MOD ILS Shelter Project Specifications.pdf

Specifications

Date: 9/8/2011

Install two Government Furnished ILS Shelters Modesto Municipal Airport

Runways 28R Modesto, California

U.S. Department of Transportation Federal Aviation Administration

TABLE OF CONTENTS

Install Two Government Furnished Electronic Equipment Shelters at the Modesto Municipal Airport

Modesto, California

Division Description No. Pages

1 Project Requirements 3

2.1 Site Work and Demolition 2

2.3 Paving 4

3 Concrete 6

4 Not Used

5 Not Used

6 Not Used

7 Not Used

8 Not Used

9 Not Used

10 Not Used

11 Not Used

12 Not Used

13 Not Used

14 Not Used

15 Not Used

16 Electrical 3

End

DIVISION 1

PROJECT REQUIREMENTS

Print Date: September 8, 2011

1.1 GENERAL:

1.1.1 Project Locations: Modesto Municipal Airport Runway 28R Localizer and Glide Slope Shelters, located on the Modesto Municipal Airport, Modesto, California.

MOD LOC: Longitude 120° 57′ 47.05″W and latitude 37° 37′ 55.80″N.

MOD GS: Longitude 120° 56′ 42.41″W and latitude 37° 37′ 23.36″N.

FAA ESCORT IS REQUIRED for all locations.

1.1.2 Scope: Furnish all necessary labor, equipment, transportation, and service to "Replace two Instrument Landing System (ILS) shelters at the Modesto Municipal Airport, Runway 28R".

Each site shall be accomplished one at a time. The contractor may not work multiple sites at once. That’s way it is going to be. Don’t ask to change this and don’t bid any other way.

Sequence shall be: 1. MOD LOC 2. MOD GS.

Work includes but is not necessarily limited to:

• Disconnecting and removing the existing shelter.

• Removing and disposing of existing concrete foundations.

• Excavating for three new grade beams. Excess material shall be hauled off site on the same day. No overnight stock piles.

• Placing base material, compacting, forming, installing rebar, placing concrete for the grade beams.

• Excavating and installing the new earth electrode system.

• Carefully setting the new government furnished shelter onto the new grade beam foundation.

• Supplying and installing building lightning protection.

• Installing and connecting new underground conduits as shown on the drawings.

• Placing base material, compacting, forming, installing rebar, placing concrete for the stoop.

• Removing the existing equipment shelter and disposing of it.

• Paving the areas where the existing paving was disturbed or removed.

• Cleaning up and restoring the site.

in accordance with this specification and the project drawings.

Prior to construction, the FAA will identify, to the best of their ability, the location of all underground FAA cables and grounding systems. The contractor shall make the necessary arrangements with an underground cable / utility location service to locate any other utilities that may be located within the construction area. The contractor shall repair or replace, at his expense, any damage to any existing cables that is caused by the contractors operations. All necessary repairs shall be performed per FAA-C-1391b, section 3.6.

Upon completion, the new ILS shelters shall be complete, ready for use by the FAA.

1.1.3 Work Hours: The Contractor shall schedule and perform work between the hours of 6:00 AM and 4:30 PM, Monday through Thursday, excluding federally-established holidays, except when prior approval has been obtained from the Resident Engineer (RE). No work shall be scheduled or performed on Fridays, Saturdays, Sundays or holidays without prior approval from the RE. Approval by the RE for overtime work shall not be construed as an agreement for payment of overtime work. If the contractor desires to work overtime, Fridays, weekends or holidays, the written request for approval shall be forwarded to the Resident Engineer at least 48 hours in advance.

1.1.4 Maximum Allowable Duration per Site: The Contractor shall be required to (a) commence work under this contract within three (3) working days after the date the Contractor receives the Notice-To-Proceed date, (b) prosecute the work diligently, and

(c) complete the entire work ready for use no later than seven (7) working days. The time stated for completion shall include final cleanup of the premises.

1.1.5 Execution of Work: The contractor shall assume full responsibility for the protection and safekeeping of products stored on the site. The contractor and his subcontractors shall maintain the job site in a neat and orderly condition. This includes the daily removal of rubbish, waste and tools, equipment and materials not required for the work in progress. Wind-borne debris will not be tolerated by the FAA, nor the Airport Authority.

1.1.6 Storage: The contractor will not be allowed to use the new shelter to store tools and materials. If the contractor requires storage, then the contractor shall make the necessary arrangements for his own storage container (Jobox, rental trailer, PODS, shipping container, whatever.).

1.2 INSPECTIONS:

1.2.1 Damage to the Site: All cost of repairs shall be paid by the contractor. After notice to proceed and prior to the commencement of construction, the contractor and the resident engineer shall conduct joint inspections of the existing areas affected by the construction. Damage or defects shall be noted and will be used as the basis for determination of damages caused by the contractors operations.

1.2.2 Protection of Existing Utilities, Vegetation, Structures, and Improvements: This item shall also apply to roadway, shoulders, slopes, culverts, guard posts, fencing, gates, etc. Where such items are disrupted or damaged, they shall be repaired or replaced at the contractors expense.

1.2.3 Protection and Clean-up: The contractor shall have the overall responsibility for the performance and enforcement of all forms of protection against the weather, and further the responsibility for repair and replacement of material or equipment damaged as a result of inadequate protection.

1.3 MISCELLANEOUS INFORMATION:

1.3.1 Brand Name or Equal Statement: The use of a brand name with, or without, an or equal statement following the purchase description in this specification or on the project drawings is intended to promote competition by encouraging the offering of products that are equal in all material respects to the brand name products cited in such descriptions.

Identification by brand name does not indicate a preference for the products mentioned but indicates the quality and characteristics that will meet the governments needs. All characteristics of a specified brand name product which are essential to the government are described in this specification or on the project drawings. The contractor shall obtain product literature from the manufacturer of the specified brand name product to determine its general quality and functional characteristics and shall use that information in making any desired substitutions.

End of Division 1

DIVISION 2

Site Work and Demolition

2.0 GENERAL: This section covers site work consisting of excavating, trenching, backfilling, compacting, soil stabilization, grading, graveling, and demolition.

2.1 Site Materials: Aggregate base Specifications shall be in accordance with that indicated in Specification Division 3, Section 3.3.1.

Trench backfill material shall be native material. If native is not available, clean sand shall be used to make up the difference.

2.1.1 Local and Import Fill: All fill material shall be free from organic matter, debris vegetation, and other deleterious substances. It shall be of a quality suitable for the purpose intended and shall compact thoroughly without the presence of excessive voids when watered and compacted.

2.1.3 Over Excavation: Where excavation for footing and foundations is carried to a depth greater than required, backfilling with earth will not be permitted. In such instances, backfilling shall be done with concrete at no additional cost to the government.

2.1.4 Trenching: Underground cable and utility trenches shall be excavated where shown on the drawings. Trenches shall be excavated to a depth as indicated on the drawings. All trenches shall run in straight lines unless otherwise shown on the Project Drawings. Conduit shall not vary more than four (4) inches either side of the straight line layout.

2.1.5 Trench Backfill and Fill: Backfill and fill shall be placed in horizontal layers not exceeding loose depths of 12 inches. Each layer shall be properly moistened and compacted, as specified herein, by power operated mechanical equipment.

2.1.5.1 Foundation Backfill: After foundations have been constructed and have reached adequate set, excavations shall be backfilled. Backfill shall be placed on both sides of the foundations at the same time, and both sides tamped prior to placing of the next layer of material. Special care must be taken to prevent any uneven wedging action against the structure. The resident engineer shall inspect all installations prior to placement of backfill. Placement of backfill shall be in 6 inch layers.

2.1.6 Site Graveling:

2.1.6.1 Ground Stabilization Fabric: Site areas, roadways, walkways, and all other areas that were disturbed during the process of replacing this shelter shall receive ground stabilization fabric prior to spreading aggregate base material. Supply and install Marafi BasXgrid, or approved equal.

2.1.6.2 Aggregate Base: The contractor shall furnish up to 10 tons of 3/4” maximum road base in the locations that were disturbed. Finished surfacing of base shall be neatly shaped and graded.

2.1.6.3 Compaction: Compaction shall include watering , drying, blading, tamping, rolling, and/or such other operations required to produce the densities specified herein.

2.2 Demolition of the Existing Building: Remove the existing 7’-9” wide by 12’ long single story building, fiberglass shelter, and entrance way concrete step as shown on the project drawings.

2.2.1 Standards: Unless they are modified or exceeded by the requirements of this specification, conform to applicable parts of ANSI A 10.6 Safety Requirements for Demolition.

2.2.2 General Requirements:

2.2.2.1 Protections: Provide barricades, coverings, etc., necessary to protect persons, electronic equipment and property from injury or damage as a result of this work.

2.2.3 Procedure:

2.2.3.1 All Existing ILS Shelters: Remove and dispose of the shelter.

The buildings contains non-friable ACM. The floor tiles used in this building are a non-friable ACM. Care must be taken to not pulverize the waste into a friable condition.

Disposal must be at a landfill which accepts non-friable ACM construction debris. This waste must be documented and tracked by the FAA Safety and Environmental Compliance Manager, so plan accordingly as taking this operation for granted may prove expensive.

2.2.4. Workmanship:

General - Keep dust, and debris to a minimum. Due to frequent strong winds, the shelters shall not be demolished on the airport.

Workmanship - Demolition work required for this structure shall be done carefully.

2.2.5 Scrap Materials: Unless otherwise indicated, material and debris resulting from demolition operations is the property of the contractor, who shall promptly remove them from the site. No sale of surplus materials shall be conducted on the site.

End of Division 2

SECTION 2.3

PAVING AND SURFACING

2.3.1 General: This section describes the labor, materials, and services necessary to perform the aggregate surfacing, asphalt paving, and asphaltic paving repair as specified and as shown on project drawings.

2.3.2 Applicable Documents:

2.3.2.1 State Specifications: The following State of California, Department of Transportation, Standard Specification Sections. of the issue in effect at the date of this solicitation. form a part of this specification.

Section 26 Aggregate Bases Section 39 Asphalt Concrete Section 93 Liquid Asphalts

2.3.3 Materials:

2.3.3.1 Aggregate Base: The aggregate shall conform to Section 26, "Aggregate Bases" in the California State Standard Specifications. The gradation shall be as follows:

Percentage Passing

1-1/2” Maximum 3/4" Maximum

Individual Individual Test Moving Test Moving Sieve Sizes Results Average Results Average

2” 100 100 --- --- 1-1/2" 87-100 90-100 --- --- 1” --- --- 100 100 3/4" 45-90 50-85 87-100 90-100 No. 4 20-50 25-45 30-60 35-55 No. 30 6-29 10-25 5-35 10-30 No. 200 0-12 2-9 0-12 2-9

2.3.3.2 Liquid Asphalt: Used for prime coat shall be medium curing asphalt, Grade W- 70, in conformance with Section 93 of California State Standard Specifications.

2.3.3.3 Asphaltic Concrete: Shall be produced by a commercial asphalt paving plant.

Mineral aggregate and asphalt concrete production shall conform to the California State Standard Specifications.

2.3.3.3.1 Mixture: The asphalt concrete mixture shall be composed of a 60-70 penetration grade paving asphalt added at a rate of 4.0 to 7.5 percent by weight of total mix to type "B" aggregate, 3/4-inch maximum, medium grading, as per Section 39 of the California State Standard Specifications.

2.3.3.4 Seal Coat: Emulsified asphalt. type SS-1h, conforming to California State Standard Specifications.

2.3.4 Installation:

2.3.4.1 Aggregate Surfacing (Gravel Road):

2.3.4.1.1 Thickness: The aggregate surfacing shall be 3 inches thick after compaction.

2.3.4.1.2 Compaction: Aggregate surfacing shall be compacted to 95 percent of maximum density.

2.3.4.2 Asphalt Concrete Pavement:

2.3.4.2.1 Aggregate Base:

2.3.4.2.1.1 Thickness: The aggregate base under the pavement shall be 6 inches thick after compaction.

2.3.4.2.1.2 Compaction: The gravel shall be compacted to 95 percent of maximum density.

2.3.4.2.2 Prime Coat:

2.3.4.2.2.1 Materials: Liquid asphalt used for the prime coat shall be a medium-curing asphalt, Grade W-70, that conforms to Section 93 of the California State Standard Specifications.

2.3.4.2.2.2 Surface Preparation: Immediately prior to application of asphalt primer, all loose and foreign material shall be removed by light sweeping and the surface shall be dampened with water.

2.3.4.2.2.3 Equipment: The primer material shall be applied by a pressure distribution or hand spray unit that is designed and operated to distribute the asphaltic material in a uniform spray without atomization in the amount and between the limits of temperature specified.

2.3.4.2.2.4 Application: The liquid asphalt primer shall be applied at the approximate total rate of 0.25 gallon per square yard of surface at a temperature between 105 and 175 degrees Fahrenheit. Asphalt concrete shall not be laid until the prime coat has been completely absorbed by the base. Any prime coat not absorbed by the base shall be lightly sanded.

2.3.4.2.3 Asphaltic Concrete:

2.3.4.2.3.1 Transportation of Mix: The mix shall be transported to the job site in vehicles cleaned of all foreign material which may affect the mix. The dispatching of the vehicles shall be so scheduled that all materials delivered may be placed in daylight.

The mix shall be delivered at a temperature of not less than 250 degrees Fahrenheit.

2.3.4.2.3.2 Spreading: The asphalt concrete shall be placed by a self-propelled asphalt paving machine, spreader box, or by hand methods as required.

2.3.4.2.3.3 Compaction: The asphalt concrete shall be compacted with power rollers.

Areas inaccessible to compaction by power rollers or abutting Portland cement concrete pavement shall be compacted by use of vibrating compactors or other mechanical means approved by the R.E.

The number of rollers on the project shall be sufficient to accomplish satisfactory compaction in an efficient manner. All equipment shall be kept in good operating condition.

Steel-wheeled rollers shall be two-axle tandem type with a contact pressure of 8 tons minimum. Pneumatic rollers used for initial (breakdown) or secondary rolling shall have a contact pressure of 12-15 tons, with tires capable of 90 p.s.i. inflation pressure.

Initial rolling shall commence longitudinally at the lower elevations, such as flow lines, and proceed parallel to such lines toward the higher elevations. Rollers shall not cross flow lines at any angle other than 90 degrees thereto. Initial rolling shall be started as soon as possible after the material has been spread without causing excessive checking and shall consist of at least two full coverages with the drive wheel.

Finish rolling shall be started after the pavement has cooled sufficiently to permit removal of the roller marks and shall be continued in whatever direction is required to produce a dense, thoroughly compacted pavement, free of roller marks, and showing no significant movement under the wheels of the roller.

Installation shall be in accordance with the aforementioned specifications so as to provide a density of at least 95 percent of the laboratory density.

2.3.4.2.3.4 Surface Requirements: The pavement surface, when completed, shall be smooth, dense, well bonded, and of uniform texture and appearance. All areas shall drain. Flow lines shall be free of depression which permit water to stand.

2.3.4.3 Seal Coat: This section covers the application of an emulsified asphalt seal coat over asphaltic surfaces.

2.3.4.3.1 Surface Preparation: Immediately prior to the application of the seal coat, all dust and loose material shall be removed by light sweeping.

2.3.4.3.2 Application: The emulsified asphalt shall be diluted with an equal amount of water and applied at the rate of 0.1 gallon per square yard of surface at a temperature between 75 and 130 degrees Fahrenheit. The temperature of the surface shall be at least 85 degrees Fahrenheit when the material is applied.

2.3.4.4 Asphaltic Pavement Cutting, Removal, and Repair: Cutting of asphaltic concrete taxiways, aircraft parking areas, etc., for cable and duct installation shall be done to neat lines by diamond saw cutting. Broken asphalt shall be disposed of off airport property. Patching shall be of same thickness as that removed. Patching shall be compacted to equal that of the concrete in place and shall be done in a workmanlike manner. Patch shall be level with abutting surfaces.

2.3.5 Quality Assurance:

2.3.5.1 Asphalt Surfacing: The Resident Engineer will remove suitable size samples of the completed pavement so he may determine the composition, compaction, and density of the pavement. The Contractor shall replace the pavement free of charge. If the pavement is deficient in composition, compaction, or thickness, satisfactory correction shall be made.

END

DIVISION 3

CONCRETE

Dated: September 8, 2011

3.1 General: This section covers concrete work for the four ILS shelter foundations at the Modesto Municipal Airport. This division includes the base material and formwork requirements for the complete project installation.

3.2 Applicable Documents:

3.2.1 Publications: The following publications, issue in effect on the date of this solicitation, form a part of this specification.

3.2.1.1 AMERICAN CONCRETE INSTITUTE (ACI)

SP4 Formwork for Concrete 309 Consolidation of Concrete 301 Specification for Structural Concrete for Buildings 302 Recommended Practice for Concrete Floor and Slab Construction 347 Recommended Practice for Concrete Formwork 613 Recommended Practice for Selecting Proportions for Concrete 614 Recommended Practice for Measuring, Mixing and placing Concrete

3.2.1.2 AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

C-33 Concrete Aggregates C-39 Test for Compressive Strength, Concrete cylinders C-94 Specification for Ready Mixed Concrete C-143 Testing for Slump of Portland Cement Concrete C-150 Portland Cement C-172 Sampling Fresh Concrete A-185 Welded Steel Wire Fabric for Concrete Reinforcement C-260 Air-Entrainment Admixtures for Concrete C-309 Liquid Membrane Forming Compounds for Curing Concrete A-615 Deformed Billet Steel Bars for Concrete Reinforcement D-1751 Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (non-extruding and resilient bituminous type)

3.2.1.3 CONCRETE REINFORCING STEEL INSTITUTE (CRSI)

CRSI-78 Recommended Practice for Placing Bars

3.2.1.4 FEDERAL SPECIFICATIONS

SS-C-1960/3A Cement, Portland SS-A-281 Aggregate: (for) Portland Cement - Concrete

3.3 Materials:

3.3.1 Aggregate Base: The aggregate shall conform to Section 26, "Aggregate Bases" in the California State Standard Specifications. The gradation shall be as follows:

Percentage Passing

1-1/2” Maximum 3/4" Maximum

Individual Individual Test Moving Test Moving Sieve Sizes Results Average Results Average

2” 100 100 --- --- 1-1/2" 87-100 90-100 --- --- 1” --- --- 100 100 3/4" 45-90 50-85 87-100 90-100 No. 4 20-50 25-45 30-60 35-55 No. 30 6-29 10-25 5-35 10-30 No. 200 0-12 2-9 0-12 2-9

3.3.2 Cement: Cement for concrete shall be Portland Cement conforming to ASTM C-

150. Cement type shall be Type 1 unless otherwise stated on the project drawings.

The type stated on the project drawing shall supersede the Type 1 specified herein.

3.3.3 Aggregate: Aggregate shall be well graded in conformance with ASTM C-33, maximum size 1 inch for coarse aggregate (Class 2). Aggregate shall be natural sand and crushed stone or gravel suitable for use in concrete structures, unless other inert material is specifically approved in writing by the Resident Engineer.

3.3.4 Water: Water shall be fresh, clean and potable.

3.3.5 Admixture: Air-entrainment admixtures (if applicable) shall conform to ASTM C- 260.

3.3.6 Grout: Grout used shall be Sonneborn "Sonogrout", or "Burke" pre-mix grout (non-metallic, non-shrink) or approved equal.

3.3.7 Reinforcement: Placement shall be in accordance with project drawings.

3.3.7.1 Reinforcing Steel: Steel bar reinforcing shall be intermediate grade, new billet, deformed and of sizes called for on the drawings and shall conform to the requirements of ASTM Serial Designations A-615, Grade 40. Reinforcing bars shall be delivered with identifying tags attached to each bundle of bent bars.

3.3.7.2 Mesh Reinforcement: Mesh reinforcement shall conform to ASTM A-185, of the sizes indicated.

3.3.7.3 Bar Supports: Chairs, spacers and bolsters shall be galvanized steel or plastic coated of galvanized design designated and spaced in accordance with the recommendations of CRSI-78, Recommended Practice for Placing Bar Supports.

3.3.8 Isolation Joint Filler: Shall be a premolded rigid canefiber board impregnated throughout with a minimum of 35% by weight of asphaltic compound, thickness as shown on the project drawings. The filler material shall conform to ASTM D-1751.

3.4 Installation:

3.4.1 Forms:

3.4.1.1 Exposed Surfaces: If forms are removed before curing is completed, the contractor shall provide protection to prevent spalling and damage to the new concrete edges.

3.4.1.2 Treating: The inside of forms shall be coated with non-staining mineral oil or other Resident Engineer approved material to provide proper release. Wood forms for unexposed concrete may be wet with water just before placing concrete in lieu of coating.

3.4.1.3 Checking Forms: As concrete is placed the contractor shall make frequent checks on forms to detect any change in position. If necessary, stop the placement operation and replace or tighten any displaced forms to bring them back to the required line and level before continuing.

3.4.1.4 Removal of Forms: The removal of forms shall not be started until the concrete has attained the necessary strength to support its own weight and any construction live loads. All VOIDS or honeycombing found upon removal of forms shall be repaired immediately with concrete grout.

3.4.2 Mixing:

3.4.2.1 "Ready Mixed" Mixing and Delivery Operation: "Ready Mixed" mixing and delivery operations shall conform with ASTM C-94. Do not add water at the job unless prior approval is given by the Resident Engineer. Record the amount of any added water on all copies of the delivery ticket. If water is added, mix batch a minimum of 70 revolutions at truck manufacturer's recommended mixing speed before placing.

Concrete which has been held in a mixer truck longer than 1 hour shall not be used.

3.4.3 Placement of Concrete:

3.4.3.1 Cold Weather: To maintain the temperature of the concrete above the minimum placing temperature of 40 degrees F the as-mixed temperature shall not be less then 55 degrees F when the mean temperature falls below 40 degrees F.

3.4.3.2 Hot Weather: The ingredients shall be cooled before mixing, if necessary, to maintain the temperature of the concrete below the maximum placing temperature of 90 degrees F. Concrete that arrives at site at a temperature above 90 degrees F shall be rejected.

3.4.3.3 Hardened Concrete: Concrete that is partially hardened shall not be tempered.

3.4.3.4 Method: Place concrete in the forms as rapidly as practical by methods that will prevent loss or separation of the ingredients. Deposit it as nearly as practical in its final position in such a manner as to maintain a plastic surface which is approximately horizontal. If necessary to accomplish this, provide additional chutes or hoppers. Place concrete continuously in layers of 12-inches to 18-inches high at deep sections and not over 10-inches in height at shallow sections, so that no concrete will be placed against concrete which has hardened, except at approved joints. Vibrators shall not be used to move concrete laterally in the forms. Remove any wood spreaders as concrete rises in forms. Method shall conform to requirements of ACI-614 and ACI-309.

3.4.4 Vibration: All concrete shall be consolidated by vibration so that the concrete is thoroughly worked around the steel reinforcement, embedded items and into corners of forms, eliminating all air or stone pockets which may cause honeycombing, pitting or planes of weakness. Mechanical vibrators shall have a minimum frequency of 7 revolutions per minute and shall be operated by competent workmen. Over-vibrating must be avoided. Vibrators shall not be attached to or held against the forms or reinforcing steel.

3.4.5 Concrete Finishing: All concrete surfaces shall have a Class 1 troweled finish in accordance with ACI-302, Section 7-2, except for exterior platforms and walkways which shall have a broom finish applied to produce a fine and uniform gritty, non-slip surface.

All housecleaning pads shall have a finish with Class A tolerances (1/8 in. in 10 ft.) in accordance with ACI-301.

3.4.6 Curing: Curing shall be accomplished by the use of rugs or plastic sheets with the concrete kept damp; or membrane forming curing compound applied in a two-coat, continuous operation using not less than one gallon for 200 square feet of surface for each coat. The second coat shall be applied in a direction approximately at right angles to the direction of the first coat. Curing compound membranes subjected to damage by construction operations within the curing period, shall be resprayed at the rate specified above. Permanently exposed surfaces shall be cured by use of a membrane forming curing compound containing a fugitive dye. If clear-type curing compounds are used, the concrete surfaces shall be shaded from the direct rays of the sun for the curing period. Curing compound shall conform to ASTM C-309. Selection of the curing compound shall be determined by compatibility with any finishes to be applied to the concrete surface.

3.4.7 Details of Concrete Reinforcement: All details not covered herein shall be in accordance with ACI-301, Chapter 5, "Reinforcement".

3.4.7.1 All Reinforced Bars: All reinforcing bars shall be supported and tied together to prevent displacement by construction loads or the placing of concrete. On ground and where necessary, supporting concrete blocks may be used. Over framework, concrete, metal, plastic or other Resident Engineer approved bar chairs and spacers shall be furnished. Where the concrete surface will be exposed to the weather in the finished structure, the portions of all accessories in contact with the formwork shall be galvanized or shall be made of plastic.

3.4.7.2 Ties: Tie reinforcing together with wire at every intersection of bars and of bars with stirrups. Provide not less than 2 ties at all joints in reinforcing to hold bars in alignment. All reinforcing shall be sufficiently tied to provide proper spacing and alignment of bars, and to prevent their dislocation during placement of concrete.

3.4.7.3 Surface Preparation: Remove from reinforcing, any scale, heavy rust, and any coating which would reduce bond.

3.4.8 Splices:

3.4.8.1 Continuous Bars: Shall be spliced by overlapping a minimum of 36 diameters.

3.4.8.2 Welded Wire Fabric: Adjacent sections of steel welded wire fabric shall edge lap two inches, exclusive of the overhang of the transverse wires, beyond the longitudinal wires and shall end lap nine inches.

3.4.9 Placing Loads:

Shelter – Placing of the shelter will be at the Resident Engineers descression, but usually the shelter can be placed on the grade beam foundations the following work day.

3.4.10 Protection of Exposed Concrete: Protect exposed surfaces as necessary to prevent staining and damage. Provide protection of exposed edges to prevent chipping.

3.5 Quality Assurance:

3.5.1 Concrete Strength: Concrete shall develop 3,000 pounds per square inch minimum compressive strength when tested at 28 days in accordance with ASTM 39.

Concrete shall be placed with a maximum slump of 4 inches. Placement and curing techniques shall conform to ACI Standard 301.

3.5.2 Testing: The Government will retain a testing laboratory to perform the testing of concrete cylinders. The costs of tests shall be born by the Government. Any retesting required because of failure of concrete to meet specification requirement shall be paid for by the Contractor.

The cylinders will represent the batch of concrete from which they were taken. Three

(3) test cylinders will be made for each strength test. Specimens will be tested at 7 and 28 days with one held in reserve in case improper sampling, molding, or testing requires an additional test. Test specimens will be tested in accordance with ASTM C-39.

Concrete that does not meet the requirements shall be removed and replaced at the expense of the Contractor.

Slump tests will be performed by the Resident Engineer. The slump cone and rod shall be furnished by the Contractor. Forming, curing, and testing of concrete cylinders will be done at the Government's expense. The concrete slump tests will be taken and tested in accordance with ASTM C-172 and ASTM C-143.

3.5.3 Forms: Forms for exposed concrete surfaces shall be designed and constructed so that the formed surface of the concrete does not undulate excessively in any direction between studs, joists, form stiffeners, form fasteners, or wales. Undulations exceeding either 3/32 inch or 1/270 of the center to center distance between studs, joists, form stiffeners, form fasteners or wales will be considered to be excessive.

Should any form or forming system even though previously approved for use, produce a concrete surface with excessive undulations, its use shall be discontinued until satisfactory modifications approved by the Resident Engineer have been made.

Portions of concrete structures with surface undulations in excess of the limits herein described may be rejected by the Resident Engineer.

3.5.4 Batch Weight Tickets: A copy of all concrete "batch weight tickets" shall be given to the Resident Engineer.

3.5.5 Field Inspections: Prior to placing any concrete in forms, reinforcing and formwork will be inspected by the Resident Engineer and any discrepancies found shall be corrected by the Contractor at his expense. The Contractor shall give the Resident Engineer at least 24 hours advance notice for such inspection. All concrete shall be placed in the presence of the Resident Engineer.

End of Division 3

DIVISION 16

ELECTRICAL and GROUNDING

16.1 ELECTRICAL: The contractor shall install new conduits and conductors according to the project plans and in accordance with this specification.

The conduits shall be stubbed up at the new foundation. They shall be accurately located at the foundation per the contract drawings and/or field measurements. The contractor shall make the final connections to the building from the stub-ups. The contractor is not responsible for providing any RF and control wiring.

Items not shown in detail or covered by detailed specifications shall be as set forth in the National Electrical Code (Most Recent Edition), FAA Standard: FAA-C-1217f (Electrical Work, Interior) and FAA-C-1391b (Electrical Work, Exterior).

16.1.1 Conduit and Fittings: All exterior conduits, installed above ground, shall be galvanized rigid steel. Where galvanized rigid steel is installed below grade, it shall be PVC coated or half lapped using 10 mil pipe wrap. All changes in direction (ie: 90’s), both above and below grade, shall be made using standard radius galvanized rigid steel.

Underground conduit shall be schedule 40 PVC. If concrete encasement is required, it will be shown or indicated on the contract drawings. Gentle changes in direction (45° or less) may be accomplished by heating the conduit with an approved conduit heater / blanket. All underground conduits shall be a minimum of 18” depth from finished grade to the top of the conduit, unless ontherwise specified or shown on the contract drawings. All PVC fittings (connectors and couplings) shall be schedule 80. Backfill shall consist of 3 inch thickness sand bedding above and below the conduit, or as per the contract drawings. The remainder of the backfill shall be native material excluding stone aggregate larger than 4 inches in diameter.

Conduits shall be installed parallel or at right angles to the building. Conduits shall be securely supported and fastened in place at intervals of not more than 5 feet and within 3 feet of each change of direction. Support shall be from building structural steel, walls, or other R.E. approved structural components. Fasteners shall be Unistrut, or B-Line Strut Systems, components with appropriate screws or bolts for the surface material.

Changes in direction shall be symmetrical bends, enclosures, or cast-metal fittings.

Each conduit entrance to outlet boxes, panel boards, and equipment cabinets shall be fitted with a lock nut and insulated throat connector.

Interior conduits shall be minimum ¾” EMT. All connectors, couplings and fittings shall be cast compression type. Screwed fittings are not allowed.

16.1.2 Conduit Grounding: All underground conduits to be installed under this contract shall be bonded to the facility grounding counterpoise. The bonding conductor size shall be 4/0 bare copper. All connections shall be made using exothermic welds.

For RF and control, insulated grounding bushings shall be installed whenever a conduit enters or exits the building. Otherwise, plastic bushings shall be installed on all conduit connectors.

For power, insulated grounding bushings shall be installed at panelboards, junction boxes, disconnects, and electrical components. Also, insulated grounding bushings shall be installed whenever a conduit enters or exits the building. Basically, anywhere there is a connector on a power conduit, it shall have an insulated grounding bushing.

Grounding bushings shall be Thomas and Betts Catalog No. 38XX, or approved equal.

16.1.3 Concrete Pull Box Penetrations: Where the conduits penetrate a concrete pull box, the box shall be sealed tight to the conduit using a mortar mix, or comparable product, prior to backfilling.

16.1.4 Entrance Box Connections: Where underground conduits enter the Entrance Box, all galvanized rigid steel conduits shall be installed with lock rings on both sides. A grounding bushing shall also be supplied and installed. The grounding bushing lugs shall be connected together using a #6 solid bare copper. This #6 solid bare copper shall be landed on an appropriate lug which is securely mounted to the enclosure. All paint shall be removed, using a grinder, from the cabinet surface where the lug is to be attached.

16.2 Wire: All wire shall have copper conductors. Size shall be American Wire Gauge (AWG) with size for power circuits as shown on the project drawings. Size for all control circuits shall be #16 AWG. Power wire #10 AWG and smaller may be stranded or solid;

#8 and larger wire, and all control wire, shall be stranded. Insulation shall be type THW or THWN for power wire and type MTW for control wire and shall be color coded as follows:

Single Phase Three Phase

120 Volts 208/240 Volts 120/208 or 240 Volts 277/480 Volts Line-Black Line 1-Black Phase A-Black Phase A-Yellow Neutral-White Line 2-Red Phase B-Red Phase B-Brown Neutral-White Phase C-Blue Phase C-Orange Neutral-White Neutral-Gray

All Circuits:

Ground Green

Control Black with numbered adhesive markers on both ends or multiconductor with unique continuous color coded insulation

Power wires #8 and smaller shall have continuous colored insulation. Wires #6 and larger may utilize continuous colored insulation or colored tape. Where conductors are color coded with tape, they shall be half lapped for a minimum length of 3 inches in all junction and pull boxes, accessible raceways, panelboards, outlets, switches and equipment cabinets.

All wire shall be continuous; no splices will be permitted unless specified on the project drawings. Where permitted, splices shall be accomplished with compression type connectors bonded to the wire with a crimping tool and procedure approved by the connector manufacturer. Wires shall not be installed until all conduit and fittings are in place. All wires shall be drawn into conduit simultaneously and with adequate lubricating compound to prevent damage to insulation.

1.3 Grounding: All noncurrent carrying metallic parts of the electrical system shall be grounded with an insulated wire sized and installed in accordance with Article 250 of the National Electrical Code. Ground wire shall be connected to ground bus in each power panel, to ground lug on receptacles, and to enclosure or frame of major electrical devices such as safety switches, motors, motor starters, terminal cabinets, light fixtures, etc. Connection of wire to these devices shall be with a separate machine screw and nut which bonds to a clean, bare metal surface. Self-tapping screws are not acceptable for this purpose. Screws that are used for support of the enclosure shall not be used for this purpose.

16.3 DEMOLITION: Any unused conduit, wire, duct, pipe, structural supports or other fittings associated with equipment or devices to be removed under this contract shall also be removed.

All conduit shall be totally removed unless approved by the R.E to only remove it back to the first existing junction box or electrical fitting. Remove all unused wire back to the source power panel. Any circuit which must continue to operate shall be rewired for continuity. Seal all unused conduit with electrical plugs.

Any equipment or material to be removed, unless shown to be given to the RE, shall become the property of the Contractor and shall transported from the site.

End of Division 16