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CONCRETE VAULT TOILET BUILDINGS SPECIFICATIONS

1.1 DESCRIPTION

A. The work of this section consists of prefabrication, on-site delivery, off-loading, placement, assembly, and complete installation of new precast concrete vault toilets.

Site work and earthwork is included for the installation of new toilets.

B. This section includes specifications for the construction of precast concrete double vault toilet buildings with or without chase and finishes as specified herein.

C. The exterior finish and color scheme for each vault toilet building is:

1. Barn Wood walls, color; Cappucino Cream

2. Shake Roof, color; Java Brown

3. Privacy latch ADA handle

4. Schlage supplied lock; two sets of keys.

5. Door Orientation – Right-hand entry or left-hand entry

6. Signs – Men, Women, Unisex and Accessible Symbols

a. Symbol designations shall be provided by the Government at the contract award.

1.2 MANUFACTURER CRITERIA

A. The manufacturer supplying the requested precast concrete vault facility must meet the following:

1. Manufacturing plant must be Precast/Prestressed Concrete Institute (PCI) certified at the time of bid.

2. Manufacturer must provide stamped, engineered drawings prior to acceptance.

3. Manufacturer must show four examples of Sweet Smelling Technology designed precast concrete vault toilet facilities produced, installed, and in use as an example of their ability to perform on this contract.

4. Manufacturer must be continuously engaged in the production of precast concrete vault toilets for five years minimum.

5. Manufacturer shall provide a 20 year warranty against defects in material or workmanship on all concrete components and a one year warranty on all other components.

1.3 DESIGN REQUIREMENTS

A. Structural Live Loads – Buildings shall be designed to meet the following load requirements in accordance with the International Building Code (IBC).

1. Snow Load – 350 psf

2. Wind Load – 120 mph (fastest mile) or 150 mph (3-second gust), Exposure C

3. Earthquake – Maximum considered ground motion shall be 175 (0.2 second spectral response acceleration) and 125 (1.0 second spectral response acceleration), Site Class D. Design requirements associated with Uniform Building Code (UBC) Zone 4 are acceptable.

4. Floor – 100 psf

B. Additional Design Standards

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1. Contractor is responsible for adding reinforcement as needed to facilitate handling, assembling building components and transporting without incurring structural damage or cracking of the building components.

2. Vault toilet shall incorporate all design aspects of Sweet Smelling Technology as outlined by Briar Cook for the U.S. Forest Service.

3. Vault toilets shall have one-piece full length and width vault units to support the building, screen area and snow loads evenly. Vault toilets shall have a one-piece floor unit to prevent panels that migrate in different directions during periods of freeze/thaw stress.

4. Vault toilets shall have an all concrete design with a minimum 3/12 roof pitch.

5. Vault toilets shall have a minimum 4 inch wall, 4 ½ inch roof, and 5 inch floor thickness.

6. All wall to floor interior surface seams shall have a minimum 1” radius coving made of high strength grout.

C. Accessibility

1. Prefabricated vault toilet buildings shall conform to the requirements of the

Americans with Disabilities Act and Architectural Barriers Act Accessibility Guidelines dated July 23, 2004 (ADA/ABA) and the Architectural Barriers Act Accessibility Standard (ABAAS).

2. Buildings shall have full 60-inch turning diameter in each interior and entry area.

D. Tolerances

1. Precast concrete panels shall be cast within ¼” of dimensions shown on shop drawings.

E. Design and Production

1. Design, production or methods cannot be changed during the contract period without prior approval of the Contracting Officer.

1.4 QUALITY ASSURANCE

A. Minimum Contractor Requirements

1. Precast concrete manufacturing plant shall be Precast/Prestressed Concrete

Institute (PCI) certified.

2. Welders shall be currently qualified according to AWS D1.1.

B. Testing

1. The Contractor shall be responsible for all sampling and concrete testing.

2. Sampling and testing shall be conducted by an independent PCI certified testing laboratory, unless otherwise approved by the Contracting Officer.

3. All testing shall be performed by qualified individuals who have been certified

ACI Technician Grade 1.

4. Sampling shall be in accordance with ASTM C172.

5. The following test shall be performed for first batch poured each day.

a. Slump, ASTM C143

b. Air content, ASTM C231; the air content will be in the range of 5.0% +/-

2.0%.

c. Compressive strength, ASTM C39

1) 1 cylinder for release, with a minimum strength of 2500 psi.

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2) 1 cylinder at 7 days, with a minimum strength of 4500 psi.

3) 1 cylinder at 28 days, with a minimum strength of 5000 psi.

d. Contractor shall provide copies of test results to the Contracting Officer upon request.

1.5 STANDARDS

ASTM C33 Concrete Aggregates ASTM C39 Method of Test for Compressive Strength of Cylindrical Concrete

Specimens ASTM C94 Standard Specification for Ready-Mixed Concrete ASTM C143 Method of Test for Slump of Concrete ASTM C150 Standard Specification for Portland Cement ASTM A185 Standard Specification for Steel Welded Wire Reinforcement, Plain, or

Concrete ASTM C192 Method of Making and Curing Test Specimens in the Laboratory ASTM C231 Standard Test Method for Air Content of Freshly Mixed Concrete by the

Pressure Method ASTM C309 Standard Specifications for Liquid Membrane-Forming Compounds for

Curing Concrete ASTM C494 Standard Specification for Chemical Admixtures for Concrete ASTM A615 Standard Specification for Deformed and Plain Carbon-Steel bars for

Concrete Reinforcement ASTM C618 Standard Specification for Coal Fly Ash and Raw or Calcined Natural

Pozzolan for Use in Concrete ASTM C979 Standard Specification for Pigments for Integrally Colored Concrete ACI 211.1 Standard Practice for Selecting Proportions for Normal, Heavyweight, and

Mass Concrete ACI 1211.1 Recommended Practice for Selecting Proportions for Normal and

Heavyweight Concrete ACI 306 Cold Weather Concreting ACI 318 Building Code Requirements Structural Concrete and Commentary (includes

Errata) PCI MNL 116 Quality Control for Plants and Production of Precast Prestressed

Concrete Products

1.6 MATERIALS

A. Concrete - General The concrete mix design will be designed to ACI 211.1 to produce concrete of good workability.

1. Concrete will contain a minimum of 675 pounds of cementitious material per yard. Cement will be a low alkali type I/II or III conforming to ASTM C-150.

2. Coarse aggregates used in the concrete mix design will conform to ASTM C33 with the designated size of coarse aggregate #67.

3. Minimum water/cement ratio will not exceed .45.

4. Air-entraining admixtures will conform to ASTM C260. Water reducing admixtures will conform to ASTM C494, Type A.

5. If Self Compacting Concrete (SCC) is used, it must conform to ASTM C1611

B. Colored Concrete

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1. Color additives will conform to ASTM C979. A 12”x12”x1” color sample will be available for customer approval.

2. The following will contain colored concrete:

a. Toilet building roof panels

b. Building walls

c. Screen panels

3. The same brand and type of color additive will be used throughout the manufacturing process.

4. All ingredients will be weighed and the mixing operation will be adequate to ensure uniform dispersion of the color.

C. Cold Weather Concrete

1. Cold weather concrete placement will be in accordance with ACI 306.

2. Concrete will not be placed if ambient temperature is expected to be below 35 degrees F. during the curing period unless heat is readily available to maintain the surface temperature of the concrete at least 45 degrees F.

3. Materials containing frost or lumps of frozen materials will not be used.

D. Hot Weather Concrete The temperature of the concrete will not exceed 95 degrees F. at the time of placement. When the ambient reaches 90 degrees F. the concrete will be protected with moist covering.

E. Concrete Reinforcement

1. All reinforcing steel will conform to ASTM A615. All welded wire fabric will conform to ASTM A185.

2. All reinforcement will be new, free of dirt, oil, paint, grease, loose mill scale and loose or thick rust when placed.

3. Details not shown of drawings or specified will be to ACI318.

4. Steel reinforcement will be centered in the cross-sectional area of the walls and will have at least 11/4” of cover on the under surface of the floor.

5. The maximum allowable variation for center-center spacing of reinforcing steel will be ½”.

6. Full lengths of reinforcing steel will be used when possible. When splices are necessary on long runs, splices will be alternated from opposite sides of the components for adjacent steel bars. Lap bars #4 or smaller a minimum of 12”.

Lap bars larger than #4 a minimum of 24 bar diameters.

7. Reinforcing bars will be bent cold. No bars partially embedded in concrete will be field bent unless approved by the customer.

F. Sealers and Curing Compounds

1. Curing compounds, if used, will be colorless, complying with ASTM C309, type

I or 1-D.

2. Weatherproofing sealer for exterior of building will be a clear water repellent penetrating sealer.

G. Caulking, Grout, Adhesive and Sealer

1. Caulking service temperatures from -40 to +194 degrees Fahrenheit.

2. Interior and exterior joints will be caulked with a paintable polyurethane sealant.

3. Grout will be a non-shrink type and will be painted to match the color of surrounding concrete as nearly as possible.

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4. Cement base coating is formulated with a very fine aggregate system and is a built in bonding agent.

H. Paint

1. All paints and materials will conform to all Federal specifications or be similar

“top-of-the-line-components”. Paints will not contain more than .06 percent by weight of lead.

2. Type of paints for toilets

a. Inside concrete surfaces

I Interior floors will be a chemical resistant urethane. The color will be gray.

II Interior walls and ceilings will be a modified acrylic, water repellent penetrating stain. The color will be white followed by a clear acrylic anti-graffiti sealer.

b. Metal surfaces both inside and out

I DTM ALKYD

c. Exterior concrete surfaces I Exterior slab will be clear sealer II Exterior walls and roof will be a water repellent penetrating stain in the same color as the walls or roof followed by a clear acrylic anti-graffiti sealer.

I. Grab bars Grab bars will be 18 gauge, type 304 stainless steel with 1-1/2” clearance. Grab bars will each be able to withstand 300 pound top loading.

J. Toilet Paper Dispenser Two (2) dispensers: will be constructed of ¼” thick, type 304 stainless steel.

Dispensers will be capable of holding three (3) standard rolls of toilet paper each.

Toilet paper holder fastening system will be able to withstand 300 pound top loading.

Dispensers will be installed parallel to each other in a way for ease of operation.

K. Steel Doors

1. Doors will be flush panel type 1-3/4” thick, minimum 16 gauge galvanized steel, top painted with DTM ALKYD.

2. Door frames will be knockdown or welded type, single rabbet, minimum 16 gauge prime coated steel top painted with DTM ALKYD, width to suit wall thickness. Three (3) rubber door silencers will be provided on latch side of frame.

L. Door Closer Each door shall include a commercial quality pneumatically operated adjustable door closer with dull chrome plating to prevent wind gusts from blowing doors too far open, and to ensure doors close fully after use. Door closer is in addition to self-closing door hinges.

M. Door Hinges Door hinges will be 3 per door with dull chrome plating 4-1/2”x4-1/2”, adjustable tension, and automatic-closing for each door.

N. Lockset

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1. Lockset will meet ANSI A156.2 Series 4000, Grade 1 cylindrical lockset for exterior door.

2. Lever handle both inside and out. Either handle operates latch unless outside handle is locked by inside push-button.

3. Push-button will automatically release when inside lever handle is turned or door is closed.

4. Emergency slot on exterior so door can be unlocked from the outside with a coin, screwdriver and etc.

5. Inside lever always active.

6. U.S. 26D finish.

O. Dead Bolt Deadbolt will be a Lori Lock standard model with a double cylinder, 2 ¾” backset, and US26D finish. The cylinder will be a standard 11/8” Schlage Mortise cylinder with compression ring and 626 finish.

P. Door Stop Doorstop will be a dome style stop meeting ANSI 156.16.

Q. Double Coat Hook Coat hook will be 304 stainless steel 16 gauge (1.5mm), formed construction with a satin finish and have 3/16”x 7/8” nail in anchor. Upper hook will extend at least 2-1/2” inches from the wall. Lower hook will extend at least 1-1/4” from the wall.

R. Door Sweep Door sweep will be provided at the bottom of door and will be an adjustable brush type.

S. Trash Receptable None Required.

T. Wall Vent Vent cover will be 14 gauge 304 stainless steel painted with DTM and anchored into the concrete wall with high strength anti-rust tap con fasteners. The vent louver frame and louvers will be non-vision .1” extruded aluminum jet coat finish. Vent to come with insect screen. Cover to be recessed a minimum ¾” on exterior walls with a 45 degree bevel. Interior to be flush mounted. Wall vent will not protrude from the wall.

U. Signs

1. Signs to have raised pictograms, letters and Braille to meet ADA. Interior to have “No Trash in Vault Sign”.

2. All signs inset a minimum of ¾” into wall with 45 degree bevel.

3. All signs to be anchored into concrete with ¼” x ¾” concrete anchor nails.

V. Windows and Vault Cleanout Cover

1. Windows and cleanout cover frames will be constructed from steel.

2. Window glazing will be 3/16” thick translucent pebble finished mar-resistant

Lexan.

3. Plate for vault cleanout cover will be ¼” thick diamond plate steel. Lid will be hinged and configured so that it can be locked with a padlock. A gasket will be provided around the entire perimeter of the lid to provide an airtight seal.

4. Windows to have ¾” recess with 45 degree bevel.

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5. Windows frames to have vandal resistant fasteners.

W. Vent Stack Vent stack to be a minimum 12 inches in diameter and a minimum 3 feet higher than the roof peak. Vent stack shall include a Raptor Vent Screen furnished and installed.

X. Vault Liner The vault liner shall be made from a single sheet black ABS/750 virgin plastic and can hold up to 1,000 gallons of waste or 15,000 uses per vault. The initial sheet thickness shall be a minimum .375. Final stamped thickness shall be a minimum .060. The vault liner shall have molded dovetail embeds to attach the liner to concrete walls of the vault. The vault liner shall have two J-rails to attach the liner to the bottom of the vault. Vaults with ABS liner shall be warranted against leaks for a period of seven years.

Y. Riser Riser will meet ADA and be a molded one piece HDPE Aquatuf®. Riser will be a smooth surface and have high impact resistance at extremely cold temperatures.

1.7 SUBMITTALS

A. Technical Proposal

1. Shop Drawings

a. Submit shop drawings for each proposed model. Indicate standard options and any additional cost options.

b. Drawings must show the exact model floor plan, and the size and location of all plumbing fixtures, partitions, electrical components, vents, screens, doors, windows, etc.

2. Specifications and Installation Manual

a. Provide one copy of the specifications and installation manual for each proposed model.

3. Provide Manufacturer’s Literature for the following:

a. Door, door closer, and door hardware

b. Toilet, toilet seat and lid, grab bars, and toilet paper holder

c. Paint - interior

d. Caulk, grout, and adhesive

e. Concrete form liners

f. Concrete color additive and stain including color chips, curing compound and sealer

g. Signs

h. Coat Hooks

i. Windows

j. Vents

4. Concrete

a. Submit aggregate test results, concrete mix design including all concrete additives, and name of concrete supplier and aggregate source. All tests must have been completed within 24 months of the submittal of the technical proposal.

B. Post-Award

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1. Design calculations and final drawings shall be stamped by a professional engineer and submitted to the Contracting Officer prior to construction of the first building for each accepted model. The professional engineer must be registered in the United States.

2. Concrete Mix Requirements

a. Provide 28-day compressive strength test results within 35 days following manufacturing of the first building for each accepted model.

b. If concrete supplier, aggregate source, or any additives change at any time, submit new concrete information to the Contracting Officer for approval.

3. Colored and Textured Concrete

a. Submit one colored concrete sample for each color and texture of exterior building surface, accompanied by manufacturer’s literature for color additive and form liner, to the Contracting Officer for approval at least 30 days prior to the first anticipated colored concrete placement.

b. Minimum sample size shall be 12” x 12” x 1”.

c. The Contracting Officer may waive sample requirement if Contractor can show evidence of successful work with same color additive and aggregates as proposed for this project. Evidence must be a completed installation accessible to the Contracting Officer or designated representative at least 30 days before first placement of colored concrete is anticipated.

1.8 MANUFACTURE

A. Mixing and Delivery of Concrete

1. Mixing and delivery of concrete will be in accordance with ASTM C94, section

10.6 through 10.9 with the following additions:

a. Aggregate and water will be adjusted to compensate for differences in the saturated surface-dry condition.

B. Placing and Consolidating Concrete

1. Concrete will be consolidated by the use of mechanical vibrators. Vibration will be sufficient to accomplish compaction but not to the point that segregation occurs.

C. Finishing Concrete

1. Interior floor and exterior slabs will be floated and troweled.

2. All exterior building walls and exterior screen walls will be texture as specified.

3. All exterior surfaces of the roof panels will be cast to simulate a wood shake roof. The underside of the overhang will have a smooth finish.

D. Cracks and Patching

1. Cracks in concrete components which are judged to affect the structural integrity of the building will be rejected.

2. Small holes, depressions and air voids will be patched with a suitable material.

The patch will match the finish and texture of the surrounding surface.

3. Patching will not be allowed on defective areas if the structural integrity of the building is affected.

E. E. Curing and Hardening Concrete

1. Concrete surfaces will not be allowed to dry out from exposure to hot, dry weather during initial curing period.

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1.9 FINISHING AND FABRICATION

A. Structural Joints

1. Wall components will be joined together with two welded plate pairs at each joint. Each weld plate will be 6” long and located one pair in the top quarter and one pair in the bottom quarter of the seam. Weld plates will be anchored into the concrete panel and welded together with a continuous weld. The inside seams will be a paintable caulk. The outside seams will use a caulk in a coordinating building color or clear.

2. Walls and roof will be joined with weld plates, 3"x6" at each building corner.

3. The joint between the floor slab and walls will be joined with a grout mixture on the inside, a matching colored caulk on the outside and two weld plates 6” long per wall.

B. Painting/Staining

1. An appropriate curing time will be allowed before paint is applied to concrete.

2. Some applications may require acid etching. A 30% solution of hydrochloric acid will be used, flushed with water and allowed to thoroughly air dry.

3. Painting will not be done outside in cold, frosty or damp weather.

4. Painting will not be done outside in winter unless the temperature is 50 degrees

F. or higher.

5. Painting will not be done in dusty areas.

6. All surface voids to be filled prior to painting

7. Schedule of finishes

a. Inside concrete surfaces I. Inside floors will be 1 coat of 1-part water based chemical resistant urethane.

II. Interior walls and ceilings will be 2 coats of a modified acrylic, water repellent penetrating stain, followed by 1 coat of clear sealer.

b. Metal surfaces both inside and out

I. 2 coats of DTM ALKYD

c. Exterior concrete surfaces

I. Exterior walls will be 2 coats of water repellent penetrating stain in the same color as the walls or roof followed by 1 coat of clear acrylic anti-graffiti sealer.

1.10 DELIVERY AND HANDLING

A. The building manufacturer shall coordinate the delivery and placement of the precast concrete toilet buildings to the locations shown on the drawings.

B. Offload and Assembly

1. The Contractor is responsible for unloading and assembling all components of the precast concrete vault toilet, and touch up of any damage or cracks prior to acceptance.

2. The Contractor shall notify the Contracting Officer 10 days prior to the anticipated delivery date and 2 days (48 hours) prior to the exact date of delivery.

3. Deliveries shall only be made between the hours of 8:00 a.m. and 4:30 p.m.

(local time), Monday through Friday, unless otherwise approved by the Ordering Unit Contracting Officer.

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1.11 REMOVAL AND DISPOSAL OF EXISTING TOILET

A. Removal of Existing Toilets

1. Contractor shall utilize road guards where necessary while operating heavy equipment (i.e. excavators, cranes, earthmoving equipment, etc.)

2. If and when necessary, Contractor shall obtain any and all permits that may be required for the transportation of “oversize” or “wide load” pieces of equipment, supplies, materials, or any other related pieces within the project. All California and Department of Transportation laws apply. Contractor must adhere to all state, local and federal laws.

3. When removing old vault toilets, Contractor shall pump out, clean, and remove the existing vault and toilet; and minimize over-excavation and damage to adjacent improvements and vegetation. Excavation shall comply with section 1.12 below.

The new toilet shall be installed in the location of the existing toilet after removal, or as shown on the plans.

4. When removing old flush toilets, Contractor shall remove existing toilet building and foundation; cap existing water and sewer lines at the edge of the excavation in accordance with applicable codes; disconnect existing secondary electrical service at the closest pole (overhead) or utility box (underground) in accordance with applicable codes; and minimize over-excavation and damage to adjacent improvements and vegetation. Excavation shall comply with section 1.12 below. Contractor is not responsible for pumping the septic tank or demolition of other sewer system components. The new toilet shall be installed in the approximate location of the old toilet which is removed, as approved by the Contracting Officer’s Representative (COR) on site.

B. Disposal of Old Existing Toilet Building (all components)

1. Contractor shall properly dispose of existing toilet building and vault, as applicable. Disposal of existing vault toilet must comply local, state, and federal law. Disposal will occur off of national Forest Systems Lands.

1.12 INSTALLATION OF NEW VAULT TOILET

A. Scope of Work

1. Work specified under this section includes excavation, backfill and placement of precast concrete vault toilet.

B. Materials

1. Bedding material to be sand or 3/8” minus crushed or screened aggregate.

2. Caulking between vault and toilet floor to be 1” x 1” Butyl tape designed specifically to bond precast concrete to precast concrete.

C. Location

1. The new toilet with vault shall be installed at the location and orientation specified for each site in the contract, as approved by the COR on site.

D. Access to Site

1. Delivery to site made on normal highway trucks and trailers.

E. Excavation and Elevation

1. Comply with all applicable OSHA standards for excavation.

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2. Excavate for the installation of the toilet vault to a depth that will allow the structure site to be free draining after installation is completed. Allow for 2” leveling course beneath the vault. Stockpile topsoil in a separate pile at sites.

3. Finish floor elevation shall be set to match the elevation specified for the location, measured at the front (entrance) of the exterior slab unless otherwise approved by the Contracting Officer’s Representative (COR). Ideally, the back of the building should be slightly higher to allow water to freely drain out of the toilet rooms. The contractor will install buildings with the floor elevation within a plus 0.05’ of the specified floor elevation.

4. No excavation is to be left open more than seven (7) days unless otherwise approved by the COR.

5. All excavations left open overnight are fenced with wire mesh or plastic mesh fence secured to steel posts all around the excavation.

a. The bottom of the fence will follow the contour of the ground.

b. Maximum spacing of steel posts is 10’.

c. Minimum height of the fence is 36”.

F. Backfill and Compaction

1. Compact the natural ground at the bottom of the vault excavation with a minimum of three (3) passes with a whacker-type mechanical compactor or equivalent approved by the COR.

2. Install sand or aggregate bedding material for leveling course if needed. Compact leveling course with one (1) pass with a whacker-type mechanical tamper or equivalent approved by the COR. Grade leveling course so there are no high spots in the middle of the vault bottom. Compact with a second pass with whacker or approved equivalent tamper.

3. Set vault in place and check for level or appropriate scope. Backfill around structure. Use excavated material for backfill except rocks larger than 6” in maximum dimension shall not be placed within 6” of the exterior vault walls.

4. Fill adjacent to the building entry, will have excavated material placed in 8” loose lifts and compacted with a minimum of two (2) passes with a whacker-type mechanical compactor or equivalent approved by the COR.

G. Finish Grading

1. Spread excess excavated material from the vault around structure to match and blend with the existing site grading. Intended final grade is flush with the top of the front slab. Allow for placement of topsoil to reach that grade. Grade backfill away from structure at maximum slope of 5% unless otherwise approved by the Forest Service.

2. Spread unneeded excavation material and oversized rocks in a designated area within 500’ of the site. Approved location will be designated by the Forest Service.

3. Removed asphalt or concrete shall be properly disposed off national Forest Systems Lands.

H. Exhaust Pipe Installation

1. Attach top pipe with four (4) stainless steel screws or other approved method.

1.13 CLOSEOUT SUBMITTALS

A. Operation and Maintenance Manual

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1. Provide three copies of the operation and maintenance manual to the Contracting Officer at the time of delivery.

2. Operation and Maintenance Manual shall include, but not limited to, start-up procedures; recommended types of cleaners and cleaning tools that should be used; plus any additional information needed to ensure a properly functioning toilet.

1.14 MEASUREMENT

Measure the items listed in the bid schedule according to the following.

Measure each precast concrete vault toilet as a unit, including manufacture, delivery, and complete installation on site.

Measure each existing toilet demolished as a unit, including demolition, offsite disposal of building components and debris, and disconnection/capping of utilities as specified.

1.15 PAYMENT

The accepted quantities will be paid at the contract price per unit of measurement for the pay items listed in the bid schedule. Payment will be full compensation for the work prescribed in this Section.

d. Contractor shall provide copies of test results to the Contracting Officer upon request.