Specifications.pdf

Sullivan County Airport Replacement of the

Runway 15 Glide Slope Shelter Monticello, NY

Removal of existing shelter and the site preparation for the installation of a prefabricated 10’x 16’ shelter for the Sullivan County County Airport, Runway 15 Glide Slope located in Monticello, NY.

PART I - SECTION B

WORK SUMMARY

A. This section is to serve as a suggested construction phasing plan. This section is for suggestion purposes only and it does not outline in entirety the detailed requirements of this contract. Contractor is fully responsible for all work outlined in this contract.

B. Contractor is required to submit a "Contractor Construction Phasing Plan And Project Schedule", for approval prior to construction start date.

C. Coordination for GFM shelter arrival date shall be done during the pre-construction meeting. Coordinate shelter delivery for anticipated completion of new foundation work. Coverage and extent of FAA GFM includes the prefabricated shelter itself, delivery to the site and one crane offload at site. Contractor is expected to coordinate with onsite RE and Dupont point of contact for the shelter delivery.

D. The local FAA (SSC) is responsible for coordinating and facilitating required facility outages and will prepare equipment for removal from old shelter. Contractor is responsible for the physical relocation of equipment and items to be replaced/ mounted into the new shelter.

E. The local FAA (SSC) responsible for wiring and terminating all control cables for the equipment in the new shelter. The contractor will remount equipment and install the power cable. FAA (SSC) will do the terminations of the power cables in the equipment.

The work shall include, but is not limited to the following:

Phase I

1. Set and prepare base for new entry road. The base to be used as access/ egress to the site and for the construction staging area. Contractor to mind all area restrictions outlined under the safety and security general notes section and those mentioned at the pre-construction meeting.

2. Provide backup power for GS tower obstruction light prior to facility.

3. Shutdown of power feeder to R/W15 Glide Slope (GS) and AWOS.

4. Remove transformers and conduits from shelter.

5. Provide storage coordination for all items and equipment planed for reinstallation into the new shelter.

Relocating the old (existing) shelter on site is an approved method for temporary storage, as long as the shelter is stored within the free working area and ensured water tight.

6. Demolition scope of work. See contract drawings and specifications. Demolish remaining shelter concrete foundations. Contractor to submit a waste management plan.

Phase II

7. New construction scope of work. See contract drawings and specifications.

8. Prepare concrete foundation for the new 10’ x 16’ prefabricated shelter.

9. Install Government Furnished prefabricated shelter on new foundations.

10. Install and test new power service to new shelter and existing steel tower.

11. Install RF conduit/junction boxes from new shelter to existing steel tower.

12. Install and test lightning protection and grounding system for new shelter and existing steel tower.

13. Install site stone.

14. Remove and dispose of old (existing) 12’ x 12’ prefabricated shelter.

15. Continue and complete road installation and site work. See contract drawings and specifications.

PART 1 - SECTION C

DESCRIPTION/SPECIFICATION

SECTION INDEX

TABLE OF CONTENTS

DIVISION 1 - GENERAL REQUIREMENTS

Section Title

1-1 Summary of Work 1-2 Construction Limits and Use of Facilities 1-3 Temporary Facilities 1-4 Contract Close-out 1-5 Project Record Documents 1-6 Completion Certificate

DIVISION 2 - SITE WORK

2-1 General 2-2 Applicable Documents 2-3 Grading 2-4 Trenching and Underground Conduit Installation 2-5 Excavation, Backfilling and Surfacing 2-6 Paving 2-7 Demolition 2-8 Submittals

DIVISION 3 – CONCRETE

3-1 Formwork 3-2 Reinforcement 3-3 Cast in Place Concrete 3-4 Grouting 3-5 Quality Assurance

DIVISION 5 – METALS

5-1 Structural Metal

DIVISION 13 – SPECIAL REQUIREMENTS

13-1 Shelter Installation

DIVISION 16 - ELECTRICAL

16-1 Electrical Material and Installation 16-2 Applicable Documents 16-3 Grounding 16-4 Wire Methods 16-5 Conductors 16-6 Quality Assurance Provisions

DIVISION 1 - GENERAL REQUIREMENTS

1-1 SUMMARY OF WORK

1-1.1 General

These specifications, together with the referenced specifications, standards and drawings specified in the Contract Documents, cover the requirements of the Federal Aviation Administration, hereinafter referred to as the Government or FAA, for all work associated with the replacement of the Sullivan County Airport, Runway 15 Glide Slope shelter located at Monticello, NY.

1-1.2 Intent of Specifications

This specification identifies all labor, materials and equipment necessary to perform the required work. All material not specifically indicated as furnished by the Government in the List of Government Furnished Materials (GFM) shall be furnished by the Contractor.

1-1.3 Construction Per Drawings

The construction of this facility shall be in accordance with the lines and grade shown on the contract drawings. The Contractor shall verify all distance by measuring in the field.

1-1.4 Contract Duration

The contractor shall have 30 calendar days from the notice to proceed (NTP) to complete the project.

1-1.5 Work Hours

Normal work hours are from 8 am to 4:30 pm, Monday through Friday. All work outside of the normal time frame shall be coordinated with the RE a minimum of 48 hours prior.

1-1.6 Health and Safety Plan

The contractor shall submit a health and safety plan for the project prior to the issuance of the notice to proceed. The Construction Safety And Phasing Plan shall be in accordance with AC 150/5370-2F and Safety Plan Compliance Document.

1-1.7 Cable Markout

The contractor shall contact “One Call” a minimum of 72 hours prior to starting work at (800) 272- 4480. Access to the site shall be coordinated with Stewart FAA office at (845) 567-9619. Contractor shall mark-out all FAA own facilities with the aid of the FAA.

1-1.8 Work Schedule

Contractor shall submit a work schedule prior to the FAA issuing notice to proceed. The schedule shall include all major milestones and cut-overs.

1-2 CONSTRUCTION LIMITS AND USE OF FACILITIES

1-2.1 Construction Limits

The Contractor shall confine operations, activities, storage of materials and employee parking within the areas designated by the RE. Any additional space the Contractor deems necessary shall be obtained off the site, at no additional cost to the Government. At no time will the Contractor disturb any of the vegetation at the site unless directed by the RE. Taxiway and Runway may be active during construction. Contractor is to mind all TSA and RSA boundaries. See contract drawings for detailed information.

1-2.2 Damage to Site

Damage to existing pavement, landscaping, structures or underground facilities caused by the contractor's activities shall be repaired. All costs of such repairs shall be paid for by the Contractor.

After notice to proceed and prior to commencement of construction, the Contractor and Resident Engineer (RE) shall conduct joint inspections of the existing area. Existing damage or defects shall be noted and will be used as the basis for determination of damages caused by the Contractor's operations.

1-2.3 Contractors' Use of Premises

The Contractor shall have use of the premises within the construction area limits for the execution of his work and shall assume full responsibility for the protection and safekeeping of products and materials stored on the site. This shall include all Government Furnished Equipment (GFE) as provided in this contract.

The Contractor and subcontractors shall maintain the job site in a neat and orderly condition. This includes the daily removal of rubbish, waste, tools, equipment, and materials not required for the work in progress.

1-2.4 Access to Site

Access to the job site shall be via specific route established at the pre- construction meeting. All contractor vehicles and personnel shall remain within the limits of the construction area, staging area, or haul routes and limits. The contractors employees shall comply with all and any security requirements of the contract documents. Due to work on aoa, construction limits will be enforced by on site re. The contractor shall not permit any unauthorized personnel or traffic to the site.

The contractor shall access the site via the airport main gate. Contractor shall have air to ground transceiver to monitor the airports Unicom frequency when moving on taxiways and runways. The contractor shall escort all vehicles not equipped to operate on the airport at the main gate and escort the vehicle to the site.

Contractor shall only work within or around an active FAA facility when a FAA employee is present.

1-2.5 Vehicle Marking

All contractor vehicles shall have the company name and/or logo permanently fixed to the vehicle with an operating amber beacon mounted to the vehicle roof.

1-3 TEMPORARY FACILITIES

1-3.1 General

The Contractor shall provide and pay for all temporary services and facilities as specified below and as necessary for the proper and expeditious execution of the work.

1-3.2 Temporary Toilets and Sanitation

The Contractor shall provide ample and suitable on-site sanitary conveniences with proper enclosures for the use of all workers. Such conveniences shall be kept clean, be properly ventilated and shall be installed and maintained in conformity with requirements of all laws and ordinances governing such installation. Locations shall be subject to the RE's approval. After completion of the work, such conveniences shall be removed from the site.

1-3.3 Temporary Electric Lighting and Power

The Contractor shall provide and maintain a temporary lighting and power system for construction and inspection purposes. The Contractor shall make all necessary arrangements for temporary electrical services and shall provide and pay for all temporary work.

1-4 CONTRACT CLOSEOUT

General

The Contractor shall require each subcontractor engaged upon the work to bear full responsibility for cleaning up during and immediately upon completion of his work. All rubbish, waste, tools, equipment and other apparatus caused by or used in the execution of the work shall be removed. This shall in no way be construed to relieve the Contractor of his primary responsibility for maintaining the site clean and free of debris, and leaving all work in a clean and proper condition acceptable to the RE.

1-4.1 Rubbish Removal

Immediately after unpacking, all packing material, case lumber, wrappings, or other rubbish, flammable or otherwise, shall be collected and removed from the site and disposed of in accordance with local regulations on a daily basis.

1-4.2 Overall Cleaning

Immediately before the final inspection, the surrounding areas shall be thoroughly cleaned by the contractor, including but not limited to the following:

a) For all construction facilities, debris and rubbish shall be removed from the site.

b) All tools, scaffolding, temporary utility connections or buildings, belonging to the contractor or used under his direction shall be removed from the site.

1-5 PROJECT RECORD DOCUMENTS

1-5.1 Maintenance of Documents

The following documents shall be maintained at the project site:

a) Contract drawings

b) Contract specifications

c) Reviewed shop drawings

d) Change orders

e) Field test reports

f) Project correspondence

g) Current Work Schedule

1-5.2 Submittals

General -- All materials that are to be installed by the Contractor, must be to the RE for approval, prior installation.

1-5.2.1 Procedure – Four (4) complete sets of all shop drawings and/or product data shall be submitted and two sets will be marked and returned to the contractor.

Each shop drawing, submitted for approval, shall have in the lower right hand corner, just above the title block, a 4 inch open space in which the RE can indicate action taken. All submittals shall be accompanied by transmittal letters identifying the contents of the submittal. Transmittal letters shall consist of one original and one copy. A schedule of submittals shall be made 10 days after contract award, showing the dates when all shop drawings and material approvals will be submitted for the entire project. This schedule shall be organized by specification division and shall indicate the referenced division section along with the proposed submittal dates. The FAA review will take (10 calendar days maximum) with possible contractor resubmittal (10 calendar days maximum) and FAA resubmittal review (10 calendar days maximum). Work requiring approval shall not be initiated, fabricated or delivered to the site prior to approval of submittal. Submittals shall be checked by the contractor and coordinated with the work of other trades involved before they are complete, detailed, and assembled in sets. Lack of completeness or inadequate description will be justification for disapproval. Shop drawings shall bear the following information:

Number of contract drawings and latest revision;

Specification page;

Name of project;

Name of subcontractor or supplier;

Clearly identified contents and location of work.

1-5.2.3 By submitting shop drawings, the contractor thereby represents that he has verified the following:

Space limitations; Coordination with equipment furnished under other specifications;

Catalog numbers and similar data; Compliance with requirements of the work and of the contract documents.

1-5.2.4 Shop drawing approval - The checking, marking or approval of the shop drawings and/or product data by the Resident Engineer shall not be construed as a complete check, but will indicate only that the general method of construction and detailing is satisfactory.

Approval will not relieve the contractor of responsibility for any error which may exist. The contractor shall be responsible for the dimensions and design of adequate connections, details, and satisfactory construction of all work.

1-5.2.4.1 Approved as submitted - If "approved as submitted" is marked by the Resident Engineer, each copy of the shop drawings or product data will be identified as having received such approval by being stamped and dated. After submittal has been approved, no substitution will be permitted without written approval by the Resident Engineer.

1-5.2.4.2 Approved as noted - If "approved as noted" is marked by the Resident Engineer, the shop drawings or product data is satisfactory contingent upon contractor acceptance of corrections, notations, or both and, if accepted, does not require resubmittal.

1-5.2.4.3 Approved as noted - resubmission required - If "approved as noted-resubmission required" is marked by the Resident Engineer, the shop drawings or product data may be satisfactory contingent upon contractor resubmission of corrections, notations, or both. The effect of the notations or corrections is such that resubmission is required in order to evaluate the corrected data or drawings. Contractor shall resubmit the corrected material, in the same quantity as specified for the original submittal.

1-5.2.4.4 Not approved - If "not approved" is marked by the Resident Engineer, the shop drawing or submittal data does not meet job requirements and the contractor must resubmit. If shop drawings or submittal data are disapproved, the contractor shall resubmit the corrected material, in the same quantity as specified for the original submittal.

1-5.2.5 Samples - The Government reserves the right to request samples of any products or materials proposed for use on this project. Specific samples currently listed under various sections of this specification will be required.

1-6 COMPLETION CERTIFICATE

When the Contractor considers the work is complete, he shall submit written certification that contract documents have been reviewed; work has been inspected for compliance with contract requirements;

equipment and systems have been tested in the presence of the RE and are operational.

1-6.1 Punch List

The Contracting Officer will furnish the Contractor with a list of discrepancies in the work, material and equipment noted during the final inspection.

DIVISION 2 - SITE WORK

2-1 GENERAL

2-1.1 Protect pavement, drainage and utility lines on or adjacent to the site, and any damage thereto shall be repaired immediately at the Contractor's expense. Remove from paved areas any material that falls from the Contractor's equipment.

It is understood and agreed that the FAA does not guarantee the accuracy or the completeness of the location information relating to existing utility services, facilities, or structures that may be shown on the plans or encountered in the work. Any inaccuracy or omission in such information shall not relieve the Contractor of his responsibility to protect such existing features from damage or unscheduled interruption of service.

Existing underground cables and ducts shown on the drawings are in their approximate locations only.

In addition, other cables and utility lines may exist but are not shown. Prior to any excavation, drilling or trenching, the Contractor shall meet with FAA Maintenance personnel and contact the “One Call Center” to stake out the location of all underground cables, pipes, ducts or other facilities which could be damaged. Contractor will be responsible for marking out all FAA owned facilities.

The Contractor shall hand dig in the vicinity of all underground utilities.

The Contractor will be responsible for horizontal and vertical control for all new structures including footings, slabs and walkways as shown on the contract drawings. Existing bench marks, if available and approved by the RE, may be used to establish the horizontal and vertical control required.

2-2 APPLICABLE DOCUMENTS

The current issues of the following documents in effect on the date of the Request for Offer form a part of this specification and are applicable to the extent specified herein.

American Association of State Highway and Transportation Officials (AASHTO)

T99 Moisture Density Relations of Soils Using a 5.5 lb. Rammer and 12-inch Drop.

FAA-C-1391b, Installation and Splicing of Underground Cables

2-3 GRADING

2-3.1 Grading

Site shall be graded in accordance with the plans. Grade areas to drain away from structures and to prevent ponding. Finish surfaces free from irregular surface changes.

2-3.2 Disposal of Excess Materials

The Contractor shall remove excess materials immediately from the site, except as otherwise specified, all excess earth and excavated materials unsuitable for fill including any rubbish. All removals shall be in conformance with applicable Government, and local regulations.

2-4 TRENCHING AND UNDERGROUND CONDUIT INSTALLATION

The contractor shall take all reasonable precautions to protect existing underground equipment and utilities. All known FAA power and control cables leading to the facility shall be marked out by the contractor with the aid of FAA personnel. All other utilities shall be marked in accordance with New York State Law . Existing utilities shall be crossed by hand excavation only.

2-4.1 Excavation

The contractor shall excavate all trenches to the depth specified on the contract drawings. Width of trench shall be wide enough to accommodate all conduits with the appropriate spacing. All trenches shall be open only for the time required to install the conduit and the trench shall be closed in the same working day.

2-4.2 Backfilling

Trenches shall not be excessively wet and shall not contain organic material during backfilling operations. Trenches shall be backfilled in 8” lifts and shall be tamped/compacted to match existing soil conditions. Final elevation of trench shall match existing elevations.

2-4.3 Restoration

Where sod has been removed it shall be replaced as soon as possible after the backfilling is completed.

All areas disturbed by the trenching operation shall be restored to the original condition. Restoration shall include any necessary grading and seeding.

Trenches that cut through a paved area shall have the surface properly backfilled and resurfaced with pavement similar to the original paving.

2-5 EXCAVATION, BACKFILLING AND SURFACING

2-5.1 Excavation

All excavation shall be considered unclassified and includes the removal of all materials of every name and nature, including all earth, rock of any type and obstructions of any type, either natural or man made which can be removed by a normal excavation practice and is required for the installation of all work.

2-5.1.2 Utilization of Excavated Material

All unsatisfactory or excess material removed from the excavations shall be disposed of off the site by the Contractor. All material shall be disposed of in accordance with instructions from the RE.

2-5.1.3 Inspection of Excavated Area

When excavations have reached the required depths, the excavated surfaces shall be inspected and approved by the RE before proceeding with further construction in the excavated area.

2-5.2 Filling and Backfilling

2-5.2.1 General

Unless otherwise specified, place all fill in layers compatible with compaction requirements, but not in layers exceeding eight inches for the entire width so that each layer can be uniformly and properly compacted.

2-5.2.2 Backfill

Backfill shall be of acceptable clean earth, free of debris, organic, foreign, expanding or shrinking material. Compact the backfill to 95 percent maximum density.

2-5.4 Site Stone

All crushed stone surfaces shall consist of 1” to ¾” crushed ledge rock. There shall not be any fine material. All crushed stone shall be set on top of geotextile fabric.

2-6 Paving

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

2-6.1 Installation/Materials

Subgrade

The surface area being paved shall be cleared of all vegetation to a depth of six (6) inches below grade, leveled and compacted with a tandem wheel roller weighing not less than 8 tons.

Base Aggregate

The base shall consist of six (6) inches (after compaction) of hard durable fragment of aggregate base material which is the product of crushing ledge rock, and shall be free from soft or disintegrated pieces, dirt, sand or debris. The aggregate base material shall have the following gradation:

Sieve Designation

2 inch (maximum) 100

1 inch 70-90

3/4-inch 55-85

No. 4 50-80

No. 40 30-55

No. 200 3-10

After placement, the base course shall be compacted with a tandem wheel roller not less than 8 tons, until it is unyielding.

Application of Liquid Bituminous Material

A) The compacted base course shall be cleaned of all foreign matter, and when the atmospheric temperature is above 50 degrees F., a tack coat shall be placed. From 0.3 to 0.6 gallons per square yard of medium curing cut-back asphalt (MC-1) or rapid curing cut-back asphalt (RC-2) shall be applied by pressure distribution at a temperature between 125 degrees F and 175 degrees F. MC-1 shall conform to ASTM D-598. RC-2 shall conform to ASTM D-497.

B) Protection of Surface

The contractor shall not allow any vehicular traffic or any substantial loads on surface until adequate stability and adhesion has been obtained and the material is sufficiently cured to prevent distortion.

Surface

The contractor shall install a 2" (after compaction) layer of asphalt. The asphalt mixture shall consist of uniformly graded aggregate, sand and asphalt cement. The asphalt shall be thoroughly mixed. The asphalt mixing shall be done at 225 degrees F with Bitumen cutout of 5 to 7.5%.

The mixture, as soon as it is spread and it will bear the roller without displacement and hair cracking, shall be rolled with a roller not less than 10 tons. Roller wheels shall be equipped with scraping and sprinkling devices and shall be kept properly moistened. Each trip of the roller shall overlap the previous trip by at least one foot. The wearing course shall be rolled until it is unyielding.

2-6.2 Asphaltic Concrete

Asphaltic concrete shall be used as paving material and shall be produced by a commercial asphalt paving plant. Mineral aggregate and asphalt concrete production shall conform to the standards specified in this section.

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% by weight of total mix to type "B" aggregate, 3/4" maximum.

2-6.2.1 Base Aggregate

The aggregate base under the pavement shall be 6" thick after compaction. The gravel shall be compacted to 95% of maximum density.

2-6.2.2 Prime Coat

Liquid asphalt used for the prime coat shall be a medium-curing asphalt, Grade MC-70. 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.

2-6.2.3 Asphaltic Concrete

The mix shall be transported to the job site in vehicles cleaned of all foreign material which could affect the mix. The dispatching of the vehicles shall be so scheduled that all materials delivered can be placed in daylight. The mix shall be delivered at a temperature of not less than 250F.

2-6.2.3.1 Spreading:

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

2-6.2.3.2 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 Resident Engineer.

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 psi 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. Initial rolling shall be started as soon as possible after the material has been spread without causing cracking 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% of the laboratory density.

2-6.2.3.3 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 depressions which permit water to stand.

2-6.3 Asphaltic Pavement Cutting, Removal and Repair

Cutting of asphaltic concrete taxiways, aircraft parking areas, etc., for cable and duct installation shall be done in neat lines by diamond saw cutting. Broken asphalt shall be disposed of off airport property.

Patching shall be of same thickness as that removed and approved by the Resident Engineer. Patching shall be compacted to equal that of the asphaltic concrete in place and shall be level with abutting surface.

2-7 DEMOLITION

The contractor shall remove the existing Glide Slope shelter and foundation. All waste shall be disposed of in a legal manner. The shelter has been tested for lead and asbestos. The test results are as follows:

Lead NONE:

Asbestos: NONE

All abandoned conduits and cable shall be cut below 1 foot grade and backfilled. All holes shall be filled and compacted in accordance with the specifications.

2-7.1 Asbestos Abatement

The contractor shall sample, abate and dispose of the asbestos containing material in accordance with the State of Connecticut and the US EPA regulations.

The contractor shall submit sampling plan, abatement plan and disposal plan to FAA prior to the notice to proceed.

The contractor shall file all required notification forms and permits with appropriate fees.

2-7.2 Lead

The shelter shall be removed from the site and disposed of wholly, as to not disturb the lead paint.

The contractor shall ship and dispose of the shelter in accordance with Federal and State regulations.

The contractor shall provide the disposal facility to the FAA for approval prior to removing the shelter and a copy of the disposal manifest shall be given to the FAA after disposal.

2-8 SUBMITTALS

Submit the following for approval in accordance with Division 1:

Mark-out Notification Case # Site Crushed Stone Shelter Disposal Plan Asbestos Abatement/Disposal Plan (Only required if ACM and/or Lead is present.)

DIVISION 3 - CONCRETE

3-1 FORMWORK

3-1.1 Design of Forms

All formwork shall be designed in accordance with ACI-318 and this section. Forms shall conform to shapes, lines, and dimensions of the members shown on the plans, and shall be sufficiently tight to prevent leakage of mortar. They shall be properly braced or tied together so as to maintain position and shape.

3-1.2 Formwork Placement

Formwork shall not be placed prior to inspection, testing, and approval of the excavated area by the

RE. Forms shall result in a final structure which does not exceed +1/2 inch variation in any dimension shown on the applicable drawings. Form joints shall be sufficiently tight to prevent leakage of mortar.

Form oils shall be lace on forms or form ties and shall be removed from reinforcing steel or conduits if accidently applied to such.

3-1.4 Form Removal

Forms shall not be loosened or removed until the concrete members have acquired strength sufficient to support their own weight and any other loads. No live loads shall be brought to bear on the concrete for at least 2 days after placing.

3-1.5 Form Ties

Form ties for concrete shall be of a type that will break back one and one-half inches (1 1/2") from the concrete surface. Ties shall be removed to a minimum depth of one and one-half inches (1 1/2") and the surface face patched where exposed.

3-2 REINFORCEMENT

3-2.1 Reinforcing Bars

All reinforcing steel, unless noted on the plans, shall be Grade 60 as defined in the American Society for Testing and Materials, "Specifications for Steel Bars and Concrete Reinforcement," A615.

3-2.1.1 Accessories

Provide spacers, chairs, wire ties, etc., necessary to properly assemble, space and support the reinforcing in place during placement of concrete, as recommended by the Concrete Reinforcing Steel Institute. Accessories shall be sized to provide required concrete coverage. Position and support bolts, anchors, and other cast-in items with appropriate accessories. Spacers, chairs, wire ties, etc., fabricated of standard bright basic wire. Chairs placed on porous fill shall have 3x3 inch 16 gauge steel base pads or plates to prevent them from penetrating the supporting surface. The tie wire used shall be 16 gauge or heavier, black annealed wire.

3-2.2 Cleaning and Bending Reinforcing Bars

At that time concrete is placed, metal reinforcement shall be free from rust scale or other coatings that will destroy or reduce the bond. Reinforcing bars with rust, mill scale, or a combination of both will be acceptable as being satisfactory without cleaning or brushing, provided that upon wire brushing the dimensions including height of deformations and weights of a cleaned sample shall not be less than the applicable ASTM specification requirements. All bars shall be bent cold. No bars partially embedded in concrete shall be field-bent except as shown on plans.

3-2.3 Fabrication

All hooks shall conform to bend dimensions defined as "ACI Standard Hooks" in the "Manual of

Standard Practice" as published by the Concrete Reinforcing Steel Institute unless otherwise shown on the plans.

Reinforcing bars shall not be bent or straightened in a manner that will injure the material.

Reinforcing bars shall conform accurately to the dimensions shown on the plans and within the fabricating tolerances as shown in the "Manual of Standard Practice" as published by the Concrete Reinforcing Steel Institute.

3-2.4 Placing Reinforcing Bars

The placement of bars should conform to "Placing Reinforcing Bars" as published by the Concrete

Reinforcing Steel Institute.

Bars should be securely tied to prevent displacement during the pouring operation and all dowels must be wired in place before depositing concrete.

Metal reinforcement shall be accurately placed according to the plans and adequately secured in position by concrete, metal, or other approved chairs, spacers, or ties.

3-2.5 Splices in Reinforcing Bars

All splicing of bars, concrete cover, and bar spacings shall conform to "Building Code Requirements for Reinforced Concrete (ACI 318)" as published by the American Concrete Institute and to recommended practices in "Splicing Reinforcing Bars" by the Concrete Reinforcing Steel Institute.

No splicing of reinforcing bars shall be performed by welding.

3-2.6 Concrete Protection for Reinforcement

The reinforcement shall be protected by the thickness of concrete shown on the drawings. Where not shown, the thickness of concrete over the reinforcement shall be as per ACI Standard 318.

3-2.7 Submittals

Submit the following in accordance with Division 1:

Reinforcing Bar Certification Reinforcing Bar Layout Drawing

3-3 CAST-IN-PLACE CONCRETE

3-3.1 General

The cement shall conform to Specification for Portland Cement ASTM C-150, Type IIIa (High-Early

Strength), unless otherwise specified. The concrete shall have a minimum of twenty-eight (28) day compressive strength of 4,000 psi unless otherwise specified.

Concrete aggregates shall conform to "Specifications of Concrete Aggregates," ASTM C33 except the fine aggregate shall be natural sand, and the coarse aggregate shall be crushed stone or gravel. The maximum size of the aggregate shall not be larger than 3/4 inch.

Water shall be clean, free from deleterious amount of acids, alkalis, or organic materials and shall preferable be potable. Non-potable water may be used if mortar cubes made with the water in question have 7 and 28 day strengths equal to at least 90% of companion specimens in which potable water was used.

The concrete mix shall contain an air-entraining admixture which shall conform to ASTM C260

"Specification for Air-Entraining Admixtures for Concrete". Air content shall be five percent (5%) to seven percent (7%).

The Contractor shall submit in accordance with Division 1, to give the RE a certificate from the concrete supplier, bearing the intended job mix and certifying that the concrete delivered will meet the above requirements. The Contractor shall obtain approval of the job mix from the RE prior to placing concrete.

3-3.2 Preparation of Equipment and Place of Deposit

Before placement, all equipment for mixing and transporting the concrete shall be cleaned. All debris and ice shall be removed from the places to be occupied by the concrete. Forms shall be thoroughly wetted (except in freezing weather) and oiled prior to placing reinforcing steel. Subgrade shall be wetted prior to placement of concrete. The reinforcement shall be thoroughly cleaned of ice, dirt, rust scale, or other coatings.

Excess water shall be removed from place of deposit before concrete is placed. All laitance and other unsound material shall be removed from hardened concrete before additional concrete is added.

Excavation deeper than the required depth shall be brought to the correct level with plain concrete, same strength as foundation concrete, which shall be allowed to harden at least twenty-four (24) hours before the foundation concrete is placed.

3-3.3 Mixing

All concrete shall be mixed until there is a uniform distribution of materials and shall be discharged completely before the mixer is recharged.

Ready-mixed concrete shall be mixed and delivered in accordance with requirements of "Specification for Ready-Mixed Concrete" (ASTM C94) or "Specification for Concrete Made by Volumetric Batching and Continuous Mixing" (ASTM C685).

Job-mixed concrete shall be mixed in accordance with the following:

a)Mixing shall be done in a batch mixer of an approved type.

b)Mixer shall be rotated at a speed recommended by the manufacturer.

c) Mixing shall be continued for at least 1-1/2 minutes after all materials are in the drum, unless a shorter time is shown to be satisfactory by the mixing uniformity tests of "Specification for Ready- Mixed Concrete" (ASTM C94).

d) Materials handling, batching, and mixing shall conform to applicable provisions of "Specification for Ready-Mixed Concrete" (ASTM C94).

e) A detailed record shall be kept to identify:

1) Number of batches produced

2) Proportions of materials used

3) Approximate location of final deposit in structure.

4) Time and date of mixing and placing.

3-3.4 Conveying

Concrete shall be conveyed from the mixer to the place of final deposit by methods that will prevent separation or loss of materials. Equipment for chuting, pumping, pneumatically conveying concrete shall be of such size and design as to ensure a practically continuous flow of concrete at the delivery end without segregation of materials.

3-3.5 Placing

Concrete shall be placed within one and one-half (1 1/2) hours after mixing begins. Concrete shall be deposited as nearly and as practicable in its final position to avoid segregation due to rehandling or flowing. The placing of concrete shall be carried on at such a rate that concrete is at all times plastic and flows readily into the spaces between the bars. No concrete that has been contaminated by foreign material shall be used, nor shall retempered concrete be used.

Once placing is started, it shall be carried on as a continuous operation until placement is completed.

Concrete shall be placed in layers not to exceed eighteen (18) inches deep and vibrated in place.

During and immediately after depositing, the concrete shall be consolidated by vibrators. The concrete shall be thoroughly worked around reinforcement, around embedded fixtures, and into corners. Accumulations of water on the surface of the concrete due to water gain, segregation, or other causes shall be prevented as much as possible by employing proper placement, consolidation, and finishing practices.

Vibrators shall of the internal immersion type, operation at speeds of not less than 7,000 pulses per minute. Vibrators shall be kept constantly moving in the concrete and shall be applied at points uniformly spaced not further apart than the radius over which the vibrator is visibly effective. The entire depth of a new layer of concrete shall be vibrated. The vibrators shall penetrate several inches into the layer below to ensure thorough union of the layers. The vibrator shall not be held in one location long enough to draw a pool of grout from the surrounding concrete. Vibration shall be such that the concrete becomes uniformly plastic. Vibrators shall not be used to push concrete laterally in the forms.

3-3.5.1 Finish

Concrete shall be finished monolithically to a smooth, level surface by floating and troweling.

Surfaces shall be finished by tamping the concrete with suitable tools to force coarse aggregate down from the surface, screed with straight edges, and floated to the required finish level. This shall include all cast in place bond beams and lintels.

Exterior concrete surfaces (i.e. foundation, sidewalk, etc.) shall be broom finished

3-3.7 Curing

Provision shall be made for maintaining concrete in a moist condition for a period of at least seven (7) days after placement.

One coat of a liquid membrane-forming compound may be used for curing the concrete in lieu of wet curing. The compound shall be Symons-Cure & Seal, "or other approved equal compound which does not permanently discolor the concrete." On exposed surfaces, the application shall be made immediately after the concrete has been finished. If there is any delay, the concrete shall be kept moist until the application is made. After the forms are removed, the concrete shall be sprayed lightly with water, and then the coat of curing compound applied. If the forms (wood only) cannot be removed within forty-eight (48) hours, they shall still be wet down and kept wet until their removal, and then the compound applied as above.

3-3.8 Cold-Weather Requirements

Adequate equipment shall be provided for heating concrete materials and protecting concrete during freezing or near-freezing weather. No frozen materials or materials containing snow or ice shall be used. Concrete shall not be placed on frozen soil.

All reinforcement, forms, fillers, and ground with which the concrete is to come in contact shall be free from snow and ice. Whenever the temperature of the surrounding air is below 40 degrees F, all concrete placed in the forms shall have a temperature of 45 degrees F or higher after placement.

Adequate means shall be provided for maintaining this temperature for four (4) days. Any additional time necessary to ensure proper curing of the concrete shall be provided as directed by the RE. The housing, covering, or other protection used in connection with curing shall remain in place and intact at least twenty-four (24) hours after the artificial heating is disconnected. The use of salt or other chemicals to prevent freezing will not be permitted. Concrete placement temperature and protection shall be in accordance with ACI-306, "Cold Weather Concreting".

In the case of cold weather concreting the contractor is to submit a Cold Weather Concrete plan for

FAA approval.

3-3.9 Submittals

Concrete Mix Design Aggregates Cement Air-Entrainment Curing Compound Cold Weather Protection Bonding Agent Test Results

3-4 GROUTING

3-4.1 General

This section specifies requirements for non-metallic, non-shrink, cement-based grouting.

3-4.2 Job Conditions

Do not mix or place grout when the ambient temperature is below 40 degrees F. or conditions indicate that the ambient temperature will fall below 40 degrees F. within 72 hours, unless the areas to be grouted are enclosed and heated in an approved manner or otherwise approved by the RE.

3-4.2.1 Delivery, Storage and Handling

a) Deliver grout in the manufacturer's sealed original bags or containers bearing the manufacturer's name and product identification, in a manner to prevent damage by breakage, water or moisture.

b) Store all material on platforms and cover as necessary to protect it from water and moisture.

c) Deliver, protect and handle all tools and equipment in a manner to prevent damage which may make them defective for the purpose for which they are intended.

3-4.3.2 Submittals

Submit, in accordance with Division 1, manufacturer's instructions and methods for handling, storage, mixing and placing of the grout for approval.

3-4.3.3 Materials

a) Grout shall be one of the following:

1. "Masterflow 713" by Master Builders

2."Five Star Grout" by U.S. Grout Corporation

3."Nbec" by U. S. Grout Corporation

4."Sika 212" by Sika Corporation

b) Grout shall be premeasured and prepacked by the manufacturer, requiring only addition of potable water for mixing.

3-4.5 Preparation

Areas to be grouted as shown on the Contract Drawings shall be cleaned of all foreign materials, to the satisfaction of the RE.

3-5 QUALITY ASSURANCE

3-5.1 Test of Concrete

The Contractor shall make all arrangements for testing. Tests for strength, slump & air content (as stated in this specification) shall be certified. Tests shall be performed in the presence of the RE. The Contractor will pay all costs of the tests.

3-5.1.1 Air Entrainment

Air content shall be determined by ASTM C231 "Test Method of Air Content of Freshly Mixed

Concrete by the Pressure Method". Concrete with air contents outside the five percent (5%) to seven percent (7%) range shall be rejected.

3-5.1.2 Strength

a) The Contractor shall make all arrangements to have an independent testing lab, approved by the RE, take all samples for strength tests. Prior to casting cylinders, concrete shall be tested for air content and slump. Samples for strength tests of foundation concrete placed each day shall be taken not less than once a day, nor less than once for each 150 cubic yard of concrete, not less than once for each 5,000 sq. ft. of surface area for slabs or walls.

Strength of concrete shall be determined by the compressive strength of standard six inch (6") by twelve inch (12") cylinder specimens cast and tested in accordance with the procedure set forth in the ASTM Specifications C31 and C39. Samples shall be secured in accordance with ASTM C172.

The Contractor shall furnish the cartons for the test cylinders. A certified testing lab shall cast and test the cylinders. The cost of testing shall be borne by the Contractor. Test results will be furnished to the RE.

Three (3) cylinders shall be made for each test. The cylinders shall be identified immediately after casting as to the point of sampling, date cylinder was cast, and whether the specimen will be tested for three (3) day or twenty-eight (28) day strength. One cylinder from each test shall be tested for three (3) day strength, and one (1) cylinder for twenty-eight (28) day strength. The remaining cylinder will be used to confirm the results of either the three (3) or twenty-eight (28) day tests should they fail to reach the recommended strength.

b) The cylinders shall be shipped to the testing laboratory on the day after casting. Moist sand or sawdust shall be used as a filler to protect cylinders from damage during shipment.

c) The strength of the twenty-eight (28) day cylinder will be the criterion of acceptability of the concrete. Strength shall be at least fifteen percent (15%) greater than that specified.

3-5.1.3 Slump

Concrete shall be tested for consistency at the mixer or at the place of deposit if delivered ready-mixed. The sample shall be taken immediately from the batch and tested by the Contractor in the presence of the RE in accordance with ASTM Standard C143 "Test Method for slump of Portland Cement Concrete." Concrete with slump of three inches (4") + one (1") inch is acceptable.

3-5.1.4 Test Results

The Contractor shall submit two copies of all test results to the RE.

3-5.2 Delivery Tickets

At the time of concrete delivery, the Contractor shall give the RE a copy of the delivery ticket bearing the quantity, air content, and strength of the concrete and a detailed listing of all components by weight (cement, aggregate, water and additives).

DIVISION 5 - METALS

5-1 Metal Framing

All metal framing, fittings and hardware shall be stainless steel (Type 304) in accordance with

ASTM A240.

DIVISION 13 – SPECIAL CONSTRUCTION

13-1 Shelter Installation

In the case where the GFM shelter is already on site in storage; the contractor shall transport the Government furnished prefabricated shelter from the storage area located on-airport to the GS site.

The contractor shall install all items delivered with the shelter (i.e. A/C Unit, canopy, grounding, lightning protection, etc.) and ensure they are working properly.

DIVISION 16 - ELECTRICAL

16-1 ELECTRICAL MATERIAL AND INSTALLATION

16-1.1 Work Included

Installation and furnishing of all materials for interior and exterior electrical work.

16-1.2 Installation - General

The rules, regulations and reference specifications enumerated herein shall be considered as minimum requirements and shall not relieve the Contractor from furnishing and installing higher grades of materials and workmanship than are specified herein or when so required by the Contract Drawings.

This specification shall govern when conflicts occur between reference documents and this specification.

16-1.3 Workmanship

All materials and equipment shall be installed in accordance with the Contract Drawings and the recommendations of the manufacturer as approved by the Resident Engineer (RE). The installation shall be accomplished by skilled workmen regularly engaged in this type of work. Where required by local regulations, the workmen shall be properly licensed.

16-1.4 Materials

The Contractor shall furnish all materials required in accordance with contract drawings and specifications. Materials must comply with all contract requirements. Materials to be furnished by the Contractor shall be new, the standard products of the Manufacturer regularly engaged in the production of such materials, and of the specification requirements. Whenever standards have been established by Underwriter's Laboratories, Inc., the materials shall bear the UL label.

16-1.5 Repair of Existing Work

Electrical work shall be carefully laid out in advance. Where cutting, channeling, chasing, or drilling of floors, wall partitions, ceilings, or other surface is necessary for the proper installation, support, or anchorage of the conduit, raceways, or other electrical work, it shall be carefully done. Damage to the building, piping, or equipment shall be repaired by skilled mechanics of the trades involved at no additional cost to the government.

16-2 APPLICABLE DOCUMENTS

The current issues of the following documents in effect on the date of invitation for bids form a part of this specification.

16-2.1 Federal Specifications

J-C-30 Cable and Wire, Electrical (Power, Fixed Installation) W-C-582 Conduit, Raceway, Metal, and Fittings; Surface W-C-586 Conduit Outlet Boxes, Bodies, and Entrance Caps, Electrical: Cast Metal

- For Shore Use W-J-800 Junction Box; Extension, Junction Box: Cover, Junction Box (Steel, Cadmium or Zinc - Coated) W-S-610 Splice, Conductor QQ-W-343 Wire Electrical Uninsulated WW-C-566 Conduit, Metal, Flexible

WW-C-581 Conduit, Metal, Rigid; and Coupling, Elbow, and Nipple, Electrical Conduit: Zinc Coated

16-2.2 Military Documents

MIL-P-15147 Primer and Enamel, Coal Tar MIL-R-21931 Resin, Epoxy

16-2.3 FAA Standards

FAA-STD-019e Lightning Protection, Grounding, Bonding and Shielding Requirements for

Facilities..

FAA-C…