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Incidental Construction

821DESCRIPTION

LA · 2016 Standard SpecificationsBook pages 850–921View official source ↗

Mechanical Systems

821.01 DESCRIPTION. Provide all material, equipment, tools, measuring

devices, and labor to purchase/fabricate, shop test, transport, install/erect, align/adjust, paint, lubricate, field test, and set -up all Mechanical Items/Systems as speci fied herein. These specification govern both new construction projects and rehabilitation/ repair projects.

821.02 ACRONYMS AND ABBREVI ATIONS. See 101.02 and 801.02 for

additional acronyms and abbreviations. ASJ All Service Jacket BOD Biological Oxygen Demand BTU British Thermal Unit CFM Cubic Feet per Minute CMU Concrete Masonry Unit CWP Cold Working Pressure GPM Gallons per Minute EPDM Ethylene Propylene Diene Monomer EEIPS Double Extra Improved Plow Steel EIPS Extra Improved Plow Steel FKM Fluorocarbon Elastomer FSK Foil-Scrim Kraft HFC Hard Fiber Core HPU Hydraulic Powe r Unit HVAC Heating, Ventilation, and Air Conditioning IWRC Independent Wire Rope Core MDFT Minimum Dry Film Thickness MERV Minimum Efficiency Reporting Value NIST National Institute of Standards and Technology NPS Nominal Pipe Size NRTL Nationally Recognized Testing Laboratories PE Polyethylene PVC Polyvinyl Chloride PVDF Polyvinylidene Diflouride Mechanical Systems

821.01 DESCRIPTION. Provide all material, equipment, tools, measuring

821.02 ACRONYMS AND ABBREVI ATIONS. See 101.02 and 801.02 for

821.03 DEFINITIONS. See 101.03 , 801.03 , 820.03 , and 822.03 for additional

definitions. ACR Tubing. Air-conditioning and refrigeration field service copper tubing. Bright Wire Rope . Wire rope with no coatings. Center Wires . Wires positioned at the center of a strand in a wire rope. See ASTM A1023, 3.6.4.1 Counterweight Ropes for Movable Barriers . Wire ropes that connect the movable barrier to the counterweight. Consists of a specified length of wire rope with sockets permanently attached at each end. Counterweight Ropes for Vertical Lift Bridges . Wire ropes that connect the movable span of a vert ical lift bridge to the counterweight. It consists of a specified length of wire rope with sockets permanently attached at each end. Drawn -Galvanized Wire . Zinc coating applied prior to the final cold drawing operation of a wire. See ASTM A1007, 3.1.3. Escutcheon . An escutcheon is a plate or ring formed to cover a gap between a penetrating pipe or valve and the finished wall surface from which it protrudes. Filler Wires . Smaller, non -load bearing wires in a wire rope. Provides support for subsequent l ayers of wires. See ASTM A1023, 3.6.2.1. Final -Galvanized Wire . Zinc coating applied after the final cold drawing operation of a wire that is galvanized at the final size of the wire. See ASTM A1007, 3.1.6. Fitted Pin. Used for turned bolts larger than 1 1/2 inch diameter. A fabricated fastener that is threaded on both ends and whose shank is machined to a high tolerance to provide a tight (LC6) fit with the hole. Fluorocarbon Elastomer (FKM) . Shaft and O -ring seal mat erial. When available, all shaft and O -ring seals shall be 100 percent FKM in accordance with ASTM D1418, (trade name “Viton”). Flux. A strong cleaning agent which cleans oxidized copper. Galvanized. Unless otherwise specified, all galvanizing shall be hot dipped in accordance with ASTM A123. Hydronic. Hydronic is the use of water as the heat -transfer medium in heating and cooling systems. Inner Wires . All wires except filler wires, center wires, core wires, and outer wires in a wire rope. See ASTM A1023, 3.6.4.3. Main Wires . Load bearing wires in a wire rope. See ASTM A1023, 3.6.2.2. Marine Duty Stainless Steel. Any of the following stainless steel types: 201, 202, 205, 301, 302, 302B, 304, 304H, 304L, 304N, 305, 308, 309, 309S, 310, 310S, 314, 316, 316F, 316H, 316L, 316N, 317, 317L, 321, 321H, 329, 330, 347, 347H, 348, 348H, 384, 434, 436, 446, 431, 15 -5 PH, 17 -4 PH, 17 -7 PH. Operating Ropes . Wire ropes that are part of the drive system of a movable bridge or a movable barrier. Outer Wires. All wires in the outer layer of the outer strand of a wire rope. See ASTM A1023, 3.6.4.4 Prestretching . A process for stretching a wire rope prior to measuring so that a more accurate measurement can be made. See ASTM A1023, 3.10. Production Length . A length of wire rope that is manufactured in one continuous operation from one setting of one stranding machine and one setting of one closing machine. See ASTM A1023, 8.3. Rope Core . Central element of a wire rope that supports the strands. See ASTM A1023, 3.3, 3.3.1, 3.3.2. Rope Lay. Describes both the direction of the twist of the wires in a strand of a wire rope, and the direction that the strands are laid in a wire rope. See ASTM A1023, 3.16. Sockets . Steel fittings permanently attached to th e end of a wire rope to facilitate connection to a structure. Strand . An assembly of main wires and filler wires. Multiple strands are used to fabricate a wire rope. See ASTM A1023, 3.4 Turned Bolt. A bolt where the shank has been machined to a high to lerance to provide a tight (LC6) fit with the hole. See also Fitted Pin. US26D. Door hardware finish specification. Satin chromium plated; brushed/satin chrome. Brass or bronze base material. US32D. Door hardware finish specification. Satin stainless s teel; brushed/satin stainless.

821.04 MATERIALS. All material for fabricated items shall be new and all

manufactured items shall be new. Comply with the following Sections. Fences Section 705 Jacked or Bored Pipe Section 728 Structural Metals Section 807 Painting and Protective Coatings Section 811 Welding Section 809 Electrical Systems Section 822 Facilities Section 823 Metals Section 1013 Epoxy Resin System Section 1017

821.05 General Requirements .

821.05.1 Federal, State, and Local Codes and Laws: Provide all

821.04 MATERIALS. All material for fabricated items shall be new and all

821.05 General Requirements .

821.05.1 Federal, State, and Local Codes and Laws: Provide all

821.04 MATERIALS. All material for fabricated items shall be new and all

821.05 General Requirements .

821.05.1 Federal, State, and Local Codes and Laws: Provide all

821.04 MATERIALS. All material for fabricated items shall be new and all

821.05 General Requirements .

821.05.1 Federal, State, and Local Codes and Laws: Provide all

Mechanical Work in accordance with, but not limited to, the following federal laws, and codes adopted by the State of Louisiana to govern the construction of mechanical items/systems. Use code editions that are in effect at the time the Contract is executed. ADA -AG Americans with Disabilities Act – Accessibility Guidelines IBC International Building Code IMC International Mechanical Code LSPC Louisiana State Plumbing Code LSAC Louisiana Sanitary Code NFPA 54 National Fire Protection Association – Natural Fuel Gas Cod e (NFGC) NFPA 58 National Fire Protection Association – Liquefied Petroleum Gas Code (LPG) NFPA 70 National Fire Protection Association – National Electrical Code (NEC) NFPA 72 National Fire Protection Association – National Fire Alarm and Signaling Code NFPA 90A National Fire Protection Association – Standard for the Installation of Air -Conditioning and Ventilating Systems NFPA 90B National Fire Protection Association – Standard for the Installation of Warm Air Heating and Air -Conditioning Systems NFPA 10 1 National Fire Protection Association – Life Safety Code (LSC) OSHA Occupational Safety and Health Administration In addition, provide all mechanical work in accordance with all local building, mechanical, electrical, and sanitary code ordinances in forc e in the work locality except that local inspection of utilities will not be required unless ownership of the work will be transferred to the local utility. Providing mechanical work in accordance with Federal, State, and local codes, laws, and ordinances is a minimum requirement. Work specified in the Contract that is more stringent than that required by the Federal, State, and local codes, laws, and ordinances shall also be provided. Work that does not meet the requirements of the Federal, State, and loca l codes, laws, and ordinances, and/or the Contract documents shall be corrected at no additional cost or time to the Department. For projects with federal funding, all mechanical equipment containing steel may require conformance with applicable provisions of the federal Buy America Act 49

U.S.C. § 5323(j). This includes roller bearings, electric motors, brakes, couplings, hydraulic cylinders, hydraulic valves, etc. If there are no domestic suppliers of equipment that will meet the contract specifications, the Contractor must submit a request to the Department to apply for a waiver to use the foreign made product. The request must provide evidence that the product is not available domestically. In addition, if there is only one domestic supplier of equipment that will meet the contract specifications, and the cost of a foreign supplied product is substantially lower, the Contractor can submit a request to the Department to apply for a waiver to use the foreign made product. The request must provide evidence o f the cost difference.

821.05.2 Specifications and Standards: Mechanical work shall be in

accordance with, but not limited to, the following specifications and standards that govern the construction of the mechanical items/systems specified in the Contract. NFPA 58 National Fire Protection Association – Liquefied Petroleum Gas Code (LPG) NFPA 70 National Fire Protection Association – National Electrical Code (NEC) NFPA 72 National Fire Protection Association – National Fire Alarm and Signaling Code NFPA 90A National Fire Protection Association – Standard for the Installation of Air -Conditioning and Ventilating Systems NFPA 90B National Fire Protection Association – Standard for the Installation of Warm Air Heating and Air -Conditioning Systems NFPA 10 1 National Fire Protection Association – Life Safety Code (LSC) OSHA Occupational Safety and Health Administration In addition, provide all mechanical work in accordance with all local building, mechanical, electrical, and sanitary code ordinances in forc e in the work locality except that local inspection of utilities will not be required unless ownership of the work will be transferred to the local utility. Providing mechanical work in accordance with Federal, State, and local codes, laws, and ordinances is a minimum requirement. Work specified in the Contract that is more stringent than that required by the Federal, State, and local codes, laws, and ordinances shall also be provided. Work that does not meet the requirements of the Federal, State, and loca l codes, laws, and ordinances, and/or the Contract documents shall be corrected at no additional cost or time to the Department. For projects with federal funding, all mechanical equipment containing steel may require conformance with applicable provisions of the federal Buy America Act 49

821.05.2 Specifications and Standards: Mechanical work shall be in

accordance with, but not limited to, the following specifications and standards that govern the construction of the mechanical items/systems specified in the Contract. AA Aluminum Association AABC Associated Air Balance Council AAMA American Architectural Manufacturers Association AASHTO American Association of State Highway Transportation Officials LRFD Bridge Design Specifications LRFD Movable Highway Bridge Desig n Specifications AIA American Institute of Architects AGMA American Gear Manufacturers Association AMCA Air Movement and Control Association International AISC American Institute of Steel Construction AISI American Iron and Steel Institute ANSI Ameri can National Standards Institute ARI American Refrigeration Institute ASCE American Society of Civil Engineers ASHRAE American Society of Heating, Refrigerating, and Air -Conditioning Engineers ASME ASME International (American Society of Mechanical Eng ineers) APWA American Public Works Association ASSE American Society of Safety Engineers ASTM ASTM International (American Society for Testing and Materials International) AWG American Wire Gauge AWPA American Wood Protection Association AWS American Welding Society AWWA American Water Works Association BHMA Builders Hardware Manufacturers Association CSA CSA International FMG Factory Mutual Global HI Hydraulic Institute IAPMO International Association of Plumbing and Mechanical Officials IESNA Illuminating Engineering Society of North America MSS Manufacturers Standardization Society NEBB National Environmental Balancing Bureau NEMA National Electrical Manufacturers Association NFRC National Fenestration Rating Association NRCA National Ro ofing Contractors Association NSF NSF International (National Sanitation Foundation International) SAE SAE International (Society of Automotive Engineers International) SDI Steel Door Institute SMACNA Sheet Metal and Air Conditioning Contractors’ Natio nal Association SSPC Society for Protective Coatings UL Underwriter’s Laboratories Providing mechanical work in accordance with these Specifications and Standards is a minimum requirement. Work specified in the Contract that is more stringent than that required by these Specifications and Standards shall also be provided. Work that does not meet the requirements of these Standards and Specifications and/or the Contract documents shall be corrected at no additional cost or time to the Department.

821.05.3 Workmans hip: Use best industry practices at all times during the

fabrication, transportation, installation, alignment, adjustment, and testing of the mechanical items/systems specified in the Contract.

821.05.4 Personnel Qualifications: Provide construction personne l who

are knowledgeable and experienced in the construction/installation of mechanical items/systems shown in the Contract. Although the contract documents are of sufficient detail and quality to convey the intent of the design to an experienced contractor , they do not necessarily depict every detail or specify every incidental or ancillary item that is required for the mechanical systems to be properly fabricated, transported, installed, aligned, adjusted, tested, painted, and to function in accordance wit h the intent of the contract documents. Regardless of the construction cost, all general contractors and subcontractors shall be licensed in Louisiana for the work they are performing.

821.06 Mechanical System Su Bmittals.

821.06.1 General Requirements: Prepare and submit original mechanical

submittals to the Bridge Engineer for review for each mechanical item as described below. Mechanical system submittals shall comply with Sections 105.02.2 , 801.05 , and

820.06 They include shop drawings, cut sheets, field measurements, calculations,

manuals, and any other document that the contractor is required by the Contract to produce and submit to the Bridge Engineer for review or record. SMACNA Sheet Metal and Air Conditioning Contractors’ Natio nal Association SSPC Society for Protective Coatings UL Underwriter’s Laboratories Providing mechanical work in accordance with these Specifications and Standards is a minimum requirement. Work specified in the Contract that is more stringent than that required by these Specifications and Standards shall also be provided. Work that does not meet the requirements of these Standards and Specifications and/or the Contract documents shall be corrected at no additional cost or time to the Department.

821.05.3 Workmans hip: Use best industry practices at all times during the

fabrication, transportation, installation, alignment, adjustment, and testing of the mechanical items/systems specified in the Contract.

821.05.4 Personnel Qualifications: Provide construction personne l who

821.06 Mechanical System Su Bmittals.

821.06.1 General Requirements: Prepare and submit original mechanical

submittals to the Bridge Engineer for review for each mechanical item as described below. Mechanical system submittals shall comply with Sections 105.02.2 , 801.05 , and

820.06 They include shop drawings, cut sheets, field measurements, calculations,

821.05.3 Workmans hip: Use best industry practices at all times during the

fabrication, transportation, installation, alignment, adjustment, and testing of the mechanical items/systems specified in the Contract.

821.05.4 Personnel Qualifications: Provide construction personne l who

821.06 Mechanical System Su Bmittals.

821.06.1 General Requirements: Prepare and submit original mechanical

submittals to the Bridge Engineer for review for each mechanical item as described below. Mechanical system submittals shall comply with Sections 105.02.2 , 801.05 , and

820.06 They include shop drawings, cut sheets, field measurements, calculations,

821.05.3 Workmans hip: Use best industry practices at all times during the

fabrication, transportation, installation, alignment, adjustment, and testing of the mechanical items/systems specified in the Contract.

821.05.4 Personnel Qualifications: Provide construction personne l who

821.06 Mechanical System Su Bmittals.

821.06.1 General Requirements: Prepare and submit original mechanical

submittals to the Bridge Engineer for review for each mechanical item as described below. Mechanical system submittals shall comply with Sections 105.02.2 , 801.05 , and

820.06 They include shop drawings, cut sheets, field measurements, calculations,

821.05.3 Workmans hip: Use best industry practices at all times during the

fabrication, transportation, installation, alignment, adjustment, and testing of the mechanical items/systems specified in the Contract.

821.05.4 Personnel Qualifications: Provide construction personne l who

821.06 Mechanical System Su Bmittals.

821.06.1 General Requirements: Prepare and submit original mechanical

submittals to the Bridge Engineer for review for each mechanical item as described below. Mechanical system submittals shall comply with Sections 105.02.2 , 801.05 , and

820.06 They include shop drawings, cut sheets, field measurements, calculations,

manuals, and any other document that the contractor is required by the Contract to produce and submit to the Bridge Engineer for review or record. The mechanical system submittal process creates an official record of the mechanical work performed on the project, how mechanical items were installed, and required construction measurements, settings, and calculations. It also allows the Department to take exception to a mec hanical item that is in conflict with the requirements of the Contract, or to correct a plan error prior to the purchase or fabrication of a mechanical item when the cost is at a minimum. Submittals related to a given mechanical assembly, such as Detail Sh eets

821.06.2 (1), Assembly Sheets 821.06.2 (2), Cut Sheets 821.06.3 , etc., shall be

submitted together in one package. The review period for these submittals will not begin until all documents have been received b y the Department. Always copy the Project Engineer whenever transmitting mechanical system submittals.

821.06.2 Mechanical Shop Drawings: Prepare and submit original

mechanical shop drawings to the Bridge Engineer for review for each shop fabricated and manufactured mechanical item. Mechanical shop drawings shall be prepared by, or under the direct supervision of, the shop that will perform the work. Mechanical shop drawings shall not be prepared by an independent entity, and given to the shop for use in fabrication. Contract plan sheets shall not be used for mechanical shop drawings.

1.Detail Sheets: Prepare and submit detail sheets for each shop fabricated mechanical item. Detail sheets shall show all views, dimensions, tolerances, fits, finishes, weld s, materials, heat treatment, hardness requirements, etc. required to fabricate an individual item. For weldments, show steel plate sizes prior to machining. Include estimated weight of each fabricated Item.

2.Assembly Sheets: Prepare and submit assembly sheets for all mechanical assemblies. Assembly sheets shall show how groups of mechanical parts, both fabricated and manufactured, are to be assembled together, and where the mechanical assemblies are located on the project. All manufactured items such as motors, speed reducers, bearings, electrical equipment, hydraulic equipment, etc., and their pertinent data shall be shown on assembly sheets. Pertinent data includes dimensions related to the assembly, weights, pressure ratings, capacities, normal operat ing settings, lubrication fitting types, manufacturer’s recommended lubricant, frequency of lubrication, etc. Obtain dimensions of all manufactured equipment from certified drawings provided by the manufacturer prior to the production of shop drawings. Sub mit certified drawings with related assembly sheets. The mechanical system submittal process creates an official record of the mechanical work performed on the project, how mechanical items were installed, and required construction measurements, settings, and calculations. It also allows the Department to take exception to a mec hanical item that is in conflict with the requirements of the Contract, or to correct a plan error prior to the purchase or fabrication of a mechanical item when the cost is at a minimum. Submittals related to a given mechanical assembly, such as Detail Sh eets

821.06.2 (1), Assembly Sheets 821.06.2 (2), Cut Sheets 821.06.3 , etc., shall be

821.06.2 Mechanical Shop Drawings: Prepare and submit original

2.Assembly Sheets: Prepare and submit assembly sheets for all mechanical assemblies. Assembly sheets shall show how groups of mechanical parts, both fabricated and manufactured, are to be assembled together, and where the mechanical assemblies are located on the project. All manufactured items such as motors, speed reducers, bearings, electrical equipment, hydraulic equipment, etc., and their pertinent data shall be shown on assembly sheets. Pertinent data includes dimensions related to the assembly, weights, pressure ratings, capacities, normal operat ing settings, lubrication fitting types, manufacturer’s recommended lubricant, frequency of lubrication, etc. Obtain dimensions of all manufactured equipment from certified drawings provided by the manufacturer prior to the production of shop drawings. Sub mit certified drawings with related assembly sheets. If any manufactured item must be modified from the way it is normally delivered by the manufacturer, provide a detail of the modification on the related assembly sheet. If the modification was made by th e manufacturer, provide a unique part number from the manufacturer such that when a replacement part is ordered, it will have the same modifications.

3.Submittal Procedure: Submit mechanical shop drawings electronically to the Bridge Engineer for review. The electronic file shall be a single PDF file for each mechanical assembly. For bidding purposes, allow a review period of 14 calendar days per submittal if the submittal consists of 30 or less shop drawing sheets. For submittals containing more than 30 shop drawing sheets, allow a review period of 14 calendar days per 30 sheets submitted rounded up (40 sheets equals 28 calendar days). Review periods for separate submittals are not concurrent. After review, rejected shop drawings will be stamped “Returned for Correction,” will be initialed and dated by the reviewer, will have comments marked in red, and will be returned to the contractor electronically as a PDF file. Correct errors and mark changes by placing a cloud shaped outline around each change. Note changes in the revision block. Resubmit electronically to the Bridge Engineer for review. Any submittal with unmarked or unnoted changes will be returned without review. This process will repeat until the Department has no further comments. Mechanical shop drawings will then be stamped “Accepted in accordance with LSSRB 105.02 ,” initialed and dated by the reviewer, and returned to the contractor electronically as a PDF file.

4.Deliverables: Provide three full scale paper reproductions and one half scale paper reproduction of all mechanical shop drawings that have been stamped “Accepted in accordance with LSSRB 105.02 ” to the Bridge Engineer for distribution. Paper reproductions shall be printed directly from the PDF file returned by the Department, shall show the “Accepted in accordance with LSSRB 105.02 ” stamp, and shall have no modifications.

821.06.3 Mechanical Cut Sheets (Manufacturer Information Sheets):

Prepare and submit mechanical cut sheets to the Bridge Engineer for review for each manufactured mechanical Item. Mechanical cut sheets shall be of good legible quality. Poor legible quality can be reason for rejection. If any manufactured item must be modified from the way it is normally delivered by the manufacturer, provide a detail of the modification on the related assembly sheet. If the modification was made by th e manufacturer, provide a unique part number from the manufacturer such that when a replacement part is ordered, it will have the same modifications.

821.06.3 Mechanical Cut Sheets (Manufacturer Information Sheets):

Prepare and submit mechanical cut sheets to the Bridge Engineer for review for each manufactured mechanical Item. Mechanical cut sheets shall be of good legible quality. Poor legible quality can be reason for rejection. Stamp each sheet of each mechanical cut sheet submittal with the project name, project number, parish name, contract i tem number, shop drawing item number (if different), contract sheet number, and shop drawing sheet number (if different). Include the manufacturer's name if not already shown on the mechanical cut sheet. If multiple sheets are related to one item, then not e each sheet with X of Y where X is the sheet number and Y is the total number of sheets. Indicate pertinent sizes, ratings, features, or any other data (voltage, gpm, etc.) specified on the plans on the mechanical cut sheet with an arrow or other such mar k. Do not use highlight markers because they do not photocopy well. Cross out items on mechanical cut sheets that are not being submitted for review. Include the manufactured item's warranty information if the warranty extends beyond the Contractor's guara ntee period. Always include documentation for extended warranties that were required to be purchased for the Contract. Extended warranties shall be in the Department’s name.

1.Submittal Procedure: Submit mechanical cut sheets electronically to the Bridge Engineer for review. The electronic file shall be a single PDF file. For bidding purposes, allow a review period of 14 calendar days per submittal if the submittal consists of 50 or less mechanical cut sheets. For submittals containing more than 50 mechanical cut sheets, allow a review period of 14 calendar days per 50 sheets submitted rounded up (60 sheets equals 28 calendar days). Review periods for separate submittals are not concurrent. After review, rejected mechanical cut sheets will be stamped "Returned for Correction," will be initialed and dated by the reviewer, will have comments marked in red, and will be returned to the contractor electronically as a PDF file. Correct errors and resubmit electronically to the Bridge Engineer for review. Th is process will repeat until the Department has no further comments. Mechanical cut sheets will then be stamped “Accepted in accordance with LSSRB 105.02 ,” initial ed and dated by the reviewer, and returned to the contractor electronically as a PDF file.

2.Deliverables: No paper reproductions of mechanical cut sheets are required. The Department will distribute “Accepted in accordance with LSSRB 105.02 ” mechanical cut sheets to all interested parties electronically as a PDF file.

821.06.4 Color and Material Samples: Prepare and submit color and

material samples t o the Bridge Engineer for review as indicated on the plans. Color samples shall be printed hard copies by the item’s manufacturer or color samples of the item itself (e.g., floor tiles of various colors). Electronic submittals of color samples are not allo wed.

821.06.5 Mechanical Record Drawings: Mechanical record drawings

shall become part of the final estimate package and submitted for archiving. They shall consist of the following: Stamp each sheet of each mechanical cut sheet submittal with the project name, project number, parish name, contract i tem number, shop drawing item number (if different), contract sheet number, and shop drawing sheet number (if different). Include the manufacturer's name if not already shown on the mechanical cut sheet. If multiple sheets are related to one item, then not e each sheet with X of Y where X is the sheet number and Y is the total number of sheets. Indicate pertinent sizes, ratings, features, or any other data (voltage, gpm, etc.) specified on the plans on the mechanical cut sheet with an arrow or other such mar k. Do not use highlight markers because they do not photocopy well. Cross out items on mechanical cut sheets that are not being submitted for review. Include the manufactured item's warranty information if the warranty extends beyond the Contractor's guara ntee period. Always include documentation for extended warranties that were required to be purchased for the Contract. Extended warranties shall be in the Department’s name.

821.06.4 Color and Material Samples: Prepare and submit color and

821.06.5 Mechanical Record Drawings: Mechanical record drawings

821.06.4 Color and Material Samples: Prepare and submit color and

821.06.5 Mechanical Record Drawings: Mechanical record drawings

shall become part of the final estimate package and submitted for archiving. They shall consist of the following:

1.Original, full size, mechanical contract plan sheets and change order sheets.

2.All reviewed and stamped mechanical shop drawings.

3.Any mechanical contract plan sheets (full scale) that have been marked to indicate construction changes (“As Built” sheets). These sheets shall have the Project Engineer's signature certifying that the changes are accurate.

821.06.6 Mechanical Operation and Maintenance Manual: For any

project with mechanical (“M”) sheets, prepare and submit a mechanical operation and maintenance manual to the Bridge Engineer for review. Cost of preparing and submitting the Mechanical Operation and Maintenance Manual shall be included in the pay items of Sections 821, 822, and 823. The Department will retain 5 percent of the bid price of all mechanical, electrical, and facility items (821, 822, and 823 items) until the manua l has been reviewed and accepted, and final paper reproductions have been received by the Department. All sheets included in the manual must be of good legible print quality. Poor legible quality can be reason for rejection. Any sheets with color must be scanned/printed in color. Include a title sheet showing “Louisiana Department of Transportation and Development,” “Mechanical Operation and Maintenance Manual,” the project name, project number, parish name, the year the project was completed, the name of the contractor, and the contractor’s contact information. Include a “Contract Plans” section that contains all original mechanical contract plan sheets and change order sheets. Scan at high quality from the full scale original and format for printing at 11 inches x 17 inches. Include a “Shop Drawings” section that contains all mechanical shop drawing sheets. Generate from the original PDF files reviewed by the Department with the “Accepted in accordance with LSSRB 105.02 ” stamp, the reviewer's initials, and the date of the review. Format for printing at 11 inches x 17 inches. Include a “Cut Sheets” section that contains all mechanical cut sheets. Generate from the orig inal PDF files reviewed by the Department with the “Accepted in accordance with LSSRB 105.02 ” stamp, the reviewer's initials, and the date of the review. Include an “As Built” section that contains all mechanical “As Built” sheets. Scan at high quality from the full scale original and format for printing at 11 inches x 17 inches. For movable bridge projects, include a “Lubrication Plan and Equipment Settings” section that contains the “Lubrication Plan and Equipment Settings” drawings from 820.06.1 . Generate from the original PDF files reviewed by the Department with the “Accepted in accordance with LSSRB 105.02 ” stamp, date, and reviewer's initia ls. Format for printing at 11 inches x 17 inches.

1.Original, full size, mechanical contract plan sheets and change order sheets.

2.All reviewed and stamped mechanical shop drawings.

821.06.6 Mechanical Operation and Maintenance Manual: For any

1.Submittal Procedure: Submit the mechanical operation and maintenance manual electronically to the Bridge Engineer for review. The electronic file shall be a single PDF file, and shall be organized and formatted to present itself as a finished maintenance manual. For bidding purposes, allow a review period of 21 calendar days. The entire maintenance manual will be considered one item. Only the title sheet shall be stamped “Returned for Corrections” or “Accepted in accordance with LSSRB 105.02 .” If the maintenance manual is rejected after review, the title sheet will be stamped “Returned for Corrections,” will be initialed and dated by the reviewer, will have comments marked in red, and will be returned electronically. Correct errors and resubmit electronically to the Bridge Engineer for review. This process will repeat until the Department has no further comments. The title sheet will then be stamped “Accepted in accordance with LSSRB 105.02 ,” initialed and dated by the reviewer, and distributed electronically by the Department.

2.Deliverables: After the electronic submittal process has been comp leted, provide two paper reproductions of the mechanical operation and maintenance manual to the Bridge Engineer for review. For bidding purposes, allow a review period of 14 calendar days. Format shall be in accordance with “Paper Reproductions” and “Lett er Size Sheets” from 801.05.2.2 . Provide each manual with a white, premium, heavy duty, 3 D -ring binder with title sleeve. Binders shall be appropriately sized to hold enclosed material, and shall be extra wide to accommodate sheet p rotectors. Binders shall not be larger than 3 inches. Use multiple binders if necessary. Provide each sheet with a top loading, 8 ½ inches x 11 inches, standard weight, clear, sheet protector. Fold half -scale sheets in half with printed material facing out, and insert in sheet protectors. Provide a top loading, 8 ½ inches x 11 inches, standard weight, clear, tab index sheet protector with labeled tab to delineate sections. If the paper reproduction of the manual is rejected after review, the title sheet of both copies will be stamped “Returned for Correction,” will be initialed and dated by the reviewer, and both copies will be returned to the contractor with instructions for corrections. Correct errors and resubmit to the Bridge Engineer for review. This process will repeat until the Department has no further comments. The title sheet will then be stamped “Accepted in accordance with LSSRB 105.02 ,” initialed and dated by the reviewer, and distributed by the Department.

821.07 General Construction Requirements for Mo Vable

BRIDGES.

821.07.1 Fabrication Standards: Fabrication of parts shall conform to all

standards shown in 821.05.2 .

821.07.2 Burrs and Sharp Edges: Remove all burrs and break all sharp

edges of fabricated parts.

821.07.3 Finished Mating Surfaces: Finished surfaces that mate with or

slide on other finished surfaces sh all have a 125 finish or as shown on the plans. Immediately after fabrication, coat the surface with NO -OX-ID "A -Special" rust preventative or an approved equal to prevent corrosion. Protect with wooden lagging or some other approved method for transportat ion to the field.

821.07.4 Unfinished Surfaces and Finished Non -Mating Surfaces:

Paint all unfinished surfaces and finished surfaces that do not mate with other finished surfaces in accordance with Section 811 .

821.07.5 Fits and Finishes: If not shown on the plans, or specified

elsewhere herein, fits and finishes shall be in accordance with Table 821 -1. If the paper reproduction of the manual is rejected after review, the title sheet of both copies will be stamped “Returned for Correction,” will be initialed and dated by the reviewer, and both copies will be returned to the contractor with instructions for corrections. Correct errors and resubmit to the Bridge Engineer for review. This process will repeat until the Department has no further comments. The title sheet will then be stamped “Accepted in accordance with LSSRB 105.02 ,” initialed and dated by the reviewer, and distributed by the Department.

821.07 General Construction Requirements for Mo Vable

BRIDGES.

821.07.1 Fabrication Standards: Fabrication of parts shall conform to all

standards shown in 821.05.2 .

821.07.2 Burrs and Sharp Edges: Remove all burrs and break all sharp

edges of fabricated parts.

821.07.3 Finished Mating Surfaces: Finished surfaces that mate with or

821.07.4 Unfinished Surfaces and Finished Non -Mating Surfaces:

Paint all unfinished surfaces and finished surfaces that do not mate with other finished surfaces in accordance with Section 811 .

821.07.5 Fits and Finishes: If not shown on the plans, or specified

821.07 General Construction Requirements for Mo Vable

BRIDGES.

821.07.1 Fabrication Standards: Fabrication of parts shall conform to all

standards shown in 821.05.2 .

821.07.2 Burrs and Sharp Edges: Remove all burrs and break all sharp

edges of fabricated parts.

821.07.3 Finished Mating Surfaces: Finished surfaces that mate with or

821.07.4 Unfinished Surfaces and Finished Non -Mating Surfaces:

Paint all unfinished surfaces and finished surfaces that do not mate with other finished surfaces in accordance with Section 811 .

821.07.5 Fits and Finishes: If not shown on the plans, or specified

821.07 General Construction Requirements for Mo Vable

BRIDGES.

821.07.1 Fabrication Standards: Fabrication of parts shall conform to all

standards shown in 821.05.2 .

821.07.2 Burrs and Sharp Edges: Remove all burrs and break all sharp

edges of fabricated parts.

821.07.3 Finished Mating Surfaces: Finished surfaces that mate with or

821.07.4 Unfinished Surfaces and Finished Non -Mating Surfaces:

Paint all unfinished surfaces and finished surfaces that do not mate with other finished surfaces in accordance with Section 811 .

821.07.5 Fits and Finishes: If not shown on the plans, or specified

821.07 General Construction Requirements for Mo Vable

BRIDGES.

821.07.1 Fabrication Standards: Fabrication of parts shall conform to all

standards shown in 821.05.2 .

821.07.2 Burrs and Sharp Edges: Remove all burrs and break all sharp

edges of fabricated parts.

821.07.3 Finished Mating Surfaces: Finished surfaces that mate with or

821.07.4 Unfinished Surfaces and Finished Non -Mating Surfaces:

Paint all unfinished surfaces and finished surfaces that do not mate with other finished surfaces in accordance with Section 811 .

821.07.5 Fits and Finishes: If not shown on the plans, or specified

821.07 General Construction Requirements for Mo Vable

BRIDGES.

821.07.1 Fabrication Standards: Fabrication of parts shall conform to all

standards shown in 821.05.2 .

821.07.2 Burrs and Sharp Edges: Remove all burrs and break all sharp

edges of fabricated parts.

821.07.3 Finished Mating Surfaces: Finished surfaces that mate with or

821.07.4 Unfinished Surfaces and Finished Non -Mating Surfaces:

Paint all unfinished surfaces and finished surfaces that do not mate with other finished surfaces in accordance with Section 811 .

821.07.5 Fits and Finishes: If not shown on the plans, or specified

821.07 General Construction Requirements for Mo Vable

BRIDGES.

821.07.1 Fabrication Standards: Fabrication of parts shall conform to all

standards shown in 821.05.2 .

821.07.2 Burrs and Sharp Edges: Remove all burrs and break all sharp

edges of fabricated parts.

821.07.3 Finished Mating Surfaces: Finished surfaces that mate with or

821.07.4 Unfinished Surfaces and Finished Non -Mating Surfaces:

Paint all unfinished surfaces and finished surfaces that do not mate with other finished surfaces in accordance with Section 811 .

821.07.5 Fits and Finishes: If not shown on the plans, or specified

elsewhere herein, fits and finishes shall be in accordance with Table 821 -1. Table 821-1 Fits and Finishes for Common Mating Parts1 Part Fit Finish µin General Machinery Parts in Fixed Contact — 125 Machinery Base in Fixed Contact with Machinery Parts — 125 Machinery Base on Steel — 250 Machinery Base on Masonry — 500 Shaft Journals RC6 8 Journal Bushings RC6 16 Split Bushings in Base LC1 125 Solid Bushing in Base ( < 0.25 inch wall) FN1 63 Solid Bushing in Base (> 0.25 inch wall) FN2 63 Hubs on Shafts ( < 2 inch bore) FN2 32 Hubs on Shafts (> 2 inch bore) FN2 63 Hubs on Main Trunnions FN2 63 Fitted Pins in Finished Holes LC6 63 Sliding Bearings RC6 32 Center Pivot Disk Bearing Sliding Surfaces (Bronze and Steel Disks) — 32 Keys and Keyways Top and Bottom LC4 63 Sides (Load Transmitting) FN2 63 Sides (Non -load Transmitting) LC4 63 Teeth of Open Spur Gears Over 3 Diametral Pitch — 32 3 - 1.75 Diametral Pitch — 63 Under 1.75 Diametral Pitch — 125 1ANSI B4.1, Fits, and ANSI B46.1, Finishes, can be found in the current edition of the Machinery's Handbook. Surface finishes are given as the arithmetic average roughness height in µin.

821.07.6 Dimensional Tolerances: If not shown on the plans, or specified

elsewhere herein, dimensional tolerances for fabricated parts shall be as follows: Integers and Fractions: …….……….. + 0.03 inch

X.XX”: ……………………………... + 0.01 inch

X.XXX”: …………………………… + 0.005 inch Angles: ……………………………... +0.5 degrees

821.07.7 Shop Storage: Store all fabricated/manufactured mechanical

parts/equipment out of the weather while at the shop.

821.07.8 Stainless Steel Bolts: Unless otherwise specified on the pla ns,

all standard bolts used with mechanical parts/equipment shall be stainless steel in accordance with the following.

1.Material: ASTM F593, Type 304 or 316, alloy groups 1 or 2, Condition CW, minimum tensile strength of 80 ksi , and minimum yield strength of 40 ksi.

2.Head: Hex head as specified in ANSI B18.2.1.

3.Threads: UNC as specified in ANSI/ASME B1.1, Class 2A tolerances.

4.Nut: ASTM F594 with a minimum proof stress equal to or greater than the bolt, and the same alloy group as the bolt. Hex head as specified in ANSI B18.2.2. One required per bolt.

5.Flat Washers: Type 304 or 316 stainless steel with a minimum tensile strength of 80 ksi and minimum yield strength of 40 ksi. For standard size holes, use American Standard Type A, narrow series. For oversized holes, use American Standard Type A, wide series. Two required per bolt, one under the head and one under the nut.

6.Beveled Washers: Fabricate from the same material as the flat washers. Bolt heads and nuts shall bear flat o n the materials being fastened. Beveled washers shall be used where bearing faces on either the head or nut of the bolt have a slope of more than 1:20.

821.07.6 Dimensional Tolerances: If not shown on the plans, or specified

elsewhere herein, dimensional tolerances for fabricated parts shall be as follows: Integers and Fractions: …….……….. + 0.03 inch

X.XX”: ……………………………... + 0.01 inch

X.XXX”: …………………………… + 0.005 inch Angles: ……………………………... +0.5 degrees

821.07.7 Shop Storage: Store all fabricated/manufactured mechanical

parts/equipment out of the weather while at the shop.

821.07.8 Stainless Steel Bolts: Unless otherwise specified on the pla ns,

all standard bolts used with mechanical parts/equipment shall be stainless steel in accordance with the following.

1.Material: ASTM F593, Type 304 or 316, alloy groups 1 or 2, Condition CW, minimum tensile strength of 80 ksi , and minimum yield strength of 40 ksi.

2.Head: Hex head as specified in ANSI B18.2.1.

3.Threads: UNC as specified in ANSI/ASME B1.1, Class 2A tolerances.

4.Nut: ASTM F594 with a minimum proof stress equal to or greater than the bolt, and the same alloy group as the bolt. Hex head as specified in ANSI B18.2.2. One required per bolt.

821.07.6 Dimensional Tolerances: If not shown on the plans, or specified

elsewhere herein, dimensional tolerances for fabricated parts shall be as follows: Integers and Fractions: …….……….. + 0.03 inch

X.XX”: ……………………………... + 0.01 inch

X.XXX”: …………………………… + 0.005 inch Angles: ……………………………... +0.5 degrees

821.07.7 Shop Storage: Store all fabricated/manufactured mechanical

parts/equipment out of the weather while at the shop.

821.07.8 Stainless Steel Bolts: Unless otherwise specified on the pla ns,

all standard bolts used with mechanical parts/equipment shall be stainless steel in accordance with the following.

1.Material: ASTM F593, Type 304 or 316, alloy groups 1 or 2, Condition CW, minimum tensile strength of 80 ksi , and minimum yield strength of 40 ksi.

2.Head: Hex head as specified in ANSI B18.2.1.

3.Threads: UNC as specified in ANSI/ASME B1.1, Class 2A tolerances.

4.Nut: ASTM F594 with a minimum proof stress equal to or greater than the bolt, and the same alloy group as the bolt. Hex head as specified in ANSI B18.2.2. One required per bolt.

821.07.6 Dimensional Tolerances: If not shown on the plans, or specified

elsewhere herein, dimensional tolerances for fabricated parts shall be as follows: Integers and Fractions: …….……….. + 0.03 inch

X.XX”: ……………………………... + 0.01 inch

X.XXX”: …………………………… + 0.005 inch Angles: ……………………………... +0.5 degrees

821.07.7 Shop Storage: Store all fabricated/manufactured mechanical

parts/equipment out of the weather while at the shop.

821.07.8 Stainless Steel Bolts: Unless otherwise specified on the pla ns,

all standard bolts used with mechanical parts/equipment shall be stainless steel in accordance with the following.

1.Material: ASTM F593, Type 304 or 316, alloy groups 1 or 2, Condition CW, minimum tensile strength of 80 ksi , and minimum yield strength of 40 ksi.

2.Head: Hex head as specified in ANSI B18.2.1.

3.Threads: UNC as specified in ANSI/ASME B1.1, Class 2A tolerances.

4.Nut: ASTM F594 with a minimum proof stress equal to or greater than the bolt, and the same alloy group as the bolt. Hex head as specified in ANSI B18.2.2. One required per bolt.

7.Bolt Holes: For shank diameters less than 1/2 inch, hole diameters shall be 1/32 inch larger than the s hank diameter. For shank diameters greater than or equal to 1/2 inch, hole diameters shall be 1/16 inch larger than the shank diameter. Where oversized holes are permitted, double these allowances. Bolt holes shall be drilled, or sub -drilled and reamed in either the shop or the field and shall be cylindrical and perpendicular to the materials being fastened. Diameters shall be accurate to within 0.01 inch. Where practical, direct drills and reamers by mechanical means. If materials being fastened do not mat e flush, draw firmly together prior to drilling/reaming. Poor matching holes will be cause for rejection. After drilling/reaming, grind bolt holes free of sharp edges or burrs. Burned holes are not allowed.

8.Handling: Carefully pack bolts and their matchin g accessories (nuts and washers) together in a water tight, resealable container by the shop in a manner that prevents damage during shipping. Clearly and permanently label the container to identify the material, type, size, and length of the enclosed bolt s, nuts, and washers. In the field, store the container out of the weather, and do not open until ready to install the bolts. Only remove from storage the number of fasteners that will be installed during a work shift.

9.Installation: Locate one flat washer under the head, and one flat washer under the nut. Torque the nut in accordance with Table 821 -2. Threads shall be clean, but not lubricated. Bolts so torqued may be reused as long as there is no visible elongation or deformation of the bolt or threads. U se only properly fitting wrenches or sockets to tighten nuts. Table 821-2 Torque Table for Stainless Steel Bolts ASTM F593 - 80 ksi Tensile, 40 ksi Yield Threads should be clean, but not lubricated Bolt Diameter (inch) Torque (ft-lbs) Bolt Diameter (inch) Torque (ft-lbs) 1/4 3 3/4 86 5/16 5 7/8 145 3/8 10 1 215 7/16 16 1 1/8 300 1/2 24 1 1/4 430 9/16 35 1 3/8 560 5/8 48 1 1/2 750

821.07.9 High Strength Bolts: When specified for use on mechanical

equipment, high strength bolts shall meet all requirements of Section 807 and Section 1013 . Bolt holes shall be drilled, or sub -drilled and reamed in either the shop or the field and shall be cylindrical and perpendicular to the materials being fastened. Diameters shall be accurate to within 0.01 inch. Where practical, direct drills and reamers by mechanical means. If materials being fastened do not mat e flush, draw firmly together prior to drilling/reaming. Poor matching holes will be cause for rejection. After drilling/reaming, grind bolt holes free of sharp edges or burrs. Burned holes are not allowed.

821.07.9 High Strength Bolts: When specified for use on mechanical

equipment, high strength bolts shall meet all requirements of Section 807 and Section 1013 .

821.07.10 High Strength Anchor Bolts: When specified for use on

mechanical equipment, high strength anchor bolts shall meet all requirements of Section 807 and Section 1013 .

821.07.11 High Strength Stainless Steel Anchor Bolts: When

specified for use on mechani cal equipment, cast -in-place and drilled -in-place high strength stainless steel anchor bolts shall comply with the following.

1.Material: Bolts less than or equal to 1 -1/2 inches diameter, use ASTM F593, alloy group 7, condition AH, minimum tensile strength 135 ksi, minimum yield strength 105 ksi. Bolts larger than 1 -1/2 inches diameter, use ASTM A564, Type 630, Condition H1150, 135 ksi minimum tensile strength, 105 ksi minimum yield strength.

2.Head: Anchor bolts less than or equal to 1 -1/2 inches diameter s hall have hex heads as specified in ANSI B18.2.1. Anchor bolts greater than 1 -1/2 inches diameter will not have a head. They shall be fabricated from bar stock and threaded on each end as shown on the plans.

3.Threads: UNC as specified in ANSI/ASME B1.1, c lass 2A tolerances.

4.Nuts: Bolts less than or equal to 1 -1/2 inches diameter, use ASTM F594 nut with a minimum proof stress equal to or greater than the bolt, and the same alloy group as the bolt. Hex head as specified in ANSI B18.2.2. One required per bol t. Bolts greater than 1 -1/2 inches diameter, fabricate from same material as the anchor bolt. Use heavy hex dimensions as specified in ANSI B18.2.2. Threads shall have Class 2B tolerances. Two nuts required with each anchor bolt.

5.Flat Washers: Fabricate from same material as the anchor bolt. Use dimensions for American Standard Type A, narrow series washers. One required for each anchor bolt.

6.Beveled Washers: Fabricate from same material as the anchor bolt. Nuts shall bear flat on the materia ls being fastened. Beveled washers shall be used where bearing faces under the nut have a slope of more than 1:20.

7.Bolt Holes: Hole diameters shall be 1/16 inch larger than the shank diameter.

8.Packaging/Shipping/Storage: Provide resealable water tight c ontainers for shipping and storage. Pack anchor bolts in containers in a manner that prevents damage during shipping. Clearly and permanently label container to identify the contents and reference the contents with the plans. Store the container out of the weather at the project site.

9.Installation: Locate anchor bolts for mechanical equipment with an anchor bolt template in accordance with 821.07.10 . Torque nut in accordance with Table 821-3. Threads shall be cleaned, but not lubricated. Anchor bolts so torqued may be reused as long as there is no visible elongation or deform ation of the bolt or threads. Use only properly fitting wrenches or sockets to tighten nuts.

821.07.10 High Strength Anchor Bolts: When specified for use on

mechanical equipment, high strength anchor bolts shall meet all requirements of Section 807 and Section 1013 .

821.07.11 High Strength Stainless Steel Anchor Bolts: When

specified for use on mechani cal equipment, cast -in-place and drilled -in-place high strength stainless steel anchor bolts shall comply with the following.

3.Threads: UNC as specified in ANSI/ASME B1.1, c lass 2A tolerances.

5.Flat Washers: Fabricate from same material as the anchor bolt. Use dimensions for American Standard Type A, narrow series washers. One required for each anchor bolt.

7.Bolt Holes: Hole diameters shall be 1/16 inch larger than the shank diameter.

821.07.10 High Strength Anchor Bolts: When specified for use on

mechanical equipment, high strength anchor bolts shall meet all requirements of Section 807 and Section 1013 .

821.07.11 High Strength Stainless Steel Anchor Bolts: When

specified for use on mechani cal equipment, cast -in-place and drilled -in-place high strength stainless steel anchor bolts shall comply with the following.

3.Threads: UNC as specified in ANSI/ASME B1.1, c lass 2A tolerances.

5.Flat Washers: Fabricate from same material as the anchor bolt. Use dimensions for American Standard Type A, narrow series washers. One required for each anchor bolt.

7.Bolt Holes: Hole diameters shall be 1/16 inch larger than the shank diameter.

821.07.12 High Strength Stainless Steel Turned Bolts and Fitted

Pins: For applications less than or equal to 1 -1/2 inches diameter, fabricate turned bolts from bolt blank s in accordance with the plans and the following specifications. For applications greater than 1 -1/2 inches diameter, fabricate fitted pins from bar stock and thread at both ends in accordance with the plans and the following specifications.

1.Material: For diameters less than or equal to 1 -1/2 inches, fabricate turned bolts from ASTM F593 bolt blanks, alloy group 7, condition AH, min. tensile strength 135 ksi, min. yield strength 105 ksi. For diameters greater than 1 1/2”, fabricate fitted pins from ASTM A5 64, Type 630, Condition H1150, 135 ksi min. tensile strength, 105 ksi min. yield strength.

2.Shank Dimensions/Tolerances: Nominal shank diameters shall be as shown on the plans. Shanks shall be straight to within 0.005 inch per inch of length, shall have a surface finish of ANSI 63 µin or better, and shall have an LC6 fit with the bolt/pin hole based on the nominal diameter.

3.Head: For diameters less than or equal to 1 -1/2 inches, turned bolts shall have hex heads as specified in ANSI B18.2.1.

4.Threads: UNC as specified in ANSI/ASME B1.1, Class 2A tolerances. Threads shall not extend into the shear plane of the bolt/pin.

5.Nuts: For diameters less than or equal to 1 -1/2 inches, use ASTM F594 nut with a minimum proof stress equal to or greater than the bolt, and the same alloy group as the bolt. Hex head as specified in ANSI B18.2.2. One required per bolt. For diameters greater t han 1 -1/2 inches, fabricate nuts from same material as the pin. Use heavy hex dimensions as specified in ANSI B18.2.2. Threads shall have Class 2B tolerances. Two nuts required with each fitted pin.

6.Flat Washers: Fabricate from same material as the anchor bolt/fitted pin. Use dimensions for American Standard Type A, narrow series washers. Two required for each anchor bolt/fitted pin.

7.Beveled Washers: Fabricate from same material as the anchor bolt/fitted pin. Nuts shall bear flat on the materials being fa stened. Beveled washers shall be used where bearing faces under the nut have a slope of more than 1:20.

8.Holes: Sub-drill and ream holes in either the shop or the field as indicated on the plans. In either case, direct drills and reamers by mechanical mean s. Holes shall be cylindrical and perpendicular to the materials being fastened, and shall be reamed to a tolerance that will provide an LC6 fit with the turned bolt/fitted pin diameter. Holes shall have an ANSI 63 µin finish or better, and shall be ground free of sharp edges or burrs. If materials being fastened do not mate flush, firmly draw together prior to drilling/reaming. Do not use burned or slotted holes for turned bolts/fitted pins.

821.07.12 High Strength Stainless Steel Turned Bolts and Fitted

3.Head: For diameters less than or equal to 1 -1/2 inches, turned bolts shall have hex heads as specified in ANSI B18.2.1.

4.Threads: UNC as specified in ANSI/ASME B1.1, Class 2A tolerances. Threads shall not extend into the shear plane of the bolt/pin.

6.Flat Washers: Fabricate from same material as the anchor bolt/fitted pin. Use dimensions for American Standard Type A, narrow series washers. Two required for each anchor bolt/fitted pin.

9.Packaging/Shipping/Storage: Provide resealable water tight conta iners for shipping and storage. Pack anchor bolts/fitted pins in containers in a manner that prevents damage during shipping. Clearly and permanently label container to identify the contents and reference the contents with the plans. Store the container out of the weather at the project site, and remove only the number of turned bolts/fitted pins that will be installed in a work shift.

10.Installation: Lightweight oil may be used to facilitate assembly; however, oil shall be cleaned from threads prior to tigh tening nuts. Locate one flat washer under each nut. Torque the nut in accordance with Table 821 -3. Turned bolts/fitted pins so torqued may be reused as long as there is no visible elongation or deformation of the pin or threads. Use only properly fitting w renches or sockets to tighten nuts. Table 821-3 Torque Table for High Strength Stainless Steel Bolts and Pins ASTM F593 & A564 - 135 ksi Tensile, 105 ksi Yield Threads should be clean, but not lubricated Bolt Diameter (inch) Torque (ft-lbs) Bolt Diameter (inch) Torque (ft-lbs) 1/2 65 1 3/4 3,100 9/16 90 2 4,650 5/8 130 2 1/4 6,900 3/4 230 2 1/2 9,400 7/8 370 2 3/4 12,900 1 550 3 17,200 1 1/8 790 3 1/4 22,300 1 1/4 1,125 3 1/2 28,300 1 3/8 1,450 3 3/4 35,300 1 1/2 1,950 4 43,400

821.07.13 Shim Packs: Fabricate shim packs for adjustment of mechanical

equipment as shown on the plans. Fabricated shim packs shall neatly match the shape of the equipment to be shimmed, have all holes/slots pre -drilled, and have the thickness marked on each shim with an indel ible marker. Submit shop drawings for fabricated shim packs to the Bridge Engineer for review. Shop drawings shall show dimensions, material and number of shims supplied with each shim pack. The shop may fabricate a single stainless steel shim to precise d imensions for any machinery assembled in the shop.

1.“A” Shim Packs: “A” shim packs contain very fine shims and are capable of positioning mechanical equipment with a high degree of accuracy. Use where indicated on the plans for machinery that require precise alignment to function correctly (electric motors, pumps, pinion bearings, etc.). Number, thickness, and material of shims in “A” shim packs shall be in accordance with Table 821 -4. Table 821-4 “A” Shim Packs - Number, Thickness, and Material Nominal Shim Pack Size (inches) Stainless Steel, ASTM A666, Type 302/304/316 Shim Thickness (inches) 1/4 1/8 1/16 1/32 .016 .008 .004 .002 Number of Shims per Shim Pack 3/8 2 1 1 1 1 1 1 1 5/16 1 2 1 1 1 1 1 1 1/4 1 1 1 1 1 1 1 1 3/16 0 2 1 1 1 1 1 1 1/8 0 1 1 1 1 1 1 1 Where appropriate (under electric motor feet, pump feet, etc.), commercially available, stainless steel, square, slotted, shim packs with an accuracy of 0.001inch may be used as “A” shim packs. Submit cut sheets for commercial shim packs to the Bridge Engineer for review.

2.“B” Shim Packs: “B” shim p acks are accurate to ± 1/16 inch. Use where indicated on the plans for machinery that does not require highly accurate positioning to operate properly. Number, thickness, and material of shims in “B” shim packs shall be in accordance with Table 821 -5. Table 821-5 “B” Shim Packs - Number, Thickness, and Material Nominal Shim Pack Size (inches) ASTM A709, GR. 36/50 Stainless Steel ASTM A666 302/304/316* Shim Thickness (inches) 1 3/4 5/8 1/2 3/8 1/4* 1/8* 1/16* Number of Shims per Shim Pack 1 1 0 0 1 0 1 1 1 3/4 0 1 0 0 1 1 1 1 5/8 0 0 1 0 1 1 1 1 1/2 0 0 0 1 0 1 1 1 3/8 0 0 0 0 1 1 1 1 1/4 0 0 0 0 0 1 1 1

3.Packaging: Carefully package/bundle individual shim packs not installed in the shop in a manner that will prevent damage or the loss of shims during shipping/handling. Permanently label package/bundle to reference the shim pack with the plans. Shim packs shall then be packed together in a watertight, resealable container by the shop in a manner that prevents damage during shipping. Clearly and permanently label the container to identify the enclosed shim packs and reference the shim packs with the plans. In the fiel d, store the container out of the weather, and do not open until ready to install the shim packs. Only remove from storage the shim packs that will be installed during a work shift.

821.07.14 Keys and Keyways: Provide keys and keyways as follows

unless otherwise shown on the plans.

1.Material: For carbon or alloy steel shafts, make keys from forged steel that meets the requirements of ASTM A668/A668M, Class D minimum. Keys less than 1/2 inch square may be cold finished carbon steel that meets the requirements of ASTM A675/A675M, Grade 80. If a gearbox or other manufactured component has been specified to have a stainless steel shaft, the key shall also be stainless steel with similar mechanical and corrosion resistant properties as the shaft. Table 821-5 “B” Shim Packs - Number, Thickness, and Material Nominal Shim Pack Size (inches) ASTM A709, GR. 36/50 Stainless Steel ASTM A666 302/304/316* Shim Thickness (inches) 1 3/4 5/8 1/2 3/8 1/4* 1/8* 1/16* Number of Shims per Shim Pack 1 1 0 0 1 0 1 1 1 3/4 0 1 0 0 1 1 1 1 5/8 0 0 1 0 1 1 1 1 1/2 0 0 0 1 0 1 1 1 3/8 0 0 0 0 1 1 1 1 1/4 0 0 0 0 0 1 1 1

821.07.14 Keys and Keyways: Provide keys and keyways as follows

unless otherwise shown on the plans.

2.Sizing and Fits: Size keys used to transmit torque generated by a prime mover to develop the full strength of the shaft. If two keys are required, locate keys 120 degrees apart, with each key capable of carrying 60 percent of the full torsional strength of the shaft. Sides of t hese keys shall have an FN2 fit with the keyway. Tops and bottoms of these keys shall have an LC4 fit with the keyway. Keys not transmitting torque (such as for rotary limit switch shafts) can be sized appropriately for the load. All four sides of these ke ys shall have an LC4 fit with the keyway. For manufactured items such as electric motors, gearboxes, etc., key size, length, and strength shall be determined by the manufacturer, but must meet the above requirements. Key length shall be sufficient to fill entire keyway.

2.Fabrication: Fabricate keys and keyways to have widths and heights in accordance with ANSI Standards. Machine keys and keyways to have parallel faces with square or rectangular cross -sections. Plane surfaces to have an ANSI 63 µin finish. I f tapered keys are specified, machine to bear on all four surfaces.

3.Keyways: Machine cut all keyways and provide a fillet in the bottom of each corner in accordance with ANSI B17.1. For keyways located in shafts, provide closed ends milled to a semi -circle equal to the width of the key where possible. Keyways shall not extend into any bearing or shaft shoulder fillet. In hubs of wheels with spokes, locate keyway in the center of the spoke. Provide safety set screws or other effective means to hold any key that is not set into closed end keyways.

821.07.15 Weldments:

Provide weldments as follows unless otherwise shown on the plans.

1.Material: Steel for weldments shall comply with ASTM A572/A572M, Grade 50, unless otherwise specified on the plans. In all cases, steel for weldments shall be weldable grades as designated by applicable ASTM standards.

2.Fabrication: All welds shall be in accordance with Section 809 , and shall be complete joint penetration unless otherwise shown on the plans. Shop drawings shall show weld type and sizes and all plate thicknesses prior to machining.

3.Tolerances: Position unfinished plates to within 0.5 degree of the specified angle on the plans. Provid e flat finished surfaces to within 0.05 degree of the reference datum and a minimum surface flatness of 0.010 inch. Flat finished surfaces that mate with a manufactured part shall have a minimum surface flatness of 0.010 inch or the recommended surface fla tness of the part manufacturer, whichever is more stringent. Where finish marks are shown on the plans, machine the entire surface of the weldment flat to the final dimension shown on the plans.

821.07.15 Weldments:

Provide weldments as follows unless otherwise shown on the plans.

4.Non-Destructive Weld Testing: Weldments that support dead lo ad, live load, or span drive forces including the counterweight sheaves, sheave pedestals, center pivot bearing housings, balance wheels, end and center wedges, span drive hydraulic cylinder mounting brackets, etc., shall be 100 percent tested by non -destr uctive methods in accordance with Section 809 .

5.Stress Relief: Provide a stress relief heat treatment prior to final machining. Submit to the Bridge Engineer for review a schedule listing the heat treatment to be performed on each weldment. Schedule shall include a description of the part, the rate of heating, soaking temperature, time at soaking temperature (min. one hour), rate of cooling, and the temperature at which the part will be removed from the chamber.

821.07.16 Anchor Bolt Templates: Provide templates for all machinery

anchor bolts even if not shown on the plans. Templates shall hold anchor bolts vertical and provide proper spacing. Submit shop drawings for all anchor bolt templates to the Bridge Engineer for review.

821.07.17 Open Gear Sets: Provide open gear sets that are spur gears with

20 degree involute, full depth teeth cut and mounted to meet requirements of the current AGMA standards. Gear quality and backlash shall be as specified on the plans. If the gear quality or backlash is not shown on the plans, request clarification from the Bridge E ngineer. Show the AGMA quality number and backlash that will be cut into each gear on the shop drawings.

1.Fabrication: Fabricate open gears from solid rims or blanks, and finish the sides and peripheries. The working surfaces of all gear teeth shall be true to the proper outline, accurately spaced on the pitch circle, free from planing or mill -cutter ridges, and the surf ace finish smoothness shall be equal to or exceed AASHTO finish guidelines. Remove cutter burrs from edges of teeth, and round the top edges of teeth to 1/16 inch radius. For all open gears that will transmit torque from a prime mover, scribe the pitch cir cle on both sides of the gear not less than 1/32 inch deep with a “V” pointed tool. Fabricate ring/bull/rack gears in segments as shown on the plans. Fit ends accurately maintaining tooth pitch across the splice. Finish the contact surfaces between the sides of the gear segments and the gear mounting surfaces.

2.Field Installation: For rack and pinion open gear installations for movable bridges, see Section 820 .

821.07.16 Anchor Bolt Templates: Provide templates for all machinery

821.07.17 Open Gear Sets: Provide open gear sets that are spur gears with

2.Field Installation: For rack and pinion open gear installations for movable bridges, see Section 820 .

821.07.16 Anchor Bolt Templates: Provide templates for all machinery

821.07.17 Open Gear Sets: Provide open gear sets that are spur gears with

2.Field Installation: For rack and pinion open gear installations for movable bridges, see Section 820 . Align the pinion gear so that the backlash is near the lower end of the range shown on the plans. For acceptable gear contact, 80 percent of the teeth shall have 80 percent contact along the face of the teeth, and no tooth shall have less than 50 percent conta ct. If tooth contact does not meet this requirement, adjust pinion alignment and retest. Repeat until gear alignment meets both the backlash and tooth contact requirements. Once gear alignment has been verified, install bolts in the pinion bearings as show n on the plans.

821.07.18 Roller Bearings: Provide roller bearings from an established

manufacturer who has produced bearings of comparable size, material, and type as that specified on the plans, and that have been in successful service for at least 10 years.

1.Shop Installation: Preferably, all roller bearings shall be installed on shafts in the shop. Large roller bearings, bore sizes 10 inches or greater, shall be installed under the direction of a representative of the bearing manufacturer. Shop shall coordinat e with the bearing representative to insure that a proper environment for installing the bearings will be provided by the Shop, and all cleaning supplies, tools, and measuring devices needed to correctly install the bearings will be on hand the day of inst allation.

2.Transportation to the Field: Bearings that have been installed on shafts must be properly prepared for transportation to the project site in accordance with the recommendations of the bearing manufacturer. For large bearings, this may include the fabrication of a structure to support/protect the bearing during transport.

821.07.19 Electric Squirrel Cage Induction Motors: Provide

electric squirrel cage induction motors that meet the following requirements, if commercially available:

1.Rated for “chemical” or “severe duty”

2.IEEE -841 standard for severe duty applications

3.NEMA MG1 standard

4.NEMA design B standard

5.NEMA premium efficiency standard

6.NEMA dimensional standards

7.Rated for continuous duty

8.1.15 service factor

9.Totally enclosed non -ventilated (TENV) if co mmercially available, otherwise totally enclosed fan cooled (TEFC)

10.Foot mounted heavy duty cast iron frame or stainless steel frame

11.Oversized cast iron rotatable junction box

12.Copper windings

13.Class F insulation Align the pinion gear so that the backlash is near the lower end of the range shown on the plans. For acceptable gear contact, 80 percent of the teeth shall have 80 percent contact along the face of the teeth, and no tooth shall have less than 50 percent conta ct. If tooth contact does not meet this requirement, adjust pinion alignment and retest. Repeat until gear alignment meets both the backlash and tooth contact requirements. Once gear alignment has been verified, install bolts in the pinion bearings as show n on the plans.

821.07.18 Roller Bearings: Provide roller bearings from an established

manufacturer who has produced bearings of comparable size, material, and type as that specified on the plans, and that have been in successful service for at least 10 years.

821.07.19 Electric Squirrel Cage Induction Motors: Provide

electric squirrel cage induction motors that meet the following requirements, if commercially available:

1.Rated for “chemical” or “severe duty”

2.IEEE -841 standard for severe duty applications

3.NEMA MG1 standard

4.NEMA design B standard

5.NEMA premium efficiency standard

6.NEMA dimensional standards

7.Rated for continuous duty

8.1.15 service factor

9.Totally enclosed non -ventilated (TENV) if co mmercially available, otherwise totally enclosed fan cooled (TEFC)

10.Foot mounted heavy duty cast iron frame or stainless steel frame

11.Oversized cast iron rotatable junction box

12.Copper windings

821.07.18 Roller Bearings: Provide roller bearings from an established

manufacturer who has produced bearings of comparable size, material, and type as that specified on the plans, and that have been in successful service for at least 10 years.

821.07.19 Electric Squirrel Cage Induction Motors: Provide

electric squirrel cage induction motors that meet the following requirements, if commercially available:

1.Rated for “chemical” or “severe duty”

2.IEEE -841 standard for severe duty applications

3.NEMA MG1 standard

4.NEMA design B standard

5.NEMA premium efficiency standard

6.NEMA dimensional standards

7.Rated for continuous duty

8.1.15 service factor

9.Totally enclosed non -ventilated (TENV) if co mmercially available, otherwise totally enclosed fan cooled (TEFC)

10.Foot mounted heavy duty cast iron frame or stainless steel frame

11.Oversized cast iron rotatable junction box

12.Copper windings

13.Class F insulation

14.Windings coated for tropical environments

15.Automatically resetting thermal overloads

16.Severe duty epoxy paint system both inside and out

17.Grease -able ball bearings

18.Premium shaft seals

19.All joints gasketed and sealed

20.Stainless steel hardware or at least corrosion resistant hardware

21.Stainless steel name plate Horsepower, frame, rpm, voltage, phase, and hertz shall be as shown on the plans.

821.07.20 Main Span Drive Speed Reducers:

Design the main span drive speed reducers in accordance with current AGMA standards, and size for the horsepower input shown on the pl ans with a service factor of 2.0 for strength and 1.25 for durability.

1.Certified Drawings: Provide manufacturer’s certified drawings that show the following as a minimum:

a.External drawings showing all mounting dimensions including shaft sizes and keyways.

b.Internal drawings showing all internal components.

c.Complete part list (with part numbers) of all components with descriptions that show materials, gear teeth information, bearing information, seal information, etc.

d.Horsepower rating, thermal rating, gear ratios, dry and wet weight, and lubricant recommendations.

14.Windings coated for tropical environments

15.Automatically resetting thermal overloads

16.Severe duty epoxy paint system both inside and out

17.Grease -able ball bearings

18.Premium shaft seals

19.All joints gasketed and sealed

20.Stainless steel hardware or at least corrosion resistant hardware

21.Stainless steel name plate Horsepower, frame, rpm, voltage, phase, and hertz shall be as shown on the plans.

821.07.20 Main Span Drive Speed Reducers:

1.Certified Drawings: Provide manufacturer’s certified drawings that show the following as a minimum:

a.External drawings showing all mounting dimensions including shaft sizes and keyways.

b.Internal drawings showing all internal components.

c.Complete part list (with part numbers) of all components with descriptions that show materials, gear teeth information, bearing information, seal information, etc.

d.Horsepower rating, thermal rating, gear ratios, dry and wet weight, and lubricant recommendations.

2.Housing: Fabricate housing from steel with adequate inspection openings to permit easy inspection of all gears after installation. Inspection openings shall have a raised lip or “picture frame” to prevent rain water from pooling at the seal. Attach inspection covers with stainless steel hardware that meets or exceeds the material requirements of stainless steel bolts in 821.07.8 . Provide a sight glass to measure the lubricant level. Provide a thermometer to show oil temperature. Provide a port to fill oil. Provide a h ygroscopic air breather with an adequate filter to prevent particulate matter from entering the housing. Provide an oil drain port with a bronze or stainless steel drain valve. Valve shall have a bronze or stainless steel plug to prevent loss of the lubric ant due to accidental opening or vandalism. Provide a permanent, stainless steel or aluminum name plate stating the name of the speed reducer manufacturer, horsepower rating, service factors, input rpm, output rpm, exact gear ratio, thermal rating, AGMA sy mbol, and a name (such as “Gearbox 1”) to differentiate the speed reducers. If the speed reducer is to be installed outdoors, provide inspection cover seals, sight glass, thermometer, air breather, and paint that are appropriate for outdoor use.

3.Gears: Speed reducer shall utilize spur, helical, herringbone, and/or bevel gears fabricated and mounted to meet requirements of the current AGMA standards. Gears shall be through -hardened, cut from solid rims or blanks, and have the AGMA gear quality of Class 9 or greater. Show the AGMA gear quality on the shop drawings. The working surfaces of the teeth shall be true to the proper outline, accurately spaced on the pitch circle, and free from planing or mill cutter ridges. Remove cutter burrs from all edges of teeth, and round the top edges of the teeth to a 1/32 -inch radius.

4.Input Shafts: Provide two non -differential input shafts parallel with two output shafts as shown on the plans. Design input shafts for two times the rated horsepower of the speed reducer. Provide diameter and length of input shafts to accommodate brake wheels, couplings, and key se ating as shown on the plans.

5.Output Shafts: Provide two output shafts parallel to the input shafts as shown on the plans. Output shafts shall be capable of diffe rential output by the means of a manual clutch mechanism. Provide diameter and length of output shafts to accommodate couplings and key seating as shown on the plans.

6.Clutch Mechanism: Provide a manual clutch mechanism capable of locking and unlocking the output shafts while the speed reducer is loaded, unloaded, rotating, or stationary. It shall be engaged and disengaged by pushing and pulling an external rod as shown on the plans.

7.Double Shaft Seals: Provide FKM double shaft seals on the input and outpu t shafts with provision to grease between the seals.

8.Bearings: Provide anti -friction type roller bearings with a B -10 life of 100,000 hours while transmitting the full rated motor horsepower.

9.Lubrication: Speed reducer shall be designed to provide automatic and continuous lubrication of all gear teeth and bearings. Provide a synthetic lubricant as recommended by the speed reducer manufacturer. Use the same lubricant for testing that will be used for opera tion. After testing, lubricant shall be removed and the gearbox shall be cleaned before shipment to the shop. New lubricant shall be used at the project site.

10.Shop Testing: Test both span drive speed reducers by the following method.

a.General: Speed reduc ers shall be tested by the manufacturer in the presence of a representative of the Department before shipment to the shop for incorporation in the span drive machinery shop assembly. The speed reducer manufacturer shall provide a 14 calendar days notice to the Bridge Engineer prior to the date of the testing. Prior to adding lubricant and testing, the speed reducer manufacturer shall blue the gears and run the speed reducers to demonstrate gear alignment. Include photographs of the gear contact patterns in the final testing report. All parts of testing shall be performed consecutively. The speed reducer manufacturer shall not start testing unless all the following testing parts can be completed.

b.Testing Part 1 – No Load Test (Both Speed Reducers): Engage cl utch (output shafts locked together), turn the input shaft at 900 rpm with no load on the output shafts. Run the speed reducer for 30 minutes. Verify and record output rpm. At 10 -minute intervals, measure and record the oil temperature and the external temperatures at each shaft seal and bearing cover. After 30 minutes, stop the gearbox and immediately open the inspection cover. Measure and record the temperature of all bearings. Repeat test for opposite direction. If no problems are found, proceed immediat ely to Part 2.

c.Testing Part 2 – No Load Test (Both Speed Reducers): Disengage clutch (output shafts not locked together), turn the input shaft at 450 rpm and hold one output shaft fixed. Run speed reducer for 30 minutes. Verify and record output rpm. At 1 0-minute intervals, measure and record the oil temperature and the external temperatures at each shaft seal and bearing cover. After 30 minutes, stop the speed reducer and immediately open the inspection cover. Measure and record the temperature of all bea rings. Repeat test holding the other output shaft fixed, and turning the input shaft in the opposite direction. If no problems are found, proceed immediately to Part 3.

d.Testing Part 3 – Load Test (Both Speed Reducers): Engage clutch (output shafts locked together), turn the input shaft at 870 rpm, slowly apply load to one output shaft until full load torque is reached. Run speed reducer for 30 minutes. Measure and record the output rpm of both output shafts to verify that there is no clutch slippage. At 10 -minute intervals, measure and record the oil temperature and the external temperatures at each shaft seal and bearing cover. After 30 minutes, stop the speed reducer and immediately open the inspection cover. Measure and record the temperature of all bear ings. Repeat test turning the input shaft in the opposite direction. If no problems are found, proceed immediately to Part 4.

e.Testing Part 4 – Load Test (Both Speed Reducers): Disengage clutch (output shafts not locked together), hold one output shaft, tu rn the input shaft at 435 rpm, slowly apply load to the other output shaft until full load torque is reached. Run speed reducer for 30 minutes. At 10 -minute intervals, measure and record the oil temperature and the external temperatures at each shaft seal and bearing cover. After 30 minutes, stop the speed reducer and immediately open the inspection cover. Measure and record the temperature of all bearings. Repeat test by holding the other output shaft, and turning the input shaft in the opposite direction .

f.Testing Report: After testing is complete, submit a report with all measurements taken during testing to the Bridge Engineer for review.

11.Shipment: After testing is complete, transport the speed reducers to the shop that is assembling the span drive machinery.

821.07.21 Motor and Machinery Brakes: Provide thruster operated shoe

brakes as follows unless otherwise specified on the plans.

1.Features: Low fo rce hand release; hydraulic, adjustable time delay on setting (0-8 seconds); stainless steel enclosure with means to access all adjustment points.

2.Shop Testing: Adjust the time delays on the “Motor” brakes to set in approximately one second. Adjust the time delays on the “Machinery” brakes to set in approximately four seconds. Verify through experimentation and testing that the torque scale on the brakes is correct, and that the brakes are set at the torque setting shown on the plans. The shop will demo nstrate the braking torque settings and the time delay settings at the shop to a representative of the Bridge Engineer prior to shipment to the field.

3.Field Testing: During the field testing and setup of the movable span, provide personnel, tools, and measurement equipment to adjust the brakes until the span performs to the satisfaction of the Bridge Engineer’s inspector.

821.07.22 Hydraulic Reservoir: The hydraulic reservoir shall serve as the

machinery platform for the hydraulic components that comprise the Hydraulic Power Unit (HPU). Design the reservoir accordingly. Utilize welded stainless steel plate construction conforming to ASTM A276, type 316 with 3/16 inch minimum Measure and record the output rpm of both output shafts to verify that there is no clutch slippage. At 10 -minute intervals, measure and record the oil temperature and the external temperatures at each shaft seal and bearing cover. After 30 minutes, stop the speed reducer and immediately open the inspection cover. Measure and record the temperature of all bear ings. Repeat test turning the input shaft in the opposite direction. If no problems are found, proceed immediately to Part 4.

f.Testing Report: After testing is complete, submit a report with all measurements taken during testing to the Bridge Engineer for review.

11.Shipment: After testing is complete, transport the speed reducers to the shop that is assembling the span drive machinery.

821.07.21 Motor and Machinery Brakes: Provide thruster operated shoe

brakes as follows unless otherwise specified on the plans.

1.Features: Low fo rce hand release; hydraulic, adjustable time delay on setting (0-8 seconds); stainless steel enclosure with means to access all adjustment points.

821.07.22 Hydraulic Reservoir: The hydraulic reservoir shall serve as the

f.Testing Report: After testing is complete, submit a report with all measurements taken during testing to the Bridge Engineer for review.

11.Shipment: After testing is complete, transport the speed reducers to the shop that is assembling the span drive machinery.

821.07.21 Motor and Machinery Brakes: Provide thruster operated shoe

brakes as follows unless otherwise specified on the plans.

1.Features: Low fo rce hand release; hydraulic, adjustable time delay on setting (0-8 seconds); stainless steel enclosure with means to access all adjustment points.

821.07.22 Hydraulic Reservoir: The hydraulic reservoir shall serve as the

machinery platform for the hydraulic components that comprise the Hydraulic Power Unit (HPU). Design the reservoir accordingly. Utilize welded stainless steel plate construction conforming to ASTM A276, type 316 with 3/16 inch minimum thickness. Total volume shall be as shown on the plans. Features shall include removabl e cleanout covers, baffles, sight gauge and thermometer, electronic low level indicator, fluid sampling ports, and drain ports with bronze plugs.

821.07.23 Hydraulic Pumps: Provide hydraulic pumps as follows unless

otherwise specified on the plans. Hydraulic pump s shall be fixed displacement, pressure and flow compensated, rated for continuous duty at 3,000 psi minimum, and shall have SAE four bolt flange ports with FKM O -ring seals.

821.07.24 Main Span Hydraulic Cylinders:

1.Fabrication: Bore size, rod size, stroke length, and other dimensional requirements shall be as shown on the plans. The intent of the design is for the cylinders to be rated for a working pressure of 3,000 psi, and rated against buckling in the fully extended position at a pressure of 1,700 psi with a sa fety factor of 3. The hydraulic cylinder manufacturer shall adjust cylinder dimensions if needed to meet this intent and submit the changes to the Bridge Engineer for review.

2.Cylinder Rods: Rods shall be high strength carbon steel, case hardened, and hard chrome plated. They shall have spanner wrench flats or other approved means to prevent the rod from rotating while assembling or removing the rod end.

3.Rod Seals and Bearings: Provide FKM seals. Sealing system for the cylinder rod shall provide for dynami c low pressure and dynamic high pressure sealing, and a scraper to prevent ingression of contaminants. Seals shall be rated for continuous use at 3,000 psi and periodic spikes of 5,000 psi. Provide wear -rings or bushings that will insure proper guidance of the rod and provide ample bearing area to prevent side loading.

4.Ports: Main ports shall be SAE code 62 four bolt flange ports with FKM O - ring seals rated for 6,000 psi.

5.Cushions: Span drive cylinders shall be cushioned at both ends. Cushions shall be ad equate to slow the span from full speed to creep speed (5 percent of full flow) prior to the cylinders reaching the end of their stroke without exceeding a 5,000 psi pressure intensification in the cushion. Use a minimum 4 -inch long cushion spear with dual adjustable needle valves in series to provide progressive cushioning action. Needle valves shall be tamper proof. Cushions shall be designed to provide similar force reactions from the cylinders during deceleration of the movable span. Show details of the cushions and a description of the cushion's performance on the hydraulic cylinder submittal. Cushions may be bolted to each end of the cylinder.

6.Calculations: Prepare and submit calculations for the cylinders to the Bridge Engineer for review. Calculatio ns shall include the cylinder buckling strength, tube yield strength, rod eye tear out yield, blind end eye tear out yield, rod pull out strength, cushion calculations, and any other strength calculation deemed necessary by the Bridge Engineer. thickness. Total volume shall be as shown on the plans. Features shall include removabl e cleanout covers, baffles, sight gauge and thermometer, electronic low level indicator, fluid sampling ports, and drain ports with bronze plugs.

821.07.23 Hydraulic Pumps: Provide hydraulic pumps as follows unless

821.07.24 Main Span Hydraulic Cylinders:

4.Ports: Main ports shall be SAE code 62 four bolt flange ports with FKM O - ring seals rated for 6,000 psi.

821.07.23 Hydraulic Pumps: Provide hydraulic pumps as follows unless

821.07.24 Main Span Hydraulic Cylinders:

4.Ports: Main ports shall be SAE code 62 four bolt flange ports with FKM O - ring seals rated for 6,000 psi.

7.Shop Testin g: The Shop shall prepare and submit to the Bridge Engineer for review a test plan for the span hydraulic cylinders. Submittal shall show a schematic of the test setup, and describe the tests to be performed. The Shop must provide a power unit that can pr ovide the pressures and flows required to perform all tests, and it shall provide all equipment needed to measure and record the test data. All testing shall be performed using the exact type of hydraulic oil that will be used on the project. Oil used in t he testing shall not be reused. At a minimum, the Shop shall perform the following tests on all span hydraulic cylinders: A pressure test, a leak test of the piston seals, a dynamic test of the cushions where the cushions must decelerate the cylinder to cr eep speed while the power unit is driving the cylinder without exceeding 5,000 psi in the cushion. The Shop must demonstrate the ability to adjust the amount of cushioning with the needle valves.

8.Field Testing: During the field testing and setup of the movable span, provide personnel, tools, and measurement equipment to perform the following procedure. Bypass the span nearly closed and closed limit switches. Open the span a few feet and close the span at a slow speed allowing only the cylinder cushions to stop the span. Measure and record the pressures in the cushions. If the span is stopping too abruptly, or if the cylinders are not equally sharing the deceleration loads, adjust the cushion needle valves until the issues are corrected. Progressively increase the closing distance and the closing speed until the span is closed at full speed and is decelerated using only the cylinder cushions, and the cylinders are equally sharing the deceleration loads.

821.07.25 Rigid, Hig h Pressure, Hydraulic Lines External to the

HPU:

1.Material: Provide seamless, low carbon, 3,000 psi, stainless steel pipe that conforms to ASTM A312/A312M, type 304/316. Pipe shall have four bolt, SAE code 61, 3,000 psi, stainless steel flanges with FKM O -ring seals.

2.Fabrication: Shop fabricate pipe sections as shown on the plans. Where possible, turns and offsets shall be made by bending the pipe. No flattening or crimping in the bends will be allowed. Weld all pipe fittings (elbows, tees, flanges, etc.). No threaded or metal compression fittings are allowed. All welds in flanges and fittings shall be full penetration welds. Air bleeds/gauge cocks shall be provided in the piping as shown on the plans and at high points of the hydraulic system.

821.07.25 Rigid, Hig h Pressure, Hydraulic Lines External to the

HPU:

3.Preparatio n for Shipment/Shop Storage: After fabrication is complete, remove all loose scale and slag from the interior and exterior of the welds. Thoroughly clean and flush pipe sections of all contaminants. Wooden plugs shall be installed in all openings, and the pipe sections shall then be covered with heavy plastic sheeting held in place by steel bands. While at the shop, store pipe sections indoors and protect from the weather.

821.07.26 Rigid, High Pressure, Hydraulic Lines Internal to the

HPU:

1.Material : Provide eithe r stainless steel pipe as specified above, or seamless, annealed, low carbon, 3,000 psi, stainless steel tubing that conforms to ASTM A269, types 304, 304L, 316, or 316L. Tubing shall have braze type, 3,000 psi, O -ring seal flanges. No threaded or metal co mpression fittings are allowed.

2.Fabrication : Shop fabricate all pipe/tubing sections. Where possible, make turns and offsets by bending. No flattening or crimping in the bends will be allowed. Weld all pipe fittings (elbows, tees, etc.). No threaded or me tal compression pipe/tubing fittings or flanges are allowed. After welding/brazing of a pipe/tubing section is complete, remove all loose scale and slag from the interior and exterior of the welds/brazing. Thoroughly clean and flush free all contaminants f rom the rigid pipe/tubing sections before they are incorporated into the HPU.

821.07.27 Rigid, Low Pressure (Tank) Hydraulic Lines, Internal and

External to the HPU:

1.Material: Provide rigid, standard duty copper or stainless steel pipe; or rigid, standard duty copp er or stainless steel tubing intended for use in industrial hydraulic applications. Threaded and metal compression fittings are allowed.

2.Fabrication: Shop fabricate pipe/tubing sections. After fabrication /assembly is complete, thoroughly clean and flush free piping/tubing sections of all contaminants before incorporating into the hydraulic system.

821.07.28 Flexible Hydraulic Hoses:

1.Material: Provide flexible hydraulic hoses as specified on the plans or approved equal. Hoses shall be intended for use with high pressure industrial hydraulic systems, and rated for 5,000 psi minimum.

821.07.26 Rigid, High Pressure, Hydraulic Lines Internal to the

HPU:

821.07.27 Rigid, Low Pressure (Tank) Hydraulic Lines, Internal and

External to the HPU:

821.07.28 Flexible Hydraulic Hoses:

821.07.26 Rigid, High Pressure, Hydraulic Lines Internal to the

HPU:

821.07.27 Rigid, Low Pressure (Tank) Hydraulic Lines, Internal and

External to the HPU:

821.07.28 Flexible Hydraulic Hoses:

821.07.26 Rigid, High Pressure, Hydraulic Lines Internal to the

HPU:

821.07.27 Rigid, Low Pressure (Tank) Hydraulic Lines, Internal and

External to the HPU:

821.07.28 Flexible Hydraulic Hoses:

2.Fabrication : Flexible hydraulic hoses shall have re -useable, stainless steel, 5,000 psi, four bolt connection fittings with FKM O -ring seals. Fittings shall conform to SAE j518, code 62 specifications. Measure dimensions in the field to verify lengths before fabrication. Hose lengths shall be the minimum length need ed to make the connection without having the hose exceed the minimum bend radius at any point during the normal operation of the span. Excessive looping that does not serve an operational function is not allowed.

821.07.29 Hydraulic Seals: All seals used in hydra ulic systems shall be

FKM seals.

821.07.30 Cleaning, Assembly, and Flushing of Hydraulic Systems:

Follow all practices specified in ASTM D4174 for cleaning, flushing, and purification of hydraulic systems that apply to the fabrication, cleaning, handling, storage , assembly, contamination control, installation, flushing, testing, and operation of hydraulic systems to produce optimum system reliability. Allow only personnel experienced with contamination prevention to work on hydraulic systems.

1.Fabricated Parts: Clean and flush fabricated parts such as rigid pipe, flexible hoses, reservoir, manifold, etc. in accordance with ASTM D4174. After cleaning and flushing has been completed, wet internal surfaces that are prone to corrosion with a VSI oil that is compatible with the hydraulic oil that will be used for testing and operation of the hydraulic system. Cover all openings to prevent recontamination. Ends of rigid pipe and flexible hoses shall be sealed with cover plates, wooden plugs, or other approved method to pr event recontamination.

2.Manufactured Parts: Do not open manufactured parts until the fabricator is ready to install them as part of the hydraulic system. Prior to installation; inspect, clean, and flush manufactured parts such as, pumps, directional contr ol valves, stop valves, relief valves, check valves, etc. in accordance with ASTM D4174.

3.Adding Hydraulic Fluid to Reservoir: Filter hydraulic fluid in accordance with ASTM D4174 any time hydraulic fluid is added to the reservoir. This includes filling th e reservoir for shop testing and field testing/operation, or the addition of make -up fluid.

4.Flushing of Hydraulic System: Prior to Shop testing or field testing/operation, flush the hydraulic system in accordance with ASTM D4174.

821.07.31 Field Setup, Testing, and Break -in of Hydraulic Systems:

1.Field Setup and Testing: After field assembly and flushing has been completed, perform a static pressure test of the entire hydraulic system by pressurizing the system to 3,000 psi and holding for 15 minutes. Inspect for le aks. If leaks are found, fix the leaks and retest.

821.07.29 Hydraulic Seals: All seals used in hydra ulic systems shall be

FKM seals.

821.07.30 Cleaning, Assembly, and Flushing of Hydraulic Systems:

4.Flushing of Hydraulic System: Prior to Shop testing or field testing/operation, flush the hydraulic system in accordance with ASTM D4174.

821.07.31 Field Setup, Testing, and Break -in of Hydraulic Systems:

821.07.29 Hydraulic Seals: All seals used in hydra ulic systems shall be

FKM seals.

821.07.30 Cleaning, Assembly, and Flushing of Hydraulic Systems:

4.Flushing of Hydraulic System: Prior to Shop testing or field testing/operation, flush the hydraulic system in accordance with ASTM D4174.

821.07.31 Field Setup, Testing, and Break -in of Hydraulic Systems:

821.07.29 Hydraulic Seals: All seals used in hydra ulic systems shall be

FKM seals.

821.07.30 Cleaning, Assembly, and Flushing of Hydraulic Systems:

4.Flushing of Hydraulic System: Prior to Shop testing or field testing/operation, flush the hydraulic system in accordance with ASTM D4174.

821.07.31 Field Setup, Testing, and Break -in of Hydraulic Systems:

2.Break -in of Hydraulic System: After field setup and testing of the hydraulic system has been completed, operate the span at least 10 times consecutively. Remove and properly dispose of the existing hydrau lic fluid and replace with new hydraulic fluid. Replace all hydraulic system filters.

821.07.32 Center Pivot Bearing for Swing Span Bridges: Center pivot

bearings shall be as follows unless otherwise shown on the plans.

1.Housing: Housing shall be a steel weldment, ASTM A709/A709M, Grade

50.Housing shall come complete with oil level sight glass, oil fill port, oil drain port, air vent with plug, seals, and non -corrosive metallic name plates as shown on the plans. The center pivot bearing base may be submitted as a c asting. All sections must have the same area as shown on the plans. Casting material shall be ASTM A27/A27M, Grade 70 -36.

2.Bronze Disk: Bronze disk shall be a bronze casting, ASTM B 22, alloy C91300.

3.Steel Disk: Steel disk shall be ASTM A291/A291M, Grade 5, Class F, Brinell hardness greater than 300.

821.07.33 Counterweight Ropes for Vertical Lift Bridges: Only

companies that specialize in the fabrication of wire ropes of the size and type specified shall supply counterweight ropes for vertical lift bridges herea fter referred to as counterweight ropes. Fabricate counterweight ropes in accordance with ASTM A1023/A1023M, ASTM A1007, all specifications referenced by these specifications, and the specifications listed herein unless otherwise specified on the plans. Di mensions for counterweight ropes shall be as shown on the plans.

1.Description: Provide all material, equipment, tools, and labor to fabricate, paint, lubricate, shop test, transport, install, and adjust the tension in counterweight ropes as specified herein and in accordance with the intent of the plans and specifications.

2.Material s: All materials for counterweight ropes (including sockets) shall be new and as specified below. Main wire material, type of rope core, and galvanizing shall be selected by the Bridge Engineer and specified on the plans. If these materials have not been specified on the plans, clarify material specifications with the Bridge Engineer.

a.Main Wires: Shall be Extra Improved Plow Steel (EIPS) or Double Extra Improved Plow Steel (EEIPS).

b.Rope Cores: Shall have either a Hard Fiber Core (HFC) made of polypropyle ne or an Independent Wire Rope Core (IWRC).

c.Sockets: Machine from forged solid blanks of ASTM A668, Class D minimum. Sockets for 1 1/2 inch diameter wire ropes or greater may be machined from cast steel conforming to ASTM A148/A148M, Grade 80 -50.

821.07.32 Center Pivot Bearing for Swing Span Bridges: Center pivot

bearings shall be as follows unless otherwise shown on the plans.

1.Housing: Housing shall be a steel weldment, ASTM A709/A709M, Grade

2.Bronze Disk: Bronze disk shall be a bronze casting, ASTM B 22, alloy C91300.

3.Steel Disk: Steel disk shall be ASTM A291/A291M, Grade 5, Class F, Brinell hardness greater than 300.

821.07.33 Counterweight Ropes for Vertical Lift Bridges: Only

a.Main Wires: Shall be Extra Improved Plow Steel (EIPS) or Double Extra Improved Plow Steel (EEIPS).

b.Rope Cores: Shall have either a Hard Fiber Core (HFC) made of polypropyle ne or an Independent Wire Rope Core (IWRC).

821.07.32 Center Pivot Bearing for Swing Span Bridges: Center pivot

bearings shall be as follows unless otherwise shown on the plans.

1.Housing: Housing shall be a steel weldment, ASTM A709/A709M, Grade

2.Bronze Disk: Bronze disk shall be a bronze casting, ASTM B 22, alloy C91300.

3.Steel Disk: Steel disk shall be ASTM A291/A291M, Grade 5, Class F, Brinell hardness greater than 300.

821.07.33 Counterweight Ropes for Vertical Lift Bridges: Only

a.Main Wires: Shall be Extra Improved Plow Steel (EIPS) or Double Extra Improved Plow Steel (EEIPS).

b.Rope Cores: Shall have either a Hard Fiber Core (HFC) made of polypropyle ne or an Independent Wire Rope Core (IWRC).

d.Shims: Fabricate from a single piece of marine duty stainless steel with a minimum yield strength of 30 ksi.

e.Cap Screw to Attach Shim: Attach shims to sockets with countersunk, flat head, hex -socket cap screws in accordance with ASTM F879, Alloy Group 1 or 2, Al loy Condition CW or CW1. Size shall be 3/8 inch diameter. Length is dependent on size of shim.

f.Zinc for Socket Connection: Connect wire rope to sockets with ASTM B6, High Grade (HG) zinc.

g.Zinc for Galvanizing: If the counterweight rope is specified to be galvanized, zinc shall be in accordance with ASTM B6, High Grade (HG).

3.Socket Fabrication: Do not fabricate sockets as a weldment. Sockets shall be as specified on the plans, shall conform to the requirements of the latest revision of Federal Specificati on RR -S-550, and shall be stronger than the wire rope. The socket shall not fail before the wire rope. The wire rope manufacturer shall notify the Bridge Engineer prior to fabrication if any of these requirements are in conflict. Sockets can be supplied by an independent machine shop; however, the sockets must be attached to the wire ropes and tested by the wire rope manufacturer. Holes for cap screws shall be tapped 3/8 inch UNC, shall allow for 5/8 inch thread engagement minimum, and shall be located on o pposite corners of the socket. Hot - dip galvanize all sockets after machining in accordance with ASTM A123/A123M.

4.Socket Testing:

a.Non-destructive Testing: Perform magnetic particle testing on all sockets in accordance with ASTM E709.

b.Socket Strength Test: See 821.07.33 .10.

5.Wire Fabrication:

a.Main Wires: Fabricate in accordance with the current revision of ASTM A1007 and these specifications. Inner wires can be joined in accordance with ASTM A1023/A1023M except that only electric welding will be allowed. Outer wires cannot be joined.

b.Filler Wires: Fabri cate according to the wire rope manufacturer's specifications.

c.Independent Wire Rope Core (IWRC): If the wire rope is specified to have an IWRC, fabricate wires in accordance with “5.1. Main Wires” except that all wires may be joined.

d.Galvanizing: If the wire rope is specified to be galvanized, the wire rope shall be final -galvanized by a hot galvanizing process, as described in ASTM A1023/A1023M, 6.4.1.

6.Wire Testing:

a.Main Wires: Wire diameter measurement, tensile testing, torsion testing, and wrap test ing shall be performed in accordance with ASTM A1007 and ASTM A1023/A1023M. Take test samples at random from not less than 10 percent of the total number of wire coils from each production heat. Test samples can be taken from either end of the coils. If a test sample fails to meet any one of the testing requirements, the wire coil from which it was taken shall be rejected, and all wire coils from that production heat must then pass the testing process in order to be used on the project.

b.Filler Wires: No te sting is required.

c.Independent Wire Rope Core (IWRC): If the wire rope is specified to have an IWRC, test wires in accordance with 821.07.33 .6.1.

7.Strand Fabrication: Each strand shall consist of 19 main wires and six filler wires fabricated in one operation with all wires interlocking. The lay of the wires in the strands sh all be such as to make the wires approximately parallel to the axis of the wire rope where it comes in contact with a circular cylinder circumscribed on the wire rope. If a strand has two or more inner wires that have been joined, the joints shall be space d at least 25 feet apart.

8.Strand Testing: No testing is required.

9.Wire Rope Fabrication: Notify the Bridge Engineer 45 calendar days prior to fabrication of the wire rope so the Department may have an inspector present. Fabricate in accordance with the current revision of ASTM A1023 and these specifications. Wire ropes shall be 6x19 classification with 6x25 filler wire construction. Wire ropes shall be preformed, have right regular lay, and the maximum length of the lay s hall be 7.5 times the diameter of the wire rope. Wire ropes shall have uniform physical properties in accordance with Tables 821 -6 and 821-7, and shall be laid in accordance with the best industry practices. All counterweight ropes used on one bridge struc ture shall be fabricated from one production length of wire rope. If this is not possible due to the amount of wire rope required, an additional production length can be used.

a.Independent Wire Rope Core (IWRC): If the wire rope is specified to have an IWR C, fabricate the IWRC in accordance with the same specifications as the wire rope, except that the classification and type of construction of the IWRC shall be in accordance with the wire rope manufacturer's standards.

b.Lubrication: Fiber cores shall be lu bricated prior to fabrication of the wire rope. All other wire rope components shall be lubricated during the fabrication process. The lubricant shall contain a rust inhibitor and shall be submitted to the Bridge Engineer for review.

c.Test Segments of Wire Rope: During the wire rope fabrication process, set aside test segments of the wire rope in accordance with 821.07.33 .10.1.

10.Wire Rope Testing: Notify the Bridge Engineer 45 calendar days prior to assembly of the test segments and any wire rope testing so the Department may have an inspector present. The wire rope manufacture r shall provide proper facilities and test equipment to perform required tests. Detailed test reports shall be submitted to the Fabrication Engineer and the Bridge Engineer for review and acceptance for each test performed. Test reports shall describe all test procedures and list all test results.

a.Test Segments of Wire Rope: Test one segment from each end of each production length of wire rope used on the project. Test segments shall be at least 50 rope diameters long, but not longer than 12 feet.

b.Test Soc kets: For testing purposes, select sockets at random from the sockets fabricated for use on the project. Use one span socket and one counterweight socket for each test segment. No sockets used in testing shall be used on the project.

c.Test Segment Assembly : Attach one span socket and one counterweight socket to each end of a wire rope test segment in a similar manner to that which will be used for the counterweight ropes. Clean area where the wire rope enters the socket, and make a suitable mark around the rope adjacent to the socket such that any movement can be readily measured. Repeat process for each test segment.

d.Wire Rope Strength Test: Stress each test segment assembly until destruction. If a test segment assembly breaks before reaching the ultimate strength listed in Tables 821 -6 and 821 -7, select two additional test segments from that production length and retest. If either of these test segments fail the strength test, the entire production length shall be rejected. Fabricate a new production leng th and repeat the testing procedure.

e.Socket Strength Test: Sockets shall be stronger than the wire rope. If a socket fails during the wire rope strength test, perform the test again with four more sockets of the same type that failed (span or counterweigh t) selected at random from the sockets that will be used on the project. If any of these sockets fail, all sockets of that type shall be rejected. Fabricate new sockets from stronger steel or a heavier design, and retest. During the strength test, the seat ing of the wire rope between the zinc and the socket shall not exceed 1/6 the diameter of the wire rope. Seating in excess of 1/6 the diameter of the wire rope shall be cause for rejection of that connection.

11.Prestretching: Lay wire rope straight and twisted to the correct lay. Paint a line along the entire length of one side of the wire rope to indicate the proper lay for installation in the field. Apply a load equal to 40 percent of the wire rope's ultimate strength as listed in Tables 821 -6 and 821 -7 and hold for five minutes. Reduce the load to five percent of the wire rope's ultimate strength, and repeat the process two more times. Release load.

12.Measurement of Segment Lengths: After prestretching is complete, support the wire rope at intervals no greater than 25 feet. Apply a load equal to 12 percent of the wire rope's ultimate strength to approximate the "as installed" load. Measure and cut the wire rope segments to lengths as shown on the plans. Segments shall be cut from one production length of wire rope. No splicing of the wire rope or its component strands will be allowed.

13.Socket Attachment: Notify the Bridge Engineer 45 calendar days prior to the attachment of sockets so the Department may have an inspector present. The wire rope manufacture r shall attach the sockets to the wire rope using a molten zinc method sufficient to meet all requirements for wire rope testing specified in 821.07.3 3.10. Use the best industry practices to make attachments. Sockets for wire ropes that are smaller than or equal to 1 1/2 inches shall be preheated to insure zinc flows to the b ottom of the socket. Clean excess wire rope lubricant from the socket connection and any excess wire rope lubricant that may have run onto the sockets due to the heat of the connection process. Paint a line around the wire rope where it enters the sockets so that any slippage between the wires and the zinc can be seen.

14.Proof Loading: Apply a load equal to 40 percent of the wire rope's ultimate strength as listed in Tables 821 -6 and 821 -7 to each counterweight rope and hold for five minutes. Remove load an d inspect the connections between the wire rope and the sockets. Seating of the wire rope between the zinc and the socket shall not exceed 10 percent of the diameter of the wire rope. Seating in excess of 10 percent of the diameter of the wire rope shall b e cause for rejection of that connection. Any visible movement between the individual wires of the wire rope and the zinc shall be cause for rejection of the connection. If either of these cases occurs, the wire rope manufacturer shall determine the cause of the failure, develop a new connection method, and assemble a replacement counterweight rope.

15.Measurement of Counterweight Ropes: After proof loading is complete, lay the counterweight ropes straight and twisted to the correct lay. Support the counterwe ight ropes at intervals not greater than 25 feet, and apply a load equal to 12 percent of the wire rope's ultimate strength to approximate the "as installed" load. Measure and record the lengths of the counterweight ropes. For counterweight ropes shorter t han or equal to 100 feet in length, the measured length shall be plus or minus 1/4 inch of the design length. For counterweight ropes longer than 100 feet in length, the measured length shall be plus or minus 0.0002 times the design length. Reject counterw eight rope lengths that do not conform to these tolerances.

16.Paint: If paint has been specified for the sockets, clean and apply all paint coatings in the Shop after measurement of counterweight ropes has been completed. Protect the wire rope during the cl eaning and painting process.

17.Shims: To adjust for the permissible deviation in counterweight rope lengths specified in 821.07.33 .15, the wire rope manufacturer shall fabricate a single, stainless steel, slotted shim (see material specification) that shall be attached to the rope end of the span socket. This shim is not load bearing, but will assist the contractor during the initial installation of the counterweight ropes by providing a visual cue for the actual counterweight rope length. Fabricate shims such that the actual counterweight rope length will be within 1/32 inch o f the design counterweight rope length. Minimum shim thickness shall be 3/8 inch. Maximum shim thickness shall be two times the counterweight rope length tolerance plus 3/8 inch. For a counterweight rope 100 feet or less, this would be 7/8 inch. Attach shi m to the span socket with two cap screws (see material specification). Cap screw length shall be based upon the thickness of the shim and a minimum thread engagement in the socket of 5/8 inch. Stamp the shim thickness and the counterweight rope number on t he outward facing side of each shim.

18.Packaging and Identification: The wire rope manufacturer shall supply the assembled counterweight ropes on individual reels. Provide reels with the span socket out or the counterweight socket out, in accordance with th e installer's preference. The diameter of the reels shall be not less than 25 times the diameter of the counterweight rope. Fabricate and permanently attach a corrosion resistant metal tag to the span end of each counterweight rope. The tag shall list the wire rope manufacturer and address, the counterweight rope number, the design length, the fabricated length, shim thickness, and a number traceable to the wire rope manufacturer's production length.

19.Field Storage: Once shipped to the project site, locate c ounterweight rope reels such that neither the wire rope nor the sockets can come in contact with vegetation, mud, or standing water.

20.Field Installation: Conform to 820.09.6 for field installation. Table 821-6 Physical Properties of Wire Rope with IWRC Diameter (in.) Weight Per Length (Lbs/ft) Minimum Ultimate Strength (Kips) EIPS with IWRC EEIPS with IWRC Bright Galvanized Bright Galvanized 1/2 0.46 26.6 23.9 29.2 26.3 9/16 0.58 33.6 30.2 37.0 33.3 5/8 0.72 41.2 37.1 45.4 40.9 3/4 1.04 58.8 52.9 64.8 58.3 7/8 1.41 79.6 71.6 87.6 78.8 1 1.85 103.4 93.1 113.8 102.4 1-1/8 2.34 130.0 117.0 143.0 128.7 1-1/4 2.89 159.8 143.8 175.8 158.2 1-3/8 3.49 192.0 172.8 212.0 190.8 1-1/2 4.16 228.0 205.2 250.0 225.0 1-5/8 4.88 264.0 237.6 292.0 262.8 1-3/4 5.66 306.0 275.4 338.0 304.2 1-7/8 6.49 348.0 313.2 384.0 345.6 2 7.39 396.0 356.4 434.0 390.6 2-1/8 8.34 442.0 397.8 486.0 437.4 2-1/4 9.35 494.0 444.6 544.0 489.6 2-3/8 10.42 548.0 493.2 602.0 541.8 2-1/2 11.60 604.0 543.6 664.0 597.6 Table 821-7 Physical Properties of Wire Rope with HFC Diameter (in.) Weight Per Length (Lbs/ft) Minimum Ultimate Strength (Kips) EIPS with HFC EEIPS with HFC Bright Galvanized Bright Galvanized 1/2 0.42 23.6 21.2 25.8 23.2 9/16 0.53 29.8 26.8 32.6 29.3 5/8 0.66 36.8 33.1 40.4 36.4 3/4 0.95 52.4 47.2 57.6 51.8 7/8 1.29 70.8 63.7 78.0 70.2 1 1.68 92.0 82.8 101.2 91.1 1-1/8 2.13 115.8 104.2 127.2 114.5 1-1/4 2.63 142.2 128.0 156.4 140.8 1-3/8 3.18 171.0 153.9 188.0 169.2 1-1/2 3.78 202.0 181.8 222.0 199.8 1-5/8 4.44 236.0 212.4 258.0 232.2 1-3/4 5.15 272.0 244.8 300.0 270.0 1-7/8 5.91 310.0 279.0 342.0 307.8 2 6.73 352.0 316.8 388.0 349.2 2-1/8 7.60 394.0 354.6 434.0 390.6 2-1/4 8.52 440.0 396.0 484.0 435.6 2-3/8 9.49 488.0 439.2 538.0 484.2 2-1/2 10.50 538.0 484.2 590.0 531.0

821.07.34 Counterweight Ropes for Movable Barriers: All

specifications for 821.07.33 shall apply to counterweight ropes for movable barriers except as follows:

1.Socket Fabrication: When fabricating sockets, do not attach shims to sockets with cap screws. Table 821-7 Physical Properties of Wire Rope with HFC Diameter (in.) Weight Per Length (Lbs/ft) Minimum Ultimate Strength (Kips) EIPS with HFC EEIPS with HFC Bright Galvanized Bright Galvanized 1/2 0.42 23.6 21.2 25.8 23.2 9/16 0.53 29.8 26.8 32.6 29.3 5/8 0.66 36.8 33.1 40.4 36.4 3/4 0.95 52.4 47.2 57.6 51.8 7/8 1.29 70.8 63.7 78.0 70.2 1 1.68 92.0 82.8 101.2 91.1 1-1/8 2.13 115.8 104.2 127.2 114.5 1-1/4 2.63 142.2 128.0 156.4 140.8 1-3/8 3.18 171.0 153.9 188.0 169.2 1-1/2 3.78 202.0 181.8 222.0 199.8 1-5/8 4.44 236.0 212.4 258.0 232.2 1-3/4 5.15 272.0 244.8 300.0 270.0 1-7/8 5.91 310.0 279.0 342.0 307.8 2 6.73 352.0 316.8 388.0 349.2 2-1/8 7.60 394.0 354.6 434.0 390.6 2-1/4 8.52 440.0 396.0 484.0 435.6 2-3/8 9.49 488.0 439.2 538.0 484.2 2-1/2 10.50 538.0 484.2 590.0 531.0

821.07.34 Counterweight Ropes for Movable Barriers: All

specifications for 821.07.33 shall apply to counterweight ropes for movable barriers except as follows:

1.Socket Fabrication: When fabricating sockets, do not attach shims to sockets with cap screws.

2.Wire Rope Fabrication: When fabricating wire rope, the maximum length of the l ay shall be 6.75 times the diameter of the wire rope. For barriers with two counterweight ropes on each side, provide ropes with opposite lay.

3.Shims: Do not attach load bearing shims to the sockets. Place shims in the socket holder.

4.Packaging and Identifi cation: Attach tag to the counterweight end of each counterweight rope.

821.07.35 Operating Ropes for Movable Bridges: All specifications

for 821.07.33 shall apply to operating ropes except as follows:

1.Socket Fabrication: Unless shown on the plans or directed otherwise, sockets will not be required for operating ropes. If sockets are required, shims do not need to be attached to sockets with cap screws.

2.Wire Rope Fabrication: When fabricating wire rope, the maximum length of the lay shall be 6.75 times the diameter of the wire rope. If sockets are not required for operating ropes, seize ends and weld wires together. Remove seizing at installation.

3.Shims: Unless shown on the plans or directed otherwise, shims will not be required for operating ropes. If shims are required, they shall be load bearing and not attached to the sockets.

4.Packaging and Identification: Attach tag to either end of the operating rope.

821.07.36 Shop Storage of Mechanical Equipment: Prepare and

package all Shop fabricated mechanical equipment for storage in the Shop immediately after fabrication is complete in a manner that will prevent distortion, corrosion, damage, and contamination. This includes painting metal surfaces, coating unpainted metal surfaces with a corrosion preventing grease (1/32 inch min. film thickness), coating interior metal surfaces with a VS I oil, use of wooden lagging to prevent damage to machined surfaces, wrapping parts with plastic, providing wooden supports/crates, etc. Store all Shop fabricated and manufactured mechanical equipment out of the weather in a manner that prevents distortion , corrosion, damage, and contamination and in accordance with the manufacturer’s recommendations. Shop must request permission from the Bridge Engineer in advance to store any mechanical equipment out of doors.

821.07.37 Delivery of Mechanical Equipment to the Proje ct Site:

Prepare and package all Shop fabricated and manufactured mechanical equipment for transport to the project site in accordance with the manufacturer’s recommendations and in a manner that will protect it from the weather and from damage during t ransport. This may include measures in addition to that which were taken for Shop storage.

3.Shims: Do not attach load bearing shims to the sockets. Place shims in the socket holder.

4.Packaging and Identifi cation: Attach tag to the counterweight end of each counterweight rope.

821.07.35 Operating Ropes for Movable Bridges: All specifications

for 821.07.33 shall apply to operating ropes except as follows:

3.Shims: Unless shown on the plans or directed otherwise, shims will not be required for operating ropes. If shims are required, they shall be load bearing and not attached to the sockets.

4.Packaging and Identification: Attach tag to either end of the operating rope.

821.07.36 Shop Storage of Mechanical Equipment: Prepare and

821.07.37 Delivery of Mechanical Equipment to the Proje ct Site:

3.Shims: Do not attach load bearing shims to the sockets. Place shims in the socket holder.

4.Packaging and Identifi cation: Attach tag to the counterweight end of each counterweight rope.

821.07.35 Operating Ropes for Movable Bridges: All specifications

for 821.07.33 shall apply to operating ropes except as follows:

3.Shims: Unless shown on the plans or directed otherwise, shims will not be required for operating ropes. If shims are required, they shall be load bearing and not attached to the sockets.

4.Packaging and Identification: Attach tag to either end of the operating rope.

821.07.36 Shop Storage of Mechanical Equipment: Prepare and

821.07.37 Delivery of Mechanical Equipment to the Proje ct Site:

3.Shims: Do not attach load bearing shims to the sockets. Place shims in the socket holder.

4.Packaging and Identifi cation: Attach tag to the counterweight end of each counterweight rope.

821.07.35 Operating Ropes for Movable Bridges: All specifications

for 821.07.33 shall apply to operating ropes except as follows:

3.Shims: Unless shown on the plans or directed otherwise, shims will not be required for operating ropes. If shims are required, they shall be load bearing and not attached to the sockets.

4.Packaging and Identification: Attach tag to either end of the operating rope.

821.07.36 Shop Storage of Mechanical Equipment: Prepare and

821.07.37 Delivery of Mechanical Equipment to the Proje ct Site:

821.07.38 Field Storage of Mechanical Equipment: As specified

elsewhere, some mechanical equipment shall not be transported to the field until the Contractor is ready to in stall the equipment in its permanent location on the bridge structure. Uninstalled mechanical equipment at the project site must be stored out of the weather in a manner that permits easy access for identification and inspection, and prevents distortion, c orrosion, damage, and contamination.

821.07.39 Field Installation of Mechanical Equipment: Provide

personnel who are trained and experienced in installing the type of mechanical equipment shown on the plans. Provide millwrights to align and install open gears, shafts, gearboxes, electric motors, brakes, etc. At all times, follow manufacturer’s installation instructions and use best industry practices when installing mechanical equipment. Remove protective grease/oil by the use of approved solvents and methods prio r to the application of operating grease/oil.

821.08 Mechanical Construct Ion Requirements for

FACILITIES. This section sets forth general requirements for the construction of new mechanical systems and/or the renovation of existing mechanical systems for facilities, such as HVAC systems, plumbing systems, sewage treatment plants, and sewage lift stations.

821.08.1 Outdoor Mechanical Equipment Requirements: All

mechanical equipment that is to be installed outdoors and exposed to the weather shall be rated for out door use, shall have a minimum 500 hour salt spray corrosion coating system in accordance with ASTM B17, and shall be installed in a manner to allow easy access for maintenance. All outdoor mechanical equipment with coils shall have coil guards. All mechan ical equipment and accessories mounted on roofing structures shall be installed in strict accordance with the roofing manufacturer’s recommendations. Installation shall not invalidate any new or existing roofing warranties. In addition, mechanical equipmen t installed on a roof shall be mounted securely to the building structure such that it meets or exceeds the IBC wind load requirements for both location and elevation.

821.08.2 Potable Water Piping: All potable water pipe and fittings shall

be NSF approved for p otable water service and bear the “NSF 14 and NSF 61” (NSF -pw for plastic pipe) mark indicating suitability for use in transporting potable water. Test the water lines in accordance with “PIPE TESTING” as defined below. After testing has been completed, th oroughly sterilize the entire potable water

821.07.38 Field Storage of Mechanical Equipment: As specified

821.07.39 Field Installation of Mechanical Equipment: Provide

821.08 Mechanical Construct Ion Requirements for

821.08.1 Outdoor Mechanical Equipment Requirements: All

821.08.2 Potable Water Piping: All potable water pipe and fittings shall

821.07.38 Field Storage of Mechanical Equipment: As specified

821.07.39 Field Installation of Mechanical Equipment: Provide

821.08 Mechanical Construct Ion Requirements for

821.08.1 Outdoor Mechanical Equipment Requirements: All

821.08.2 Potable Water Piping: All potable water pipe and fittings shall

821.07.38 Field Storage of Mechanical Equipment: As specified

821.07.39 Field Installation of Mechanical Equipment: Provide

821.08 Mechanical Construct Ion Requirements for

821.08.1 Outdoor Mechanical Equipment Requirements: All

821.08.2 Potable Water Piping: All potable water pipe and fittings shall

821.07.38 Field Storage of Mechanical Equipment: As specified

821.07.39 Field Installation of Mechanical Equipment: Provide

821.08 Mechanical Construct Ion Requirements for

821.08.1 Outdoor Mechanical Equipment Requirements: All

821.08.2 Potable Water Piping: All potable water pipe and fittings shall

821.07.38 Field Storage of Mechanical Equipment: As specified

821.07.39 Field Installation of Mechanical Equipment: Provide

821.08 Mechanical Construct Ion Requirements for

821.08.1 Outdoor Mechanical Equipment Requirements: All

821.08.2 Potable Water Piping: All potable water pipe and fittings shall

1.Inside Building Walls and Under Foundations: Use copper water tube conforming to ASTM B88, Type L annealed and/or drawn tempered. No joints will be allowed under foundations. Drawn tempered copper piping may be run in walls and ceiling spaces only. Connections shall be wrought copper and copper alloy solder joint pressure fittings in accordance with ASME 16.22. Flux shall meet or exceed alloy grade ASTM B813.

2.Exposed Inside or Outside of Building: Use Schedule 40 seamless galvanized steel pipe with welded fittings conforming to ASTM A53/A53M, Type E, Grade B, standard weight. Fittings shall be galvan ized in accordance with ANSI B16.4, Class 125, Standard Pattern. Galvanized pipe nipples shall be ASTM A733 made of ASTM A53/A53M or ASTM A106/A106M, Standard Weight, seamless pipe with threaded ends.

3.Underground Water Pipe and Fittings (Excluding Hydronic Piping): Use plastic pipe conforming to ASTM D2239. Plastic pipe shall be polyethylene DR 11 minimum, PE 3608, rated for a working pressure of 160 psi minimum. Working pressures which exceed 160 psi due to elevation changes or system pressures will requi re the use of polyethylene pipe which exceeds these working pressures. Fittings shall be of like material and have the same or greater pressure rating. Join all polyethylene piping into continuous lengths at the job site, above ground, using the butt fusio n method conforming to ASTM D3261.

821.08.3 Vent Piping:

1.Concealed, Above Foundations: Vent pipe and fittings three inches in diameter and smaller installed in concealed spaces above foundations shall conform to ASTM D2665, Schedule 40. Use solvent weld joints con forming to ASTM D2564.

2.Exposed: Use Service Weight, centrifugal -coated, cast iron pipe conforming to ASTM A74 for any exposed vent pipe installation. Hubs and spigots shall have neoprene gaskets with no -hub joints conforming to ASTM C564. No exposed PVC piping shall be allowed.

821.08.4 Gravity Sanitary Waste Piping:

1.Concealed, Exposed, and Below Foundations: Use Service Weight, centrifugal -coated cast iron pipe meeting ASTM A74, hub and spigot with neoprene gaskets with no -hub joints conforming to ASTM C564.

2.Unde rground (Outside Foundations): Use plastic pipe and fittings conforming to ASTM D2665, Schedule 40 with solvent weld joints conforming to ASTM D2564.

821.08.5 Forced -Main Sanitary Waste Piping:

piping system as specified under “POTABLE WATER PIPING STERILIZATION” below. Piping materials shall be as follows:

821.08.3 Vent Piping:

821.08.4 Gravity Sanitary Waste Piping:

1.Concealed, Exposed, and Below Foundations: Use Service Weight, centrifugal -coated cast iron pipe meeting ASTM A74, hub and spigot with neoprene gaskets with no -hub joints conforming to ASTM C564.

2.Unde rground (Outside Foundations): Use plastic pipe and fittings conforming to ASTM D2665, Schedule 40 with solvent weld joints conforming to ASTM D2564.

821.08.5 Forced -Main Sanitary Waste Piping:

piping system as specified under “POTABLE WATER PIPING STERILIZATION” below. Piping materials shall be as follows:

821.08.3 Vent Piping:

821.08.4 Gravity Sanitary Waste Piping:

1.Concealed, Exposed, and Below Foundations: Use Service Weight, centrifugal -coated cast iron pipe meeting ASTM A74, hub and spigot with neoprene gaskets with no -hub joints conforming to ASTM C564.

2.Unde rground (Outside Foundations): Use plastic pipe and fittings conforming to ASTM D2665, Schedule 40 with solvent weld joints conforming to ASTM D2564.

821.08.5 Forced -Main Sanitary Waste Piping:

piping system as specified under “POTABLE WATER PIPING STERILIZATION” below. Piping materials shall be as follows:

821.08.3 Vent Piping:

821.08.4 Gravity Sanitary Waste Piping:

1.Concealed, Exposed, and Below Foundations: Use Service Weight, centrifugal -coated cast iron pipe meeting ASTM A74, hub and spigot with neoprene gaskets with no -hub joints conforming to ASTM C564.

2.Unde rground (Outside Foundations): Use plastic pipe and fittings conforming to ASTM D2665, Schedule 40 with solvent weld joints conforming to ASTM D2564.

821.08.5 Forced -Main Sanitary Waste Piping:

1.Above Ground: Use Schedule 40 seamless galvanized steel pipe with wel ded fittings conforming to ASTM A53/A53M, Type E, Grade B, standard weight. Fittings shall be galvanized in accordance with ANSI B16.4, Class 125, Standard Pattern. Galvanized pipe nipples shall be ASTM A733 made of ASTM A53/A53M or ASTM A106/A106M, Standa rd Weight, seamless pipe with threaded ends.

2.Underground: Use plastic pipe conforming to ASTM D2239. Plastic pipe shall be polyethylene DR 11 minimum, PE 3608, rated for a working pressure of 160 psi minimum. Working pressures which exceed 160 psi due to elevation changes or system pressures will require the use of polyethylene pipe which exceeds these working pressures. Fittings shall be of like material and have the same or greater pressure rating. Join all polyethylene piping into continuous lengths at the job site, above ground, using the butt fusion method conforming to ASTM D3261.

821.08.6 Hydronic Piping:

1.Above Ground: Use ASTM A53/A53M Schedule 40, seamless black pipe with grooved ends for piping equal to 3 inches in diameter and above. Join pipe sections and fittings together using either welded (plain end) or grooved mechanical joint type rigid and flexible pipe cou plings. Piping under 3 inches in diameter shall be copper water tube conforming to ASTM B88, Type L hard drawn. Connections shall be wrought copper and copper alloy solder joint pressure fittings in accordance with ASTM B32. Flux shall meet or exceed alloy grade ASTM B813.

2.Underground: Use a pre -insulated piping system with 1½ inch polyurethane insulation and with a 0.070 inch minimum thick, high -density, black industrial grade polyethylene jacket. Carrier pipe shall be standard weight carbon steel, ASTM A53/A53M Grade B, Type E, Schedule 40. The pre -insulated pipe shall be in unitized factory pre -fabricated sections. Pipe shall be rated for use with chilled water systems. Insulation shall be 90 to 95 percent formed -in-place closed -cell polyurethane with 2 pounds per cubic foot density, completely filling the annular space between the carrier pipe and pipe casing. Thermal conductivity shall be a minimum of 0.16 BTU -in/(hr -ft²-°F) at 73°F. Pipe shall be pressure tested at 150 psig for a minimum of 24 continuo us hours in the presence of the Project Engineer or representative. After hydrostatic testing of the pipe, insulate field joint with kits provided by the pre -insulated pipe manufacturer. Apply field joint insulation in straight sections by pour forming in -situ using molds furnished by system manufacturer. Seal field joint insulation surface with heat shrinkable sleeve. Insulation and jacket on all fittings shall be factory -applied after pipe spool fabrication, extending continuously onto adjoining straight sections of pipe.

821.08.7 Natural Gas Piping:

821.08.6 Hydronic Piping:

821.08.7 Natural Gas Piping:

821.08.6 Hydronic Piping:

821.08.7 Natural Gas Piping:

1.Above Ground: Use ASTM A53/A53M, black steel, Schedule 40, Type E or S, Grade B. Malleable -iron threaded fittings shall be ASME B16.3, Class 150, standard pattern. Unions shall be ASME B16.39, Class 150, malleable iro n with brass -to-iron seat, ground joint, and threaded ends.

2.Underground: Use polyethylene plastic pipe and fittings conforming to ASTM D2513. Piping shall be marked “gas” and “ASTM D2513.” Join all polyethylene piping into continuous lengths at the job si te, above ground, using the butt fusion method ASTM D3261 with dimensions matching PE pipe. Polyethylene pipe shall be yellow in color conforming to ANSI/ASME A13.1 standard.

3.Painting: Paint exterior and exposed interior gas piping from the service point (gas regulator/meter) to gas appliance connections. Prepare pipe surfaces to receive paint using solvent cleaners in accordance with SSPC -SP1 and hand tool method in accordance with SSPC -SP2. All pipe scheduled for painting shall be clean, dry, and in soun d condition free of rust, oil, grease, and other contaminants. Use one coat of a metal alkyd primer and two finish coats of high -solids, alkyd industrial enamel. Gas pipe color shall be yellow and shall meet ANSI/ASME A13.1.

821.08.8 Refrigerant Piping: Use seam less copper tube conforming to

ASTM B280, Type ACR for air conditioning and refrigeration field service. Fittings and unions shall conform to ASME B16.22. Solder shall conform to ASTM B32, 95 -5, tin antimony, or alloy HB solder to join copper socket fittin gs on copper pipe. Brazing filler metals shall comply with AWS A5.8. A moisture flow and sight glass indicator shall be installed in the piping.

821.08.9 Pipe Insulation Materials:

1.Mineral -Fiber, Preformed Pipe Insulation: Type I, 850 ºF. Mineral or glass fibers s hall be bonded with a thermosetting resin. Comply with ASTM C547, Type I, Grade A. Mineral -fiber adhesive shall comply with MIL -A-3316C, Class 2, Grade A.

2.Flexible Elastomeric Pipe Insulation: Closed -cell, sponge, or expanded -rubber materials. Comply with ASTM C534, Type I for tubular materials. Flexible elastomeric adhesive shall comply with MIL -A-24179A, Type II, Class I.

3.Mastics: Materials shall be compatible with insulation materials, jackets, and substrates; comply with MIL -PRF-19565C, Type II.

821.08.10 Insul ation Type and Thickness:

1.Exposed Interior Potable Water Piping : Mineral fiber; 1 inch thick.

2.Exposed Exterior Potable Water Piping : Mineral fiber, 2 inches thick.

3.Interior Hydronic Piping : Mineral fiber; 2 inches thick.

4.Exterior Hydronic Piping : Miner al fiber; 3 inches thick.

5.Refrigerant Piping : Flexible elastomeric; 2 inches thick.

821.08.8 Refrigerant Piping: Use seam less copper tube conforming to

821.08.9 Pipe Insulation Materials:

3.Mastics: Materials shall be compatible with insulation materials, jackets, and substrates; comply with MIL -PRF-19565C, Type II.

821.08.10 Insul ation Type and Thickness:

1.Exposed Interior Potable Water Piping : Mineral fiber; 1 inch thick.

2.Exposed Exterior Potable Water Piping : Mineral fiber, 2 inches thick.

3.Interior Hydronic Piping : Mineral fiber; 2 inches thick.

4.Exterior Hydronic Piping : Miner al fiber; 3 inches thick.

5.Refrigerant Piping : Flexible elastomeric; 2 inches thick.

821.08.8 Refrigerant Piping: Use seam less copper tube conforming to

821.08.9 Pipe Insulation Materials:

3.Mastics: Materials shall be compatible with insulation materials, jackets, and substrates; comply with MIL -PRF-19565C, Type II.

821.08.10 Insul ation Type and Thickness:

1.Exposed Interior Potable Water Piping : Mineral fiber; 1 inch thick.

2.Exposed Exterior Potable Water Piping : Mineral fiber, 2 inches thick.

3.Interior Hydronic Piping : Mineral fiber; 2 inches thick.

4.Exterior Hydronic Piping : Miner al fiber; 3 inches thick.

5.Refrigerant Piping : Flexible elastomeric; 2 inches thick.

821.08.8 Refrigerant Piping: Use seam less copper tube conforming to

821.08.9 Pipe Insulation Materials:

3.Mastics: Materials shall be compatible with insulation materials, jackets, and substrates; comply with MIL -PRF-19565C, Type II.

821.08.10 Insul ation Type and Thickness:

1.Exposed Interior Potable Water Piping : Mineral fiber; 1 inch thick.

2.Exposed Exterior Potable Water Piping : Mineral fiber, 2 inches thick.

3.Interior Hydronic Piping : Mineral fiber; 2 inches thick.

4.Exterior Hydronic Piping : Miner al fiber; 3 inches thick.

5.Refrigerant Piping : Flexible elastomeric; 2 inches thick.

821.08.11 Pipe Jackets: Install the following types of piping jackets and

markers on all exposed above ground piping:

1.Exterior: Cover exposed exterior insulated piping with an aluminum jacket, complying with ASTM B209, Alloy 3003, 3005, 3105, or 5005, Temper H -14. Sheet and roll stock shall be ready for shop or field sizing. Finish and thickness shall be a minimum of 0.032 inch. Moisture barrier for outdoor applications shall be 3 -mil thick, heat -bonded polyethylene and kraft paper. Factory fabricated fitting covers shall have the same material, finish, and thickness as the jacket. Use preformed 2 -piece or gore, 45 - and 90 -degrees , short - and long -radius elbows, tee covers, flange and union covers, end caps, beveled collars, and valve covers. Use field fabricated fitting covers only if factory fabricated fitting covers are not available.

2.Interior: Cover exposed insulated piping in mechanical rooms with a 20 -mil minimum PVC jacket, meeting ASTM D1784, Class 16354 -C. PVC jacket shall be rated to a 150°F temperature limit. Clean insulation surface thoroughly before application of PVC jacket. Factory fabricated fitting covers shall hav e the same material, finish, and thickness as jacket. Use preformed 2 -piece or gore, 45 - and 90 -degree, short - and long -radius elbows, tee covers, flange and union covers, end caps, beveled collars and valve covers. Use field fabricated fitting covers only if factory fabricated fitting covers are not available.

3.Colors: Colors shall be in accordance with ANSI/ASME A13.1 and Table 821-8. Table 821-8 Pipe Jacket Colors Type of Pipe Color Chilled Water Blue Hot Water Orange Fire Suppression Systems Red City Water (Makeup) White Natural Gas Yellow Process Water Purple

821.08.11 Pipe Jackets: Install the following types of piping jackets and

markers on all exposed above ground piping:

4.Pipe Markers: For pipes located in mechanical rooms in buildings, provide and install pipe markers to indicate direction of flow. Apply markers so as to remove any doubt as to the circulation characteristics of the system. Markers shall be plastic wrap -around type wit h lettering a minimum of 1/2 inch in height on pipe sizes up to NPS 6. Markers on pipe sizes larger than NPS 6 shall be plastic strap -retained, secured with nylon ties with lettering a minimum of 1 -1/4 inches in height. Pressure adhesive markers will not b e allowed. Lettering and background color shall be as specified in ANSI/ASME A13.1 and Table 821 -9. Table 821-9 Pipe Marker Colors Type of Pipe Label Text Color Background Color Chilled Water Supply CHWS White Green Chilled Water Return CHWR White Green Hot Water Supply HWS White Green Hot Water Return HWR White Green City Water (Makeup) City Water White Green Natural Gas Gas Black Yellow Process Water Process Water White Green Fire Suppression Fire Sprinkler White Red Compressed Air Compressed Air White Blue

821.08.12 Pipe Installation (All Pipe): Install all piping in a neat,

workmanlike manner. Mark each length of pipe and each pipe fitting in accordance with the approved standard and specification to which it is manufactured. Install piping so as to eliminate air pockets and permit drainage. Provide air relief at all high points and drains at all low points. Make allowances for expansion and contraction. Pipe all air vents to drain. Slope horizontal soil waste and drain pipe as shown o n the plans, or where not specifically indicated, grade in the direction of flow at 1/4 inch per foot for pipe diameters of less than 4 inches and 1/8 inch per foot on line sizes of 4 inches or greater. Make changes in pipe size on soil, waste, and drain l ines using reducing fittings, recessed reducers, or flush bushings. Make all changes in direction using long radius fittings, except that sanitary tees may be used on vertical stacks, and short quarter bends or elbows may be used where the change is from h orizontal to vertical. Where it becomes necessary because of space conditions to use short radius fittings in any other location, obtain permission from the Project Engineer before installation. Where pipes extend through roof or outside walls, flashings w ill be required for weatherproofing. Roof and wall flashings shall be in strict accordance with the state sanitary code and the roofing manufacturer’s requirements. Where pipes pass through walls and floors, provide weather tight stainless steel split pla te escutcheons. Escutcheons shall be 16 gauge 300 series stainless steel with a satin finish and spring clip fasteners. Escutcheons shall fit snuggly around the pipe outer diameter and shall cover the entire wall opening. Support suspended piping every fou r feet using beam clamps or beam clamps in combination with anchor rods and hangers. Install pipe supports so as not to damage insulation or jacketing. All beam clamps, anchor rods, hangers, and associated hardware shall be marine grade stainless steel. Underground piping shall be as follows:

1.Bury piping a minimum of 36 inches below grade and a minimum of 60 inches below roadway surface. Water lines shall not be buried in the same trench as sewer lines.

2.Pipe trench excavation shall be in accordance with 701.03 .

3.Install underground piping with restrained joints at horizontal and vertical changes in direction. Use restrained -joint piping, thrust blocks, anchors, tie -rods and clamps, and other supports. Concrete shall be Class A in accordance with Section 901.

4.Place and tamp a 4 -inch thick layer of sand in the trench to provide uniform bedding for the piping system. After piping is installed, evenly backfill the entire trench with sand in 6 -inch compacted layers to a minimum height of 6 inches above the top of the insulated piping system. Evenly and continuously backfill the remaining trench in uniform layers with select fill in accordance with Section 701 to the finished grade level.

5.Hydroseed backfilled areas in accordance with Section 739 ; seed species to match existing.

6.Provide detectable warning tape on all underground non -metallic lines. Use acid and alkali -resistant, PE film warning tape manufactured for marking and identifying underground utilities, a minimum of 6 inches wide and 4 mils t hick, continuously inscribed with a description of the utility. The tape shall have a metallic core encased in a protective jacket for corrosion protection, detectable by metal detector when tape is buried up to 30 inches deep. Follow APWA and ANSI/ASME A13.1 for installation and color requirements.

821.08.13 Pipe Testing:

1.Pressure Piping Systems: Test for leaks at 50 psi above working pressure or 100 psi whichever is greater for a minimum of four hours before placing slabs, closing walls, ceilings or before backfil ling. Repair leaks found by replacing the entire defective section and retest the system until proven free of defects. Perform testing in the presence of the Project Engineer or his representative.

2.Gravity Piping Systems: Test for four hours under a head of 10 feet and show no leaks. Provide a copy of the manufacturer’s recommended testing procedure to the Project Engineer prior to the test and use as the basis for inspection. Repair leaks found by replacing the entire defective section and retest the syst em until proven free of defects. Perform testing in the presence of the Project Engineer or his representative.

3.Gas Piping Systems: Test and purge in accordance with NFPA 54.

4.Refrigerant Line Testing: Comply with ASME B31.5, Chapter VI. Test refrigerant piping and specialties. Isolate compressor, condenser, evaporator, and safety devices from test pressure if they are not rated above the test pressure. Test high and low pressure side piping of each system separately at no less than 300 psig for suction li nes, 535 psig for heat pumps, and no less than 535 psig for liquid and hot gas lines. Fill system with nitrogen to the required test pressure. System shall maintain test pressure at the manifold gauge throughout duration of test. Test joints and fittings w ith electronic leak detector or by brushing a small amount of soap and glycerin solution over joints. Remake leaking joints using new materials, and retest until satisfactory results are achieved.

821.08.14 Heat Trace Wiring for Freeze Protection: Use heat trace

wiring to protect water piping from freezing in outdoor and unconditioned areas. Heat trace wiring shall be listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application. All components shall be f rom the same manufacturer. Do not exceed the maximum wire length list by the manufacturer for a given electrical circuit size.

821.08.13 Pipe Testing:

3.Gas Piping Systems: Test and purge in accordance with NFPA 54.

821.08.14 Heat Trace Wiring for Freeze Protection: Use heat trace

821.08.13 Pipe Testing:

3.Gas Piping Systems: Test and purge in accordance with NFPA 54.

821.08.14 Heat Trace Wiring for Freeze Protection: Use heat trace

1.Ambient Thermostats for Freeze Protection: Shall have an ambient -sensing probe with adjustable temperature range from 0 to 225 ºF. Switch shall be snap action, open -on-rise, single pole with minimum current rating adequate for connected cable. Shall have a resistance temperature device or thermis tor for sensing ambient air temperature, and a NEMA 4X enclosure.

2.Heating Element: Heating elements shall consist of a pair of parallel No. 16 AWG, tinned, stranded copper bus wires embedded in cross -linked conductive polymer core, which vary heat output in response to temperature along its length. Terminate with waterproof, factory -assembled, non -heating leads with connectors at one end, and seal the opposite end watertight. Cable shall be capable of crossing over itself once without overheating. Electric al insulating jacket shall be flame - retardant polyolefin. Cable cover shall be tinned -copper braid and polyolefin outer jacket with ultraviolet inhibitor.

3.Cable Installation: Cable installation accessories include fiberglass tape, heat - conductive putty, c able ties, silicone end seals and splice kits, and installation clips all furnished by the manufacturer, or as recommended in writing by the manufacturer.

821.08.15 Potable Water Piping Sterilization: Sterilize the potable

water piping system in the presence of t he Project Engineer or other designated Department representative. Clean interior of new domestic water piping system. Remove dirt and debris as work progresses. Before using, purge new piping and parts of existing piping that have been altered, extended, or repaired. Use purging and disinfecting procedures prescribed by authorities having jurisdiction (AHJ). If methods are not prescribed, use procedures described in either AWWA C651 or AWWA C652 or the following procedure:

1.Flush piping system with clean, p otable water until clean water appears at all outlets.

2.Sterilize system according to either of the following:

a.Fill potable water system or part thereof with a water/chlorine solution that has at least 50 ppm of chlorine. Isolate with valves and allow to st and for 24 hours.

b.Fill potable water system or part thereof with a water/chlorine solution that has at least 200 ppm of chlorine. Isolate with valves and allow to stand for three hours.

3.After the standing times are complete, flush the system with clean, po table water until no chlorine can be detected coming from any outlets.

4.Repeat procedures if biological examination shows contamination.

821.08.15 Potable Water Piping Sterilization: Sterilize the potable

1.Flush piping system with clean, p otable water until clean water appears at all outlets.

2.Sterilize system according to either of the following:

a.Fill potable water system or part thereof with a water/chlorine solution that has at least 50 ppm of chlorine. Isolate with valves and allow to st and for 24 hours.

b.Fill potable water system or part thereof with a water/chlorine solution that has at least 200 ppm of chlorine. Isolate with valves and allow to stand for three hours.

3.After the standing times are complete, flush the system with clean, po table water until no chlorine can be detected coming from any outlets.

4.Repeat procedures if biological examination shows contamination.

5.When no contamination is found, submit water samples in sterile bottles to authorities having jurisdiction (AHJ).

6.Prepar e and submit reports of purging and disinfecting activities, including test reports.

821.08.16 Plumbing Specialties: Plumbing fixtures shall be rigidly

supported and fitted with necessary trimmings. Exposed metal parts, trim, brackets, drains, supply lines, etc. shall have a chrome -plated finish. Flexible supply hoses shall be braided stainless steel with compression fittings on one end and pipe thread on the other end, and shall comply with ASME 112.18.6. Fixtures shall have a water seal trap of not less than two inches or greater than four inches. Traps shall have cleanouts, and shall be placed as close to the fixture as possible. Immediately after installation of plumbing fixtures, cover each fixture with a fixture protector. Each fixture shall have an accessibl e shut -off valve in the water supply line that allows the fixture to be shut -off without interfering with the water supply to any other fixture. Shut -off valves shall comply with ASME A112.18.1/CSA B125.1. All pipes passing through walls shall have stainl ess steel escutcheons on finished sides of walls. All escutcheons shall be held in place by stainless steel set screws. Plumbing fixtures in publically accessible buildings shall comply with all ADA requirements. Water hammer arrestor devices shall be inst alled at each individual fixture. Water hammer arrestors shall be 1 -1/2 inches copper pipe, 18 inches high. Supply and install the quantity and type of plumbing fixtures in the locations as shown on the plans in full accordance with the manufacturer’s instructions and the LSAC and LPC.

821.08.17 Natural Gas Accessories: Fixtures shall have individual shut -

off valves consisting of two -piece, full -port, bronze ball valves with bronze trim: MSS SP -110. Install flexible connectors from each fixture to the shut -off val ve on equipment. Flexible connectors shall comply with ANSI Z21.26 and Z21.75. Install appliance regulators where required. Install dielectric unions where required conforming to ASSE 1079. Install line and equipment regulators conforming to ANSI Z21.80a where required.

821.08.18 Water Closet - Close Coupled (Gravity Tank) Type:

Provide commercial grade water closets and accessories that conform to ASME A112.19.2/CSA B45.1 and ASME A112.19.5. Use wall or floor mounted water closets as specified. Provide wall carr iers on all wall mounted water closets. Comply with ADA if required. Close coupled type water closets shall have the following features:

1.Material: Vitreous china.

2.Bowl Type: Siphon Jet.

3.Height: Standard or as required by ADA, if applicable.

5.When no contamination is found, submit water samples in sterile bottles to authorities having jurisdiction (AHJ).

6.Prepar e and submit reports of purging and disinfecting activities, including test reports.

821.08.16 Plumbing Specialties: Plumbing fixtures shall be rigidly

821.08.17 Natural Gas Accessories: Fixtures shall have individual shut -

821.08.18 Water Closet - Close Coupled (Gravity Tank) Type:

1.Material: Vitreous china.

2.Bowl Type: Siphon Jet.

3.Height: Standard or as required by ADA, if applicable.

5.When no contamination is found, submit water samples in sterile bottles to authorities having jurisdiction (AHJ).

6.Prepar e and submit reports of purging and disinfecting activities, including test reports.

821.08.16 Plumbing Specialties: Plumbing fixtures shall be rigidly

821.08.17 Natural Gas Accessories: Fixtures shall have individual shut -

821.08.18 Water Closet - Close Coupled (Gravity Tank) Type:

1.Material: Vitreous china.

2.Bowl Type: Siphon Jet.

3.Height: Standard or as required by ADA, if applicable.

5.When no contamination is found, submit water samples in sterile bottles to authorities having jurisdiction (AHJ).

6.Prepar e and submit reports of purging and disinfecting activities, including test reports.

821.08.16 Plumbing Specialties: Plumbing fixtures shall be rigidly

821.08.17 Natural Gas Accessories: Fixtures shall have individual shut -

821.08.18 Water Closet - Close Coupled (Gravity Tank) Type:

1.Material: Vitreous china.

2.Bowl Type: Siphon Jet.

3.Height: Standard or as required by ADA, if applicable.

4.Rim Contour: Elongated.

5.Water Consumption: 1.6 gal per flush.

6.Color: White.

7.Fasteners: Marine Grade Stainless Steel.

821.08.19 Water Closet - Top Spud (Flush Valve) Type: Provide

commercial grade water closets and accessories that conform to ASME A112.19.2/CSA B45.1 and ASME A112.19.5. Use wall or floor mounted water closets as specified. Provide wall carriers on all wall mounted water closets. Comply with ADA if required. Top spud type water closets shall have the following features:

1.Material: Vitreous china.

2.Bowl Type: Siphon Jet.

3.Height: Standard or as required by ADA, if applicable.

4.Rim Contour: Elongated.

5.Water Consumption: 1.6 gal per flush.

6.Spud Size and Location: NPS 1 -1/2; top.

7.Color: White.

8.Flushometer Valve: Comply with ASSE 1037. Provide with diaphragm, integral check stop device, integral backflow prevention device, exposed brass body with corrosion resistant components, a lever handle, chrome plated finish (US26D), and an NPS 1 minimum inlet.

821.08.20 Toilet Seats: Provide toilet seats that conform to IAPMO/ ANSI

Z124.5. Toilet seats shall have the following features:

1.Material: Plastic.

2.Type: Commercial (Standard).

3.Shape: Elongated rim, closed front.

4.Hinge: Check.

5.Hinge Material: Stainless steel; concealed.

6.Seat Cover: Required.

7.Color: White.

821.08.21 Lavatories: Provide commercial grade lavatories and accessories

that conform to ASME A112.19.3/CSA B45.4 and NSF 61. Use wall or countertop mounted lavatories as specified. Provide wall carriers on all wall mounted lavatories. Use and install in accordance with ADA requirements where required. Lavatories shall have the following features:

1.Material: Vitreous china.

2.Color: White.

3.Bowl Type: Rectangular.

4.Size: As specified or as required by ADA, if applicable.

4.Rim Contour: Elongated.

5.Water Consumption: 1.6 gal per flush.

6.Color: White.

7.Fasteners: Marine Grade Stainless Steel.

821.08.19 Water Closet - Top Spud (Flush Valve) Type: Provide

1.Material: Vitreous china.

2.Bowl Type: Siphon Jet.

3.Height: Standard or as required by ADA, if applicable.

4.Rim Contour: Elongated.

5.Water Consumption: 1.6 gal per flush.

6.Spud Size and Location: NPS 1 -1/2; top.

7.Color: White.

821.08.20 Toilet Seats: Provide toilet seats that conform to IAPMO/ ANSI

Z124.5. Toilet seats shall have the following features:

1.Material: Plastic.

2.Type: Commercial (Standard).

3.Shape: Elongated rim, closed front.

4.Hinge: Check.

5.Hinge Material: Stainless steel; concealed.

6.Seat Cover: Required.

7.Color: White.

821.08.21 Lavatories: Provide commercial grade lavatories and accessories

1.Material: Vitreous china.

2.Color: White.

3.Bowl Type: Rectangular.

4.Size: As specified or as required by ADA, if applicable.

4.Rim Contour: Elongated.

5.Water Consumption: 1.6 gal per flush.

6.Color: White.

7.Fasteners: Marine Grade Stainless Steel.

821.08.19 Water Closet - Top Spud (Flush Valve) Type: Provide

1.Material: Vitreous china.

2.Bowl Type: Siphon Jet.

3.Height: Standard or as required by ADA, if applicable.

4.Rim Contour: Elongated.

5.Water Consumption: 1.6 gal per flush.

6.Spud Size and Location: NPS 1 -1/2; top.

7.Color: White.

821.08.20 Toilet Seats: Provide toilet seats that conform to IAPMO/ ANSI

Z124.5. Toilet seats shall have the following features:

1.Material: Plastic.

2.Type: Commercial (Standard).

3.Shape: Elongated rim, closed front.

4.Hinge: Check.

5.Hinge Material: Stainless steel; concealed.

6.Seat Cover: Required.

7.Color: White.

821.08.21 Lavatories: Provide commercial grade lavatories and accessories

1.Material: Vitreous china.

2.Color: White.

3.Bowl Type: Rectangular.

4.Size: As specified or as required by ADA, if applicable.

4.Rim Contour: Elongated.

5.Water Consumption: 1.6 gal per flush.

6.Color: White.

7.Fasteners: Marine Grade Stainless Steel.

821.08.19 Water Closet - Top Spud (Flush Valve) Type: Provide

1.Material: Vitreous china.

2.Bowl Type: Siphon Jet.

3.Height: Standard or as required by ADA, if applicable.

4.Rim Contour: Elongated.

5.Water Consumption: 1.6 gal per flush.

6.Spud Size and Location: NPS 1 -1/2; top.

7.Color: White.

821.08.20 Toilet Seats: Provide toilet seats that conform to IAPMO/ ANSI

Z124.5. Toilet seats shall have the following features:

1.Material: Plastic.

2.Type: Commercial (Standard).

3.Shape: Elongated rim, closed front.

4.Hinge: Check.

5.Hinge Material: Stainless steel; concealed.

6.Seat Cover: Required.

7.Color: White.

821.08.21 Lavatories: Provide commercial grade lavatories and accessories

1.Material: Vitreous china.

2.Color: White.

3.Bowl Type: Rectangular.

4.Size: As specified or as required by ADA, if applicable.

5.Height: Standard or as required by ADA, if applicable.

6.Mounting: For countertop type, provide material sealant and under -counter mounting kit. For wall -mounted type, provide chair carrier.

7.Fasteners: Marine grade stainless steel.

821.08.22 Sinks: Provide commercial g rade sinks and accessories that

comply with ASME A112.19.2/CSA B45.1 and NSF 61. Use and install in accordance with ADA requirements where required. Sinks shall have the following features:

1.Material: 0.050 -inch stainless steel.

2.Finish: Satin stainless st eel.

3.Bowl Type: Compartments are to be as specified on the plans.

4.Size: As specified or as required by ADA, if applicable.

5.Height: Standard or as required by ADA, if applicable.

6.Mounting: Material sealant and under -counter mounting kit.

7.Fasteners: Marine grade stainless steel.

821.08.23 Faucets: Provide two -handle center set faucets with rigid

gooseneck spouts that conform to ASME A112.18.1/ANSI A117.1 and NSF 61. Device is to be certified as lead free. Faucets shall have the following features:

1.Material: Solid Brass Construction.

2.Finish: Polished chrome – US26D.

3.Type: 4-inch lever handles with rigid gooseneck spout.

4.Height: Standard or as required by ADA if applicable.

5.Valve Type: Ceramic disc.

6.Fasteners: Marine grade stainless steel.

821.08.24 Water Coolers: Provide commercial grade water coolers and

accessories that comply with NSF 61 and ASHRAE 34, "Designation and Safety Classification of Refrigerants," for water coolers. Provide HFC 134a (tetrafluoroethane) refrigerant unless otherwise indicated. Use f lush-to-wall mounted type water coolers and provide wall carriers. Provide bi -level type water coolers and install in accordance with ADA requirements, where required.

1.Cabinet Material: Stainless steel.

2.Finish: Satin finish stainless steel.

3.Bowl Type: Rectangular

4.Size: As specified or as required by ADA, if applicable.

5.Height: Standard or as required by ADA, if applicable.

6.Mounting: Chair carrier.

7.Bubbler: One with adjustable stream regulator, located on deck.

8.Control: Push button

9.Fasteners: Marine grade stainless steel.

5.Height: Standard or as required by ADA, if applicable.

6.Mounting: For countertop type, provide material sealant and under -counter mounting kit. For wall -mounted type, provide chair carrier.

7.Fasteners: Marine grade stainless steel.

821.08.22 Sinks: Provide commercial g rade sinks and accessories that

comply with ASME A112.19.2/CSA B45.1 and NSF 61. Use and install in accordance with ADA requirements where required. Sinks shall have the following features:

1.Material: 0.050 -inch stainless steel.

2.Finish: Satin stainless st eel.

3.Bowl Type: Compartments are to be as specified on the plans.

4.Size: As specified or as required by ADA, if applicable.

5.Height: Standard or as required by ADA, if applicable.

6.Mounting: Material sealant and under -counter mounting kit.

7.Fasteners: Marine grade stainless steel.

821.08.23 Faucets: Provide two -handle center set faucets with rigid

gooseneck spouts that conform to ASME A112.18.1/ANSI A117.1 and NSF 61. Device is to be certified as lead free. Faucets shall have the following features:

1.Material: Solid Brass Construction.

2.Finish: Polished chrome – US26D.

3.Type: 4-inch lever handles with rigid gooseneck spout.

4.Height: Standard or as required by ADA if applicable.

5.Valve Type: Ceramic disc.

6.Fasteners: Marine grade stainless steel.

821.08.24 Water Coolers: Provide commercial grade water coolers and

1.Cabinet Material: Stainless steel.

2.Finish: Satin finish stainless steel.

3.Bowl Type: Rectangular

4.Size: As specified or as required by ADA, if applicable.

5.Height: Standard or as required by ADA, if applicable.

6.Mounting: Chair carrier.

7.Bubbler: One with adjustable stream regulator, located on deck.

8.Control: Push button

9.Fasteners: Marine grade stainless steel.

5.Height: Standard or as required by ADA, if applicable.

6.Mounting: For countertop type, provide material sealant and under -counter mounting kit. For wall -mounted type, provide chair carrier.

7.Fasteners: Marine grade stainless steel.

821.08.22 Sinks: Provide commercial g rade sinks and accessories that

comply with ASME A112.19.2/CSA B45.1 and NSF 61. Use and install in accordance with ADA requirements where required. Sinks shall have the following features:

1.Material: 0.050 -inch stainless steel.

2.Finish: Satin stainless st eel.

3.Bowl Type: Compartments are to be as specified on the plans.

4.Size: As specified or as required by ADA, if applicable.

5.Height: Standard or as required by ADA, if applicable.

6.Mounting: Material sealant and under -counter mounting kit.

7.Fasteners: Marine grade stainless steel.

821.08.23 Faucets: Provide two -handle center set faucets with rigid

gooseneck spouts that conform to ASME A112.18.1/ANSI A117.1 and NSF 61. Device is to be certified as lead free. Faucets shall have the following features:

1.Material: Solid Brass Construction.

2.Finish: Polished chrome – US26D.

3.Type: 4-inch lever handles with rigid gooseneck spout.

4.Height: Standard or as required by ADA if applicable.

5.Valve Type: Ceramic disc.

6.Fasteners: Marine grade stainless steel.

821.08.24 Water Coolers: Provide commercial grade water coolers and

1.Cabinet Material: Stainless steel.

2.Finish: Satin finish stainless steel.

3.Bowl Type: Rectangular

4.Size: As specified or as required by ADA, if applicable.

5.Height: Standard or as required by ADA, if applicable.

6.Mounting: Chair carrier.

7.Bubbler: One with adjustable stream regulator, located on deck.

8.Control: Push button

9.Fasteners: Marine grade stainless steel.

5.Height: Standard or as required by ADA, if applicable.

6.Mounting: For countertop type, provide material sealant and under -counter mounting kit. For wall -mounted type, provide chair carrier.

7.Fasteners: Marine grade stainless steel.

821.08.22 Sinks: Provide commercial g rade sinks and accessories that

comply with ASME A112.19.2/CSA B45.1 and NSF 61. Use and install in accordance with ADA requirements where required. Sinks shall have the following features:

1.Material: 0.050 -inch stainless steel.

2.Finish: Satin stainless st eel.

3.Bowl Type: Compartments are to be as specified on the plans.

4.Size: As specified or as required by ADA, if applicable.

5.Height: Standard or as required by ADA, if applicable.

6.Mounting: Material sealant and under -counter mounting kit.

7.Fasteners: Marine grade stainless steel.

821.08.23 Faucets: Provide two -handle center set faucets with rigid

gooseneck spouts that conform to ASME A112.18.1/ANSI A117.1 and NSF 61. Device is to be certified as lead free. Faucets shall have the following features:

1.Material: Solid Brass Construction.

2.Finish: Polished chrome – US26D.

3.Type: 4-inch lever handles with rigid gooseneck spout.

4.Height: Standard or as required by ADA if applicable.

5.Valve Type: Ceramic disc.

6.Fasteners: Marine grade stainless steel.

821.08.24 Water Coolers: Provide commercial grade water coolers and

1.Cabinet Material: Stainless steel.

2.Finish: Satin finish stainless steel.

3.Bowl Type: Rectangular

4.Size: As specified or as required by ADA, if applicable.

5.Height: Standard or as required by ADA, if applicable.

6.Mounting: Chair carrier.

7.Bubbler: One with adjustable stream regulator, located on deck.

8.Control: Push button

9.Fasteners: Marine grade stainless steel.

821.08.25 Tank Water Heaters (Electric): Provide electric tank water

heaters that conform to UL 1453. Water heaters shall have the following features:

1.Storage -Tank: ASME -code steel pressure rated for 150 psig. Tappings shall be factory fab ricated of materials compatible with tank and piping connections. Attach tappings to tank before testing. Interior finish shall comply with NSF 61 barrier materials for potable -water tank linings, including extending lining material into tappings.

2.Anode Rod: Replaceable magnesium.

3.Drain Valve: Corrosion -resistant metal complying with ASSE 1005.

4.Insulation: Comply with ASHRAE/IESNA 90.1.

5.Jacket: Steel with enameled finish.

6.Heating Elements: Electric, screw -in or bolt -on immersion type, arranged in multiples of three.

7.Temperature Control: Adjustable thermostat.

8.Safety Controls: High -temperature -limit and low -water cutoff devices or systems.

9.Relief Valves: ASME rated and stamped for combination temperature -and- pressure relief valves. Include one or more relief valves with total relieving capacity at least as great as heat input, and include pressure setting less than domestic -water heater working -pressure rating. Select one relief valve with sensing element that extends into storage tank. The drain is to be piped inside of an exterior wall and penetrate the wall outside 12 inches above finished grade.

821.08.26 Water Heater Accessories:

1.Drain Pan: Use 16 gauge marin e grade stainless steel. Sides are a minimum of 3 inches in height and a minimum of 3 inches wider than sides of the storage tank. The drain is to be piped inside of an exterior wall and penetrate the wall outside 12 inches above finished grade. If located in a mechanical room, pipe drain lines to nearest floor drain.

2.Temperature and Pressure Piping: Use copper water tube conforming to ASTM B88, Type L drawn tempered. Drawn tempered copper piping may be run in walls and ceiling spaces only. Connections sha ll be wrought copper and copper alloy solder joint pressure fittings in accordance with ASME 16.22. Flux shall meet or exceed alloy grade ASTM B813.

3.Cold Water Shut -off Valve: Provide a gate valve (specified below) on the entering cold water line.

4.Tank D rain Valve: Provide a gate valve (specified below) on the exiting hot water line, mounted below the water tank, if no means to drain the water tank is provided by the manufacturer.

821.08.25 Tank Water Heaters (Electric): Provide electric tank water

heaters that conform to UL 1453. Water heaters shall have the following features:

2.Anode Rod: Replaceable magnesium.

3.Drain Valve: Corrosion -resistant metal complying with ASSE 1005.

4.Insulation: Comply with ASHRAE/IESNA 90.1.

5.Jacket: Steel with enameled finish.

6.Heating Elements: Electric, screw -in or bolt -on immersion type, arranged in multiples of three.

7.Temperature Control: Adjustable thermostat.

8.Safety Controls: High -temperature -limit and low -water cutoff devices or systems.

821.08.26 Water Heater Accessories:

3.Cold Water Shut -off Valve: Provide a gate valve (specified below) on the entering cold water line.

4.Tank D rain Valve: Provide a gate valve (specified below) on the exiting hot water line, mounted below the water tank, if no means to drain the water tank is provided by the manufacturer.

821.08.25 Tank Water Heaters (Electric): Provide electric tank water

heaters that conform to UL 1453. Water heaters shall have the following features:

2.Anode Rod: Replaceable magnesium.

3.Drain Valve: Corrosion -resistant metal complying with ASSE 1005.

4.Insulation: Comply with ASHRAE/IESNA 90.1.

5.Jacket: Steel with enameled finish.

6.Heating Elements: Electric, screw -in or bolt -on immersion type, arranged in multiples of three.

7.Temperature Control: Adjustable thermostat.

8.Safety Controls: High -temperature -limit and low -water cutoff devices or systems.

821.08.26 Water Heater Accessories:

3.Cold Water Shut -off Valve: Provide a gate valve (specified below) on the entering cold water line.

4.Tank D rain Valve: Provide a gate valve (specified below) on the exiting hot water line, mounted below the water tank, if no means to drain the water tank is provided by the manufacturer.

5.Gate Valves: The gate valve shall conform to MSS SP -80, Type 2, be Class 125, and have a CWP rating of 200 psig. Body shall be bronze with integral seat and screw -in bonnet, and ends shall be threaded or soldered joint. Hand wheel shall be malleable iron, bronze or aluminum. Valve stem shall be bronze, disc shall be a solid bronze wedge, and packing shall be asbestos free.

821.08.27 Split System Air Conditioners - 5 Tons or Less - Electric

Heat:

1.Air Handling Units:

a.Chassis: Galvanized steel with flanged edges, faced glass fiber duct liner, and removable insulated panels for servicing.

b.Electrical: Provide a single point power connection and breaker sized in accordance with the manufacturer's recommendation and NEC code requirements. See Section 822 for electrical requirements.

c.Expansion Coil: Provide with copper tube, mechanically bonded aluminum fins, and an expansion valve. Comply with ARI 206/110.

d.Electric Heating Coil: Provide with helical, nickel -chrome, resistance wire heating elements with refractory ceramic support bushings, automatic reset thermal cutout, built -in magnetic contactors, manual reset thermal cutout, airflow proving device, and one time fuses in terminal box for over current protection.

e.Fan: Provide with double -width wheel of galvanized steel, and forward -curved blades. Fan shall be directly connected to the motor.

f.Fan Motor: Provide a multi -tapped, multi -speed motor with internal thermal protection, permanent lubrication, and a plug connection. Motor shall comply with NEMA designation, temperature rating, service factor, enclosure type, and efficiency requirements as specifi ed.

g.Air Filtration Section: Provide filter holding frames arranged for flat or angular orientation, with access doors on both sides of the unit. Filters shall be removable from one side or by lifting out from the access plenum. Provide permanent cleanable filters. Air filtration section shall comply with NFPA 90A. Minimum resistance shall be in accordance with ASHRAE 52.1, and MERV shall be in accordance with ASHRAE 52.2.

821.08.27 Split System Air Conditioners - 5 Tons or Less - Electric

Heat:

1.Air Handling Units:

a.Chassis: Galvanized steel with flanged edges, faced glass fiber duct liner, and removable insulated panels for servicing.

b.Electrical: Provide a single point power connection and breaker sized in accordance with the manufacturer's recommendation and NEC code requirements. See Section 822 for electrical requirements.

c.Expansion Coil: Provide with copper tube, mechanically bonded aluminum fins, and an expansion valve. Comply with ARI 206/110.

e.Fan: Provide with double -width wheel of galvanized steel, and forward -curved blades. Fan shall be directly connected to the motor.

h.Condensate Drain Pan: Provide with one percent slope in at least two planes to colle ct condensate from cooling coils (including coil piping connections, coil headers, and return bends) and humidifiers, and to direct water toward drain connection. Drain pan shall have a minimum height of three inches, and a length and width that extends a minimum of three inches beyond the air handling unit. Provide a float switch on the drain pan to de -energize the air conditioning system when positive contact is made. Fabricate drain pan from a single -wall, 16 gauge, marine grade stainless -steel sheet. Pr ovide a drain connection located at the lowest point of the drain pan and size to prevent overflow. Terminate with threaded nipple on one end of drain pan. Connection size to be a minimum of 1 inch.

2.Condensing Units:

a.Casing: Steel finished with baked enam el in color selected by the Architect, with removable panels for access to controls, weep holes for water drainage, and mounting holes in base. Mounting base shall be polyethylene. Provide brass service valves, fittings, and gauge ports on exterior of casi ng.

b.Electrical: Provide a single point power connection and disconnect sized as per the manufacturer's recommendation and as per NEC code requirements. See Section 822 for electrical requirements.

c.Compressor: Provide a scroll type with two speeds, a manual reset high pressure switch, and an automatic reset low pressure switch. Compressor shall be hermetically sealed, have a crankcase heater, and be mounted on a vib ration isolation device.

d.Compressor Motor: Provide with thermal and current sensitive overload devices, a start capacitor, a relay, and contactor.

e.Condensing Coils: Provide with copper tubing, mechanically bonded aluminum fins, and liquid subcooler. Cond ensing coils shall comply with ARI 206/110be.

f.Refrigerant: R-410A.

g.Fan: Aluminum propeller type directly connected to motor.

h.Fan Motor: Permanently lubricated, with integral thermal overload protection.

i.Low Ambient Kit: Shall allow operation down to 45 ºF.

3.Thermostat: Low voltage with subbase to control compressor and evaporator fan. Shall have “heat -off-cool” and “on -auto” selector switches. All thermostat wiring shall be installed in accordance with Section 822 .

a.Display: Provide Liquid -crystal display to indicate room temperature, set-point temperature, time setting, operating mode, and fan speed.

b.Automatic Reset Timer: Provide to prevent rapid cycling of the compressor.

4.Accessories:

a.Refrigerant Line Kits: Provide soft -annealed, factory cleaned, copper suction and liquid lines, dried, pressurized, and sealed. Suction line shall be factory insulated with flared fittings at both ends.

b.Condensate Drain Piping: Provide copper water tube conforming to ASTM B88, Type L, drawn tempered. Copper piping may be run in walls and ceiling spaces only. Connections shall be made wrought copper and copper alloy solder joint pressure fittings in accordance with ASME 16.22. F lux shall meet or exceed alloy grade ASTM B813.

c.Firestats: For systems with a supply air of less than 2000 cfm, provide firestats with a dust protected steel enclosure and a baked enamel finish, a relay rated to interrupt the fan motor -control circuit to de-energize the air handler on a temperature rise in excess of 125ºF, and a manual reset. Locate in the return air intake. Install in accordance with the manufacturer's instructions.

d.Duct Smoke Detectors: For systems with a supply air of greater than 2000 cfm, provide duct smoke detectors in accordance with NFPA 90A. Duct smoke detectors shall be photoelectric type in accordance with UL 268A. Provide with a weatherproof housing in accordance with NEMA 250, Type 4X; NRTL, and listed for use with the supplie d detector for smoke detection in HVAC system ducts. Provide with a relay rated to interrupt the fan motor -control circuit to de - energize the air handler on the detection of smoke in the ductwork. Locate in both the supply and return air ducts. Install in accordance with the manufacturer's instructions.

821.08.28 Split System Ductless HVAC System: Provide a unit that

includes a factory test log sheet for each unit consisting of the unit tested pressures, temperatures and amperage, as tested prior to shipment.

1.Indoor Ceiling -Mounted Cassette Units (5 Tons Or Less): Where specified, provide a ceiling cassette fan coil unit, operable with R -410A refrigerant, equipped with an electronic expansion valve, for installation into the suspended ceiling with an air panel grille, and factory -tested prior to shipment. Provide each component as follows:

a.Chassis: Galvanized steel, polyethylene insulation.

b.Panel Grille: Impact -resistant polypropylene; White.

c.Outside Air Intake: Integral, side mounted.

d.Fan: Direct -drive, tu rbo fan type with statically and dynamically balanced impeller with high, medium, and low speeds available.

e.Refrigerant Coils: Direct expansion type, copper tubes mechanically bonded with aluminum fins; charged with dehydrated air prior to shipment from the factory.

4.Accessories:

821.08.28 Split System Ductless HVAC System: Provide a unit that

includes a factory test log sheet for each unit consisting of the unit tested pressures, temperatures and amperage, as tested prior to shipment.

a.Chassis: Galvanized steel, polyethylene insulation.

b.Panel Grille: Impact -resistant polypropylene; White.

c.Outside Air Intake: Integral, side mounted.

d.Fan: Direct -drive, tu rbo fan type with statically and dynamically balanced impeller with high, medium, and low speeds available.

e.Refrigerant Coils: Direct expansion type, copper tubes mechanically bonded with aluminum fins; charged with dehydrated air prior to shipment from the factory.

f.Air Distribution: Four -way.

g.Filter: Long -life, washable with mildew -proof resin.

h.Condensate: 21-inch lift mechanism provided with built -in safety alarm.

i.Controls: Provide with a self diagnostic function, three minute time delay, automatic r estart, emergency operation function, and test run switch.

2.Indoor Wall -Mounted Units (5 Tons Or Less): Wall -mounted fan coil unit, operable with R -410A refrigerant, equipped with an electronic expansion valve, for installation onto a wall within condition ed space, and factory -tested prior to shipment.

a.Cabinet: Galvanized steel frame, affixed to a factory -supplied wall mounting template and located in conditioned space; polyethylene insulation.

b.Fan: Direct -drive, cross -flow; statically and dynamically bal anced impeller with high and low fan speeds; thermally protected.

c.Refrigerant Coils: Direct expansion type, copper tubes mechanically bonded with aluminum fins; charged with dehydrated air prior to shipment from the factory.

d.Controls: Provide with a self diagnostic function, three minute time delay, automatic restart, emergency operation function, and test run switch.

3.Outdoor Units (5 Tons Or Less): Direct expansion (DX), air -cooled heat pump, with variable speed, inverter -driven compressors. Unit shall be factory assembled and pre -wired with all necessary electronic and refrigerant controls. Unit shall be capable of providing heating to indoor units at 0ºF ambient temperature without additional low -ambient controls or auxiliary heat source. The condensin g unit shall automatically restart following power failure and will not cause any settings to be lost.

a.Refrigerant: R-410A.

b.Cabinet: Weatherproof; galvanized steel with corrosion -resistant baked enamel finish.

c.Fan: Direct -drive, propeller type with mult iple speed operation; permanently -lubricated bearings.

d.Compressor Type: Scroll.

e.Coils: Copper tubes mechanically bonded with aluminum fins; fins shall have anti -corrosion acrylic resin.

f.Safety Devices: Provide a high pressure sensor and switch, a low pressure switch, control circuit fuses, crankcase heater, fusible plug, overload relay, inverter overload protector, thermal protector for compressor and fan motors, over current protection for inverter, and anti -recycling timers.

g.Controls: Provide zone the rmostats where indicated on the drawings. Thermostat shall have “heat -off-cool” and “on -auto” selector switches, and be from the same manufacturer as the system. System shall provide constant fan operation or automatic fan operation on both the heating and cooling cycles.

h.Air Filters: Provide factory -manufactured, gasketed, framing systems and accessories. Provide and maintain temporary air filters during construction and install permanent filters after final acceptance.

821.08.29 Circular and Rectangular Rigid Duct work: Size and locate

circular and rectangular rigid ductwork as scheduled on the plans. Ductwork shall be galvanized steel, lock forming quality, conforming to ASTM A653 having G90 coating designation.

1.Ductwork Construction and Installation: Const ruct ductwork in accordance with SMACNA Duct Construction Standards – Metal and Flexible based on indicated static -pressure class unless otherwise indicated.

a.Collars: Always use collars when appropriate for duct transitions.

b.Bends: Radii of ben ds shall not be less than 1.5 times the width of the duct on centerline unless otherwise indicated on the plans.

c.Transitions: Offset angles of transitions shall not exceed 20 degrees.

d.Dampers: Provide galvanized (G90) lockable spin -in type manu al dampers for all diffuser branch lines as required for air balancing and on all individual duct runs. Install dampers a minimum of two duct widths from branch takeoff. Provide a minimum thickness of 26 gauge galvanized steel with 2 inches extension handl es.

e.Hanger Materials: Provide electro galvanized, all -thread rods. Straps and rod sizes shall be galvanized (G90) and shall comply with SMACNA’s HVAC Duct Construction Standards – Metal and Flexible for steel sheet thickness and for steel rod diamete rs. Ductwork shall be supported so as not to crush or damage insulation.

f.General Sealant and Gasket Requirements: Surface -burning characteristics for sealants and gaskets shall be a maximum flame -spread index of 25 and a maximum smoke -developed index of 50 when tested according to UL 723; certified by an NRTL. Whether required or not by SMACNA standards, seal all joints and seams on all duct systems. Apply sealant to male end connectors before insertion and afterward to cover entire joint and sheet me tal screws. Seal duct seams and joints according to SMACNA’s HVAC Duct Construction Standards – Metal and Flexible for duct pressure class or nearest class requiring continuous sealing.

821.08.29 Circular and Rectangular Rigid Duct work: Size and locate

circular and rectangular rigid ductwork as scheduled on the plans. Ductwork shall be galvanized steel, lock forming quality, conforming to ASTM A653 having G90 coating designation.

a.Collars: Always use collars when appropriate for duct transitions.

b.Bends: Radii of ben ds shall not be less than 1.5 times the width of the duct on centerline unless otherwise indicated on the plans.

c.Transitions: Offset angles of transitions shall not exceed 20 degrees.

g.Firewall Penetrations: Where ductwork passes through fire -rated interior partitions and exterior walls, install appropriately rated fire dampers, sleeves, and fire -stopping sealant that meet or exceed NFPA requirements and as per the wall UL listing.

821.08.30 Ductwork Insulation: All ductwork shall be externally

insulated. P rovide insulation that is a minimum of 2 -1/8 inches thick with a nominal density of 0.75 pounds/cubic foot.

1.Insulation: Provide mineral or glass fibers bonded with a thermosetting resin. Comply with ASTM C553, Type II and ASTM C1290, Type III with fac tory- applied FSK jacket. Insulation shall have a minimum installed thickness of 2 1/8 inches and a nominal density of 0.75 pounds/cubic foot.

2.Mineral -Fiber Adhesive: Comply with MIL -A-3316C, Class 2, Grade A.

3.ASJ Adhesive and FSK Jacket Adhesive: Comply with MIL -A-3316C, Class 2, Grade A for bonding insulation jacket lap seams and joints.

4.Mastic: Materials shall be compatible with insulation materials, jackets, and substrates; comply with MIL -PRF-19565C, Type II

5.FSK Tape: Foil-face, vap or-retarder tape matching factory -applied jacket with acrylic adhesive. Shall comply with ASTM C1136. Tape shall be minimum three inches wide, 6.5 mils thick, 90 ounces force per inch width adhesion, two percent elongation, and 40 lbf per inch width tensil e strength. Precut disks or squares of FSK tape may also be used.

6.Exterior Ductwork Jacket: In addition to the external insulation, exterior ductwork shall have a weatherproof flexible jacket with SMACNA Class A seals.

821.08.31 Flexible Connectors (HVAC): Where ducts are to be fastened

to the intake or discharge of an air -moving device, provide a flexible connection between the duct and fan.

1.Material: Use glass fabric, double coated with weatherproof, synthetic rubber, resistant to UV rays and ozone.

2.Minimum Weight: 24 ounces/sq yd.

3.Tensile Strength: 530 lbf/inch in the warp and 440 lbf/inch in the filling.

4.Service Temperature: Minus 50 to plus 250 ºF.

5.Compliance: Flexible connectors shall be in accordance with NFPA 45 and 90A and shall not provide pockets of stagnation or concentrations of vapor.

821.08.32 HVAC Testing, Adjusting, and Balancing: Projects

containing new or renovated HVAC systems shall be balanced to the requirements set forth in this subsection. HVAC systems shall be tested, adjusted, and balanced

821.08.30 Ductwork Insulation: All ductwork shall be externally

insulated. P rovide insulation that is a minimum of 2 -1/8 inches thick with a nominal density of 0.75 pounds/cubic foot.

2.Mineral -Fiber Adhesive: Comply with MIL -A-3316C, Class 2, Grade A.

3.ASJ Adhesive and FSK Jacket Adhesive: Comply with MIL -A-3316C, Class 2, Grade A for bonding insulation jacket lap seams and joints.

4.Mastic: Materials shall be compatible with insulation materials, jackets, and substrates; comply with MIL -PRF-19565C, Type II

6.Exterior Ductwork Jacket: In addition to the external insulation, exterior ductwork shall have a weatherproof flexible jacket with SMACNA Class A seals.

821.08.31 Flexible Connectors (HVAC): Where ducts are to be fastened

to the intake or discharge of an air -moving device, provide a flexible connection between the duct and fan.

1.Material: Use glass fabric, double coated with weatherproof, synthetic rubber, resistant to UV rays and ozone.

2.Minimum Weight: 24 ounces/sq yd.

3.Tensile Strength: 530 lbf/inch in the warp and 440 lbf/inch in the filling.

4.Service Temperature: Minus 50 to plus 250 ºF.

5.Compliance: Flexible connectors shall be in accordance with NFPA 45 and 90A and shall not provide pockets of stagnation or concentrations of vapor.

821.08.32 HVAC Testing, Adjusting, and Balancing: Projects

containing new or renovated HVAC systems shall be balanced to the requirements set forth in this subsection. HVAC systems shall be tested, adjusted, and balanced

821.08.30 Ductwork Insulation: All ductwork shall be externally

insulated. P rovide insulation that is a minimum of 2 -1/8 inches thick with a nominal density of 0.75 pounds/cubic foot.

2.Mineral -Fiber Adhesive: Comply with MIL -A-3316C, Class 2, Grade A.

3.ASJ Adhesive and FSK Jacket Adhesive: Comply with MIL -A-3316C, Class 2, Grade A for bonding insulation jacket lap seams and joints.

4.Mastic: Materials shall be compatible with insulation materials, jackets, and substrates; comply with MIL -PRF-19565C, Type II

6.Exterior Ductwork Jacket: In addition to the external insulation, exterior ductwork shall have a weatherproof flexible jacket with SMACNA Class A seals.

821.08.31 Flexible Connectors (HVAC): Where ducts are to be fastened

to the intake or discharge of an air -moving device, provide a flexible connection between the duct and fan.

1.Material: Use glass fabric, double coated with weatherproof, synthetic rubber, resistant to UV rays and ozone.

2.Minimum Weight: 24 ounces/sq yd.

3.Tensile Strength: 530 lbf/inch in the warp and 440 lbf/inch in the filling.

4.Service Temperature: Minus 50 to plus 250 ºF.

5.Compliance: Flexible connectors shall be in accordance with NFPA 45 and 90A and shall not provide pockets of stagnation or concentrations of vapor.

821.08.32 HVAC Testing, Adjusting, and Balancing: Projects

containing new or renovated HVAC systems shall be balanced to the requirements set forth in this subsection. HVAC systems shall be tested, adjusted, and balanced

821.08.30 Ductwork Insulation: All ductwork shall be externally

insulated. P rovide insulation that is a minimum of 2 -1/8 inches thick with a nominal density of 0.75 pounds/cubic foot.

2.Mineral -Fiber Adhesive: Comply with MIL -A-3316C, Class 2, Grade A.

3.ASJ Adhesive and FSK Jacket Adhesive: Comply with MIL -A-3316C, Class 2, Grade A for bonding insulation jacket lap seams and joints.

4.Mastic: Materials shall be compatible with insulation materials, jackets, and substrates; comply with MIL -PRF-19565C, Type II

6.Exterior Ductwork Jacket: In addition to the external insulation, exterior ductwork shall have a weatherproof flexible jacket with SMACNA Class A seals.

821.08.31 Flexible Connectors (HVAC): Where ducts are to be fastened

to the intake or discharge of an air -moving device, provide a flexible connection between the duct and fan.

1.Material: Use glass fabric, double coated with weatherproof, synthetic rubber, resistant to UV rays and ozone.

2.Minimum Weight: 24 ounces/sq yd.

3.Tensile Strength: 530 lbf/inch in the warp and 440 lbf/inch in the filling.

4.Service Temperature: Minus 50 to plus 250 ºF.

5.Compliance: Flexible connectors shall be in accordance with NFPA 45 and 90A and shall not provide pockets of stagnation or concentrations of vapor.

821.08.32 HVAC Testing, Adjusting, and Balancing: Projects

containing new or renovated HVAC systems shall be balanced to the requirements set forth in this subsection. HVAC systems shall be tested, adjusted, and balanced to set the proper airflow and water flow within distribution systems, including sub mains, branches, and terminals to indicate quantities according to the speci fied tolerances; adjusting total HVAC systems to provide quantities indicated on the plans; measuring electrical performance of HVAC equipment; verifying automatic control devices are functioning properly, measuring sound and vibration; and reporting resul ts of activities and procedures as specified in this subsection.

1.Quality Assurance: Provide an independent testing, adjusting, and balancing Agent (hereafter referred to as Agent) certified by either the AABC or NEBB.

2.Submittal Requirements: Prov ide submittals including a procedural step-by-step testing, adjusting, and balancing strategy. These submittals shall be provided to the Bridge Engineer for review on approved forms certified by the testing, adjusting, and balancing Agent. Testing, adjusti ng, and balancing reports shall conform to the AABC or NEBB standard form.

3.Coordination: If controls are involved on the project, the balancing Agent shall coordinate work with a control contractor to support and assist with testing, adjusting, and ba lancing.

4.Testing: The Agent shall perform testing and balancing procedures on each HVAC system according to the procedures contained in AABC national standards or NEBB’s “Procedural Standards for Testing, Adjusting, and Balancing of Environmental Syst ems.” Make any adjustments and/or replacement of items such as pulleys, belts, and dampers as recommended by the Agent at no additional cost or time to the Department. The Agent shall balance the HVAC system to the following tolerances:

a.Supply Fans: 0 to plus 10 percent of the design cfm.

b.Exhaust Fans: 0 to minus 5 percent of the design cfm.

c.Air Outlets and Inlets: Plus 10 percent to minus 10 percent of the design cfm.

d.Water Flow Rates: Plus 5 to minus 5 percent of the design gpm.

5.Reports: The Agent shall submit to the Bridge Engineer a preliminary testing report for review. The report shall be marked and returned to the Agent for corrections (if any). After outstanding comments are resolved, the Agent shall submit to the Bridge Engineer a bound and typewritten final report that he/she has signed, sealed, and dated to certify the accuracy of the report. As a minimum the report shall include the following:

a.Title page that includes the name and address of the Agent; the project number, name, and location; the architect’s name and address; the engineer’s name and address; the report date, and the signature of Agent who certified the report.

b.A summary of the contents including design versus final performance, notable characte ristics of systems, and a description of the system operation sequence if it varies from the plans.

c.List of the instruments used in the testing along with proof of calibration.

d.Pump curves, fan curves, manufacturer’s test data.

e.Field quality control test reports prepared by the system and equipment installers, and other information relative to equipment performance.

f.Nomenclature sheets for each item of equipment.

g.Terminal unit data including manufacturer, model, type, size, fittings , motors, air flows, static pressures, etc.

h.Coil data including flow rates (water and air), pressure drop (water and air), etc.

i.Duct traverse reports.

j.Do not include shop drawings.

821.08.33 In Ground Basins for Sewer Lift Stations: Provide precast

concrete pipe conforming to ASTM C478 for in ground lift station basins. Grout the bottom and slope to pumps. Basins shall be a minimum of 6 inches thick and shall be capable of handling geotechnical loading. Install an attached concrete base at the botto m of the basin for both geotechnical loading and to prevent the basin from lifting out of the ground. Excavation and backfill for in ground installations shall be in accordance with Section 802 . All piping and conduit into basins shall be grouted and watertight.

1.Access Hatch: Provide a heavy duty aluminum hatch for basin equipment access. The hatch shall have a minimum loading requirement of 300 psf.

2.Vent P ipes: Ventilate basin with a minimum 3 inch schedule 40 galvanized steel pipe. Vents shall have stainless steel insect screens.

821.08.34 Above Ground Basins for Sewer Lift Stations: Fabricate

from ASTM A709 Grade 36 galvanized steel, minimum ¼ inch. Basin shall be mounted to withstand all IBC wind loads. All penetrations into basin shall have a watertight flange.

1.Access Hatch: Provide a heavy duty aluminum hatch for basin equipment access. The hatch shall have a minimum loading requirement of 300 psf.

2.Vent Pipes: Ventilate basin with a minimum 3 -inch schedule 40 galvanized steel pipe. Vents shall have stainless steel inse ct screens.

821.08.35 Non-Clog Submersible Pumps for Sewer Lift Stations:

Provide a factory -assembled and factory -tested sewage -pump unit with guide -rail supports. The submersible sewage pumps shall consist of the following:

b.A summary of the contents including design versus final performance, notable characte ristics of systems, and a description of the system operation sequence if it varies from the plans.

c.List of the instruments used in the testing along with proof of calibration.

d.Pump curves, fan curves, manufacturer’s test data.

e.Field quality control test reports prepared by the system and equipment installers, and other information relative to equipment performance.

f.Nomenclature sheets for each item of equipment.

g.Terminal unit data including manufacturer, model, type, size, fittings , motors, air flows, static pressures, etc.

h.Coil data including flow rates (water and air), pressure drop (water and air), etc.

i.Duct traverse reports.

j.Do not include shop drawings.

821.08.33 In Ground Basins for Sewer Lift Stations: Provide precast

1.Access Hatch: Provide a heavy duty aluminum hatch for basin equipment access. The hatch shall have a minimum loading requirement of 300 psf.

2.Vent P ipes: Ventilate basin with a minimum 3 inch schedule 40 galvanized steel pipe. Vents shall have stainless steel insect screens.

821.08.34 Above Ground Basins for Sewer Lift Stations: Fabricate

from ASTM A709 Grade 36 galvanized steel, minimum ¼ inch. Basin shall be mounted to withstand all IBC wind loads. All penetrations into basin shall have a watertight flange.

1.Access Hatch: Provide a heavy duty aluminum hatch for basin equipment access. The hatch shall have a minimum loading requirement of 300 psf.

2.Vent Pipes: Ventilate basin with a minimum 3 -inch schedule 40 galvanized steel pipe. Vents shall have stainless steel inse ct screens.

821.08.35 Non-Clog Submersible Pumps for Sewer Lift Stations:

Provide a factory -assembled and factory -tested sewage -pump unit with guide -rail supports. The submersible sewage pumps shall consist of the following:

b.A summary of the contents including design versus final performance, notable characte ristics of systems, and a description of the system operation sequence if it varies from the plans.

c.List of the instruments used in the testing along with proof of calibration.

d.Pump curves, fan curves, manufacturer’s test data.

e.Field quality control test reports prepared by the system and equipment installers, and other information relative to equipment performance.

f.Nomenclature sheets for each item of equipment.

g.Terminal unit data including manufacturer, model, type, size, fittings , motors, air flows, static pressures, etc.

h.Coil data including flow rates (water and air), pressure drop (water and air), etc.

i.Duct traverse reports.

j.Do not include shop drawings.

821.08.33 In Ground Basins for Sewer Lift Stations: Provide precast

1.Access Hatch: Provide a heavy duty aluminum hatch for basin equipment access. The hatch shall have a minimum loading requirement of 300 psf.

2.Vent P ipes: Ventilate basin with a minimum 3 inch schedule 40 galvanized steel pipe. Vents shall have stainless steel insect screens.

821.08.34 Above Ground Basins for Sewer Lift Stations: Fabricate

from ASTM A709 Grade 36 galvanized steel, minimum ¼ inch. Basin shall be mounted to withstand all IBC wind loads. All penetrations into basin shall have a watertight flange.

1.Access Hatch: Provide a heavy duty aluminum hatch for basin equipment access. The hatch shall have a minimum loading requirement of 300 psf.

2.Vent Pipes: Ventilate basin with a minimum 3 -inch schedule 40 galvanized steel pipe. Vents shall have stainless steel inse ct screens.

821.08.35 Non-Clog Submersible Pumps for Sewer Lift Stations:

Provide a factory -assembled and factory -tested sewage -pump unit with guide -rail supports. The submersible sewage pumps shall consist of the following:

b.A summary of the contents including design versus final performance, notable characte ristics of systems, and a description of the system operation sequence if it varies from the plans.

c.List of the instruments used in the testing along with proof of calibration.

d.Pump curves, fan curves, manufacturer’s test data.

e.Field quality control test reports prepared by the system and equipment installers, and other information relative to equipment performance.

f.Nomenclature sheets for each item of equipment.

g.Terminal unit data including manufacturer, model, type, size, fittings , motors, air flows, static pressures, etc.

h.Coil data including flow rates (water and air), pressure drop (water and air), etc.

i.Duct traverse reports.

j.Do not include shop drawings.

821.08.33 In Ground Basins for Sewer Lift Stations: Provide precast

1.Access Hatch: Provide a heavy duty aluminum hatch for basin equipment access. The hatch shall have a minimum loading requirement of 300 psf.

2.Vent P ipes: Ventilate basin with a minimum 3 inch schedule 40 galvanized steel pipe. Vents shall have stainless steel insect screens.

821.08.34 Above Ground Basins for Sewer Lift Stations: Fabricate

from ASTM A709 Grade 36 galvanized steel, minimum ¼ inch. Basin shall be mounted to withstand all IBC wind loads. All penetrations into basin shall have a watertight flange.

1.Access Hatch: Provide a heavy duty aluminum hatch for basin equipment access. The hatch shall have a minimum loading requirement of 300 psf.

2.Vent Pipes: Ventilate basin with a minimum 3 -inch schedule 40 galvanized steel pipe. Vents shall have stainless steel inse ct screens.

821.08.35 Non-Clog Submersible Pumps for Sewer Lift Stations:

Provide a factory -assembled and factory -tested sewage -pump unit with guide -rail supports. The submersible sewage pumps shall consist of the following:

1.Pump Type: Submersible, end -sucti on, single -stage, close -coupled, overhung -impeller, centrifugal sewage pump as defined in ANSI/HI 1.1 -1.2 and ANSI/HI 1.3. Pumps shall be capable of passing 3 -inch solids without clogging.

2.Pump Casing: Cast iron, with open inlet, and discharge fitting s for connection to guide -rail support.

3.Impeller: Statically and dynamically balanced, stainless steel, non - clog, for solids handling, and keyed and secured to shaft.

4.Pump and Motor Shaft: Stainless steel, with factory -sealed, grease - lubricated b all bearings

5.Moisture -Sensing Probe: Internal moisture sensor and moisture alarm.

6.Motor: Hermetically sealed, capacitor -start type (if required); with built-in overload protection; lifting eye or lug; and three -conductor, waterproof power cable o f length required with grounding plug and cable -sealing assembly for connection at pump.

821.08.36 Chopper Type Submersible Pumps for Sewer Lift

Stations: Provide a factory -assembled and factory -tested sewage -pump unit with guide -rail supports. The submersible se wage pumps shall consist of the following:

1.Casing and Back Pull -Out Plate: The pump casing shall be of volute design, spiraling outward to the 125 lb. flanged centerline discharge. Back pull -out design shall incorporate jacking bolts for accurate adju stment of impeller -to-cutter bar clearance. Casing and back plate shall be ductile cast iron with all water passages to be smooth, and free of blowholes and imperfections for good flow characteristics. A pressure tap shall be included on or near the discha rge flange. Back plate shall include a replaceable Rockwell C 60 steel cutter adjustable for 0.005 -0.015 -inch clearance to cut against the rotating impeller pump out vanes for removing fiber and debris. Provide a minimum three mil MDFT epoxy coating.

2.Impeller: The impeller shall be semi -open type with pump out vanes to reduce seal area pressure. Chopping/maceration of materials shall be accomplished by the action of the cupped and sharpened leading edges of the impeller blades moving across the cutter bar at the intake openings, with a maximum set clearance between the impeller and cutter bar of 0.015 -0.025 inch cold. Impeller shall be cast alloy steel heat treated to minimum Rockwell C 60 and dynamically balanced. The impeller shall be keyed to the sha ft and shall have no axial adjustments and no set screws.

2.Pump Casing: Cast iron, with open inlet, and discharge fitting s for connection to guide -rail support.

3.Impeller: Statically and dynamically balanced, stainless steel, non - clog, for solids handling, and keyed and secured to shaft.

4.Pump and Motor Shaft: Stainless steel, with factory -sealed, grease - lubricated b all bearings

5.Moisture -Sensing Probe: Internal moisture sensor and moisture alarm.

821.08.36 Chopper Type Submersible Pumps for Sewer Lift

Stations: Provide a factory -assembled and factory -tested sewage -pump unit with guide -rail supports. The submersible se wage pumps shall consist of the following:

3.Cutter Bar Plate: The cutter bar plate shall be recessed into the pump bowl and shall contain at least two shear bars extending diametrically across the intake opening to within 0.010 -0.020 -inch of the rotating cutter nut tooth, for the purpose of preventing intake opening blockage and wrapping of debris at the shaft area. Chopper pumps utilizing individually mounted shear bars shall not be acceptable. Cutter bar shall be alloy steel heat -treate d to minimum Rockwell C 60.

4.Cutter Nut: The impeller shall be secured to the shaft using a cutter nut, designed to cut stringy materials and prevent binding using a raised, rotating cutter tooth. The cutter nut shall be cast steel heat treated to mini mum Rockwell C 60.

5.Upper Cutter: The upper cutter shall be threaded into the back pull -out adapter plate behind the impeller, designed to cut against the pump -out vanes and the impeller hub, reducing and removing stringy materials from the mechanical seal area. Upper cutter shall be cast steel heat treated to minimum Rockwell C 60. The upper cutter teeth are positioned as closely as possible to the center of shaft rotation to minimize cutting torque and nuisance motor tripping. The ratio of upper cutte r cutting diameter to shaft diameter in the upper cutter area of the pump shall be 3.0 or less.

6.Shafting: Pump shafting shall be heat -treated alloy steel. The pump shaft shall be directly coupled to the motor shaft, with a bolt and keyway.

7.Submers ible Electric Motor: The submersible electric motor shall be UL listed explosion proof for Class 1, Group D, Division 1 hazardous locations, rated at 3 phase, with a 1.15 service factor and Class F insulation. Motor shall be equipped with tandem, independ ently mounted, mechanical seals in oil bath and with dual moisture sensing probes. The inner and outer seals shall be separated by an oil - filled chamber. The oil chamber shall act as a barrier to trap moisture and provide sufficient time for a planned shut down. The oil shall also provide lubrication to the internal seal. The inner seal shall be a standard UL listed with carbon rotating faces and ceramic stationary faces. The outer seal construction shall be designed for easy replacement. Outer mechanical se al shall be 316 stainless steel metal bellows type with silicon carbide or tungsten carbide faces. Seal shall be positively driven by set screws. Elastomers shall be two normally closed automatic resetting thermostats connected in series and imbedded in ad joining phases. Motor frame shall be cast iron, and all hardware and shaft shall be stainless steel.

8.Nameplates: Provide stainless steel or aluminum nameplates permanently attached to the pump and drive motor giving the manufacturer’s model and serial number, rated capacity, head, speed, and any other pertinent data.

9.Guide Rail System: Provide a guide rail system consisting of two stainless steel guide rails, stainless steel pump guide bracket and discharge elbow with mounting feet and 125 lb flan ges, an upper guide rail mounting bracket and intermediate guide brackets every 10 feet.

10.Spark Proof Guide Rail System: Provide a non -sparking guide rail system consisting of two stainless steel guide rails, cast aluminum bronze pump guide bracket, c ast ductile iron discharge elbow with mounting feet and 125 lb flanges, upper guide rail mounting bracket, and intermediate guide brackets every 10 feet. System design shall prevent spark ignition of explosive gases during pump installation and removal.

11.Moisture -Sensing Probe: Provide an internal moisture sensor and moisture alarm.

821.08.37 Control Panels for Sewer Lift Stations: Provide NEMA 4X

stainless steel panels with the following features:

1.Alternate between pumps for each run cycle.

2.Audible and visual high water alarms.

3.Mercury float type switch with mounting rod and electric cables.

4.External indicator lights for each pump on/off status and each pump seal failure.

5.All components, wiring, and conduit shall be in accordance with Section 822, Electrical Systems.

821.08.38 Valves for Sewer Lift Stations: Each pump and motor

assembly shall have a shut -off valve and a swing check valve located above the high water alarm. Shut -off and swing check valves shall be as follows:

1.Shut-off Valves: Provide cast iron shut -off valves that conform to ASME B16.1. Valves shall be line size, Class 125, non -rising stem, and an epoxy coating.

2.Swing Check Valv es: Provide cast iron swing check valves that conform to ASME B16.1. Valves shall be line size, Class 250, horizontal swing type, rated for non -clog service, and an epoxy coating.

821.08.39 Accessories for Sewer Lift Stations:

1.Lift Assembly: Provide a marine g rade stainless steel lift assembly for each pump and motor.

2.Conduit Seals: Provide conduit seals on every conduit leaving the lift station basin. Seals shall be airtight, line sized, and code compliant.

821.08.40 In-Ground Sewage Treatment Facilities: Excava tion and

backfill for in -ground installations shall be in accordance with Section 802 .

11.Moisture -Sensing Probe: Provide an internal moisture sensor and moisture alarm.

821.08.37 Control Panels for Sewer Lift Stations: Provide NEMA 4X

stainless steel panels with the following features:

1.Alternate between pumps for each run cycle.

2.Audible and visual high water alarms.

3.Mercury float type switch with mounting rod and electric cables.

4.External indicator lights for each pump on/off status and each pump seal failure.

5.All components, wiring, and conduit shall be in accordance with Section 822, Electrical Systems.

821.08.38 Valves for Sewer Lift Stations: Each pump and motor

assembly shall have a shut -off valve and a swing check valve located above the high water alarm. Shut -off and swing check valves shall be as follows:

1.Shut-off Valves: Provide cast iron shut -off valves that conform to ASME B16.1. Valves shall be line size, Class 125, non -rising stem, and an epoxy coating.

2.Swing Check Valv es: Provide cast iron swing check valves that conform to ASME B16.1. Valves shall be line size, Class 250, horizontal swing type, rated for non -clog service, and an epoxy coating.

821.08.39 Accessories for Sewer Lift Stations:

1.Lift Assembly: Provide a marine g rade stainless steel lift assembly for each pump and motor.

2.Conduit Seals: Provide conduit seals on every conduit leaving the lift station basin. Seals shall be airtight, line sized, and code compliant.

821.08.40 In-Ground Sewage Treatment Facilities: Excava tion and

backfill for in -ground installations shall be in accordance with Section 802 .

11.Moisture -Sensing Probe: Provide an internal moisture sensor and moisture alarm.

821.08.37 Control Panels for Sewer Lift Stations: Provide NEMA 4X

stainless steel panels with the following features:

1.Alternate between pumps for each run cycle.

2.Audible and visual high water alarms.

3.Mercury float type switch with mounting rod and electric cables.

4.External indicator lights for each pump on/off status and each pump seal failure.

5.All components, wiring, and conduit shall be in accordance with Section 822, Electrical Systems.

821.08.38 Valves for Sewer Lift Stations: Each pump and motor

assembly shall have a shut -off valve and a swing check valve located above the high water alarm. Shut -off and swing check valves shall be as follows:

1.Shut-off Valves: Provide cast iron shut -off valves that conform to ASME B16.1. Valves shall be line size, Class 125, non -rising stem, and an epoxy coating.

2.Swing Check Valv es: Provide cast iron swing check valves that conform to ASME B16.1. Valves shall be line size, Class 250, horizontal swing type, rated for non -clog service, and an epoxy coating.

821.08.39 Accessories for Sewer Lift Stations:

1.Lift Assembly: Provide a marine g rade stainless steel lift assembly for each pump and motor.

2.Conduit Seals: Provide conduit seals on every conduit leaving the lift station basin. Seals shall be airtight, line sized, and code compliant.

821.08.40 In-Ground Sewage Treatment Facilities: Excava tion and

backfill for in -ground installations shall be in accordance with Section 802 .

11.Moisture -Sensing Probe: Provide an internal moisture sensor and moisture alarm.

821.08.37 Control Panels for Sewer Lift Stations: Provide NEMA 4X

stainless steel panels with the following features:

1.Alternate between pumps for each run cycle.

2.Audible and visual high water alarms.

3.Mercury float type switch with mounting rod and electric cables.

4.External indicator lights for each pump on/off status and each pump seal failure.

5.All components, wiring, and conduit shall be in accordance with Section 822, Electrical Systems.

821.08.38 Valves for Sewer Lift Stations: Each pump and motor

assembly shall have a shut -off valve and a swing check valve located above the high water alarm. Shut -off and swing check valves shall be as follows:

1.Shut-off Valves: Provide cast iron shut -off valves that conform to ASME B16.1. Valves shall be line size, Class 125, non -rising stem, and an epoxy coating.

2.Swing Check Valv es: Provide cast iron swing check valves that conform to ASME B16.1. Valves shall be line size, Class 250, horizontal swing type, rated for non -clog service, and an epoxy coating.

821.08.39 Accessories for Sewer Lift Stations:

1.Lift Assembly: Provide a marine g rade stainless steel lift assembly for each pump and motor.

2.Conduit Seals: Provide conduit seals on every conduit leaving the lift station basin. Seals shall be airtight, line sized, and code compliant.

821.08.40 In-Ground Sewage Treatment Facilities: Excava tion and

backfill for in -ground installations shall be in accordance with Section 802 .

11.Moisture -Sensing Probe: Provide an internal moisture sensor and moisture alarm.

821.08.37 Control Panels for Sewer Lift Stations: Provide NEMA 4X

stainless steel panels with the following features:

1.Alternate between pumps for each run cycle.

2.Audible and visual high water alarms.

3.Mercury float type switch with mounting rod and electric cables.

4.External indicator lights for each pump on/off status and each pump seal failure.

5.All components, wiring, and conduit shall be in accordance with Section 822, Electrical Systems.

821.08.38 Valves for Sewer Lift Stations: Each pump and motor

assembly shall have a shut -off valve and a swing check valve located above the high water alarm. Shut -off and swing check valves shall be as follows:

1.Shut-off Valves: Provide cast iron shut -off valves that conform to ASME B16.1. Valves shall be line size, Class 125, non -rising stem, and an epoxy coating.

2.Swing Check Valv es: Provide cast iron swing check valves that conform to ASME B16.1. Valves shall be line size, Class 250, horizontal swing type, rated for non -clog service, and an epoxy coating.

821.08.39 Accessories for Sewer Lift Stations:

1.Lift Assembly: Provide a marine g rade stainless steel lift assembly for each pump and motor.

2.Conduit Seals: Provide conduit seals on every conduit leaving the lift station basin. Seals shall be airtight, line sized, and code compliant.

821.08.40 In-Ground Sewage Treatment Facilities: Excava tion and

backfill for in -ground installations shall be in accordance with Section 802 . Foundations shall be in accordance with Section 823.07.1 , Foundations. Sewage treatment facilities shall consist of the following items:

1.General Requirements: The extended aeration sewage treatment plant shall provide primary and secondary treatment of wastewater flow. Primary treatment shall be accomplished in the aeration chamber of the facility. All incoming wastewater shall enter and be retained in the aeration chamber for 24 hours. Air shall be introduced along one wall near the bottom to produce a mixing and rolling action in the tank. Secondary treatment of the wastewater shall be accomplished in a clarification chamber. Mixed liquids shall flow from the aeration chamber into the clarification chamber by hydraulic displacement. The effective holding capacity of the clarifier shall be of sufficient volume to provide in excess of 4 hour retention of the daily flow. Capability of a plan t shall be certified by an independent testing laboratory. The manufacturer shall make certified data available to the regulatory agency, customer, consultant, and contractor as required. Principal items of equipment supplied with the system shall include concrete aeration and clarification tank(s), air distribution system, air diffused system, airlift sludge return pumping system, airlift surface skimming system, galvanized grating with bolted locking device for all tank openings, rotary blowers, motors, electrical controls, mechanical equipment housing, effluent weir trough, and all necessary internal piping and mechanical equipment. Reinforce the sewage treatment plant structure to withstand normal pressures from external soil and internal hydrostatic loads.

2.Aeration Chamber(s): Construct the clarifier of properly reinforced 5,000 psi, 28 day compressive strength concrete. Each casting shall be a monolithic unit with all four walls incorporated into the tank section. The aeration chamber(s) shall pr ovide 24 hour retention of daily waste water flow. The chamber shall be of sufficient size to provide a minimum of 80 cubic feet of tank capacity per pound of applied BOD. Install concrete fillets in the bottom of the chamber parallel to the treatment fl ow to ensure uniform tank roll and prevent deposition of solids. Overall design of the chamber shall be such that effective mixing shall be maintained to provide optimum treatment.

3.Air Distribution Piping: Provide galvanized steel Schedule 40 piping and galvanized malleable iron pipe fittings throughout the air distribution system. Provide individual galvanized pipe unions, dresser couplings, and flexible couplings with stainless steel clamps in the air distribution piping as required to allow individ ual adjustment of each separate element within the system. Provide primary air distribution through a galvanized air header. The air header shall have individual drop pipes connected to the header assembly for air supply to individual diffused assemblies. Provide each drop pipe with an air brass bodied adjustment valve to control air flow individually to each diffused assembly. In addition, provide a brass bodied quick release coupling or union for each pipe diffused assembly downstream from the air adjus tment.

4.Air Diffusion System: Provide diffusers parallel to the treatment flow in the aeration chamber. Install each diffuser assembly no more than 12 inches off the floor of the chamber and no more than 12 inches away from the chamber sidewall. Cons truct diffusers of Schedule 40 galvanized steel and design to ensure uniform mixing within the aeration chamber. Fine air bubble distribution effected by the diffusers shall be adequate to provide all oxygen necessary for the aerobic digestion process whi le maintaining an acceptable dissolved oxygen level in the final plant effluent.

5.Clarification Chamber: Provide a final clarification chamber for secondary treatment of the daily flow. Construct the clarifier of properly reinforced 5,000 psi, 28 -day c ompression strength concrete. Each casting in the clarifier shall be a monolithic unit with all four walls incorporated into the tank section. Provide an inlet baffle zone at the flow inlet to the clarification chamber. The area contained behind the baffl e shall allow adequate capacity and retention for surfacing of all buoyant material entering the clarifier. Settled sludge shall be returned to the aeration chamber by continuous airlift pumping.

6.Airlift Sludge Return: Provide an airlift sludge return pump for the hopper(s) in the clarification chamber. Air shall be supplied to the airlift(s) through a secondary air distribution system connected to the main air header of the treatment plant. Install individual air manifold piping for each airlift and e quip with a brass bodied valve for fine adjustment or shut -off. Construct the airlift(s) proper of Schedule 40 galvanized steel pipe and fittings. Install a removable clean -out plug at the top of the vertical airlift pipe. Arrange piping so that returned sludge is deposited in the aeration chamber at a point which prevents short -circuiting and with positive visible return. The airlift pump(s) shall be designed and manufactured of adequate size pipe and with sufficient air supply to provide a pumping rate i n excess of the total daily flow. Provide air required to achieve this in excess of the necessary air for aeration, mixing, and treatment. Equip the airlift pump inlet(s) to achieve this. Provide stainless steel brackets to position the inlet correctly at the base of the hopper.

7.Airlift Surface Skimmer: Provide an airlift surface skimming system in the settling zone of the clarification chamber(s). Construct the airlift skimmer(s) of Schedule 40 galvanized pipe and fittings. Equip the skimmer inlet(s) with an adjustable cone. Provide a removable galvanized cleanout plug at the top of the skimmer airlift pipe where it joins the horizontal discharge line. The discharge line shall run on top of the plant and return back to the aeration chamber for final d ischarge. Connect the skimmer air supply to the main air header of the treatment plant.

8.Disinfection: Disinfection of treatment plant effluent shall be done by a chlorine contact chamber. The chlorine contact chamber shall have a retention time of 15 minutes at peak hourly flow.

9.Mechanical Equipment: Provide air required for the treatment process and operation of airlifts in the clarifier by two rotary positive displacement blowers. Provide each blower unit with inlet air filter silencer(s), disch arge flexible coupling connector to air header assembly, and a bronze bodied check valve on the discharge piping. Each blower shall be capable of providing all air capacity for the sewage treatment facility. Blower connection to the drive motor(s) shall be conventional v - belts power transmission drive assembly. Motors shall be severe -duty TENV electric motor(s) used to drive the blower(s). When in operation at the rated horsepower, the motor(s) shall reach maximum speed that shall exceed 97 percent of the reference synchronous speed. The motor(s) for the facility shall be designed and rated for continuous duty applications and shall not overload or exceed motor nameplate ratings when operating as outlined for this facility.

10.Control Panel: Provide NEMA 4X stainless steel panels with the following features:

a.Alternate between blowers based on the time clock.

b.Audible and visual alarm for blower failure.

c.External indicator lights for each blower on/off status.

d.All components, wiring, and conduit shall be in accordance with Section 822 , Electrical Systems.

821.08.41 Above Ground Sewage Treatment Plants: Provide a U.S.

Coast Guard Certified Type II Marine S anitation Device (MSD). Equip the aeration -type mechanical sewage treatment system with clarification and chlorination chambers, valves, blowers, and chemical injection pump. Sewer and vent piping shall be Schedule 40 ductile iron with corrosion resistant coating. Exposed PVC piping will not be allowed. The sewage treatment plant shall contain the following:

1.Construction: Marine -grade aluminum with corrosion resistant finish.

2.Fasteners: Marine -grade stainless steel.

3.Finish: Ceramic -filled epo xy coating. Construct the airlift skimmer(s) of Schedule 40 galvanized pipe and fittings. Equip the skimmer inlet(s) with an adjustable cone. Provide a removable galvanized cleanout plug at the top of the skimmer airlift pipe where it joins the horizontal discharge line. The discharge line shall run on top of the plant and return back to the aeration chamber for final d ischarge. Connect the skimmer air supply to the main air header of the treatment plant.

8.Disinfection: Disinfection of treatment plant effluent shall be done by a chlorine contact chamber. The chlorine contact chamber shall have a retention time of 15 minutes at peak hourly flow.

10.Control Panel: Provide NEMA 4X stainless steel panels with the following features:

a.Alternate between blowers based on the time clock.

b.Audible and visual alarm for blower failure.

c.External indicator lights for each blower on/off status.

d.All components, wiring, and conduit shall be in accordance with Section 822 , Electrical Systems.

821.08.41 Above Ground Sewage Treatment Plants: Provide a U.S.

1.Construction: Marine -grade aluminum with corrosion resistant finish.

2.Fasteners: Marine -grade stainless steel.

3.Finish: Ceramic -filled epo xy coating.

4.Capacity: Minimum of 50 gallon per day.

5.Control Panel: NEMA 4X stainless steel enclosure meeting the following requirements:

a.Alternate between blowers based on the time clock.

b.Audible and visual alarm for blower failure.

c.External indicator light for blower on/off status.

d.All components, wiring, and conduit shall be in accordance with Section 822 , Electrical Systems.

821.08.42 Fencing Around Sewage System: Provide a 6 feet high fence

around all sewage treatment plants, lift stations, and accessories. Fence shall be as detailed on the plans. If not detailed on the plans, fence shall be in accordance with Section 705 and the Department’s standard chain link fence details. Fence shall have a 3 feet wide lockable gate or a lockable double gate if access for service vehicles is needed.

821.08.43 Equipment Nameplates: Where shown on the plans or as

required by the Project Engineer, all mechanical equipment shall have a nameplate as shown on Figure 821 -1. Refer to plan sheets and details for nameplate text and location. Nameplates shall be fabric ated from 1/16 -inch thick phenol plate engraved stock, have satin black outer layer, have white inner layer, and have 45 degree beveled edges. Nameplate wording shall have 1/4 -inch or 1/2 -inch size block -style letters. Nameplates shall have four 1/8 -inch d iameter pre -drilled holes, one at each corner, for mounting nameplate. Nameplates shall be fastened to equipment with #6 -32 marine duty stainless steel self -tapping machine screws having 30,000 psi yield strength. Nameplates shall be level after installati on. Any variation in nameplate size shall be submitted to the Bridge Engineer for review.

4.Capacity: Minimum of 50 gallon per day.

5.Control Panel: NEMA 4X stainless steel enclosure meeting the following requirements:

a.Alternate between blowers based on the time clock.

b.Audible and visual alarm for blower failure.

c.External indicator light for blower on/off status.

d.All components, wiring, and conduit shall be in accordance with Section 822 , Electrical Systems.

821.08.42 Fencing Around Sewage System: Provide a 6 feet high fence

821.08.43 Equipment Nameplates: Where shown on the plans or as

4.Capacity: Minimum of 50 gallon per day.

5.Control Panel: NEMA 4X stainless steel enclosure meeting the following requirements:

a.Alternate between blowers based on the time clock.

b.Audible and visual alarm for blower failure.

c.External indicator light for blower on/off status.

d.All components, wiring, and conduit shall be in accordance with Section 822 , Electrical Systems.

821.08.42 Fencing Around Sewage System: Provide a 6 feet high fence

821.08.43 Equipment Nameplates: Where shown on the plans or as

821.09 Measurement.

No measurement of materials will be made; material quantities shown on the plans are for informational purposes only. Preparing and submitting the Mechanical Operation and Maintenance Manual will not be measured for payment. The cost is to be included in the mechanical, electrical, and facility items contained in the plans.

821.10 PAYMENT. Payment for the completed and accepted items will be made

821.09 Measurement.

821.10 PAYMENT. Payment for the completed and accepted items will be made

821.09 Measurement.

821.10 PAYMENT. Payment for the completed and accepted items will be made

at the contract lump sum price, which includes furnishing, shop and field fabricating, erecting, cleaning and painting, galvanizing, or other coating materials; furnishing all required labor, equipment and materials, tools, stag ing, falsework, forms, welding, bolts, and other hardware; and the performance of all work necessary to complete the item. Cost of preparing and submitting the Mechanical Operation and Maintenance Manual shall be included in the pay items of Sections of 82 1, 822, and 823. The Department will retain 5 percent of the bid price of all mechanical, electrical, and facility items (821, 822, and 823 items) until the manual has been reviewed and accepted, and final paper reproductions have been received by the Depa rtment. When changes in the work are ordered by the Project Engineer, which vary from the contract, compensation will be in accordance with 109.04 . Payment will be made under: Item No. Pay Item Pay Unit 821-01 Swing Span Bridge Mechanical System (Type) Lump Sum 821-02 Vertical Lift Bridge Mechanical System (Type) Lump Sum 821-03 Bascule Span Bridge Mechanical System (Type) Lump Sum 821-04 Pontoon Span Bridge Mechanical System (Type) Lump Sum 821-05 Movable Barriers (Type) Lump Sum 821-06 Facility Mechanical Systems (Type) Lump Sum Section 822 Electrical Systems

822.01 DESCRIPTION . Furnish equipment, materials, tools, and labor to

purchase/fabricate, shop test, transport, install/erect, wire, align/adjust, paint, field test, and set -up electrical items/systems as specified.

822.02 Acronyms and Abbreviations.

IES Illuminating Engineering Society NEC National Electrical Code NESC National Electrical Safety Code NFPA National Fire Protection Association UL Underwriters Laboratories, Inc. See 101.0 2, 801.02, and 820.02 for additional acronyms.

822.03 Definitions .

System Compatibility . System compatibility covers the overall functionality, appropriateness, and integration with all components used to make up that system and interfacing with adjacent systems or components , whether electrical or non - electrical . See 101.03 , 801.03, and 820.03 for additional definitions.

822.04 Equipment and Materials .

Furnish equipment and materials suitable for the intended use with all necessary hardware and components. References to a specific manufacturer ’s name and/or catalog number are intended to denote the quality and function of equipment or material and not to specifically exclude other products. When specified model or catalog numbers conflict with descriptive specifications, plans , or system compatibility, the descriptive specifications, plans, or system compatibility shall govern. Except for those products designated as fabricated or those that are no longer produced, all specified products shall be manufactured by companies that regularly engage in the production of the specified products.

Source: Louisiana Standard Specifications for Roads and Bridges, 2016 Edition. Pages 850–921 of 1,145.

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820 DESCRIPTION

822 DESCRIPTION