25-8367_-_Exhibit_J_-_Technical_Special_Provisions.pdf

Technical Special Provisions 1 of 47 Stan Gober Bridge Rehabilitation Collier County, Florida

Technical Special Provisions for

Collier County Project No. 66066.2 Stan Gober Memorial Bridge Rehabilitation

Unless otherwise specified, all applicable Articles and Subarticles of the January 2025 edition of the Florida Department of Transportation Standard Specifications for Road and Bridge Construction Division II & III (Construction Details and Materials divisions) shall be adhered to, except where revised or amended, as follows:

Technical Special Provisions 2 of 47

Collier County, Florida

SECTION T104-30 TURBIDITY MONITORING

SECTION T110-3 LADDERS AND PLATFORMS, REMOVE

SECTION T400-142-2 CATHOTIC PROTECTION SYSTEM, ZINC ARC SPRAY

SECTION T400-142-10 EMBEDDED GALVANIC ANODE

SECTION T400-142-11 GALVANIC OVERBUILD WITH ANODES FOR

FOOTINGS/STRUTS

SECTION T401-70 RESTORE SPALLED AREAS, CONTRACTOR’S OPTION

SECTION T413-150 PENETRATING CORROSION INHIBITOR

SECTION T457-2-131 CATHODIC PROTECTION INTEGRAL COLUMN JACKET,

NON-STRUCTURAL, GALVANIC SYSTEM

SECTION T457-2-221 CATHODIC PROTECTION INTEGRAL PILE JACKET,

STRUCTURAL, 16.1-30” GALVANIC SYSTEM

SECTION T470-75 TIMBER FENDER SYSTEM REPAIR

SECTION T561-1 COATING EXISTING STRUCTURAL STEEL, bearing

SECTION T630-2-30 CONDUIT ANCHOR REPLACE

SECTION T630-2-31 CONDUIT REPAIR/REPLACE

Technical Special Provisions 3 of 47

Collier County, Florida

SECTION T104-30

TURBIDITY MONITORING

T104-1 Description.

The work under this section includes monitoring and testing for turbidity as outlined in the plans.

T104-2 Turbidity Monitoring Plan.

Submit a Turbidity Monitoring Plan in accordance with the requirements outlined in the Plans and Permits for review and acceptance prior to the start of work.

T104-3 Method of Measurement.

The quantity to be paid for will be per lump sum.

T104-4 Basis of Payment.

Price and payment will be full compensation for furnishing all labor, equipment, incidentals, testing, and reporting necessary to complete the work specified in this Section.

Payments will be made under:

Pay Item 104-30 Turbidity Monitoring Plan

Technical Special Provisions 4 of 47

Collier County, Florida

SECTION T110-3

LADDERS AND PLATFORMS, REMOVE

T110-1 Description.

The work under this Section includes the labor, equipment, and materials necessary to remove and dispose of the existing ladder and platform system and patch the anchor bolt locations in the concrete.

T110-2 Method of Removal.

Remove and dispose of all components of the ladder and platform system. All measures necessary to maintain safe passage of vehicles on the bridge or vessels on the water below are incidental to this item.

Anchor bolt for the ladder and platform system embedded in the concrete structure to remain shall be cut back a minimum of 1 inch beyond the finish surface of the concrete. Prepare the surface of the cavity in accordance with the patch material manufacturer’s recommendations.

Apply an applicable concrete patch repair mortar on the FDOT Approved Product List, as approved by the Engineer, and finish the surface flush with the adjacent concrete.

T110-3 Ownership of Materials.

Take ownership of all materials, structures, appurtenances, and other materials removed and dispose of them in accordance with T110-4.

T110-4 Disposal of Materials.

Follow FDOT Standard Specifications Section 110-9 for the disposal of materials.

T110-5 Method of Measurement.

The quantity to be paid will be per ladder and platform system removed and disposed of as accepted by the Engineer.

T110-6 Basis of Payment.

Price and payment will be full compensation for furnishing all labor, equipment, and materials necessary to complete the work specified in this Section.

Pay Item 110-3-10 Ladders and Platforms, Remove

Technical Special Provisions 5 of 47

Collier County, Florida

SECTION T400-142-2

CATHODIC PROTECTION SYSTEM, ZINC ARC SPRAY

T400-1 Description.

The work under this Section includes the installation of a galvanic cathodic protection (CP) system. This cathodic protection system consists of applying an arc-sprayed zinc (ASZ) (anode) over areas of structural elements to be protected, such as girders. This application shall be performed by thermal spraying (metalizing) the concrete surface with the required surface preparation necessary to produce a minimum bond of 100 psi between the zinc and the concrete.

The Contractor shall secure the services of a NACE-certified Cathodic Protection Specialist (CPS) to provide quality assurance for every phase of the application of the thermally sprayed zinc.

T400-2 References.

ACI 222R – Protection of Metals in Concrete Against Corrosion ASTM B6 – Standard Specification for Zinc ASTM B418 – Standard Specification for Cast and Wrought Galvanic Zinc Anodes

SSPC-10 – Near-White Blast Cleaning

T400-3 Submittals.

T400-3.1 Prequalification of Bidders:

T400-3.1.1 NACE Certified Cathodic Protection Specialist: Secure the services of a CPS accredited by the National Association of Corrosion Engineers (NACE). The NACE-certified CPS shall be either a registered professional engineer in the State of Florida with a minimum of five years of experience in the field of cathodic protection on concrete or a corrosion engineering practitioner with no less than 10 years of certifiable experience in the field of cathodic protection (CP) of reinforced concrete. The CPS shall be independent from the Contractor and the construction operation. Submit, in writing, the qualifications of the individual satisfying these requirements for approval by the Engineer. Acceptance of the CPS shall be subject to the approval of the Engineer.

T400-3.1.2 NACE Certified Cathodic Protection Technician: A NACE-certified CPT can perform field measurements on behalf of the CPS. The CPT must work for the same company and under the direct supervision of the CPS. The CPT must be accredited by NACE as a CPT and have a minimum of five years of experience in the field of cathodic protection of reinforced concrete. The CPT shall be independent from the Contractor and the construction operation. Submit, in writing, the qualifications of the individual satisfying these requirements for approval by the Engineer. Acceptance of the CPT shall be subject to the approval of the Engineer.

T400-3.1.3 Metalizing Spray Technician: The Metalizing Spray Technician must have a minimum of three years of experience operating thermal spray equipment. The technician must provide written documentation of prior experience using a wire metalizing arc unit on at least two projects of similar scope, including locations, contact names, and phone numbers of Owners of previous projects for verification.

T400-3.1.4 Metalizing Contractor and Subcontractor Qualifications: The metalizing contractor and subcontractor conducting the installation of the metalized coating must be engaged in thermal spray operations and have a minimum of five years of previous experience

Technical Special Provisions 6 of 47

Collier County, Florida in metalizing operations in concrete. Provide written documentation of locations, contact names, and phone numbers of Owners of previous projects for verification.

T400-3.2 Procedures:

T400-3.2.1 Work Plan and Work Schedule: Submit a detailed work plan and schedule for the type of work as stated on the Plans and the Technical Special Provision for review and approval before beginning any work.

T400-3.2.2 Quality control plan prepared by the CPS: Submit a detailed quality control plan prepared by the CPS for review and approval before beginning any work.

T400-3.3 Equipment:

Provide technical data sheets for the following

1. Metalizing equipment

2. Blasting equipment

3. QA/QC testing equipment, including calibration sheets for equipment

T400-3.4 Materials:

Provide manufacturer’s certifications for the following:

1. Metalizing zinc anode wire shall indicate chemical composition, wire diameter, lot number, manufacturing date, and relative manufacturing data where applicable.

2. Blasting material data sheet and MSDS

3. Zinc silicate overcoat

4. Connection plates and associated hardware

T400-4 Materials.

T400-4.1 Metalizing Wire: The metalizing material shall be essentially pure zinc (99.9% pure) produced in wire form of 1/8-inch diameter standard size, which can be molten and sprayed with the equipment described in sub-article T400-5.5 of this Technical Special Provision. The zinc wire shall be available on a commercial basis and shall meet the requirements of ASTM B833.

T400-4.2 Zinc Silicate Overcoat: Inorganic zinc silicate overcoat T400-4.3 Zinc connection plates: The anode connector plate shall be a flattened expanded zinc mesh plate at least 4 inches by 4 inches and with a minimum thickness of 3/16 in.

and grade 316 stainless steel threaded studs, nuts, and washers. The connector plate shall have a minimum of 4 holes drilled in the corners for attachment with nylon anchors.

T400-5 Arc-Sprayed Zinc (ASZ) Cathodic Protection.

T400-5.1. General: This system requires the application of ASZ (anode) to selected areas after concrete restoration has been completed. The application shall be performed by thermal spraying (metalizing) the concrete with the required surface preparation necessary to produce a good bond between the zinc and the concrete. A good bond is essential to provide an efficient system.

The Contractor shall furnish labor, materials, testing, and installation equipment and shall apply ASZ to all surfaces as defined in the contract plans.

For this work, the CPS shall provide quality assurance and, as a minimum, shall provide the following services:

1. Responsible for inspection and testing of test patches to determine the target bond strength of the sprayed zinc.

2. Overseeing the quality of all phases of work related to the metalizing operation.

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Collier County, Florida

3. Review and randomly verify the electrical continuity on at least 10% of the area that is being protected, results, and provide a written report.

4. Review and approve all contractor documents related to the cathodic protection work before submittal to the County for approval.

5. Conduct and document random QA testing on a minimum of 50% of the components metalized during CPS absence. These random tests shall be in addition to the Contractor's QC tests specified in this Technical Special Provision.

Random testing shall be conducted at a minimum frequency of once per month, and satisfactory approval shall be required for partial payment of the metalizing work.

6. Conduct all other specified testing to meet the requirements of the contract documents.

7. Visit the project monthly (minimum) to perform random QA testing and directly update the Engineer (verbally and in writing) regarding the quality of the work in progress.

8. Provide final report.

T400-5.2 QC/QA Plan: Provide a Quality Control Plan certified by the CPS and approved by the Contractor for the County’s approval at least 4 weeks prior to the start of work.

Such plan shall include:

1. method and frequency of Contractor's QC testing

2. continuity testing by the CPT under the direct supervision of a CPS

3. zinc anode application

4. time dedicated to training

5. frequency of random QA testing

6. method of updating the Engineer

7. method for initial activation of the cathodic protection systems.

The CPS shall also provide a final report describing the general characteristics of the metalizing work and the thickness and bond strength results for each metalized component. The report and all collected data shall be in typed form, and a digital version of the report must be provided along with four bound hard copies.

The Quality Control Plan and CPS qualifications must be approved before commencing any concrete removal or cathodic protection work.

T400-5.3 Surface Preparation Execution: Blasting for preparation of the surfaces to receive metalizing shall be performed by the metalizing group in charge of the metalizing application and achieving the established target bond. Different levels of blasting and abrasive media may be necessary to achieve the target bond for different types of concrete. Debris and abrasive media shall be contained and disposed of off-site.

T400-5.4 Key Personnel: The Contractor shall always maintain his/her own skilled personnel on the job site. The Contractor shall be responsible for the proper installation of the cathodic protection systems and the proper maintenance of the installation equipment.

T400-5.5 Metalizing Equipment: Before commencing work, the Contractor shall submit a list of the equipment intended to be used for the ASZ applications. No metalizing shall be performed before equipment approval by the County. The Contractor shall require a representative of the ASZ equipment manufacturer to observe the application of the zinc spray and determine whether the equipment is being operated properly. Zinc application equipment must meet the minimum requirements outlined in sections T400-5.5.1 through T400-5.5.4.

Technical Special Provisions 8 of 47

T400-5.5.1 Metalizing Unit: The metalizing unit shall be a portable, electric arc spray unit capable of spraying zinc wire of 1/8-inch diameter and should meet the following minimum requirements:

1. The application gun shall be provided with a self-contained electric arc.

2. The spray pattern shall be elliptical in shape and have provisions for adjustments to the circular pattern.

3. The application gun shall be capable of operating remotely from the wire feed unit at least 10 feet.

4. The wire feed unit must have moisture/oil separators provided within it (in addition to the separators already in the line) and shall be enclosed to protect the anode wire from the environment.

5. The wire feed method shall be a dual drive wheel, push-type system only.

Other wire feed systems may only be given temporary approval based on performance.

6. The system shall be capable of operation at 500 amps continuous duty cycle.

7. The system shall be able to operate remotely from the power supply unit for a minimum distance of 50 feet.

8. The wire feed unit and thermal spray gun assembly shall be reasonably portable and capable of operating from a reach-all, scaffolding, boat, or a small barge.

T400-5.5.2 DC Power Supply Unit: The power supply unit shall be a gasoline or diesel engine-driven, direct current power source with a minimum NEMA output rating of 600 amps at 40 volts operating at 80 percent duty cycle. The unit shall have a built-in auxiliary 60-hertz (Hz) alternating current power unit capable of delivering 115/230 volts and a minimum of 50 amps.

Alternate power supplies may be approved based on satisfactory recommendations of the metalizing unit manufacturer.

The power supply shall be capable of operation at constant current or constant voltage modes with fully adjustable output over the entire voltage and current range and shall be capable of connection to the metalizing unit at a minimum distance of 50 feet. An ammeter, voltmeter, and oil pressure and engine temperature gauges shall be mounted in the control panel of the unit. The gauges shall always be maintained clean and readable during the metalizing operation.

T400-5.5.3 Air Supply Equipment: The air supply unit shall be capable of delivering a minimum of 250 CFM of air at 100 pounds of pressure and having an adjustable pressure range of 50 to 125 pounds per square inch. The air compressor shall be provided with a minimum of 1 1/4-inch high-pressure air hose with standard couplers and produce moisture-free air at the blast nozzle. When used in conjunction with the metalizing unit and an operator temperature control unit, the system shall be capable of maintaining a minimum air volume of 175 CFM at 90 pounds of pressure at the gun head.

The air compressor shall be provided with moisture/oil separators mounted within the unit and additional separators or filters as necessary to produce moisture free air. Separators and filters shall be serviced at a minimum of once per day to provide moisture free air.

The air supply unit (engine and compressor) shall be mounted on a rugged frame

Technical Special Provisions 9 of 47

Collier County, Florida enclosure provided with lift-off service side panels to provide restricted safe access to serviceable components.

T400-5.5.4 Abrasive Blast Equipment: The blasting equipment shall be a conventional force-fed pressure-type stationary sandblaster and include the following:

1. The nozzle size shall be such that a minimum of 80 psi is maintained at the blast nozzle.

2. The sandblasting equipment shall be capable of operating at a minimum of 50 feet away from the pot and shall be provided with an electrical abrasive cut-off switch.

3. The unit shall be equipped with a minimum of 1 1/4-inch piping and valves to provide enough air-sand volume.

4. Blast hoses shall be provided in 25 to 50-foot sections.

5. The inside diameter of the hose shall be 1 1/4 inches, and the ends shall be provided with appropriate couplers.

6. The blast hose shall be capable of withstanding a working pressure of 175 psi.

T400-6 6. Surface Preparation for ASZ Cathodic Protection.

T400-6.1 Concrete Removal: All concrete removal shall be made as shown on the plans and the Technical Special Provisions for Concrete Spall Repairs.

T400-6.2 Blasting: All concrete surfaces to be metalized shall be thoroughly blasted with silica sand or other suitable material to remove all existing coatings, cement splatter or foreign materials before ASZ application. Sandblasting of the concrete should leave a clean, rough surface, which leaves the appearance of medium grit sandpaper without exposing the coarse aggregate.

The abrasive stream should be directed against the work surface at an angle of approximately 15 degrees from the plane and not more than 30 degrees unless necessary to reach specific areas. The level of sandblasting of the concrete surface to achieve the highest possible bond of the zinc shall be determined in the field for every type of concrete present to receive metalizing. Blast material must always be plant-packaged and maintained in a clean and dry condition. Material stored in the sand-blaster pot overnight shall not be used.

Although not anticipated, any steel component requiring metalizing shall receive an abrasive blast to the extent that a near-white appearance is obtained as per NACE 2 as referenced in NACE12/AWS C2.23/SSPC- 23 Standard.

T400-6.3 Electrical Continuity: The Contractor shall provide written details of the procedure for continuity testing for approval by the CPS. After written approval by the CPS, such procedure shall be included in the CPS QC/QA plan. Electrical continuity of the reinforcing steel shall be tested and corrected by the Contractor for every piece of reinforcement within the metalizing limits and supervised by the CPS. Although not part of the cathodic protection work, continuity shall be provided during the concrete restoration operation. Care shall be observed so as not to damage any rebar connecting rods or wires for connection plates, which may have been installed during the concrete restoration work.

All connection plates shall be verified as electrically continuous.

T400-6.4 Connection for Connection Plates: The Contractor shall have the option to install the connections for the connecting plates during the concrete removal/restoration operation or the surface preparation for metalizing work. However, the surface of the concrete to

Technical Special Provisions 10 of 47

Collier County, Florida be in contact with the connection plates shall be sufficiently smooth and uniform as to provide 100% contact between the plates and the concrete. There shall be two connection plates per continuous spray area. No concrete removal shall be performed without approval, and no metalizing shall be performed until concrete removal/restoration and surface preparation have been approved. The County shall be allowed to stop work due to poor workmanship, unapproved materials, or unapproved work procedure at any time without consequence to the County.

T400-7 ASZ Anode Application.

T400-7.1 Test Sections -Target Bond: Before commencing the arc-spraying operation, the Contractor shall metalize a minimum of four on-site test sections with minimum dimensions of 4 square feet each. These test sections shall be used to determine the field application rate for the specified thickness, grain size, texture acceptability, and target adhesion strength. The test sections shall be representative of all the concrete conditions present on the bridge to receive metalizing.

Adhesion strength shall be measured on all test sections per ASTM D7234 to determine the target bond for production and acceptance. Testing shall be conducted at least 3 hours and at most 24 hours after metalizing. All bond tests shall be made in triplicate, and the results will be averaged. Target bond shall be established based on the higher strengths obtained from the test areas. It is expected that a minimum of 100 psi of bond strength will be achieved, and strengths lower than expected will not be accepted. Various levels of sandblasting of the test sections' concrete may be necessary to determine the proper surface condition to achieve the target bond.

The Contractor shall provide a minimum of 14 days advanced notice for the preparation and metalizing of the test sections, such that the CPS and appropriate County personnel are present for the zinc application and adhesion testing.

Before zinc application, the concrete surface shall be air-blasted to remove any residue from the sandblasting operation. Air stream shall be 100% moisture free and discharge a minimum pressure of 50 psi. Moisture and pressure of the air stream shall be tested daily.

T400-7.2 Zinc Application: Thermal spraying operation shall not be performed during periods where rainfall, high seas, rough waters, or any other wet conditions are present. Zinc spraying shall not be performed when excessive wind blows, which could interfere with the operation as determined. The Contractor shall be responsible for compliance with Florida Administrative Code, Chapter 62-302, and any other Federal or Local codes regulating the quality of the surface waters.

Metalizing shall only be applied to surface areas that have been properly prepared as per section T400-6.2 and approved satisfactory. Metalizing shall be continuous and uninterrupted within each complete element. Cold overlaps of the zinc will only be allowed for deficiency correction with Engineer approval.

Metalizing shall cover the concrete restored area and continue to the opposite face, as shown in the construction drawings. Zinc application shall be performed employing multiple spray passes crossing at a 90-degree angle to achieve a coating thickness of 15 to 20 mils as determined by thickness measurements on test coupons or by other acceptable means.

T400-7.3 Metalizing Time Window: Coordinate the metalizing and concrete restoration operations such that metalizing is completed and connected to the reinforcement on each component no sooner than 10 days and no more than 90 days after placing the concrete for the concrete restoration operation. Any metalizing to be accepted after 90 days following the placement of the concrete shall be tested and certified in writing by the CPS as having a low probability of corrosion activity around the repaired area. Metalizing accepted after 90 days will

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Collier County, Florida be paid for at a reduced price. Price reduction will be calculated at a rate of $1.00/square foot/day for each day after day 90. No metalizing will be approved if placed after 120 days following the placement of the concrete. Metalizing shall be completed within two hours following sandblasting and before any contamination on the concrete develops.

T400-7.4 Thickness Measurements: The Contractor shall conduct a minimum of one thickness measurement on each metalized element or at every 25 square feet as applicable (if the metalized area is larger than 25 square feet in one component).

Measurements shall be obtained and recorded in writing by the Contractor as part of the Contractor's QC. In addition, the CPS shall conduct thickness measurements on a minimum of 50% of the components metalized by the Contractor. Thickness measurements are also subject to verification by the Engineer.

Thickness measurements shall be obtained using a spherical anvil and spindle micrometer with a digital display capable of performing measurements ranging from zero to one inch.

Electronic thickness measuring devices may be allowed as approved. The Contractor shall provide all equipment and materials necessary to perform all QC testing as required by this Technical Special Provision.

Where deficient coat thickness values are found, the deficient section and the immediate surface around (one square foot minimum), shall receive additional coating so that the coat thickness of the repaired area will reach a minimum of 15 mils. This shall be performed immediately (not to exceed 2 hours) following the first application or the metalizing shall be removed, and the entire element shall then be re-metalized.

T400-7.5 Bond Strength Test: The Contractor shall conduct a minimum of one coating adhesion strength test (pull-off test) on each metalized element or at every 100 square feet as applicable (if the metalized area is larger than 100 square feet in one component).

Each test shall be made in triplicate, and the values will be averaged. Results shall be recorded by the Contractor, reviewed by the CPS, and shall be subject to verification by the Engineer. The CPS shall conduct testing on a minimum of 50% of the components metalized during the CPS’ absence.

Pull-off tests shall be conducted using a mechanical 0 to 500 psi fixed alignment adhesion tester as per ASTM D7234. Pull-off strength shall be a minimum of 90% of the target values determined from the preliminary on-site test areas on the bridge, but no less than 100 psi.

Measurements shall be obtained at least 24 hours but at most 72 hours after metalizing. Limits of areas not meeting the required bond strength shall be identified and marked, and then all sprayed metal shall be blasted clean before re-spraying as directed. A description of such areas shall be included in the CPS report.

T400-7.6 Zinc Defects: If a defective coating area is found, the correction shall be performed in the same manner as for deficient thickness. Sandblasting of the defective areas may be required as directed. Cold overlaps during reapplication may be necessary. However, re-application on the sprayed zinc anode over previously metalized areas shall not blister, burn, or otherwise damage the bottom anode layer. Should this occur, the entire element should be sandblasted and re-metalized.

T400-7.7 Overcoat: After zinc coating is approved as satisfactory by the Engineer, the Contractor shall apply a coat of water-based inorganic zinc silicate over the metalized areas of the structure.

This work shall be performed within 72 hours after the metalizing.

Zinc coating shall be spray-applied only in accordance with the manufacturer’s

Technical Special Provisions 12 of 47

Collier County, Florida recommended thickness and specifications. No roller application is allowed, and brush application can only be used as a touch-up for correction of small deficient areas. The silicate coating application shall extend a minimum of six inches beyond the metalized areas in each direction whenever possible and shall have a minimum dry-film thickness of 5 mils. Thickness measurements of the silicate overcoat shall be made at a minimum of two locations per metalized element. Areas not to be coated shall be properly masked to protect them from over-spraying or over-run and to form neat horizontal or vertical lines.

T400-8 Method of Measurement.

The quantity to be paid for will be per square foot of sprayed surface area completed and accepted, determined by field measure.

T400-9 Basis of Payment.

Price and payment will be full compensation for furnishing all equipment, incidentals, materials and labor necessary to performing the work specified in this Section.

Pay Item 400-142-2 Cathodic Protection System, Zinc Arc Spray

Technical Special Provisions 13 of 47

Collier County, Florida

SECTION T400-142-10

EMBEDDED GALVANIC ANODE

The work under this Section includes furnishing all labor, tools, materials, equipment, and services necessary to properly install embedded galvanic anodes.

The removal and replacement of concrete is covered under a separate Item.

T400-2 References.

ACI Repair Application Procedure (RAP) Bulletin 8 – Installation of Embedded Galvanic

Anodes ACI Guideline No. 222 – Corrosion of Metals in Concrete ACI 562 - Code Requirements for Evaluation, Repair and Rehabilitation of Concrete

Buildings ASTM B418 – Standard Specification for Cast and Wrought Galvanic Zinc Anodes ICRI Guideline 310.1R - Guide for Surface Preparation for the Repair of Deteriorated

Concrete resulting from Reinforcing Steel Corrosion ISO 12696 – Cathodic Protection of Steel in Concrete

T400-3 Manufacturer Extended Limited Warranty.

The contractor shall provide a Limited Warranty with a notarized signature from a corporate officer of the anode manufacturer.

The Limited Warranty shall state the following:

1. The published anode spacing guidelines for anode size and spacing are based on an estimated 10 to 30-year anode service life.

2. The galvanic anodes will remain electrochemically active and produce galvanic current in relation to the environment in which it is installed for a minimum of 5 years from the date of anode installation.

3. If the galvanic anodes fail to perform, corrections shall be made to restore the performance at no additional cost.

4. The anode unit, including its constituents, does not include intentionally added substances that may cause corrosion to reinforcing steel over the life of the structure.

T400-4 Anode Manufacturer Corrosion Technician.

The contractor will enlist and pay for a technical representative employed by the galvanic anode manufacturer to provide training and on-site technical assistance during the initial installation of the galvanic anodes. The technical representative shall be a NACE-qualified corrosion technician (NACE CP2 Cathodic Protection Technician or higher).

The qualified corrosion technician shall have verifiable experience of at least 3 years in the installation and testing of embedded galvanic protection systems for reinforced concrete structures.

The contractor shall coordinate their work with the designated corrosion technician to allow for site support during project startup and initial anode installation. The corrosion technician shall provide contractor training and support for development of application procedures, verification of electrical continuity, and project documentation.

Technical Special Provisions 14 of 47

T400-5 Materials.

T400-5.1 Embedded Galvanic Anodes: Embedded galvanic anodes shall be Anode Type 1A Class C. The anodes shall be pre-manufactured with a nominal 160 grams of zinc in compliance with ASTM B418 Type II cast around an integral, unspliced, uncoated, non-galvanized double loop steel tie wire and encased in a highly alkaline cementitious shell with a pH of 14 or greater.

The galvanic anodes shall be alkali-activated and shall contain no intentionally added chloride, bromide, or other constituents that are corrosive to reinforcing steel as per ACI 562 and the following:

1. The zinc anode is alkali-activated with an alkaline cementitious shell with a pH of 14 or greater.

2. The galvanic anode shall contain no intentionally added constituents corrosive to reinforcing steel, e.g., chloride, bromide, etc.

3. The anode manufacturer shall provide documented test results from field installations showing that the anodes have achieved a minimum of 20 years in service.

4. The galvanic anode shall have been used in a minimum of ten projects of similar size and application.

5. The galvanic anode units shall be supplied with solid zinc core (ASTM B418) cast around an uncoated, non-galvanized, non-spliced steel tie wire for wrapping around the reinforcing steel and twisting to provide a durable steel-to-steel connection between the tie wire and the reinforcing steel.

T400-5.2 Storage: Deliver, store, and handle all materials in accordance with manufacturer’s instructions. Anode units shall be stored in dry conditions in the original unopened containers in a manner to avoid exposure to extremes of temperature and humidity.

Outside storage is not permitted.

T400-6 Execution.

T400-6.1 Concrete Removal: Remove concrete under Item 407-70-5.

T400-6.2 Cleaning and Repair of Reinforcing Steel: Clean exposed reinforcing steel of rust, mortar, etc., to provide sufficient electrical connection and mechanical bond.

If significant reduction in the cross section of the reinforcing steel has occurred, replace or install supplemental reinforcement as directed by the engineer.

Secure loose reinforcing steel by tying it tightly to other bars with a steel wire tie.

Verify electrical continuity of all reinforcing steel, including supplemental steel, as per

Section T400-6.3.

If the reinforcing steel is to receive a barrier coating, do not coat the reinforcing steel within 1 in. of the anode, and do not apply coating to any surface of the anode’s steel wire ties.

T400-6.3 Galvanic Anode Installation: Install anode units and repair material immediately following preparation and cleaning of the steel reinforcement.

Galvanic anodes can be used at the interface of new and old concrete to provide targeted protection around the perimeter of repairs.

Galvanic anodes shall be installed along the perimeter of the repair at a maximum spacing of 12 inches.

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Collier County, Florida

Place the galvanic anodes as close as possible to the interface with the parent concrete (maximum 4 in.) while still providing sufficient clearance between anodes and substrate to allow the repair material to fully encase the anode.

If less than 1 in. of concrete cover is expected, place anode beneath the bar and secure to clean reinforcing steel or increase the size of the repair cavity to accommodate the anodes.

Wrap the tie wires around the clean reinforcing steel at least one full turn in opposite directions, bring the two free ends together, and twist tight to create a secure electrical connection and allow no anode movement during concrete placement.

Confirm the electrical connection between the anode tie wire and reinforcing steel by measuring DC resistance (ohm Ω) or DC potential (mV) with a multimeter. The electrical connection is acceptable if the DC resistance measured with the multi-meter is 1 Ω or less or the DC potential is 1 mV or less.

Confirm electrical continuity of the exposed reinforcing steel within the repair area. If necessary, electrical continuity shall be established by tying discontinuous steel to continuous steel using steel tie wire. Electrical continuity between test areas is acceptable if the DC resistance measured with a multi-meter is 1 Ω or less or the potential is 1 mV or less.

T400-6.1 Concrete Repair: Repair concrete under Item 407-70-5.

T400-7 Method of Measurement.

The quantity to be paid for will be per each embedded galvanic anode installed and accepted by the Engineer.

T400-7 Basis of Payment.

Price and payment will be full compensation for furnishing all equipment, incidentals, materials, testing and labor necessary to performing the work specified in this Section.

Pay Item 400-142-10 Embedded Galvanic Anode

Technical Special Provisions 16 of 47

Collier County, Florida

SECTION T400-142-11

GALVANIC OVERBUILD WITH ANODES FOR FOOTINGS/STRUTS

The work under this Section includes installing a sacrificial cathodic protection (CP) system consisting of zinc anodes on the pier footings and struts. Provide all necessary surveying to determine the specified elevations at no additional cost to the County.

T400-2 References.

ACI 222R – Protection of Metals in Concrete Against Corrosion ASTM B6 – Standard Specification for Zinc ASTM B418 – Standard Specification for Cast and Wrought Galvanic Zinc Anodes SSPC-10 – Near-White Blast Cleaning

T400-3 Submittals.

The following submittals are required to be reviewed and approved by the Engineer prior to commencing any work.

1. Qualifications of a NACE-certified Cathodic Protection Specialist (CPS) and

NACE-certified Cathodic Protection Technician qualifications (CPT)

2. CPS approved shop drawings indicating galvanic anode and installation details including reinforcing connections, method of continuity correction, system wiring, and methods for placing concrete.

3. Forms and Construction Methods: Prior to commencing the overbuild installation, submit shop drawings indicating the form design, materials, and procedures for constructing the overbuilds for approval.

4. Overbuild Fill Material: Submit a material(s) for approval by the Engineer prior to the start of construction.

5. Repairs Outside Overbuilt Limits: Restore to original dimensions concrete delaminations, cracks, and/or spalls on the footing/struts. If damage is located outside of the planned extent of the overbuilds, immediately notify the Engineer.

6. CPS reviewed the quality control plan.

T400-4 Quality Assurance/Quality Control.

T400-4.1 Prequalification of Bidders:

T57-4.1.1 NACE Certified Cathodic Protection Specialist: Secure the services of a CPS accredited by the National Association of Corrosion Engineers (NACE). The NACE-certified CPS shall be either a registered professional engineer in the State of Florida with a minimum of five years of experience in the field of cathodic protection on concrete or a corrosion engineering practitioner with no less than 10 years of certifiable experience in the field of cathodic protection on concrete. The CPS shall be independent from the Contractor and the construction operation. Submit, in writing, the qualifications of the individual satisfying these requirements for approval by the Engineer. Acceptance of the CPS shall be subject to the approval of the Engineer.

T400-4.1.2 NACE Certified Cathodic Protection Technician: A NACE-certified CPT can perform field measurements on behalf of the CPS. The CPT must work for the same company and under the direct supervision of the CPS. The CPT must be accredited by

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Collier County, Florida

NACE as a CPT and have a minimum of five years of experience in the field of cathodic protection on concrete. The CPT shall be independent from the Contractor and the construction operation. Submit, in writing, the qualifications of the individual satisfying these requirements for approval by the Engineer. Acceptance of the CPT shall be subject to the approval of the Engineer.

T400-4.2 Quality Control: Submit a Quality Control/Quality Assurance (QC/QA) plan, which has been reviewed and approved by the CPS, to the County for approval prior to commencing the system installation. QC/QA Plan shall include tasks to be executed by the Contractor, as well as those executed by the CPS. It is recommended that the Contractor discuss the intended installation schedule with the CPS prior to preparing his bid to ensure that the intended schedule does not conflict with the QC/QA plan.

T400-4.3 Quality Assurance Tasks: The minimum quality assurance tasks are as follows:

1. CPS personally supervise every phase of the installation of the cathodic protection system.

2. CPS perform all the continuity testing, check all the continuity corrections, and perform the initial energizing on all the cathodic protection systems including:

anode-cathode resistance, current, static, and energized potential measurements.

3. Conduct a minimum of one Quality Assurance visit to the job site per month during construction and update the Engineer directly, verbally and in writing, on the quality of the work.

4. Check for shorts between the anode and every steel component in the overbuilds and notify the Contractor for correction as necessary.

5. Certification Statement: Submit the final construction reports from the CPS to the county after the completion of the project. The report shall describe the general characteristics of the system, installation sequence, and the energizing data for the CP system, including but not limited to continuity testing and correction, anode to steel resistance, energizing current, and static and energized on and off potentials for each overbuild. The report and all collected data shall be in typed form, and a digital version of the report must be provided. The report shall include the following statement signed and notarized by the CPS:

“I hereby certify that the cathodic protection facilities constructed have been completed and are functionally complete. I further certify that construction on these cathodic protection facilities has preceded substantially in accordance with the contract Plans and Specifications and that any deviations which are noted below will not prevent the system from functioning in compliance with the intent of the Contract when properly operated and maintained. These determinations have been based upon my on-site observation of construction, scheduled and conducted by me or by a project representative under my direct supervision, for the purpose of determining if the work proceeded is in compliance with the Contract Plans, Specifications, and modifications.”

T400-5 Materials.

T400-5.1 Overbuild Fill Material: For the non-structural overbuild, use a non-shrink grout that meets the requirements of FDOT Specifications Section 934 and is on the FDOT’s Approved Products List. Submit the design mix to the Engineer for approval before placing any

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Collier County, Florida grouting material.

T400-5.2 Test Samples: Meet the requirements for compression testing in the FDOT

Specifications Section 934.

T400-5.3 Zinc Anode in Overbuild: Two different zinc anode products for inside the overbuilds are provided as acceptable options. The Contractor shall submit the one they intend to use in the material submittals.

Regardless of the anode that is selected, at a minimum, 1.2 lbs. of zinc must be present per 1 square foot of overbuild concrete surface

T400-5.3.1 Option 1: Expanded zinc mesh attached to the inside the overbuild conforming to ASTM B69 with the following metal composition:

1. Lead (Pb) 0.003 % weight maximum

2. Iron (Fe) 0.001% weight maximum

3. Cadmium (Cd) 0.001 % weight maximum

4. Copper (Cu) 0.7 - 0.9% weight maximum

5. Aluminum (Al) 0.001% weight maximum

6. Titanium (Ti) 0.001 % weight maximum

7. Magnesium (Mg) 0.0005 % weight maximum

8. Manganese (Mn) 0.001% weight maximum

9. Nickel (Ni) 0.001 % weight maximum

10. Tin (Sn) 0.001 % weight maximum

11. Zinc (Zn) balance

12. Additionally, the mesh anode shall have the following physical properties:

13. Electrical conductivity = 28% minimum

14. Solid zinc density = 0.26 pounds per cubic inch

15. Weight of expanded mesh = 1.6 pounds per square foot minimum

16. Open area of expanded mesh = 53% (density)

17. Solid zinc sheet thickness = 3/32 inches

The expanded mesh anode shall also conform to the following nominal geometry to allow proper grout encapsulation:

1. 0.5-inch Hex pattern

2. 0.125 inch Strand width in the short direction

3. 0.500 inch Strand width in the long direction

4. 0.320 inch Short opening

5. 0.750-inch Long opening

T400-5.3.1 Option 2: Embeddable alkali-activated zinc anodes.

The embedded anode units shall consist of zinc anode cast around two integral stainless-steel lead wires of sufficient length to make proper connections. The zinc anode shall be manufactured in compliance with ASTM B 418 Type II (Z13000) using zinc in compliance with ASTM B6 Special High Grade (Z13001) with iron content less than 15 ppm.

The embedded zinc anodes shall be alkali-activated with a pH greater than 14 and encased in an alkaline, low-resistance cementitious precast mortar. The anode unit shall contain no constituents that are corrosive to reinforcing steel as per ACI 222R, such as chlorides, bromides, or other halides.

Application for approved equals shall be requested in writing two weeks before the submission of project bids. Application for galvanic anode equals shall include verification of the following information:

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1. Proven track record of the anode technology showing satisfactory field performance with a minimum of three projects of similar size and application.

2. The anode unit does not contain any corrosive constituents detrimental to reinforcing steel, such as chloride, bromide, etc.

3. Independent third-party evaluation of the anode technology, e.g., Hitec, Concrete Innovations Appraisal Service, BRE, etc.

The zinc anodes shall be provided with connection wires to the designated connection box location as shown in the Plans.

T400-5.4 Junction Boxes: PVC junction boxes shall be a Schedule 80, shall be UV resistant, shall be suitable for marine environment use, and shall conform to NEMA 4X. The box shall be closed and sealed when work is not being performed inside the box.

T400-5.5 Conduit: The conduit shall be PVC type EPC-80 and shall conform to NEMA TC 2. Non-metallic clamps, allowing expansion, shall be installed and spaced per NEC, Article

352. Conduit and clamps shall be UV resistant and suitable for marine environment exposure.

The clamp attachment shall utilize Type 316 stainless steel hardware.

T400-5.6 Wire: Type HMWPE (High Molecular Weight Polyethylene) stranded copper conductors of sufficient length to extend to the accompanying junction box without splicing.

T400-6 Execution.

T400-6.1 Inspection: Inspect the structure and locate all deteriorated concrete areas that are to receive cathodic protection to verify that the specified overbuild lengths will encompass all cracked, spalled, and delaminated areas. Conduct the inspection prior to ordering materials. If damage is located outside of the planned extent of the overbuilds, immediately notify the Engineer. The County reserves the right to add or delete repair and protection as required at the same bid unit price. Dimensions of the spalled areas shall be recorded by the Contractor and verified by the Engineer. A final report detailing the locations and size of the spalls and cracks shall be provided by the Contractor at the end of the project as an addendum to the CPS report.

Verify mud-line elevations and proposed jacket limits prior to ordering materials or beginning footing/strut preparation. Inspect all areas to receive overbuilds and locate all deteriorated concrete areas on the exposed portion of the concrete. Each overbuild should encompass the major deficiency area within the specified overbuild limits. The Engineer reserves the right to increase or reduce repair limits.

T400-6.2 Construction Sequence:

T400-6.2.1 Surface Preparation: Prepare the footing/strut surface as follows:

cracked or unsound concrete, sand, lime rock, oyster shells, and other marine growth or foreign material shall be removed. Completely clean all footing/strut surfaces of corrosion, oil, grease, dirt, broken concrete, and any other deleterious material that would prevent proper bonding.

Clean all exposed reinforcing steel and the new structural reinforcing cage to meet WJ-2 condition per SSPC SP12 to remove all rust and scale before installing the overbuild. Clean existing concrete surfaces. Do not place the reinforcing steel or forms until the footing/strut cleaning has been approved by the Engineer.

Exposed steel shall not be left unprotected for a period greater than 72 hours.

T400-6.2.2 Anode Overbuild Installation: The CP overbuilds shall be installed on the designated area starting at a location below the water elevation or as directed in the

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Collier County, Florida construction Plans and extending upward to the required elevation as also shown in the Construction Plans.

On concrete footing/struts with vent holes, if the cathodic protection overbuild will cover the holes, plug the holes with compatible cementitious material and drill other holes with the same diameter above the limits of the overbuild. This work shall take place before installing the CP footing/strut overbuild. If sufficient space is not available above the overbuild, a new vent hole is to be core drilled through the installed overbuild. The new holes shall be in line with the existing holes.

T400-6.2.3 Negative Connections: Install a redundant electrical negative connection on each element receiving cathodic protection. Negative connections shall be made to the existing reinforcement of the element receiving the overbuild.

The connection shall be performed using two black No. 10 AWG HMWPE copper strand wires to different areas of a steel reinforcement at the elevation shown in the construction drawings for the existing elements to receive overbuilds. The proposed method of connection shall be submitted for approval. Sufficient lengths of wire shall be used such that the wires can be routed to the connection box mounted above the overbuild without any splices.

The brazed or mechanical part of the negative connection wire (at the steel) shall receive a coat of 100% solids and nonconductive epoxy such that no wire or brazing material will be in contact with the concrete when patching. Each wire shall be brazed to a minimum length of 1 inch of steel.

All connection lead wires shall be routed to the PVC connection box as shown in the plans, identified by different colors of insulation, and consistent throughout the project. The negative leads shall be connected to the wires originating at the embedded anode within the connection box. Soldered marine-grade tin-coated electrical ring connectors shall be used for the connection. The connection between the ring connectors shall be made wire to wire or through a shunt using stainless steel bolts, nuts, and washers. The connection shall be completely insulated after completion.