at temperatures above 60°F, five (5) days for temperatures between 50°F and 60°F and for seven

(7) days for temperatures 40°F to 50°F. If the temperature drops below 40°F, the forms shall remain in place for an additional amount of time equal to the duration of the sub-40°F exposure. The Contractor shall be responsible for form removal timing.

10. Finishing.

Imperfections such as blemishes, bugholes, voids, fins, etc. exposed upon form removal shall be corrected. Excessive honeycombing shall be repaired using a method acceptable to the COR. Tie holes shall be patched and smoothed and this should be done within four (4) hours of form removal for exposed concrete. Floor slab surfaces shall be steel-troweled and shall receive an integral cement finish applied before the initial set has taken place. The concrete shall be tamped until the top 1/4 in. is free of coarse aggregate, then the surface shall be floated and troweled to a uniform, true surface. The finished surfaces shall be protected from damage until the concrete has gained sufficient strength.

11. Curing.

Provision shall be made for maintaining the concrete in a moist condition and at a temperature between 45°F and 75°F for a period of at least seven (7) days after placement. All slabs shall be moist-cured using curing blankets or other means approved by the COR. Blankets shall be “Transguard 4000” as manufactured by Reef Industries, Houston, Texas, or approved equivalent. All walls, piers, footings and similar items shall be moist cured using soaked burlap covered with polyethylene sheeting at least 6 mils thick. The methods of curing must be reviewed and accepted by the COR prior to the start of concrete work.

12. Repair of Unacceptable Concrete.

Any concrete determined to be unacceptable by the COR shall be repaired, or removed and replaced at the expense of the Contractor. This includes excessively cracked, spalled, honeycombed, or otherwise damaged concrete. Random cracks or cracked floor slabs, if deemed repairable by the COR, may be repaired by means of a procedure acceptable to the COR.

e. Quality Control.

1. Testing and Inspection. The Contractor shall retain an independent construction materials testing laboratory acceptable to the Corporation to provide testing and inspection services for field quality control. These services shall include visual inspection of the formwork and reinforcement before concrete placements and also testing and inspection of the concrete during the placement. Slump, air content, water content and temperature shall be tested on each truck load. Four

(4) compressive strength test cylinders shall be taken for each fifty (50) cubic yards of concrete or fraction thereof. One cylinder shall be tested at seven (70 days, two at twenty-eight (28) days, and one shall be retained as a “hold” specimen.

The Contractor shall provide the COR a copy of each delivery ticket on which the water added to each truckload at the plant and in the field as well as the aggregate moisture content shall be recorded. The COR will have the authority to reject any concrete not meeting the specifications. All testing and inspection shall be performed in accordance with the appropriate ASTM and/or ACI standards and methods. Field reports shall be furnished to the COR within two (2) business days after the placement, and compressive strength test reports shall be delivered to the COR within two (2) weeks after the compressive strength test is performed except if the test shows low strength as defined below; in that case the report shall be rendered within one (1) business day after the test.

2. Test Result Evaluation. A compressive test result is considered the average of two cylinders. No single twenty-eight (28) day test result (the average of two cylinders) shall be more than 500 psi below the specified strength. In addition, the average of any three successive 28-day tests must equal or exceed the specified strength. In the event of low strength test results, the “hold” cylinder shall be tested. If this test shows a low strength, the concrete shall be considered rejectable. In that event, at the option of the COR, drilled core test specimens may be obtained and tested in order to provide supplemental information for use by the COR in deciding whether to reject or accept the concrete represented by the low strength tests. Any such coring and testing shall be performed at the Contractor’s expense and with the approval of the COR.

C.23. SITE WORK

a. General. The scope of this item includes all excavation, fill and backfill required for installation of the new cable feeders, and for general site grading as required.

b. Materials.

1. Select Granular Fill (Structural Fill). Select granular fill shall consist of clean sand and gravel conforming to the requirements for New York State Department of Transportation (NYSDOT) Item 304.04 “Subbase Course, Type 3”. NYSDOT Item 304.02, Subbase Course, Type 1, or Item 304.05, Subbase Course, Type 4 may also be used at the option of the Contractor.

2. Crusher-Run Stone. Crusher-run stone shall have 100% of the material passing the 2 in. screen and shall be solely the product of crushing ledge rock at a NYSDOT-approved quarry.

3. Random Fill. Random fill may consist of soil from on-site sources but shall exclude material in excess of 6 inches in size, organic matter and other unsuitable materials as determined by the COR.

c. Procedures.

1. Procedures. The excavation shall be advanced to lines and grades as shown on the contract drawings. Any topsoil must be carefully stripped from the site and spoiled in an approved location. Excavations shall be of sufficient size and no larger than required for the proper construction of the structures. This includes allowance for dewatering, formwork, shoring and other similar work necessary to complete the Contract. Over-excavation will not be allowed except where required for dewatering, to remove unstable material or as otherwise approved by the COR.

2. Safety. Excavation safety must be maintained in accordance with 29 CFR 1926, Subpart P, “Excavations”. Excavations deeper than 5 ft. must be shored or sloped for sidewall stability in accordance with the above. If sheeting and bracing are to be used, this must be designed and constructed in accordance with the applicable provisions of 29 CFR 1926, Subpart P, “Excavations”, and good engineering practice. All sheeting and bracing must be removed as the excavation is filled.

3. Dewatering. As/if needed to control groundwater or surface water accumulation in excavations, sumps for pumping shall be constructed outside the excavation neat lines The water level shall be maintained below the level of the excavation bottom at all times while work is in progress and until the completed structure is backfilled. Sufficient standby pumping equipment must be provided to insure maintenance of the water level below the excavation. Water pumped from the excavation must be disposed of in a suitable manner without damage to adjacent property or the work under construction. Mud residues must not be disposed of in the river or storm sewers or on paved or traveled surfaces.

4. Subgrades. Subgrades to support structures shall consist of undisturbed in-situ soils. Saturated and unstable soil conditions at the bottoms of foundation excavations shall not be tolerated. If saturated and unstable soils are encountered, they shall be removed using hand methods or a toothless backhoe bucket to minimize disturbance, and replaced with a 6 to 8 in. layer of No. 2 crushed stone as described under C.17.b.2. “Crushed Stone”. The crushed stone shall be compacted with two to three passes of a hand-guided compactor. This crushed stone layer will provide a stable working surface and a medium for drainage.

5. Placement. Select granular fill shall be placed in a 1 ft. layer over the subgrade under the wall footing, as backfill to within 1 ft. of the surface inside the building perimeter, and within 3 ft. of the building exterior. Random fill may be used for site fill in areas other than the above. All backfill shall be placed in lifts not to exceed 8 in. in loose thickness and be compacted to a density of no less than 95% of the maximum dry density as determined by laboratory testing in accordance with American Society for Testing and Materials (ASTM) D-1557 “Modified Proctor”. The moisture content during compaction should be within + 2% of the Optimum Moisture Content as determined thorough laboratory testing per ASTM D-1557.

6. Unsuitable Materials. The following materials shall not be included in fill or backfill; organic materials, boulders or rocks more than 6 in. diameter, topsoil, frost, ice, snow, saturated materials, debris, trash or other unsuitable materials as determined by the COR.

7. Storage of Excavated Materials. All excavated materials that are to be re-used on site shall be stored in locations so as not to impact the work and such that easy access may be had at all times to all parts of the excavation. These materials must be kept neatly piled and trimmed and must be covered to prevent runoff of silt and fines. Waste excavated soils may be disposed on Corporation property at a spoil area at the east end of the storage yard at the Marine Base/Maintenance Facility.

d. Quality Control.

• The Contractor shall retain an independent construction material testing laboratory acceptable to the Corporation to provide testing and inspection services for field quality control. The scope of these services will include testing and analysis to determine properties and suitability of fill, backfill and other materials as described in these specifications and contract drawings. The services shall also include compaction testing/inspection of fill and backfill as described in this sub-paragraph.

• The suitability of proposed select granular fill material shall be evaluated through the performance of a gradation analysis in accordance with appropriate ASTM procedures. A laboratory compaction curve for this material shall be established through a three point Modified Proctor test per ASTM-D1557. This testing shall be repeated if the material varies during the course of the work or at the request of the COR.

• In-place density testing shall be performed at a minimum of three tests per lift.

Areas not meeting the specified compaction criteria shall be reworked (adjust moisture content as necessary and re-compact) and re-tested.

• Two copies of all test results shall be submitted to the COR within forty-eight (48) hours of the performance of the test and copies of the field test results shall be submitted to the COR prior to the end of each day.

C.18. FENCING.

a. Scope. The Contractor shall repair, replace, fabricate, furnish, deliver and erect new chain link fencing as described in these specifications and as shown on the contract drawings.

b. Materials. The materials shall conform to the following:

• Fabric: The fabric shall be made of 9-gauge zinc-coated steel wire, ASTM A-

392. 1.2 oz./sq. ft, wire spec ASTM A-817-83. It shall be helically wound, 2-inch mesh size, woven to the full height of 7 ft. and knuckled at both selvages.

• Posts: Minimum sizes of posts shall be as designated on the drawings. All posts shall be hot dip galvanized and shall consist of cold formed and welded steel pipe complying with ASTM F-1043, Group 1C with minimum yield strength of 50,000 psi. The post material shall have external coating Type B 0.9-oz/sq. ft. zinc coating with chromate conversion coating and organic clear coat. Internal coating shall be Type B, minimum 0.9-oz. /sq. ft. zinc or Type D, zinc pigmented, 81% nominal coating, and minimum 3 mils thick. Standard weight steel pipe may also be used, Type I, ASTM F1083, Schedule 40, minimum yield strength 25,000 psi, hot-dipped galvanized with minimum average 1.8 oz. /sq. ft. of zinc coating. Alternative zinc-coated posts (square tubing, formed steel “C” sections, “H” sections, etc.) may be used if part of an integrated fence system approved by the COR.

• Top rail and horizontal bracing shall be of the same material and surface treatment as the posts, of 1-5/8 in. OD. If an alternative post is used, the rail shall be of compatible size and type, and shall be approved by the COR.

• Tension wire shall be 7 gauge, galvanized, coated steel wire, with a minimum tensile strength of 77,000 psi.

• Tension bars shall be provided in one-piece lengths 2 in. less than the full fabric height wherever the chain link fabric meets the end (or terminal) posts, and shall have a minimum cross section of 3/16 in. x ¾ in.

• Truss rods shall be galvanized steel rods with a minimum diameter of 5/16 in.

and be…