SOW - Shelter Foundation Replacement Spec.pdf

DEPARTMENT OF TRANSPORTATION

FEDERAL AVIATION ADMINISTRATION

GREAT LAKES REGION

DES PLAINES, ILLINOIS

SPECIFICATION NO. 1701026

DATED: DECEMBER 30, 2021

SPECIFICATION FOR REPLACEMENT OF

RUNWAY 26L GLIDE SLOPE SHELTER FOUNDATION

GERALD FORD INTERNATIONAL AIRPORT

GRAND RAPIDS, MICHIGAN

Division Title

1 GENERAL REQUIREMENTS

Section 1A - Summary of the Work Section 1B - Schedule Section 1C - Submittals

2 SITE WORK

Section 2A – Demolition Section 2B – Earthwork and Site

Improvements Section 2C – Crushed Aggregate Road and

Site Surfacing

3 CONCRETE

Section 3A – Concrete Formwork and Reinforcement Section 3B – Cast In-Place Concrete

4 through 15 NOT USED

1701026

Division Title

16 ELECTRICAL

Section 16A - Basic Methods and Materials

Section 16B - 600-Volt Power Cable for Underground

Installation Section 16C - 600-Volt Armored Power Cable Section 16D - Control Cable Section 16E - Cable Installation Section 16F – Cable Testing

1A-1

DIVISION 1 - GENERAL REQUIREMENTS

SECTION 1A

SUMMARY OF THE WORK

1A.1 GENERAL: The work described hereunder consists of furnishing all necessary materials, labor, equipment, tools and supervision to replace the existing Runway 26L glide slope shelter foundation at Gerald Ford International Airport, Grand Rapids, Michigan.

1A.2 SCOPE OF WORK: The work consists of, but is not limited to, the following principal items:

A. Disconnect, pull back, and later reconnect to the existing shelter all underground power and control cables.

B. Disconnect, remove, and dispose of all existing conduit and cables between the existing shelter and the glide slope antenna tower.

C. Disconnect, remove, and dispose of all existing conduit and cables between the transformer and the meter pedestal, and from the meter pedestal to the shelter. Remove and dispose of the existing meter pedestal.

D. Disconnect, pull back, and later reconnect to the existing shelter the power and control cables for the PAPI and RVR.

E. Disconnect, pull back, and later reconnect to the existing shelter the control cables tied to additional facilities not receiving their power from the glide slope shelter.

F. Provide a temporary junction box, complete with punch blocks, for all control cables currently attached to the demarcation (Demarc) box in the shelter.

Temporary wiring connections shall be witnessed by an FAA site technician.

G. Remove the existing equipment shelter from the pier foundations and set aside for later reinstallation on new foundation.

1A-2

H. Remove the welds between the shelter’s floor beams and the cross beams that were previously added to retrofit the shelter to the existing pier foundations. Dispose of the cross beams, and all related hardware.

I. Remove and dispose of the existing concrete pier foundations and earth electrode system (EES) around foundation.

J. Furnish and install new concrete foundation and EES.

Connect EES to existing antenna tower counterpoise.

K. Reinstall existing glide slope equipment shelter on new foundation, and reconnect all underground power and control cables to the shelter. Provide new conduit. Furnish and install a new meter pedestal.

L. Furnish and install new conduit and cables between the shelter and the glide slope antenna tower. All RF cable installation shall be witnessed by both the COR and the FAA site technician.

M. Furnish and install new conduit and cables between the transformer and the meter pedestal, and from the meter pedestal to the shelter.

N. Furnish and install all electrical work inside the shelter. Terminations to equipment shall be witnessed by an FAA site technician.

O. Remove existing bollard and provide two new bollards.

P. Refurbish construction damaged asphalt, gravel and grass surfaces.

1A.3 LOCATION OF UNDERGROUND FACILITIES: Prior to beginning any excavation, the Contractor shall contact the Airport Management, local FAA maintenance personnel, and utility companies to have underground utilities located and staked out.

1A-3

1A.4 INGRESS AND EGRESS TO WORK AREAS: Ingress and egress to the work areas shall be as directed by the COR.

The Contractor and any subcontractors will have to be escorted in and out of the work site by the COR.

Security precautions against unauthorized site entrance shall be maintained. In no case will trucks, workmen, and associated equipment be allowed on active taxiways without permission from the airport authorities and properly escorted by the COR.

Security passes will be required of all workmen.

Information on how to obtain these passes will be available at the pre-construction conference. The Contractor shall keep all vehicles, working equipment and materials where directed by the COR.

1A.5 CLEANING:

A. Working Area. The contractor shall keep the working area in a clean and proper condition. All rubbish and waste resulting from the execution of the work shall be removed at the end of each day or stored as directed by the COR.

B. Final Clean-Up. Upon completion of work, and before final inspection, the Contractor shall remove all working tools, equipment, debris, rubbish, and unused materials from the site.

C. Disposal. Disposal of rubbish and debris will be off the site at Contractor's expense or as directed by the

COR.

1A.6 SUBMISSION OF WASTE MANAGEMENT PLAN: The Contractor shall submit a waste management plan in accordance with the FAA’s Construction Waste Management Contract Clause.

1A.7 CONTRACTOR'S LIABILITY: The Contractor is required to meet the airport’s minimum liability insurance for all work done on the airport property. Damage to existing facilities and equipment caused by the Contractor shall be reported to the COR without delay. The

Contractor will be responsible for repairing, or having repaired all damaged areas or equipment at the Contractor's expense. All repairs shall be accomplished to the satisfaction of the COR. The Contractor shall keep all his working personnel within the work area or in approved access routes.

1A.8 PERMITS: The Contractor shall be responsible for obtaining all permits required to complete the job at no expense to the Government.

1A-4

1A.9 WORKMANSHIP: All work shall be accomplished by experienced workers in accordance with the highest standards of the various work trades involved.

1A.10 SITE VISIT: The Contractor shall visit the work site prior to bidding the job, to verify all dimensions and quantities of materials as specified and to obtain first-hand knowledge of existing conditions.

Contractors can contact the System Service Center Manager at 616-464-5371, to arrange for a site visit.

No subsequent extras will be allowed due to any claim of lack of knowledge for conditions which can be determined by examining the site. Once the Contractor is chosen to do the job, additional claims for materials, equipment, and labor for represented scope of work areas will not be allowed, unless the FAA has a need for additional work to be accomplished.

1A.11 WARRANTIES: Contractor shall furnish manufacturers' warranties on all materials and products where available. Warranties shall identify the FAA as the owner. The location and effective date of warranty shall be indicated.

1A.12 RESTRICTED USE OF ASBESTOS CONTAINING MATERIAL (ACM):

A. Requirements: Contractor shall not use any asbestos containing material (ACM) at any time during the construction process. Contractor shall verify that all material, including that from third party suppliers, are asbestos free materials. The Contractor shall provide a written letter of certification to the FAA, stating that the project is asbestos free.

The Contractor shall provide to the Contracting

Officer (CO) a signed statement stating that, to the best of his/her knowledge, no asbestos containing building materials were used during the construction, renovation, and/or modernization of this facility.

1A-5

If the FAA suspects the presence of ACM’s, the FAA will sample the suspect material to verify that no

ACM’s were utilized. The testing shall be performed at the expense of the FAA. If ACM’s are subsequently found during the sampling of the building materials, the Contractor shall remove and replace the product or material at his/her expense. In addition, the Contractor shall incur the costs of the original testing and/or any re-testing that may be necessary.

1B-1

SECTION 1B

WORK SCHEDULE

1B.1 WORK SCHEDULE: The Contractor shall submit a work schedule for approval prior to beginning work. The Contractor shall keep the COR advised daily of any changes.

1B.2 GLIDE SLOPE SHUTDOWN: The existing glide slope facility, as well as the PAPI and RVR facilities, require shutdown in conjunction with this project. The Contractor shall schedule and coordinate this work with the FAA and COR to bring the facility back on line at the end of the scheduled outage.

1C-1

SECTION 1C

SUBMITTALS

1C.1 SUBMITTALS AND BRAND NAME USAGE

A. Introduction: Each product required for use in the Contract drawings and Specifications must meet the actual minimum needs of the Government as demonstrated in the salient characteristics for that product. If a brand name product is used in the drawings or Specifications, it should be regarded as a “known acceptable source". The use of the term “known acceptable source” and “brand name or equal” in referencing a specific product or manufacturer is not intended to indicate a preference for the products mentioned, but indicates the quality and characteristics of products that will meet the Government requirements. Should the Contractor decide to use a product other than that identified as a “known acceptable source” or “brand name or equal”, the Contractor shall provide a submittal for this product.

This does not relieve the Contractor from providing submittals for products or materials required in other sections of this Specification.

A brand name product or known acceptable source mentioned is not required for use unless the drawings and Specifications make it clear that the brand name product is required, and substitution is prohibited.

B. Requirements: Each product that a Contractor wishes to use that is not a known acceptable source, must be approved before use, by the Contracting Officer or his/her designee. To gain approval, the Contractor must submit documents and/or samples that will demonstrate the product clearly will meet the Government's minimum needs, and demonstrates appropriate salient characteristics. All submittals must be in writing. The information presented in a submittal shall be sufficient to demonstrate that all specification requirements for the subject material, submittal shall be sufficient to demonstrate that all specification requirements for the subject material, equipment, methods, or plans, are met by the Contractor's proposal.

1C-2

The Contractor shall submit for approval samples of each material to be used in the roof system, including each component manufacturer’s literature and applicable MSDS. This is to include (but not limited

to) applicable product literature, sample guarantee, detailed drawings of proposed flashing applications where they will differ from the project drawings, and fastening for insulation and membrane. Deviations from contract drawings and specifications shall be submitted in writing to the Contracting Officer for approval by the Project Engineer. The Contractor, as part of the bid, shall submit to the Contracting Officer a company "Site Health and safety Plan" for review and approval.

C. Submittal Review: Contractor shall send the submittal package(s) directly to the Contracting Officer. The submittal will return directly from the Contracting Officer to the Contractor, with the Contracting Officer's approval, approval with comments, or disapproval.

D. Submittal Approval Time Frame: To provide adequate time for document review, the FAA reserves the right to take the necessary time to complete a review. It should be anticipated that the review period may be one week, although every effort will be made to expedite this process.

E. Procurement Before Approval: The Contractor is advised not to procure any item for which submittal approval is required but not yet granted. If approval is denied, the Contractor will not be paid for the disapproved item(s). The Contractor must transmit a new submittal package for the new items replacing the disapproved items, and must procure only approved items. The Contractor shall take responsibility for any items purchased, fabricated, or delivered before submittal approval is granted.

2B-1

DIVISION 2 - SITE WORK

SECTION 2A

DEMOLITION

2A.1 SCOPE OF WORK: The extent of work is indicated on the drawings and by the requirements of this section.

2A.2 EXECUTION: By careful study of the contract documents, determine the location and extent of demolition to be performed.

A. In company with the COR, verify the extent and location of demolition required.

1. Carefully identify limits of demolition.

2. Mark interface surfaces as required to enable workmen also to identify items to be removed and items to be left in place intact.

B. Prepare and follow an organized plan for demolition and removal of items.

1. Protect existing utility lines in accordance with the utility having jurisdiction.

2. Completely remove items scheduled to be so demolished and removed, leaving surfaces clean, solid, and ready to receive new materials specified elsewhere.

C. The COR shall be notified before any demolition is performed. The FAA will be allowed to salvage any items from the equipment that is to be removed.

Materials and equipment to be removed and salvaged shall remain the property of the FAA. Materials and equipment not salvaged by the FAA are the Contractor's property and shall be removed from the site.

D. Initiate, maintain, and supervise safety precautions and programs in connection with the work. Erect and maintain, as required by conditions and progress of the work, all necessary safeguards for safety and protection of personnel.

E. In the event of demolition of items not scheduled to be demolished, promptly replace such items to the approval of the COR at no cost to the Government.

2B-2

DIVISION 2 - SITE WORK

SECTION 2B

EARTHWORK AND SITE IMPROVEMENTS

2B.1 DESCRIPTION OF WORK. The extent of earthwork is indicated on the drawings and by the provisions of this section.

Requirements for access road and site surfacing and paving are covered in Sections 2B and 2C.

2B.2 QUALITY ASSURANCE.

A. Codes and Standards. Perform all earthwork in compliance with applicable requirements of governing authorities having jurisdiction.

B. Testing and Inspection.

1. Soil materials and degree of compaction shall conform to ASTM specifications referenced herein.

Professional soil testing methods associated with this specification will generally not be required, but the FAA reserves the right to engage a state-licensed soil testing service to resolve disputes regarding adequacy of all earthwork performed.

2. Visual inspection and qualitative testing shall be performed by the contractor in the presence of, and wherever directed by, the Resident Engineer.

2B.3 SAFETY REQUIREMENTS.

A. Refer to Division 1 for construction within classified and unclassified areas.

B. To protect life, property, and work, all earthwork operations shall be performed in compliance with local and OSHA (Occupational Safety and Health Administration) requirements. The Contractor shall provide all sheeting, shoring, and other bracing as necessary.

C. All trenches in classified areas, excavated in one day, shall be backfilled during the same day. An effort shall be made to backfill other excavations in classified areas, during the same day.

2B.4 JOB CONDITIONS.

A. Existing Utilities.

1. Locate all underground cables, utility lines, and other underground construction before beginning excavation work. Any damage to such lines or construction belonging to the FAA, utility companies, or others, shall be promptly repaired, at contractor's expense, to the complete satisfaction of the owner.

2B-3

2. Project drawings generally indicate locations of cables maintained by the Federal Aviation Administration only. The FAA will field establish approximate locations of its own cables.

B. Weather Conditions.

1. Excavating and backfilling for foundations, trenches, and jacking or boring pits, shall not proceed when excessively wet or freezing weather conditions could adversely affect the load-bearing characteristics of the soil, or prevent proper compaction.

2. When freezing weather is expected, excavations shall not be made to full depth unless concrete or conduits can be placed immediately. If an excavation is already at full depth, the excavation shall be protected from frost.

C. Drainage.

1. All excavations shall be continually drained by natural means or pumping to prevent any decrease in soil bearing capacity or damage to poured foundations or to trenches.

2. Provide and maintain pumps, well points, sumps, suction and discharge lines, and other dewatering system components necessary to convey water away from excavations.

3. Establish and maintain temporary drainage ditches and other diversions outside excavations limits to convey rain water and water removed from excavations to collecting or run-off areas. Do not use trench excavations as temporary drainage ditches.

2B.5 MATERIALS.

A. Structure and Foundation Materials. In-place undisturbed inorganic soils will be adequate to support all project structures, unless otherwise indicated.

Highly organic soils (topsoil, peat, and swamp location soils) shall be removed entirely from areas to be occupied by structures.

B. Backfill and Fill. Material shall be inorganic soil excavated from site, or borrow comprised of inorganic soil approved by the COR. All such soils shall be free of rock, gravel, and cohesive lumps greater than two inches in any direction, and debris, waste, vegetation, frozen material, and other deleterious materials.

2B-4

C. Base Course for Concrete Slabs. Material shall be a graded mixture of washed crushed stone or crushed or uncrushed gravel with 100% passing a 1 1/2 inch sieve, and not more than 5% passing a number 4 sieve.

2B.6 SITE PREPARATION.

A. Clearing and Grubbing. The Contractor shall scalp areas where excavation or embankment will be made.

Scalping shall include the removal of materials such as trees, brush, roots, sod, grass, residue of agriculture crops, sawdust, and decayed vegetable matter, from the surface of the ground. These materials shall be removed from the site and disposed of off airport property.

B. Topsoil Removal.

1. Topsoil shall be considered soil containing visible vegetable matter and black loam that will not compact with the usual compacting methods.

2. Unless otherwise specified, topsoil shall be removed from all areas to receive fill, granular surfacing, pavement, and structures, and from all areas where subsoil excavating is required, such as for roadway cuts and ditches. Dispose of excess topsoil on or off airport property, as directed by the COR, at no additional cost to the Government.

2B.7 EXCAVATION.

A. Excavation Classification. Excavation is unclassified and includes excavation to subgrade elevation indicated, regardless of character of materials and obstructions encountered excepting as qualified herein.

B. Rock Excavation. If rock is encountered above the design footing elevations of any facility structure, such foundation shall bear entirely on clean solid rock or on soil, but not on both. If the soil-and-rock bearing condition is encountered, the COR will determine which material shall support the structure.

If rock surface is used, it shall be reasonably level or shall be stepped to make level segments.

C. Unauthorized Excavation. Removal of materials beyond design subgrade elevations or dimensions without specific direction from the COR constitutes unauthorized excavation. Remedial work for such excess excavation shall be as directed by the COR at the Contractor's expense.

D. Additional Excavation. When any excavation has reached required subgrade elevation, notify the COR, who will inspect soil conditions. If the COR determines that the soil possesses inadequate bearing capacity, carry such excavation deeper as directed by the COR.

2B-5

E. Excavation for Structures.

1. Conform to elevations and dimensions shown within a tolerance of plus or minus 0.10 foot, and extending a sufficient distance from footings and foundations to permit placing and removal of concrete formwork, installation of services and other construction, and for inspection.

2. In excavating for footings and foundations, take care not to disturb the bottom of the excavation.

Excavate by hand to final grade just before concrete reinforcement is placed. Trim bottoms to required lines and grades to leave a solid base.

F. Excavation for Cable and Conduit Trenches.

1. Excavate in compliance with lines and depths shown on drawings. Minimum trench depth shall allow for cables to be installed at the depths specified in Paragraph 16F.3b(2), unless otherwise specified.

Slope trenches to same elevations as conduits where cables will be routed to a building interior.

Minimum trench width shall be that required to accept power-operated mechanical tampers.

2. Grade bottom surfaces of trenches to provide uniform bearing and continuous support for cable and conduit.

3. Material excavated in excess by error, or due to unsuitable bearing, shall be replaced with mechanically compacted inorganic soil.

4. If solid rock is encountered, the COR will decide if such rock need be removed or if an alternate trench route or lesser depth conduit installation will be acceptable.

5. If a trench must cross a concrete or asphalt paved surface, all cuts shall be saw cuts, unless otherwise specified.

2B.8 COMPACTION.

A. General.

1. All compaction shall be accomplished by using power-operated mechanical equipment except for limited use of manual tampers in constricted areas.

Operate all power equipment as herein specified to achieve the minimum degree of compaction subject to acceptance by testing.

2. Cohesive soils are defined herein as those containing less than 60 percent sand, gravel, or stone.

Percentages greater than 60 percent are herein termed non-cohesive soils.

2B-6

B. Cohesive Soil Compaction.

1. Use sheepsfoot roller of such minimum weight that at least 200 psi will be transmitted to surface area of studs or feet. Operate at speeds not exceeding 4 mph on each layer of fill until roller walks itself to top of grade.

2. Use motor-operated soil tamper (stomper) in confined areas, including trenches, on each layer of fill until no further visible consolidation is evident.

3. Use a heavy blunt tamping rod on each layer of fill in the most constricted locations where power equipment cannot be used.

C. Non-Cohesive Soil Compaction.

1. Use pneumatic tire roller fully loaded and weighing not less than 275 pounds per inch of tire tread width. Operate at speeds not exceeding 4 mph. A minimum of ten passes of the roller is required on each layer of fill.

2. Use motor-operated vibratory tamper in confined areas, including trenches, on each layer of fill until no further visible consolidation is evident.

3. Use heavy blunt tamping rods on each fill layer in constricted locations where power equipment cannot be used.

D. Moisture Control.

1. Where soil material must be moisture-conditioned before compaction, uniformly apply water to a layer of soil material in such quantity that free water will not appear on the surface during or subsequent to compaction operations.

2. Scarify and air-dry soil material that is too wet to permit compaction to specified density.

E. Percentage of Maximum Density Requirements.

1. General Requirements. The required densities for cohesive and non-cohesive soils are determined by quantitative testing procedures defined by ASTM Standards D 1557 and D 4253/4254, respectively. To assure compliance, the Contractor may arrange for such professional soil testing services, at no additional cost to the Government. The FAA, at its expense, may also make such arrangements if qualitative testing procedures appear inadequate.

2B-7

2. Structures, Slabs, and Access Roads/Parking Areas.

Compact top surfaces of subgrade and each layer of backfill or fill material to 90% of maximum density for cohesive soils, or to 95% relative density for non-cohesive material.

3. Turf and Non-Vehicular Surfaced Areas. Compact top surfaces of subgrade and each layer of backfill or fill material to 90 percent of maximum density for cohesive soils, or to 90 percent relative density for non-cohesive material.

F. Qualitative Testing and Inspection Procedures.

1. General. The Contractor shall perform qualitative soil compaction testing and inspection procedures for each type of backfill or fill material used wherever directed by, and in the presence of, the COR. Special attention shall be given to the backfilling of structures and trenches.

2. Qualitative Testing.

a. Qualitative soil testing will consist of comparing the resistance to penetration of undisturbed soil to that of compacted backfill of the same composition. For borrow material the penetration comparison shall be made between maximum test sample density and in-place fill density.

b. A soil penetration device (penetrometer) indicating depth and force exerted shall be utilized. Compaction will be adequate if backfill or fill possesses at least 95% of the resistance to penetration of undisturbed soil or test sample, respectively.

c. Borrow test sample shall be a four inch deep

(compacted measurement) layer of soil, aerated or moistened as directed by the COR, and compacted by power equipment until no further consolidation occurs, as approved by the COR.

3. Concrete Slab Base Course. Compact with vibratory tamper until no further visible consolidation is evident.

2B.9 BACKFILL AND FILL.

A. Structure Foundations. Backfill or fill as promptly as work permits, but not until completion of the following:

1. Acceptance of construction below grade.

2. Recording locations of underground conduit.

3. Removal of concrete formwork, bracing, trash, and debris.

2B-8

B. Ground Surface Preparation. Remove vegetation, debris, topsoil, and unsatisfactory subsoil from ground surface, and compact the subgrade, prior to placement of fill layers.

C. Placement and Compaction.

1. Place acceptable backfill and fill materials in layers not more than eight inches in loose depth for material to be compacted by heavy equipment, and not more than four inches in loose depth for material to be compacted by hand-operated tampers.

2. Before compaction, moisten or aerate each layer as necessary to provide optimum moisture content. Do not place backfill or fill on water, ice, snow, frozen soil, or excessively wet soil.

D. Cable Trench Backfill.

1. Before laying cables, inspect the bottom of the cable trench. If it is not smooth, or if any rock or stone that would be retained on a 1/4-inch sieve is present, place a two-inch layer of bedding material, according to Paragraph (2) below, in the trench. Do not compact this layer. Lay cables on top of this layer.

2. The first layer of backfill material over cables shall be three inches deep, loose measurement, and shall be sand or other homogeneous inorganic soil containing no mineral aggregate particles that would be retained on a 1/4-inch sieve. This layer shall not be mechanically compacted.

3. The second layer, in turf and crushed rock surface areas, shall be four inches deep, loose measurement, and shall contain no mineral aggregate particles that would be retained on a one-inch sieve. Subsequent layers shall be clean soil containing no rock particles larger than two inches in their largest dimension.

4. Except for surfacing material, all layers of trench backfill, for areas to be paved or surfaced with crushed rock, shall be sand, placed and compacted as required for access roads.

a. If a trench crosses an area surfaced with crushed rock, the top 12 inches of trench backfill shall be crushed rock, placed and compacted as required for access roads. The finished grade elevation of the crushed rock backfill shall equal the grade elevation of existing adjacent crushed rock.

2B-9

b. If a trench crosses an area surfaced with concrete or asphalt pavement, the pavement shall be replaced with materials of the same composition, thickness, and degree of compaction as the adjacent pavement structure, except that the crushed rock base shall be a minimum of 12 inches deep. Replacement concrete shall have a 28-day compressive strength of 3,000 psi. Finished grade of the pavement patch shall be flush with the adjacent pavement surfaces.

E. Backfill and Fill Surface Elevations. Finished grade, shown on the drawings, is the top surface of turf and crushed rock or crushed stone surfaced areas.

Therefore, make allowances for six inches of topsoil and depths as detailed or specified for surfaced areas when establishing top surface of fill or backfill.

2B.10 GRADING.

A. General. Uniformly grade areas within limits of grading, including adjacent transition area. Smooth the finished surfaces within specified tolerances, and compact with uniform slopes between points where elevations are indicated, or between such points and existing grades.

B. Grading Outside Building Lines. Grade areas adjacent to building lines to drain away from structures and to prevent ponding. Finish areas to receive topsoil and surfacing within 0.10 feet above or below required subgrade elevations.

C. Grading Surface of Fill Under Building Slabs. Grade smooth and level and to proper elevation to within a tolerance of 1/2 inch when tested with a 10-foot straightedge.

2B.11 MAINTENANCE.

A. Protection of Graded Areas. Protect newly graded areas from traffic and erosion. Keep free of trash and debris.

B. Reconditioning. Where compacted areas are disturbed by construction operations, adverse weather, or where any settlement has occurred, scarify surface, add acceptable fill, reshape, grade, and compact as necessary.

2B.12 DISPOSAL OF EXCESS AND WASTE MATERIALS. Remove and dispose of all excess soil and waste material from the project site and adjacent lands. All costs associated with disposal shall be at Contractor's expense.

2C-1

DIVISION 2 - SITEWORK

SECTION 2C

CRUSHED AGGREGATE SITE SURFACING

2C.1 DESCRIPTION OF WORK. The extent of work is indicated on the drawings and by the provisions of this section.

2C.2 STATE SPECIFICATIONS. State highway construction specifications, latest edition, form a part of this Specification and are applicable for all work unless otherwise specified. This referenced specification will be hereinafter referred to as "State Specifications."

Disregard all references in the State Specifications to layout of work by others, and to measurements and payments.

All layout work will be accomplished by the Contractor, and payment for all work under this section will be a part of the lump-sum contract.

2C.3 MATERIALS.

A. Geotextile.

1. Application. The most common application of geotextiles in FAA navaids construction is as a separator. In this application, the geotextile is placed over prepared roadway subgrade soil, and crushed aggregate is placed and compacted on top of the geotextile. The geotextile permits water to permeate into the subgrade, while preventing the aggregate from mixing with the subgrade soil. The geotextile specified below is for application as a separator.

2C-2

2. Separator Geotextile Selection Criteria. The geotextile fibers, and the threads used in joining the geotextile by sewing, shall consist of long chain polymeric fibers composed of polypropylene, polyester, polyolefins, or polyamide. Both the geotextile and threads shall be resistant to chemical attack, mildew, and rot. The geotextile shall conform to the physical property requirements listed in the following table. All values shall represent certifiable minimum values in the weakest principle direction of the fabric.

Property Test Method Requirement

Tensile Strength ASTM D-4595 2460 lbs/ft Tensile Strength ASTM D-4595 480 lbs/ft (at 2% strain) Tensile Strength (5%) ASTM D-4595 1212 lbs/ft Tensile Strength (10%) ASTM D-4595 2340 lbs/ft Factory Seam Strength ASTM D-4632 1250 lbs/ft Flow Rate ASTM D-4491 50 gpm/ ft2 Permeability ASTM D-4491 .04 cm/sec Permittivity ASTM D-4491 .70 sec-1

Apparent Opening Size ASTM D-4751 U.S. Sieve #30, max UV Resistance ASTM D-4355 80% str.

retained

Mirafi HP270 manufactured by Royal Ten Cate

Corporation is one of the products which meets these Specifications. For any substitution, provide the Contracting Officer with complete product literature, including values of the properties tabulated above, and a sample of fabric.

Do not procure any substitute before receiving the Contracting Officer's approval. See Paragraph 1A.4 above.

3. Geotextile Fabric Width. Fabric width shall be at least 15 feet for the normal 13-foot-wide access road. Fabric in other vehicular areas shall be cut to fit, and overlapped per Paragraph 2B.4c(2)(b), below, to fully cover such areas.

2C-3

B. Landscape Fabric.

1. Application. Landscape fabric shall be applied under all non-roadway crushed rock surfacing, such as walkways around navaid shelters, at RVR sites, and between light bars of a MALSR. In these applications, landscape fabric is placed over prepared walkway subgrade soil, and crushed aggregate is placed and compacted on top of the landscape fabric. The landscape fabric acts as a separator, as does geotextile, and blocks weed growth. The Contractor shall have the option of substituting geotextile per Paragraph 2B.3a, for landscape fabric.

2. Landscape Fabric Selection Criteria. The landscape fabric fibers shall be a needlepunched nonwoven geotextile composed of polypropylene, polyester, polyolefin, or polyamide fibers. The fabric shall be resistant to chemical attack, mildew, and rot.

The fabric shall conform to the physical property requirements listed in the following table. All values shall represent certifiable minimum values in the weakest principle direction of the fabric.

Property Test Method Requirement

Grab Tensile Strength ASTM D-4632 120 lbs Grab Elongation ASTM D-4632 50% Trapezoidal Tear ASTM D-4533 50lbs CBR Puncture Strength ASTM D-6241 310 lbs Apparent Opening Size ASTM D-4751 U.S. Sieve #70, max Permittivity ASTM D-4491 1.7 sec-1 Flow Rate ASTM D-4491 135 gpm/ft2

Mirafi 140N manufactured by Royal Ten Cate

Corporation is one of the products which meets these Specifications. For any substitution, provide the Contracting Officer with complete product literature, including values of the properties tabulated above, and a sample of fabric.

Do not procure any substitute before receiving the

Contracting Officer's approval. See Paragraph 1A.4 above.

3. Landscape Fabric Width. Fabric width shall be 3 feet wide for a 3-foot-wide crushed rock walkway.

Fabric in other walkway areas shall be cut to fit, and overlapped per Paragraph 2B.4c(2)(a), below, to fully cover such areas.

2C-4

C. Crushed Aggregate Surfacing.

1. Crushed rock or crushed stone aggregate shall comply with State Specification quality requirements for crushed rock or crushed stone used for road surface course, and shall be of the State gradation most closely conforming with the following gradation:

Sieve Size Total Passing, Percent

1-inch 100 3/4-inch 80-100 3/8"-inch 30-60 No. 4 48-65 No. 8 35-50 No. 30 19-30 No. 50 13-23 No. 100 7-15 No. 200 0-8

2. A certified sieve analysis, referenced to State

Specification gradation, shall be submitted to the COR for approval.

2C.4 CONSTRUCTION.

A. General Requirements. All earthwork requirements in

Section 2A for areas to receive surfacing are applicable, excepting as qualified herein. Where the additional work or more stringent requirements in this section conflict with Section 2A, requirements herein shall prevail.

B. Foundation Preparation.

1. Foundation Material. All topsoil shall be removed from areas to receive paving and surfacing or fill under such surfaces. Only inorganic soil shall exist under surfaced or paved areas.

2. Compaction. Compact as required in Section 2A.

3. Grading. Shape with motor grader to achieve such surface trueness that when tested with a 10-foot straightedge, no deviation greater than 1/2-inch shall exist.

4. Corrective Work. Any ruts or soft-yielding spots that may appear in the subgrade, any areas having inadequate compaction, and deviations of the surface from the requirements specified shall be corrected by loosening, removing, and adding approved material and reshaping and recompacting the affected areas to line and grade, and to the specified density.

2C-5

C. Geotextile or Landscape Fabric.

1. General. Geotextile or landscape fabric, if required on the drawings, shall be installed on prepared subgrade for all areas that will experience vehicular traffic or pedestrian traffic, respectively.

2. Construction Requirements.

a. Prepared subgrade and foundations shall be compacted smooth and level as specified elsewhere and as shown on the drawings.

b. The fabric shall be rolled out directly upon the prepared surface, and shall not be dragged over any surface. Fabric in place shall have a smooth surface and shall be free of folds, wrinkles, cuts, or other imperfections.

Individual panels of fabric shall be overlapped at least 24 inches, with the preceding layer overlapping the following layer in the direction that surfacing material will be spread. No vehicular traffic will be permitted directly upon the fabric.

D. Crushed Aggregate Surfaced Areas and Crushed Aggregate

Base Course for Bituminous Pavement.

1. Spreading. Crushed aggregate surfaced areas and base course shall be constructed in one or more layers of maximum 6-inch compacted thickness each.

Crushed aggregate shall be deposited directly and uniformly on the prepared subgrade, if no geotextile or landscape fabric is used. If geotextile fabric is required, the aggregate shall be back-dumped on the fabric, and machine spread in the direction of overlap. Dumping in windrows, which requires excessive rehandling, will not be permitted. When deposited, the aggregate shall be free from segregation, and shall require minimum blading or manipulation.

2. Compaction and Grading.

a. Each layer of aggregate shall be compacted using equipment required in the State Specifications. For compacting aggregate on a geotextile or landscape fabric, use a smooth-drum roller. Compaction shall closely follow the spreading operation to prevent loss of contained moisture or displacement of materials.

2C-6

b. When the surface stability of the crushed aggregate cannot be obtained due to lack of fines, additional fines shall be added to the upper portion of the course in an amount sufficient to secure stability, at no additional cost to the Government. In no case, however, shall the quantity of fines added increase the percent passing the Number 200 sieve by more than 15 percent in the upper portion.

c. Any irregularities or depressions that develop in the layers under rolling operations shall be corrected by loosening the material and removing or adding aggregate and rerolling. The rolling shall be continued until the surface is shown to be smooth and uniform, and to such trueness that when tested with a 10-foot straightedge it shall not show any deviation in excess of 1/4-inch. At all places not accessible to the roller, the aggregate of each layer shall be tamped separately and compacted to grade and line with mechanical tampers.

d. If any subgrade material is worked into the aggregate material during the compacting or finishing operations, all granular material within the affected areas shall be removed and replaced with new aggregate. The COR may restrict hauling or traffic over the completed or partially completed base after inclement weather or at any time when the subgrade is soft, and there is a tendency for the subgrade material to work into the base material.

e. If considered necessary by the COR, water shall be applied to each layer to aid in compaction and prevent segregation of the material. Disc or harrow surfacing material during moistening operations to secure uniform moisture distribution. Add water in a manner that will not soften the subgrade. All work associated with the additional water shall be accomplished at no additional cost to the Government.

f. The aggregate shall be compacted to 95 percent maximum density as determined by AASHTO-T99.

Compaction shall continue until no further discernible compaction is evidenced under action of the compaction equipment. If in the opinion of the COR, the required degree of compaction has not been achieved, testing in accordance with the standard will be conducted and paid for by the Government. If testing confirms unacceptable compaction, reconstruction or other remedial work may be required by the Contractor at no additional cost to the Government.

3A-1

DIVISION 3 - CONCRETE

SECTION 3A

CONCRETE FORMWORK AND REINFORCEMENT

3A.1 DESCRIPTION OF WORK. Extent of work is indicated on the drawings and by the requirements of this section.

3A.2 CONCRETE FORMWORK.

A. Design of Forms. 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 tied together so as to maintain position and shape.

B. Form Removal. Forms shall not be loosened or removed until the concrete members have acquired strength sufficient to support their own weight. No additional loads shall be placed on the concrete for at least 48 hours after placing.

C. Form Ties. Form ties for concrete shall be of a type that will break back 1 1/2 inches from the concrete surface. Ties shall be removed to a minimum depth of 1

1/2 inches, and the surface patched.

3A.3 CONCRETE REINFORCEMENT.

A. Materials. Reinforcement bars shall conform to

"Standard Specification for Deformed and Plain Carbon-

Steel Bars for Concrete Reinforcement", ASTM A-615.

All bars shall be Grade 60 deformed bars.

B. Cleaning and Bending Reinforcement. At the time concrete is placed, metal reinforcement shall be free from rust scale or other coatings that will destroy or reduce the bond. All bent bars shall be bent cold. No bars partially embedded in concrete shall be field bent except as shown on plans.

C. Placing Reinforcement. 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.

3A-2

D. Splices in Reinforcement. No splices or reinforcement shall be made except as shown on the plans or as authorized by the COR.

E. 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 follows:

1. Where concrete is deposited against the ground without the use of forms, not less than 3 inches.

2. Where concrete is exposed to the weather or to the ground but placed in forms, not less than 2 inches for bars larger than number 5, and 1 1/2 inches for number 5 bars or smaller.

3B-1

DIVISION 3 - CONCRETE

SECTION 3B

CAST-IN-PLACE CONCRETE

3B.1 DESCRIPTION OF WORK. The extent of work is indicated on the drawings and by the provisions of this section.

3B.2 MATERIALS. Cement shall conform to Specification for

Portland Cement ASTM C-150, Type I, or Specification for Air-Entraining Portland Cement ASTM C-175, Type 1A, unless otherwise specified. The concrete shall have a minimum 28-day compressive strength of 3,000 PSI, a maximum slump of 4 inches, and a maximum aggregate size of 1-inch. The concrete mix shall contain an air-entraining admixture.

Air content shall be 5 to 7 percent. The Contractor shall give the COR 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 COR prior to placing concrete.

3B.3 PREPARATION OF EQUIPMENT AND PLACE OF DEPOSIT.

A. 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. The reinforcement shall be thoroughly cleaned of ice, dirt, rust scale, or other coatings.

B. 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.

3B.4 CONVEYANCE. Concrete shall be conveyed from the mixer to the place of final deposit by methods that will prevent segregation or loss of materials. Equipment for chuting concrete shall be of such size and design so as to ensure a continuous flow of concrete at the delivery end without segregation of materials.

3B.5 PLACEMENT.

A. Concrete shall be placed within 1 1/2 hours after mixing begins. Concrete shall be deposited as nearly as practicable in its final position to avoid segregation due to rehandling or flowing. The placing of concrete shall be carried on at such 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.

3B-2

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

C. Concrete shall be placed in layers not exceeding 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. Provisions shall be made to remove such water as may accumulate, so that under no conditions will concrete be placed in such accumulations.

D. Vibrators shall be the internal immersion type, operating at speeds of not less than 7,000 RPM.

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 insure 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.

3B.6 FOOTINGS. All footings and foundations without footings shall bear on firm, undisturbed soil.

3B.7 CYLINDRICAL CONCRETE PIERS.

A. All cylindrical concrete piers, if required, shall be formed to full depth in fiber forms. Tops of piers shall be finished flat within the confines of the fiber forms. No spillage (mushrooming) over the tops of forms will be permitted. Where conduit emerges from vertical surfaces of concrete piers, no appreciable amount of concrete shall be permitted to spill through forms adjacent to such conduit.

3B-3

B. Fiber forms for cylindrical concrete piers shall be spirally constructed of laminated plies of fiber. The total wall thickness shall be as published by the manufacturer. The width of each ply shall not be less than 6 inches. Plies shall be laminated with an adhesive of a non-water-sensitive type, with a proven record of satisfactory service in concrete forms. The exterior surface shall be uniformly wax impregnated for weather and moisture protection. The interior surface shall be coated with pure polyethylene uncontaminated by paraffin or other additives. A-Coated Sonotube forms by Sonoco Products Company of Hartsville, South Carolina, are among the products that meet these Specifications.

C. Remove all loose soil from bore holes so that concrete will bear on undisturbed soil. Support forms rigidly and in proper horizontal and vertical alignment. After pouring, remove only that part of each form that will be exposed above grade. Backfill excess space between bore holes and forms with thoroughly compacted inorganic soil. Do not use sand backfill unless adjacent undisturbed soil is sand.

3B.8 ANCHOR BOLT INSERTS. No drilling for or placing of anchor bolt inserts or anchors will be permitted in concrete for a period of three days after placement, unless noted otherwise on the drawings.

3B.9 CURING.

A. Provision shall be made for maintaining concrete in a moist condition for a period of at least 5 days after placement.

B. In lieu of wet curing, one coat of a concrete curing sealer which forms a film over the concrete surface, may be used for curing the concrete. The sealer shall meet the ASTM C-309 standard for moisture retention. The compound shall be a type that does not permanently discolor the concrete. Dayton Superior J11W is one of the products which meet this Specification. Where concrete is to receive vinyl composition tile (VCT), or any other flooring, curing compound shall not be used, and only wet sheet curing is allowed. On exposed surfaces, 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 48 hours, they shall be wetted down and kept wet until their removal, and then the compound applied as above.

3B-4

3B.10 COLD-WEATHER REQUIREMENTS.

A. 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.

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