Attachment No. 04 - Section L-110 - Installation of Airport Underground Electrical Duct.pdf

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Establishment of the NAVAIDS Facilities Serving Extended Runway 9R-27L at O'Hare International Airport, Chicago, Illinois
Solicitation number
697DCK-20-R-00436
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This solicitation is for construction services to establish NAVAIDS facilities serving an extended runway at O'Hare International Airport in Chicago, Illinois. The contractor shall provide all labor, supervision, materials and equipment to perform the project in accordance with contract clauses, drawings and specifications over a 605 calendar day performance period starting November 15, 2020. The estimated price range for this procurement is between $5,000,000 to $10,000,000. Offerors must have successfully completed similar projects both in dollar amount and scope of work at an operational airport. Offers are due by October 7, 2020 and shall include: a signed solicitation form, past experience references for similar projects over the past five years between $5,000,000 to $10,000,000, a proposed construction schedule adhering to the specified performance period, letters confirming financial capability and bonding capacity, completed bid bond and small business subcontracting plan forms, and customer satisfaction questionnaires. The solicitation number is 697DCK-20-R-00436 and is issued by the Department of Transportation Federal Aviation Administration Southwestern Region.

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O’HARE MODERNIZATION PROGRAM INSTALLATION OF AIRPORT UNDERGROUND ELECTRICAL DUCT

MASTER SPECIFICATIONS

VOLUME IIIC

REV.14, ISSUED 3/31/10

L-110-1

INSTALLATION OF AIRPORT UNDERGROUND ELECTRICAL

DUCT

SECTION L-110

PART 1 DESCRIPTION

1.01 GENERAL

A. The work consists of underground electrical conduit and ducts installed in accordance with this Specification at the locations and in accordance with the dimensions, designs, and details shown in the Drawings. The work includes the installation of all underground electrical ducts or underground conduits. It includes the connection of the ducts and conduit into the existing underground electrical system, including all trenching, jacking steel casing where shown on the Plans, backfilling, removal, restoration of any paved areas, connection to new or existing manholes and handholes, concrete encasement, installation of innerducts, mandreling and installation of nylon or polypropylene rope, capping and the testing of the installation as a completed duct system ready for installation of cables, to the satisfaction of the COR. The work under this Section is subject to the requirements of the Contract Documents.

B. Special Requirements for ComEd Utility Ductbanks – Unless otherwise indicated on the Contract Plans, all ComEd ductbank materials, installation, ductbank run formations, curve layouts, transposition and connection to ComEd manholes must be in accordance with the ComEd Standards. Refer to CE-100, PART 2 EQUIPMENT AND MATERIALS

2.01 GENERAL

A. Equipment and materials covered by referenced Specifications must be subject to acceptance through manufacturer's certification of compliance with the applicable Specification when so requested by the

COR.

2.02 POLYVINYLCHLORIDE (PVC) CONDUIT

A. Non-metallic conduit must be PVC Schedule 40 or Schedule 80 concrete encased as indicated on the Drawings.

B. PVC conduit, including elbows and couplings, must meet the requirements of NEMA standards TC2 (latest edition), UL Standard 651, Federal Specifications WC-1094A, and must be UL rated and

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L-110-2 listed for use with 90 degrees C-rated conductors in compliance with Article 352 of the NEC.

C. The conduit must be manufactured from PVC compound that meets the applicable requirements of ASTM No. D 1784.

D. PVC conduit fittings must meet with the requirements of NEMA Standard TC3 (latest edition), UL Standard 514 supplement, and Federal Specifications WC-1094A.

E. All PVC conduit and fittings for communication conduits that will carry fiber optic cables must utilize sweeping bends. The bend must allow for the minimum bending (radius) requirements of the innerduct manufacturer and installer.

F. Standard PVC fittings and PVC cement adhesive must be compatible with the conduits and must be obtained from the same conduit manufacturers.

G. Acceptable PVC conduit manufacturers will be Carlon, J-M, National Pipe, or Georgia Pipe.

2.03 PVC-COATED GALVANIZED RIGID STEEL (GRS) CONDUIT

A. A Polyvinyl Chloride (PVC) coating nominal thickness 0.04 inches (40 mil), will be bonded to the exterior of the conduit. The bond between the coating and the conduit must be greater than the tensile strength of the plastic.

B. Fittings must be coated in the same manner as the conduit. Fittings must have a PVC sealing sleeve extending from the ends. The sleeve length must be approximately equal to the outside diameter of the conduit or 1-1/2 inches, whichever is smaller.

C. The PVC coated galvanized rigid conduit must be U.L. listed /labeled.

The Manufacturer must submit certified test results from a recognized independent testing company validating that their product meets or exceeds the requirements of ASTM D870-02 Testing Water Resistance of PVC Coating Using Water Immersion and ASTM D2247- 02 Testing Water Resistance of PVC Coating in 100% Relative Humidity, to signify compliance to the adhesion performance standards.

D. A urethane chemical coating must be uniformly and consistently applied to the interior of the conduit and fittings. The internal coating must be applied at a minimum thickness of 2 mils.

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E. Provide solvent cement and patching compound as recommended by the manufacturer for sealing joints and repairing gouges and cuts.

F. Provide PVC coating cement and patching compound as recommended by the PVC coated conduit and fitting manufacturer.

G. PVC coated conduit and fittings must be 1 inch trade size or larger.

H. Galvanized rigid steel conduit heavy wall must be milled steel, hot-dip galvanized conduit, complying with ANSI C80.1 and Federal Specification WWC-581 and must be U.L. listed.

I. Elbows, bends, and fittings must be made of full weight materials and must comply with the above and threaded the same as conduit.

J. Threads for conduit, couplings and fittings must be full depth and clean cut. Field cut threads must be coated with Coppercoat or in accordance with manufacturer’s instruction.

2.04 CONCRETE

A. Concrete used to form duct banks with conduit must be as specified in FAA-GL-918D.. Reinforcing bars where required will be as shown on the Drawings and in accordance with FAA-GL-918D.

2.05 INNERDUCT

A. Materials for innerducts for airfield communication cables will be subject to acceptance through manufacturer’s certification of compliance with applicable Specifications.

1. All innerduct must be provided with a pull rope.

2. Footage label must be sequentially marked on the innerduct.

B. Outdoor Installations

1. Innerduct that is to be installed outside, as indicated in the

Contract Drawings, must meet the following requirements:

a. The innerduct must meet or exceed the minimum standards of PE334470E/C as defined in ASTM D3350.

b. The innerduct must conform to ASTM F2160.

c. As indicated on the Contract Drawings, provide 1.00-inch for FAA or 1.25-inch for CDA innerduct for outdoor applications. The innerduct must meet the following Specifications.

(1) Type Solidwall

(2) Wall Construction SDR 11

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(3) Material High Density Polyethylene

(4) Color Yellow for FAA single mode fiber; grey for FAA copper control cable; orange for all other applications.

d. All solid wall innerduct, after final length trimming in manholes or building entrances, and prior to any cable installations within the innterduct must be reamed at the inside diameter edge at both ends of the innerduct to provide a smooth, rounded edge for protection to all copper and fiber optic cables and cable jacketing.

C. Indoor Installations

1. Innerduct that is installed indoors, as indicated in the Contract

Drawings, must meet the following requirements.

a. The plenum rated innerduct must be recognized per NEC

Articles, 770 and 800 for Plenum, Riser and General Purpose Raceway for optical fiber and telecommunications cables.

b. The riser rated innerduct must be recognized per NEC Articles, 770 and 800 for Riser and General Purpose Raceway for optical fiber and telecommunications cables.

c. The innerduct must conform to UL 2024.

d. As indicated on the Contract Drawings, provide 1.00-inch plenum or riser rated innerduct for FAA indoor applications. The innerduct for indoor applications must meet the following Specifications.

(1) Type Corrugated

(2) Material PVC (Riser Rated)

PVDF Resin (Plenum Rated)

(3) Inner Diameter 1.05 inches (+0.010 inch, -0.020 inch)

(4) Outside Diameter 1.31 inches (+0.010 inch, -0.020 inch

e. As indicated on the Contract Drawings, provide 1.25-inch plenum or riser rated innerduct for CDA indoor applications. The innerduct for indoor applications must meet the following Specifications.

(1) Type Corrugated

(2) Material PVC (Riser Rated)

PVDF Resin (Plenum Rated)

(3) Inner Diameter 1.38 inches (+0.010 inch, -0.020 inch)

(4) Outside Diameter 1.65 inches (+0.010 inch, -0.020 inch

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f. Innerduct color must be yellow for FAA single mode fiber, grey for FAA copper control cable, and must be orange for all other applications.

D. Pull Rope

1. Provide pull rope in all innerduct with minimum pull strength of

1250 pounds for outdoor applications and 900 pounds for indoor applications. The pull rope must extend 6 feet beyond the termination at each end.

E. Duct Plugs and Conduit Seals

1. Duct plugs and conduit/innerduct seals must be constructed of high impact plastic and fully corrosion resistant. Where fasteners are required they must be stainless steel. The duct plugs and conduit/innerduct seals must provide a water tight and gas tight installation. The devices must be easily installed or removed. The design must be of a split type configuration for retrofitting without any disassembly of existing conduits, innerducts, or cables. The compressible gaskets must be elastic, expandable, and durable for a permanent or temporary installation. Where conduits or innerducts contain pull ropes or cords the plug devices must have internal fastening loops to secure the rope or cord with slack within the conduit or innerduct for access at a later date during cable installations.

a. Blank Duct Plugs – Compression type mechanical plugs must be installed to seal spare conduits and spare innerducts of various sizes at all building/facility entrances and at the first manhole or handhole outside of the building/facility entrance. Plugs are to be sized per conduit inside diameters as required.

b. Innerduct Seals – Compression type mechanical seals must be provided to seal annular space around innerducts within conduits at all building entrances and at the first manhole or handhole outside of the building/facility entrance. Seals must be split type that can be installed around existing innerducts that are in place with or without cable.

c. Cable Seals – Compression type mechanical seals must be provided to seal all cable entrances in conduits and all cable entrances in innerduct at all building entrances and at the first manhole or handhole outside of the building/facility entrance. Fiber optic cable are installed individually, one cable of various diameter within one

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L-110-6 innerduct. 5KV or 600 volt power cables must have seals selected per total number of cables, diameter of cables, and conduit sizes as required.

F. Pulling Lubricant

1. A water based propylene glycol solution must be used when placing innerduct into duct banks as well as placing cable into innerduct.

2. The lubricant must have characteristics intended for the pulling of MDPE and HDPE fiber sheaths through PVC innerduct.

G. Provide all fittings, terminations, connectors, etc. for a complete integrated raceway system.

H. Acceptable innerduct manufacturers are Carlon, EW&C and Innerduct.

2.06 STEEL CASING FOR ELECTRICAL DUCTBANK

A. Furnish and install steel casing with electrical conduits inside of the specified dimensions at the locations, lines, and grades shown on the Drawings in accordance with FAA-GL-918D.

PART 3 CONSTRUCTION METHODS

3.01 GENERAL

A. The Contractor must install underground duct banks at the locations and grades as indicated in the Drawings. Conduits must be of the size, material, and type indicated in the Plans or Specifications. Where no size is indicated in the Drawings or Specifications, the conduits must not be less than 3 inches inside diameter. All duct banks must be laid to pitch toward structures for drainage as shown on the Drawings.

Pockets or traps where moisture may accumulate are not acceptable unless pre-existing underground field conditions prohibit ductbank pitch to structure.

B. The Contractor must mandrel each conduit. After completion of construction, each conduit must first be thoroughly cleaned before being mandrelled. Cleaning can be accomplished by drawing a wire duct brush, a flexible mandrel or power water rodding/jetting through each conduit to make sure that no foreign materials are left in the conduits after construction. When cleaning is completed, each conduit must be mandrelled with a non-flexible, durable, wood or metal conduit mandrel made specifically for this purpose. The diameter of the mandrel must not be more than ¼ inch smaller in diameter of the bore

VOLUME IIIC

REV.14, ISSUED 3/31/10

L-110-7 of the conduit and the length of the mandrel must be at least 1 inch longer than the diameter of the bore.

C. Conduit installed must be provided with a nylon or polypropylene rope for pulling the permanent wiring. Sufficient length must be left in handholes and secured to prevent it from slipping back into the conduit.

D. Conduit must be securely fastened in place during construction and progress of the work and must be plugged to prevent seepage or grout, water, or dirt. Conduits must be placed on supports/spacers designed and manufactured for this specific purpose. When not being worked, conduits must be capped using metal or plastic caps designed for this purpose. The use of materials such as rags, paper, plastic bags or tape is forbidden. Any duct bank having a defective joint must not be installed.

E. Conduit must be encased in concrete, with a 3 inch minimum concrete envelope poured around all conduit.

F. Where turf is well established and the sod can be removed, it must be carefully stripped and properly stored and replaced after backfilling in accordance with Section 3.06, as directed by the COR.

G. Trenches for conduit and ducts may be excavated manually or with mechanical trenching equipment. Walls of trenches must be essentially vertical so that a minimum of base material or soil is disturbed.

H. Dozers, wheel loaders, or motor graders must not be used to excavate the trench. The Contractor must ascertain the type of soil or rock to be excavated before bidding. All excavation material will be unclassified.

Work shall be performed in accordance with Section 3.08-Unclassified Excavation.

I. Conduit must be provided with slip couplings where it crosses through or under transverse construction joints in Portland cement concrete pavement.

J. Conduit must be provided with approved expansion and deflection couplings where it crosses through expansion joints.

K. PVC-Coated Galvanized Rigid Steel Conduit must be provided with grounding bushings to insure continuity of ground for the underground electrical system. The grounding bushings must be threaded onto the conduit.

VOLUME IIIC

REV.14, ISSUED 3/31/10

L-110-8

L. The Contractor must connect into the electrical duct bank system at the location indicated on the Plans by core drilling into structures, by connecting to existing conduit or ducts, or as directed by the COR.

3.02 CONDUIT ENCASED IN CONCRETE

A. Unless otherwise shown in the Plans, concrete-encased conduit must be installed so that the top of the concrete envelope is not less than 30 inches below the finished subgrade where installed under runways, taxiways, aprons, or roads, and not less than 30 inches below finished grade where installed in unpaved areas. Ducts under paved areas must extend at least 5 feet beyond the edges of the pavement or 5 feet beyond any underdrains which may be installed alongside the paved area. Trenches for concrete encased conduit must be opened the complete length before concrete is laid, so that if any obstructions are encountered, proper provisions can be made to avoid them. Concrete for the duct must be placed to form a single unit, not incrementally.

The concrete cover thickness must be a minimum of three inches on all sides. Where two or more conduits are encased in concrete, the Contractor must space them not less than 2 inches apart (measured from outside wall to outside wall) using spacers applicable to the type of conduit. End bells or end couplings must be installed flush with the end of the concrete encasement where required.

B. Tracing FAA and Common Electric Ductbank (CED) Containing FAA Fiber Tracer wire is required by the FAA to trace and locate concrete encased ductbank containing FAA fiber optic cable. Tracer wire will allow traceability of a fiber optic cable segment into and out of all facilities along the path of the specific fiber optic cable FOTS loop for every facility with FAA fiber optic equipment connected to the cable being traced.

Because the routing of FAA fiber optic cable for Communication FOTS loops and NAVAID (ILS) FOTS loops often follow the same ductbank route, the number of tracer wires in a given ductbank will vary as required to achieve traceability of each segment on a whole fiber optic loop. Most ductbanks will require only a single tracer wire, however other short facility branch ductbanks from the main would require multiple tracer wires when fiber optic cable segments overlap. When in the case of a NAVAID fiber optic cable loop which can double back on itself, at a facility that uses a single ductbank branch to access both of the cable segments serving it by ductbank with multiple segment entrances, 2 or 3 tracer wires would be required within that short ductbank branch to the FAA site/shelter. Where tracer wires converge

VOLUME IIIC

REV.14, ISSUED 3/31/10

L-110-9 at the lower level, Concourse “E” and “G” entrances of the main terminal, and the south entrance to the SATCT three (3) tracer wires within a common ductbank would be needed.

All new fiber installations and tracer wire routings for design packages must be coordinated with the OMP/FAA to conform with the overall or master Airport FAA fiber routing plan developed by FAA.

1. Provide and install 6” wide red plastic warning tape above all ductbanks and #14 AWG insulated copper tracer wire within all FAA dedicated ductbanks, handholes and manholes; all Common Electrical Ductbanks (CED), handholes and manholes containing FAA fiber optical cable; and existing ductbanks, handholes and manholes when used to route FAA fiber. (These requirements apply to both single-mode FAA fiber and multi-mode FAA fiber installations).

2. Tracer wire must be placed by the contractor installing FAA fiber optic cable to follow the entire fiber segment route between FAA buildings and facilities through new infrastructure and existing infrastructure. It is the contractor’s responsibility to coordinate all fiber tracer wire requirements with the OMP/FAA for all new FAA fiber work or expansion of existing fiber/tracer wire work.

3. The tracer wire must be #14 AWG insulated solid copper wire.

The insulation color must be orange for multi-mode fiber or yellow for single-mode fiber. The tracer wire must be placed with the installation of innerduct within a conduit in conjunction with the later installation of FAA fiber cable in that contract. The tracer wire should optimally be pulled in with the innerduct, in the conduit void between innerducts or in a FAA spare innerduct with the FAA’s approval and is run continuously from FAA facility/shelter to FAA facility/shelter without splices. Within manholes or handholes the tracer wire must be fastened to the cable racks and tagged “FAA Fiber Optic Tracer Wire”.

4. The tracer wire must follow the entire run of FAA fiber optic cable segments from Airport Traffic Control Tower or Concourse lower level duct entrances into and out of each of the respective FAA NAVAID and Communication / Radar facility to accommodate the tracing of each fiber segment. Tracer wire is not required beyond the Concourse ductbank entrances, in the lower level Concourse tunnels or to the ATCT. A separate tracer run in general follows each fiber segment from building to building and will not be shared nor spliced / tied together.

5. When the tracer wire is brought into a facility it will not be

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L-110-10 terminated. The tracer wire must be coiled in an interior mounted fiber optic junction box . The contractor must provide ten (10) feet of cable, coiled and tagged “FAA Fiber Optic Tracer Wire”. The junction box must also be tagged “FAA Fiber Optic Tracer Wire”.

6. Tracer wire continuity between facilities along each fiber optic cable segment must be demonstrated by the contractor to the FAA for acceptance.

7. When a field manhole tracer wire splice is required due only to the cable spool limitations the splice must be made with approved mechanical type connectors, Pro-Trace TW Connector. The connection must also be wrapped with electrical tape.

8. In the event tracer wire is damaged or rendered inoperable during the course of construction activities, the contractor will be responsible to re-establish or install new tracer wire between facilities.

C. ComEd Ductbank, Common Electrical Ductbank (CED) Warning Tape

1. Unless the ComEd Ductbank or Common Electrical Ductbank is being jacked in place, or the Plans indicated otherwise, a 6 inch wide red plastic warning tape must be placed 12 inches below grade directly over the entire length of a proposed ComEd Ductbank or Common Electrical Ductbank. The CED ductbanks contain as part of the OMP both electrical power and communications assigned cells.

2. The plastic warning must be colorfast and chemically inert.

Clips for bonding tears and completing end-of-roll splices must be provided and installed per manufacturers’ recommendations.

3.03 STEEL CASING INSTALLATION

A. For equipment and installation of steel casing for electrical conduits, refer to FAA-GL-918D.

3.04 INNERDUCT INSTALLATION

A. Equipment

1. Cable tuggers, tension metering equipment, break-away swivels, sheaves, quadrant blocks, hooked hanger sheaves, cable feeding sheaves, corner cable guides, reel trailers, reel trucks and continuous lubricating equipment are the most suitable types of equipment for this Project; however, the

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Contractor must make its own determination and selection of the equipment to use to install the innerduct.

2. Use pulling means, including fish tape, cable rope and basket weave innerduct grips that will not damage the innerduct media or raceway. Pull innerducts simultaneously in the same raceway as shown on the Drawings with equipment to equalize pulling tensions on each innerduct. A reliable non-freezing type of swivel must be inserted between the pulling line and the innerduct grips to prevent twisting under strain. The swivel must be equipped with shear to tension pins with a breaking strength recommended by the innerduct manufacturer. Pulling equipment must be equipped with a hydraulic bypass which must be set so that a maximum tension (recommended by the innerduct manufacturer) is not exceeded.

3. Prior to being installed, multiple innerducts must be bundled and secured with lashing ties per the manufacturers recommendations. The lashing ties must be installed every two

(2) meters.

B. Joints and Breaks

1. Innerducts must be installed continuous in the ductbank. No joints or breaks of any kind will be allowed in any of the innerduct segments. Innerduct breaks are allowed only in manholes/handholes/pullboxes and at Panel locations.

C. Placing Innerduct In Segments

1. Contractor must utilize secured sheaves and quadrant blocks to guide the innerduct from reels above the manhole or from buildings into the manhole chamber and into the 4 inch conduit.

Contractor must maintain tension on the innerduct from the supply reel to the 4 inch conduit.

2. Contractor must lubricate the innerduct at the point that it enters the conduit. Use pulling compound or lubricant as recommended by the innerduct manufacturer. Contractor must use a lubricant application system to minimize lubricant loss and spillage in the manhole and/or immediate work surface area. All spilled lubricant must be cleaned completely from the surfaces of the manhole and work surface area.

D. Manhole Terminations

1. The innerduct must enter the manholes through conduit fittings cast into the side of the manholes.

2. To compensate for innerduct elongation due to installation

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L-110-12 pulling stress and installation temperature, the Contractor must pull the multiple innerducts past the conduit system and/or manholes to allow the innerduct to recover to its original length.

The amount of innerduct left after the initial cutting in manholes must be coordinated with the innerduct manufacturer. This coordination must take into account allowable pulling tension, pulling techniques/equipment, conduit conditions, length of innerduct pulls, size/quantity of innerducts per conduit, and installation temperature. The time needed for innerduct recovery must be per innerduct manufacturer’s requirements prior to the final innerduct trimming to 6 inches extending out of the interior side of the manhole wall. Any innerduct improperly trimmed or compensated for elongation, that contracts into the conduit after relaxation must be removed and replaced at the Contractor’s expense.

E. Building Terminations

1. The innerduct must enter the buildings through 4 inch conduit fittings. Mechanical compression type seals are to be installed based on quantity and size of innerducts to provide a water and gas tight seal.

2. After installation of innerduct seals, Contractor must cut all HDPE innerduct per manufacturer’s requirements as described in Paragraph 3.04.D.2. If the Contract Drawings call for the innerduct to continue from the building wall, an innerduct transition piece must be installed and plenum rated innerduct is to be connected to it and extended into the building.

3. Contractor must provide an innerduct connector on all innerduct that is to be terminated onto an enclosure. The connector is to be securely fastened on the innerduct and enclosure. The 4 inch openings in buildings that are not used for innerduct entry must be plugged with a 4 inch blank compression type conduit plug.

F. Innerduct Support

1. Exposed innerduct must be supported in an approved manner.

Innerducts must not be fastened to or come in contact with any mechanical system pipes, ducts or equipment of other trades, except as approved by the COR. In all innerduct work including vertical runs, acceptable electrical support devices including hangers, racks, ties or a combination thereof must be used as supports.

G. Innerduct and Conduit Mechanical Seals

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1. The conduit and innerduct must be sealed with compression type mechanical seals at building penetrations and at the first manhole/handhole to building only.

2. Corrosion resistant compression type mechanical cable seals must be used to terminate the various cables at building entrance conduits and innerducts at buildings.

3. Duct tape must be used to temporarily seal all innerduct segments during the course of construction.

4. Immediately upon installation of an innerduct segment, the Contractor must place duct tape temporarily at both ends of each innerduct in the segment. Contractor must attach the pulling rope to the exterior of the innerduct with duct tape temporarily.

5. At the close of each workday, all innerduct installed as of the end of the workday is to be taped with duct tape to insure that innerducts remain free of liquids and particles.

H. Prior to installing new innerducts inside existing underground ductbanks, the existing ducts must be cleared and cleaned, If required, clearing and cleaning by mandrelling, power rodding, power washing or other means necessary for the installation of the new innerducts will be included in the unit price for the Innerduct Pay Item.

3.05 DUCTBANK END DELINEATION

A. In locations where ductbank ends; but, will be extended at a later date, the ductbank ends will be bulkheaded or stubbed and capped below grade. The ends of these ductbanks must be surveyed by the Contractor for their exact locations based on O’Hare Survey Control Monuments (easting and northing of each corner referred to the IL State Plane Coordinates NAD 1983 and the vertical elevation of the top of each corner referred to NAVD 1988). This survey information must be provided and indicted by the Contractor on the As-built Drawings for reference.

3.06 BACKFILLING

A. After concrete-encased conduits have been properly installed and the concrete has set, the trench must be backfilled in accordance with FAA-GL-918D for Trench Backfilling.

B. Trenches must not be excessively wet and must not contain pools of water during backfilling operations.

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C. Excess excavated material must be removed and disposed of in accordance with instructions issued by the COR.

3.07 RESTORATION

A. Where sod has been removed, it must be replaced as soon as possible after the backfilling is completed. All areas disturbed by the trenching, storing of soil, cable laying, pay construction, and other work must be restored to its original condition. The restoration must include any necessary topsoiling, fertilizing, liming, or seeding. All such work must be performed in accordance with turfing Specifications. The Contractor must be held responsible for maintaining all disturbed surfaces and replacements until final acceptance.

3.08 UNCLASSIFIED EXCAVATION

A. Provide all excavation for ductbank to the lines and grades for elevations, shown on the Drawings or as stated by the FAA. The excavation is to be of sufficient size to permit the placing of the full width and length of the ductbank shown. Excavated material is to be stockpiled where directed by the FAA Resident Engineer. The elevations, as shown on the Drawings, are to be considered as approximate only; and the Contracting Officer may order, in writing, changes in dimensions or elevations necessary to secure a satisfactory installation.

B. Boulders, logs, or other objectionable materials encountered in excavation are to be removed. All rock or other hard foundation material is to be cleaned of all loose material and cut to a firm surface either level, stepped or serrated, as directed by the Contracting Officer or their delegate.. All seams or crevices are to be cleaned out and grouted. Remove all loose and disintegrated rock and thin strata.

When concrete is to rest on a surface other than rock, special care is to be taken not to disturb the bottom of the excavation, and excavation to final grade is not to be made until just before the concrete or reinforcing is to be placed.

C. Provide all bracing, sheathing or shoring necessary to implement and protect the excavation and the ductbank, as well as protect existing adjacent structures located above or below grade as required, as required for safety or conformance to governing laws. .

D. Unless otherwise provided, bracing, sheathing, or shoring involved in the construction of this item is to be removed by the Contractor after the completion of the structure. Removal is to be effected in a manner which will not disturb or mar finish masonry. The Contractor is to

VOLUME IIIC

REV.14, ISSUED 3/31/10

L-110-15 notify the FAA to the effect; and concrete or reinforcing steel is to be placed after the FAA Resident Engineer has approved the depth of the excavation and the character of the foundation material.

END OF SECTION L-110

PART 1
PART 1
PART 1
PART 1
PART 1
PART 1 DESCRIPTION
1.01 GENERAL
A. The work consists of underground electrical conduit and ducts installed in accordance with this Specification at the locations and in accordance with the dimensions, designs, and details shown in the Drawings. The work includes the installation of...
B. Special Requirements for ComEd Utility Ductbanks – Unless otherwise indicated on the Contract Plans, all ComEd ductbank materials, installation, ductbank run formations, curve layouts, transposition and connection to ComEd manholes must be in accor...
PART 1
PART 1
PART 1
PART 1
PART 2 EQUIPMENT AND MATERIALS
2.01 GENERAL
A. Equipment and materials covered by referenced Specifications must be subject to acceptance through manufacturer's certification of compliance with the applicable Specification when so requested by the COR.
2.02 POLYVINYLCHLORIDE (PVC) CONDUIT
A. Non-metallic conduit must be PVC Schedule 40 or Schedule 80 concrete encased as indicated on the Drawings.
B. PVC conduit, including elbows and couplings, must meet the requirements of NEMA standards TC2 (latest edition), UL Standard 651, Federal Specifications WC-1094A, and must be UL rated and listed for use with 90 degrees C-rated conductors in complian...
C. The conduit must be manufactured from PVC compound that meets the applicable requirements of ASTM No. D 1784.
D. PVC conduit fittings must meet with the requirements of NEMA Standard TC3 (latest edition), UL Standard 514 supplement, and Federal Specifications WC-1094A.
E. All PVC conduit and fittings for communication conduits that will carry fiber optic cables must utilize sweeping bends. The bend must allow for the minimum bending (radius) requirements of the innerduct manufacturer and installer.
F. Standard PVC fittings and PVC cement adhesive must be compatible with the conduits and must be obtained from the same conduit manufacturers.
G. Acceptable PVC conduit manufacturers will be Carlon, J-M, National Pipe, or Georgia Pipe.
2.03 PVC-COATED GALVANIZED RIGID STEEL (GRS) CONDUIT
A. A Polyvinyl Chloride (PVC) coating nominal thickness 0.04 inches (40 mil), will be bonded to the exterior of the conduit. The bond between the coating and the conduit must be greater than the tensile strength of the plastic.
B. Fittings must be coated in the same manner as the conduit. Fittings must have a PVC sealing sleeve extending from the ends. The sleeve length must be approximately equal to the outside diameter of the conduit or 1-1/2 inches, whichever is smaller.
C. The PVC coated galvanized rigid conduit must be U.L. listed /labeled. The Manufacturer must submit certified test results from a recognized independent testing company validating that their product meets or exceeds the requirements of ASTM D870-02 ...
D. A urethane chemical coating must be uniformly and consistently applied to the interior of the conduit and fittings. The internal coating must be applied at a minimum thickness of 2 mils.
E. Provide solvent cement and patching compound as recommended by the manufacturer for sealing joints and repairing gouges and cuts.
F. Provide PVC coating cement and patching compound as recommended by the PVC coated conduit and fitting manufacturer.
G. PVC coated conduit and fittings must be 1 inch trade size or larger.
H. Galvanized rigid steel conduit heavy wall must be milled steel, hot-dip galvanized conduit, complying with ANSI C80.1 and Federal Specification WWC-581 and must be U.L. listed.
I. Elbows, bends, and fittings must be made of full weight materials and must comply with the above and threaded the same as conduit.
J. Threads for conduit, couplings and fittings must be full depth and clean cut. Field cut threads must be coated with Coppercoat or in accordance with manufacturer’s instruction.
2.04 CONCRETE
A. Concrete used to form duct banks with conduit must be as specified in FAA-GL-918D.. Reinforcing bars where required will be as shown on the Drawings and in accordance with FAA-GL-918D.
2.05 INNERDUCT
A. Materials for innerducts for airfield communication cables will be subject to acceptance through manufacturer’s certification of compliance with applicable Specifications.
1. All innerduct must be provided with a pull rope.
2. Footage label must be sequentially marked on the innerduct.
B. Outdoor Installations
1. Innerduct that is to be installed outside, as indicated in the Contract Drawings, must meet the following requirements:
a. The innerduct must meet or exceed the minimum standards of PE334470E/C as defined in ASTM D3350.
b. The innerduct must conform to ASTM F2160.
c. As indicated on the Contract Drawings, provide 1.00-inch for FAA or 1.25-inch for CDA innerduct for outdoor applications. The innerduct must meet the following Specifications.
(1) Type Solidwall
(2) Wall Construction SDR 11
(3) Material High Density Polyethylene
(4) Color Yellow for FAA single mode
fiber; grey for FAA copper control cable; orange for all other applications.

d. All solid wall innerduct, after final length trimming in manholes or building entrances, and prior to any cable installations within the innterduct must be reamed at the inside diameter edge at both ends of the innerduct to provide a smooth, rounde...

C. Indoor Installations
1. Innerduct that is installed indoors, as indicated in the Contract Drawings, must meet the following requirements.
a. The plenum rated innerduct must be recognized per NEC Articles, 770 and 800 for Plenum, Riser and General Purpose Raceway for optical fiber and telecommunications cables.
b. The riser rated innerduct must be recognized per NEC Articles, 770 and 800 for Riser and General Purpose Raceway for optical fiber and telecommunications cables.
c. The innerduct must conform to UL 2024.
d. As indicated on the Contract Drawings, provide 1.00-inch plenum or riser rated innerduct for FAA indoor applications. The innerduct for indoor applications must meet the following Specifications.
(1) Type Corrugated
(2) Material PVC (Riser Rated)
PVDF Resin (Plenum Rated)
(3) Inner Diameter 1.05 inches (+0.010 inch,
-0.020 inch)
(4) Outside Diameter 1.31 inches (+0.010 inch,
-0.020 inch
e. As indicated on the Contract Drawings, provide 1.25-inch plenum or riser rated innerduct for CDA indoor applications. The innerduct for indoor applications must meet the following Specifications.
(1) Type Corrugated
(2) Material PVC (Riser Rated)
PVDF Resin (Plenum Rated)
(3) Inner Diameter 1.38 inches (+0.010 inch,
-0.020 inch)
(4) Outside Diameter 1.65 inches (+0.010 inch,
-0.020 inch

f. Innerduct color must be yellow for FAA single mode fiber, grey for FAA copper control cable, and must be orange for all other applications.

D. Pull Rope
1. Provide pull rope in all innerduct with minimum pull strength of 1250 pounds for outdoor applications and 900 pounds for indoor applications. The pull rope must extend 6 feet beyond the termination at each end.
E. Duct Plugs and Conduit Seals
1. Duct plugs and conduit/innerduct seals must be constructed of high impact plastic and fully corrosion resistant. Where fasteners are required they must be stainless steel. The duct plugs and conduit/innerduct seals must provide a water tight and ...
a. Blank Duct Plugs – Compression type mechanical plugs must be installed to seal spare conduits and spare innerducts of various sizes at all building/facility entrances and at the first manhole or handhole outside of the building/facility entrance. ...
b. Innerduct Seals – Compression type mechanical seals must be provided to seal annular space around innerducts within conduits at all building entrances and at the first manhole or handhole outside of the building/facility entrance. Seals must be sp...
c. Cable Seals – Compression type mechanical seals must be provided to seal all cable entrances in conduits and all cable entrances in innerduct at all building entrances and at the first manhole or handhole outside of the building/facility entrance. ...
F. Pulling Lubricant
1. A water based propylene glycol solution must be used when placing innerduct into duct banks as well as placing cable into innerduct.
2. The lubricant must have characteristics intended for the pulling of MDPE and HDPE fiber sheaths through PVC innerduct.
G. Provide all fittings, terminations, connectors, etc. for a complete integrated raceway system.
H. Acceptable innerduct manufacturers are Carlon, EW&C and Innerduct.
2.06 STEEL CASING FOR ELECTRICAL DUCTBANK
A. Furnish and install steel casing with electrical conduits inside of the specified dimensions at the locations, lines, and grades shown on the Drawings in accordance with FAA-GL-918D.
PART 3 CONSTRUCTION METHODS
3.01 GENERAL
A. The Contractor must install underground duct banks at the locations and grades as indicated in the Drawings. Conduits must be of the size, material, and type indicated in the Plans or Specifications. Where no size is indicated in the Drawings or ...
B. The Contractor must mandrel each conduit. After completion of construction, each conduit must first be thoroughly cleaned before being mandrelled. Cleaning can be accomplished by drawing a wire duct brush, a flexible mandrel or power water roddin...
C. Conduit installed must be provided with a nylon or polypropylene rope for pulling the permanent wiring. Sufficient length must be left in handholes and secured to prevent it from slipping back into the conduit.
D. Conduit must be securely fastened in place during construction and progress of the work and must be plugged to prevent seepage or grout, water, or dirt. Conduits must be placed on supports/spacers designed and manufactured for this specific purpos...
E. Conduit must be encased in concrete, with a 3 inch minimum concrete envelope poured around all conduit.
F. Where turf is well established and the sod can be removed, it must be carefully stripped and properly stored and replaced after backfilling in accordance with Section 3.06, as directed by the COR.
G. Trenches for conduit and ducts may be excavated manually or with mechanical trenching equipment. Walls of trenches must be essentially vertical so that a minimum of base material or soil is disturbed.
H. Dozers, wheel loaders, or motor graders must not be used to excavate the trench. The Contractor must ascertain the type of soil or rock to be excavated before bidding. All excavation material will be unclassified. Work shall be performed in acco...
I. Conduit must be provided with slip couplings where it crosses through or under transverse construction joints in Portland cement concrete pavement.
J. Conduit must be provided with approved expansion and deflection couplings where it crosses through expansion joints.
K. PVC-Coated Galvanized Rigid Steel Conduit must be provided with grounding bushings to insure continuity of ground for the underground electrical system. The grounding bushings must be threaded onto the conduit.
L. The Contractor must connect into the electrical duct bank system at the location indicated on the Plans by core drilling into structures, by connecting to existing conduit or ducts, or as directed by the COR.
3.02 CONDUIT ENCASED IN CONCRETE
A. Unless otherwise shown in the Plans, concrete-encased conduit must be installed so that the top of the concrete envelope is not less than 30 inches below the finished subgrade where installed under runways, taxiways, aprons, or roads, and not less ...
B. Tracing FAA and Common Electric Ductbank (CED) Containing FAA Fiber
1. Provide and install 6” wide red plastic warning tape above all ductbanks and #14 AWG insulated copper tracer wire within all FAA dedicated ductbanks, handholes and manholes; all Common Electrical Ductbanks (CED), handholes and manholes containing F...
2. Tracer wire must be placed by the contractor installing FAA fiber optic cable to follow the entire fiber segment route between FAA buildings and facilities through new infrastructure and existing infrastructure. It is the contractor’s responsibilit...
3. The tracer wire must be #14 AWG insulated solid copper wire. The insulation color must be orange for multi-mode fiber or yellow for single-mode fiber. The tracer wire must be placed with the installation of innerduct within a conduit in conjunction...
4. The tracer wire must follow the entire run of FAA fiber optic cable segments from Airport Traffic Control Tower or Concourse lower level duct entrances into and out of each of the respective FAA NAVAID and Communication / Radar facility to accommod...
5. When the tracer wire is brought into a facility it will not be terminated. The tracer wire must be coiled in an interior mounted fiber optic junction box . The contractor must provide ten (10) feet of cable, coiled and tagged “FAA Fiber Optic Trace...
6. Tracer wire continuity between facilities along each fiber optic cable segment must be demonstrated by the contractor to the FAA for acceptance.
7. When a field manhole tracer wire splice is required due only to the cable spool limitations the splice must be made with approved mechanical type connectors, Pro-Trace TW Connector. The connection must also be wrapped with electrical tape.
8. In the event tracer wire is damaged or rendered inoperable during the course of construction activities, the contractor will be responsible to re-establish or install new tracer wire between facilities.
C. ComEd Ductbank, Common Electrical Ductbank (CED) Warning Tape
1. Unless the ComEd Ductbank or Common Electrical Ductbank is being jacked in place, or the Plans indicated otherwise, a 6 inch wide red plastic warning tape must be placed 12 inches below grade directly over the entire length of a proposed ComEd Duct...
2. The plastic warning must be colorfast and chemically inert. Clips for bonding tears and completing end-of-roll splices must be provided and installed per manufacturers’ recommendations.
3.03 STEEL CASING INSTALLATION
A. For equipment and installation of steel casing for electrical conduits, refer to FAA-GL-918D.
3.04 INNERDUCT INSTALLATION
A. Equipment
1. Cable tuggers, tension metering equipment, break-away swivels, sheaves, quadrant blocks, hooked hanger sheaves, cable feeding sheaves, corner cable guides, reel trailers, reel trucks and continuous lubricating equipment are the most suitable types ...
2. Use pulling means, including fish tape, cable rope and basket weave innerduct grips that will not damage the innerduct media or raceway. Pull innerducts simultaneously in the same raceway as shown on the Drawings with equipment to equalize pulling...
3. Prior to being installed, multiple innerducts must be bundled and secured with lashing ties per the manufacturers recommendations. The lashing ties must be installed every two (2) meters.
B. Joints and Breaks
1. Innerducts must be installed continuous in the ductbank. No joints or breaks of any kind will be allowed in any of the innerduct segments. Innerduct breaks are allowed only in manholes/handholes/pullboxes and at Panel locations.
C. Placing Innerduct In Segments
1. Contractor must utilize secured sheaves and quadrant blocks to guide the innerduct from reels above the manhole or from buildings into the manhole chamber and into the 4 inch conduit. Contractor must maintain tension on the innerduct from the suppl...
2. Contractor must lubricate the innerduct at the point that it enters the conduit. Use pulling compound or lubricant as recommended by the innerduct manufacturer. Contractor must use a lubricant application system to minimize lubricant loss and spi...
D. Manhole Terminations
1. The innerduct must enter the manholes through conduit fittings cast into the side of the manholes.
2. To compensate for innerduct elongation due to installation pulling stress and installation temperature, the Contractor must pull the multiple innerducts past the conduit system and/or manholes to allow the innerduct to recover to its original lengt...
E. Building Terminations
1. The innerduct must enter the buildings through 4 inch conduit fittings. Mechanical compression type seals are to be installed based on quantity and size of innerducts to provide a water and gas tight seal.
2. After installation of innerduct seals, Contractor must cut all HDPE innerduct per manufacturer’s requirements as described in Paragraph 3.04.D.2. If the Contract Drawings call for the innerduct to continue from the building wall, an innerduct tran...
3. Contractor must provide an innerduct connector on all innerduct that is to be terminated onto an enclosure. The connector is to be securely fastened on the innerduct and enclosure. The 4 inch openings in buildings that are not used for innerduct ...
F. Innerduct Support
1. Exposed innerduct must be supported in an approved manner. Innerducts must not be fastened to or come in contact with any mechanical system pipes, ducts or equipment of other trades, except as approved by the COR. In all innerduct work including ...
G. Innerduct and Conduit Mechanical Seals
1. The conduit and innerduct must be sealed with compression type mechanical seals at building penetrations and at the first manhole/handhole to building only.
2. Corrosion resistant compression type mechanical cable seals must be used to terminate the various cables at building entrance conduits and innerducts at buildings.
3. Duct tape must be used to temporarily seal all innerduct segments during the course of construction.
4. Immediately upon installation of an innerduct segment, the Contractor must place duct tape temporarily at both ends of each innerduct in the segment. Contractor must attach the pulling rope to the exterior of the innerduct with duct tape temporarily.
5. At the close of each workday, all innerduct installed as of the end of the workday is to be taped with duct tape to insure that innerducts remain free of liquids and particles.

H. Prior to installing new innerducts inside existing underground ductbanks, the existing ducts must be cleared and cleaned, If required, clearing and cleaning by mandrelling, power rodding, power washing or other means necessary for the installation...

3.05 DUCTBANK END DELINEATION
A. In locations where ductbank ends; but, will be extended at a later date, the ductbank ends will be bulkheaded or stubbed and capped below grade. The ends of these ductbanks must be surveyed by the Contractor for their exact locations based on O’Har...
3.06 BACKFILLING
A. After concrete-encased conduits have been properly installed and the concrete has set, the trench must be backfilled in accordance with FAA-GL-918D for Trench Backfilling.
B. Trenches must not be excessively wet and must not contain pools of water during backfilling operations.
C. Excess excavated material must be removed and disposed of in accordance with instructions issued by the COR.
1.01
3.07 RESTORATION
A. Where sod has been removed, it must be replaced as soon as possible after the backfilling is completed. All areas disturbed by the trenching, storing of soil, cable laying, pay construction, and other work must be restored to its original conditio...
3.08 UNCLASSIFIED EXCAVATION
A. Provide all excavation for ductbank to the lines and grades for elevations, shown on the Drawings or as stated by the FAA. The excavation is to be of sufficient size to permit the placing of the full width and length of the ductbank shown. Excava...

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