SI2001E1 - New Jersey
PROJECT Specific SI
DESIGNER/CONSULTANT: PARSONS BRINCKERHOFF QUADE & DOUGLAS
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THE CONTRACT FOR THIS PROJECT IS AUTHORIZED BY THE PROVISIONS OF TITLE 27 OF THE REVISED STATUTES OF NEW JERSEY AND SUPPLEMENTS THERETO, AND TITLE 23 OF THE UNITED STATES CODE - HIGHWAYS.
SPECIFICATIONS TO BE USED
THE 2001 U.S. CUSTOMARY ENGLISH STANDARD SPECIFICATIONS FOR ROAD AND BRIDGE CONSTRUCTION, OF THE NEW JERSEY DEPARTMENT OF TRANSPORTATION AS AMENDED HEREIN WILL GOVERN THE CONSTRUCTION OF THIS PROJECT AND THE EXECUTION OF THE CONTRACT.
These Special Provisions consist of the following:
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Americans with Disabilities Act for 100 Percent State Funded Contracts, page 1, dated August 1993.
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The project work has areas of asbestos identified for removal, as shown on the plans. Project specific requirements for removal, handling, and disposal are attached to these special provisions as Appendix A – Asbestos Removal, consisting of 12 pages, dated March 30, 2006.
The project work has areas of lead contaminated soil designated for removal, as shown on the plans. Project specific requirements for removal, handling, and disposal are included in these Special Provisions. Lead Contaminated Soil items are shown in Section 201.
The project work has areas of lead contaminated paint removal, as shown on the plans. Project specific requirements for removal, handling, and disposal are part of these provisions Section 514 – Painting Existing Bridges.
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DIVISION 100 - GENERAL PROVISIONS
SECTION 101 - GENERAL INFORMATION
101.01 GENERAL.
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PURSUANT TO NJSA 27:1B-21.6 AND USC (UNITED STATES CODE) SECTION 115, THE COMMISSIONER INTENDS TO ENTER INTO AN ADVANCED CONSTRUCTION CONTRACT FOR THE ADVANCEMENT OF THE PROJECT. ALTHOUGH THE ADVANCED CONSTRUCTION CONTRACT WILL PLEDGE FUNDS ANTICIPATED TO BE APPROPRIATED FOR THE PROJECT BY THE LEGISLATURE, PAYMENT OF THE MONEYS PLEDGED IS SUBJECT TO THE AVAILABILITY OF FUNDS IN THE FISCAL YEAR (FY) IN WHICH THE FUNDS ARE TO BE APPROPRIATED. ONLY AMOUNTS APPROPRIATED BY LAW MAY BE EXPENDED.
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The Contractor shall not expend or cause to be expended any sum in excess of the amount allocated in the current fiscal year's Capital Program (as specified below). The Department will notify the Contractor when each level of additional funding has been appropriated by the Legislature or approved or provided by the Federal Government. Any expenditure by the contractor which exceeds the amount actually appropriated or exceeds the amount of approved federal funding is at the Contractor's risk and the Contractor waives any right to recover any sum in excess of that appropriated amount or the amount approved or provided by the Federal Government even if the State terminates or suspends work under the Contract because the Legislature has failed to appropriate or the Federal Government has not provided or approved sufficient funds to advance the Project.
The approved 2007 Capital Program has an item with $ 20.0 million for the construction of the Project.
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The Commissioner intends to proceed expeditiously with the Project. However, there is no assurance that the Annual Appropriations Act will contain an appropriation for the Project. The Legislature has no legal obligation to make such an appropriation. Failure by the Legislature to appropriate funds sufficient to advance the Project will not constitute a default under, or breach of, any contract entered into by the State for the construction of the Project. However, if the State terminates the Contract or suspends work under the Contract because the Legislature has failed to appropriate sufficient funding to advance the Project, the parties to the Contract will retain their rights pursuant to the suspension of work and termination of Contract Provisions of the Project specifications; except as indicated below.
The Contractor shall not expend or cause to be expended any sum in excess of the amount allocated in the current fiscal year's Capital Program (as specified below). The Department will notify the Contractor when each level of additional funding has been appropriated by the Legislature. Any expenditure by the Contractor that exceeds the amount actually appropriated is at the Contractor's risk and the Contractor waives any right to recover any sum in excess of that appropriated amount even if the State terminates or suspends work under the Contract because the Legislature has failed to appropriate sufficient funds to advance the Project.
The approved 2007 Capital Program has an item with $ 20.0 million for the construction of the Project.
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*****OR*****
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WHEN THE FOLLOWING TERMS ARE USED IN THE CONTRACT DOCUMENTS, THE INTENT AND MEANING SHALL BE STRICTLY CONSTRUED AS FOLLOWS:
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ADDITIONAL COMPENSATION. A MONETARY PAYMENT(S), SOUGHT BY THE CONTRACTOR, PREMISED UPON (1.) AN ADJUSTMENT OR MODIFICATION TO THE CONTRACT PAY ITEM(S) FOR PARTICULAR WORK OR (2.) ANY OR ALL FORMS OF COMPENSATION OVER AND ABOVE THAT WHICH IS SPECIFICALLY PROVIDED UNDER THE VARIOUS INDIVIDUAL CONTRACT PAY ITEMS OR CONTRACT PAYMENT PROVISIONS.
COMPLETION OF THE CONTRACT. The event termed “Completion of the Contract”, under the Specifications and the Contractual Liability Act NJSA 59:13-1 et seq., shall be deemed to have occurred as of the date the Contractor accepts or accepts with reservation of specific claims, in writing in accord with forms supplied by the Department, the Final Certificate issued by the Department or the 31st day after issuance of said Final Certificate by the Department, whichever event may be the first to occur.
CLAIM. The Contractor has reason to believe it is entitled to additional compensation and/or an extension of contract time, in accordance with and subject to the Contract Documents and the provisions of the Contractual Liability Act, N.J.S.A. 59:13-1 et seq., arising out of or relating to the happening of an event, thing or occurrence or an act or failure to act by the Engineer. A claim accrues when it arises, meaning when a situation or occurrence takes place or comes about which has or possesses the potential to support or become the basis for additional compensation and/or an extension of time.
DISPUTE (AS TO A CLAIM). A disagreement between the Department and the Contractor with regard to the Work or Contract Documents arising out of a claim by the Contractor for additional compensation or an extension of time.
FINAL CERTIFICATE. It is the final payment document that sets forth the total amount payable to the Contractor, including therein an itemization of said amount segregated as to Pay Item quantities, Extra Work, and any other basis for payment; it also includes therein any retainage to be released and all deductions made or to be made from prior payments as required pursuant to the provisions of the Contract Documents, which may result in either a Final Payment to the Contractor or a Credit (payment) due the Department.
NON-BINDING MEDIATION. The fourth and final step in the Department’s Contractual Claim Resolution Process for claims arising under the Contract utilizing a non-binding mediation forum wherein an independent mediator is engaged in an attempt to resolve a claim presented by a Contractor.
PARCEL. Property to be acquired for transportation purposes, described by metes and bounds.
SECRETARY, DEPARTMENT CLAIMS COMMITTEE. The individual employed by the Department who gathers information and provides administrative assistance to the members of the Department Claims Committee. This individual is the conduit between the Department Claims Committee members and the Contractor. Contact by the Contractor regarding any issue involving the Claims Committee or Mediation shall be through the Secretary.
The following terms are changed:
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3. THE CONTRACTOR HAS SATISFACTORILY EXECUTED AND DELIVERED TO THE ENGINEER ALL DOCUMENTS, WHICH IS TO INCLUDE THE FEDERAL FORM FHWA-47 “CONTRACTOR’S STATEMENT OF MATERIALS AND LABOR” ACCORDING TO 23CFR 635, FOR FEDERAL FUNDED PROJECTS, CERTIFICATIONS, AND PROOFS OF COMPLIANCE REQUIRED BY THE CONTRACT DOCUMENTS, IT BEING UNDERSTOOD THAT THE SATISFACTORY EXECUTION AND DELIVERY OF SAID DOCUMENTS, CERTIFICATES, AND PROOFS OF COMPLIANCE IS A REQUIREMENT OF THE CONTRACT.
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DESIGN UNIT. The term “Design Unit” means the Department’s consultant engineering firm, the in-house design unit(s), or both that prepared the Contract Documents for a project. The design unit(s) for any particular project shall be as designated by letter to the awarded Contractor.
EXTREME WEATHER CONDITIONS. When, solely as a result of adverse weather, the Contractor is not able to work, the Contractor is entitled to claim that progress of the Work has been affected by extreme weather conditions and may seek an extension of Contract Time consistent with the provisions of Subsection 108.11.
HOT MIX ASPHALT (HMA) PAVEMENT. The combination of base course, intermediate course, and surface course of hot mix asphalt.
ON-DUTY POLICE. The term “on-duty” with regard to municipal police shall mean that the work of providing traffic safety services shall be an extension of regular employment for, and sanctioned by, the municipality, even if it is on an overtime pay rate basis. The municipal police, while so working, shall be covered by the municipality’s liability insurance coverage; and must have successfully completed a traffic safety program approved by the Department.
PAVEMENT STRUCTURE. The combination of surface, intermediate and base courses, and when specified, a subbase course, placed on a subgrade to support the traffic load and distribute it to the roadbed (see Figure 101-1). These various courses are defined as follows:
1. Surface Course. One or more layers of specified material of designed thickness at the top of the pavement structure.
2. Intermediate Course. One or more layers of specified material of designed thickness placed on the base course.
3. Base Course. One or more layers of specified material of designed thickness placed on the subgrade or subbase.
4. Subbase. One or more layers of specified material of designed thickness placed on the subgrade.
PLANS. The approved plans, profiles, typical sections, cross-sections, approved working drawings, and supplemental drawings, or exact reproductions thereof, which show the location, character, dimensions, quantities, and details of the Work to be done. This includes the latest version of all Standard Construction Details in effect at the time of Advertisement. Certified working drawings are not plans and not part of the Contract Documents.
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PROPOSAL FORM: The term “Proposal form” means the Department approved proposal form produced from the Expedite software downloaded from the Department’s Bid Express web site at , prepared and submitted for the Work.
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REMEDIATE. The term “remediate” means the process that is approved by the New Jersey Department of Environmental Protection to address all regulated discharges.
SPECIFICATIONS. The compilation of provisions and requirements for the performance of prescribed work contained in the Standard Specifications, as supplemented by the Supplemental Specifications and Special Provisions, and modified by Addenda which, before the receipt of bids, are transmitted to prospective Bidders.
1. Standard Specifications. The term “Standard Specifications” means the 2001 Standard Specifications for Road and Bridge Construction of the New Jersey Department of Transportation, which has been approved for general application and repetitive use.
2. Supplemental Specifications. Approved additions and revisions to the Standard Specifications.
3. Special Provisions. Revisions to the Standard and Supplemental Specifications applicable to an individual project.
4. Electrical Materials Specifications. Approved standards for electrical materials, equipment, and installations that are in addition to the above specifications.
SUBSTANTIAL COMPLETION. The term “Substantial Completion” means the point at which the performance of all Work on the Project has been completed except landscaping items (including the planting of trees, shrubs, vines, ground covers, and seedlings), final cleanup, and repair of unacceptable work, and provided the Engineer has solely determined that:
1. the Project is safe and convenient for use by the public, and
2. failure to complete the Work and repairs excepted above does not result in the deterioration of other completed Work; and provided further, that the value of landscaping work remaining to be performed, repairs, and cleanup is less than two percent of the Total Adjusted Contract Price.
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SUBSTANTIAL COMPLETION. THE TERM “SUBSTANTIAL COMPLETION” MEANS THE POINT AT WHICH THE PERFORMANCE OF ALL WORK ON THE PROJECT HAS BEEN COMPLETED EXCEPT FINAL CLEANUP AND REPAIR OF UNACCEPTABLE WORK, AND PROVIDED THE ENGINEER HAS SOLELY DETERMINED THAT:
1. the Project is safe and convenient for use by the public, and
2. failure to complete the Work and repairs excepted above does not result in the deterioration of other completed Work; and provided further that the value of repairs and cleanup is less than two percent of the Total Adjusted Contract Price.
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COMPUTER DISK
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CLAIMS REVIEW BOARD
DISPUTE
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INQUIRIES REGARDING THE VARIOUS TYPES OF WORK OF THIS CONTRACT SHALL BE DIRECTED TO THE FOLLOWING REPRESENTATIVES OF THE DEPARTMENT HAVING OFFICES AT P.O. BOX 600, TRENTON, NEW JERSEY 08625, OR SUCH OTHER INDIVIDUALS AS MAY HEREAFTER BE DESIGNATED:
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1.
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All inquiries shall include the following:
a. Name of the company;
b. Telephone number, fax number, and contact person; and
c. Specifics of the inquiry, including anticipated impacts.
The Department will investigate the information provided in the inquiry and then respond through an addendum only if determined to be necessary.
2. After Award of the Contract. All inquiries shall be directed to the Resident Engineer through the following Regional Construction Office:
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Mr. Thomas J. Dowd, Regional Construction Engineer
100 Daniels Way
Freehold, NJ 07728
Telephone: 732-308-4074
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102.01 PREQUALIFICATION OF PROSPECTIVE BIDDERS.
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BIDS WILL BE RECEIVED ONLY FROM BIDDERS WHO MEET ALL OF THE FOLLOWING REQUIREMENTS:
1. Before the delivery of the bid, have been prequalified according to Regulations Covering the Classification of Prospective Bidders issued according to NJSA 27:7-35.1 et seq.
2. At the time of delivery of bid, have effective prequalification ratings of not less than the amounts of its bid.
3. At the time of delivery of bid, the Bidder has disclosed ownership as required by NJSA 52:25-24.2.
4. If the bidder is a corporation not incorporated in the State, it is authorized to do business in the State as required by NJSA 14A:15-2 et seq.
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5. The bidder shall also be in compliance with P.L. 2005, c.51.
6. The bidder must have a valid business registration with the Division of Revenue in the New Jersey Department of Treasury as required by NJSA 52:32-44 (P.L. 2001, c.134).
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102.03 BIDDER REGISTRATION AND DOWNLOADING OF THE BID DOCUMENTS; CONTENTS OF THE BID.
Electronic bidding information is available on Bid Express at . Registration and a subscription fee are required to access the bid documents and plans. The bidder shall download the Expedite bidding software by navigating to State and clicking the “Utilities Tab”. Before running the electronic bidding program, the Bidder shall read the on-line help documentation for the Expedite Bidding Software.
All bid documents with the exception of the Power of Attorney for the Proposal Bond shall be downloaded from the Bid Express web site. A bid shall consist of the downloaded and properly completed documents plus the Power of Attorney for the Proposal Bond which shall all be submitted to the Department on or before the time for the opening of bids.
The Proposal Form states the location and description of the Project, shows the estimate of the various quantities and kinds of work to be performed, includes a schedule of Pay Items for which bid prices are invited, and the date and time for the opening of bids. The Special Provisions state the number of days or date by which the Project must be completed.
The Bidder shall submit both a paper bid which is produced using the Expedite software as well as an electronic copy. No alteration to that software is permitted. The paper bid submitted to the Department will be reviewed and evaluated by the Department and serve as the basis for the award and subsequent Contract. In case of discrepancies between the paper bid and the electronic copy, the paper bid shall govern.
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THE BIDDER SHALL EXAMINE CAREFULLY THE SITE OF THE PROPOSED PROJECT, THE CONTRACT DOCUMENTS, AND OTHER INFORMATION BEFORE SUBMITTING A PROPOSAL. THE CONTRACT DOCUMENTS ARE NOT TO BE CONSTRUED AS AN AVERRED REPRESENTATION OR WARRANTY OF THE EXISTING CONDITIONS. IN THE EVENT THE BIDDER’S EXAMINATION REVEALS THAT THE SITE CONDITIONS ARE INCONSISTENT WITH THE CONTRACT DOCUMENTS OR THERE ARE DISCREPANCIES, ERRORS, OMISSIONS OR PATENT AMBIGUITIES WITHIN THE CONTRACT DOCUMENTS, THE BIDDER SHALL IMMEDIATELY NOTIFY THE DEPARTMENT AS PROVIDED IN SUBSECTION 101.04. BIDDERS SHALL MAKE SUCH INDEPENDENT INVESTIGATION AND EXAMINATION AS NECESSARY TO SATISFY THE BIDDER AS TO THE CONDITIONS TO BE ENCOUNTERED IN THE PERFORMANCE OF THE WORK AND THE TYPE OF EQUIPMENT AND OPERATIONS REQUIRED TO PERFORM THE WORK. THE BIDDER SHALL INVESTIGATE, WITH RESPECT TO POSSIBLE LOCAL MATERIAL SOURCES, THE QUALITY AND QUANTITY OF MATERIAL AVAILABLE AND THE TYPE AND EXTENT OF PROCESSING THAT MAY BE REQUIRED TO PRODUCE MATERIAL CONFORMING TO THE REQUIREMENTS OF THE CONTRACT DOCUMENTS. THE SUBMISSION OF A PROPOSAL SHALL BE CONSIDERED PRIMA FACIE EVIDENCE THAT THE BIDDER HAS MADE SUCH INDEPENDENT INVESTIGATION AND EXAMINATION, INCLUDING THE INFORMATION PROVIDED BELOW, AND IS FULLY AWARE OF THE REQUIREMENTS OF THE CONTRACT DOCUMENTS, INCLUDING ALL RESTRICTIONS. FURTHER, THE BIDDER WARRANTS THAT THE PROPOSED CONTRACT PRICES IN THE PROPOSAL INCLUDE ALL COSTS TO COMPLETE THE WORK.
The Bidders must provide written notice to the Regional Construction Engineer as listed in the Special Provisions Subsection 101.04, at least 24 hours in advance of any investigation at the site, and insure any staff at the site have two forms of identification and the site authorization form received with the purchase of the Contract Documents.
What is specified below is not a part of the Contract and is made available for information only. The Department makes no representation, warranty or guarantee, expressed or implied, by making available such information. It is also the Bidder’s responsibility to access such information.
1. Investigation of Subsurface and Surface Conditions.
The records of the Department’s subsurface investigation, including, but not limited to, boring logs and Geotechnical Engineering Design Reports, may be inspected at or ordered through the Department’s plan file room, 1035 Parkway Avenue, P.O. Box 600, Trenton, New Jersey 08625. This investigation, while considered by the Department to be sufficient for design purposes, may not be a sufficient substitute for the Bidder’s own investigation, interpretation, or judgement in preparing a Proposal for construction purposes. The Bidder shall not rely on any estimates and quantities included in these investigations. The conditions indicated by such investigations or records thereof, and as shown by the cross-sections in the Plans, may not be representative of those existing throughout such areas, or that materials other than, or in proportions different from those indicated, may be encountered.
The soil and rock descriptions shown on the boring logs are determined by a visual inspection of samples from the various explorations unless otherwise noted. These samples may be available for nondestructive examination. The observed water levels and other water conditions indicated on the boring logs are as recorded at the time of the exploration. These levels and other conditions may vary considerably, with time, according to the prevailing climate, rainfall, and other factors. If a generalized soil profile is described in the text it is intended to convey trends in subsurface conditions. The boundaries between strata are approximate and idealized and have been developed by interpretations of widely spaced explorations and samples.
The Bidder is charged with knowledge of the State’s physical geography, and in performing its site investigation shall be fully aware of the following publications and such others as may be listed in the Special Provisions:
a. Bulletin 50, Geologic Series, “The Geology of New Jersey” by H. Kummel, out of print, available generally as library reference material.
b. Geologic Maps of New Jersey, available through NJDEP.
c. Engineering Soils Survey of New Jersey, available through the Bureau of Research, College of Engineering, Rutgers University, New Brunswick, New Jersey 08903.
d. Soil Surveys of Individual Counties prepared by the US Department of Agriculture, Soil Conservation Service, in cooperation with the New Jersey Agricultural Experiment Station and Cook College, Rutgers University, available through local Soil Conservation District Offices.
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PAVEMENT CORE RECORD WILL BE PROVIDED IN THE SPECIAL PROVISION FOR THE CONTRACTOR’S INFORMATION ONLY. THIS INVESTIGATION, WHILE CONSIDERED BY THE DEPARTMENT TO BE SUFFICIENT FOR DESIGN PURPOSES, MAY NOT BE A SUFFICIENT SUBSTITUTE FOR THE BIDDER’S OWN INVESTIGATION, INTERPRETATION, OR JUDGMENT IN PREPARING A PROPOSAL. THE CONDITIONS INDICATED BY SUCH INVESTIGATION MAY NOT BE REPRESENTATIVE OF THOSE EXISTING THROUGHOUT SUCH AREAS, OR THOSE MATERIALS OTHER THAN, OR IN PROPORTIONS DIFFERENT FROM THOSE INDICATED, MAY BE ENCOUNTERED. THE BIDDER SHALL NOT SOLELY RELY ON ANY INFORMATION INCLUDED IN THIS INVESTIGATION.
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PAVEMENT CORE RECORD
PROJECT/ROUTE & SECTION: ___________________________________________________________
DRILLER: _____________________________________________________________________________
INSPECTOR: ___________________________________________________________________________
COUNTY/TOWNSHIP: ___________________________________________________________________
DATE STARTED: _____________ DATE COMPLETED: __________________
|CORE NUMBER |1 |2 |3 |4 |5 |
|ROUTE | | | | | |
|DIRECTION | | | | | |
|(N, E, S, W) | | | | | |
|MILE POST | | | | | |
|(MP or Station) | | | | | |
|LANE NO. | | | | | |
|(Left to Right) | | | | | |
|SHOULDER | | | | | |
|(Inside or Outside) | | | | | |
|CORE DIAMETER | | | | | |
|(Inches) | | | | | |
|TOTAL CORE DEPTH | | | | | |
|(Inches) | | | | | |
|CORE DRILLED TO | | | | | |
|SURFACE TYPE | | | | | |
|(AC/PC) | | | | | |
|AC THICKNESS | | | | | |
|(Inches) | | | | | |
|PC THICKNESS | | | | | |
|(Inches) | | | | | |
* Lane 1 is the left lane in the direction of travel.
The pavement information shown herein was obtained for State design and estimate purposes. It is made available to the authorized users only that they may have access to the same information available to the State. It is presented in good faith, but is not intended as a substitute for investigations, interpretation or judgment of such authorized users.
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3. Existing Plans and As-builts. As-built plans of Department owned facilities may be inspected at the Department’s plan file room or copies ordered upon written request through the Engineering Documents Unit, New Jersey Department of Transportation, 1035 Parkway Avenue, P.O. Box 600, Trenton, New Jersey 08625. Contour maps may be available for some Projects and the Bidders may inspect such maps or obtain copies for their use upon written request to the Engineering Documents Unit. Plans of Municipal owned or County owned facilities shall be obtained through the Municipality or County. Any information obtained from the existing documents shall be verified by the Bidder in regards to its application for bidding and completing the Project. A list of existing structures within the Project will be provided on the Plans. The existing plans and as-builts used in the development of Contract Documents will be listed in the Special Provisions.
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THE BIDDER SHALL SUBMIT A PROPOSAL FORM, THE PROPOSAL FORM SHALL INCLUDE ALL ADDENDA WHICH SHALL ALSO BE DOWNLOADED FROM THE DEPARTMENT BID EXPRESS WEB SITE. THE BIDDER SHALL SPECIFY A PRICE IN FIGURES FOR EACH PAY ITEM. FOR LUMP SUM ITEMS, THE PRICE SHALL APPEAR SOLELY IN THE BOX PROVIDED FOR THE LUMP SUM ITEM UNDER THE COLUMN DESIGNATED AS “AMOUNTS.” FOR UNIT PRICE ITEMS THE PER UNIT PRICE SHALL APPEAR UNDER THE COLUMN DESIGNATED “UNIT PRICE” IN THE APPROPRIATE BOX, AND THE PRODUCT OF THE RESPECTIVE UNIT PRICE AND THE APPROXIMATE QUANTITY FOR THAT ITEM SHALL APPEAR UNDER THE COLUMN DESIGNATED “AMOUNTS.” THE TOTAL CONTRACT PRICE IS THE SUM OF ALL FIGURES SHOWN IN THE COLUMN DESIGNATED “AMOUNTS” AND SHALL APPEAR AT THE LOCATION PROVIDED THEREFOR. WHEN THE BIDDER INTENDS TO BID ZERO ($0.00) FOR A PAY ITEM, A “0” SHALL APPEAR IN THE “UNIT PRICE” AND “AMOUNTS” COLUMNS FOR UNIT PRICE ITEMS OR IN THE “AMOUNTS” COLUMN FOR LUMP SUM ITEMS.
When the Proposal Form contains alternate items, the Bidder shall only provide the unit price and amount for the lowest priced alternate item. When alternate items in the Proposal Form have a lump sum pay quantity, the Bidder shall only provide the amount for the lowest priced alternate item. The alternate item for which a price has been provided shall be constructed. When the Proposal Form contains alternate groups of items, the Bidder shall only provide the unit price and amount for each item within the lowest priced alternate group. The alternate group of items for which a price has been provided shall be constructed.
The only entries permitted in the Proposal Form produced using the Expedite software will be the unit or lump sum prices for items that must be bid. The Expedite software will perform all extensions of the unit or lump sum prices, calculate the total bid amounts, and print a completed Proposal Form.
The Proposal Form printed from the Expedite software shall be printed on 8 ½” x 11” white papers and shall include all revisions to the proposal included in issued addendum. Bids will be accepted only if submitted on the Proposal Form generated and printed from Expedite software.
The Bidder shall check its bid prior to submission using the Expedite software. The Bidder shall select “tools” and then select “check bid” and assure there are no errors prior to printing the electronic bid. After final printing, the Bidder may make changes to the bid by indicating the changes in ink and initialing prior to submitting the bid. In the event of a discrepancy between the electronic copy and the paper bid, the paper bid will govern.
The paper bid must be signed in ink by the Bidder. If the Bidder is an individual, the Bidder’s name and post office address must be shown; by a partnership, the name and post office address of each partnership member must be shown; as a joint venture, the name and post office address of each member or officer of the firms represented by the joint venture must be shown; by a corporation, the name of the corporation and the business address of its corporate offices must be shown. For bids submitted by Joint Ventures the bidder shall select “tools” from the Expedite menu and mark the electronic bid as “Joint Bid.”
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ONCE THE BIDDER HAS COMPLETED THE BID AND MADE ALL DESIRED CHANGES, THE PAPER BID WITH ORIGINAL SIGNATURES AND AN ELECTRONIC COPY ON A CD-R SHALL BE SUBMITTED TO THE DEPARTMENT. DELIVER EACH BID IN ONE ENVELOPE, WITH THE ADDENDA ACKNOWLEDGEMENTS ATTACHED, CONTAINING THE FOLLOWING:
(1) Signed paper bid
(2) Proposal Bond and Power of Attorney
(3) Updated Financial Statement form DC-74B
(4) Wholly State funded contracts, proof of the registration as specified in Subsection 102.01
(5) Wholly State funded contracts, the Certification and Disclosure form (P.L. 2005, c.51)
(6) Electronic copy in a protective case
(7) Other related documents as specified, including the Demolition/Asbestos attachments
The specified SBE or DBE/ESBE attachments may be included in the bid envelope. Clearly indicate its contents on the envelope, including the bidder’s name and the DP number of the electronic bid. The bid shall be mailed or hand carried to the Department at the address and in care of the official in whose office the bids are to be received. Bids must be received before or at the time and at the place specified in the Advertisement. Bids will not be accepted after the receipt of bids has been declared closed by the Presiding Officer.
When the Bidder submits bids for two or more Projects, a single Updated Financial Statement, submitted in a separate envelope, is acceptable instead of a separate statement for each Project.
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THE PROPOSAL BOND GUARANTEES EXECUTION OF THE CONTRACT BY THE BIDDER RECEIVING THE AWARD.
The bid, when submitted, shall be accompanied by a Proposal Bond satisfactory to the Department, on the form furnished by the Department, for a sum of 50 percent of the Total Contract Price. Proposal bonds which do not comply in all respects with the provisions of N.J.A.C. 16:44-5.1 (d), including no reinsurance, will not be accepted.
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102.13 REVISIONS DURING BIDDING.
Any written, graphic, or electronic information to clarify, correct, or change the Contract Documents or bidding notices will be issued only as Addenda (or “Addendum” can be used interchangeably) before the opening of bids that clarify, correct, or change the Contract Documents. The Department will not send addenda to individual prospective bidders, but will only post addenda on the Department Bid Express web site. No addenda shall be posted less than 24 hours before the time set for the receipt of bids, with the exception of addenda postponing the bid opening date and time.
When Addenda are posted on the Department Bid Express web site, acknowledgment thereof must be made by the Bidder. Attach each acknowledgement to the Bid envelope. If all acknowledgments have not been attached, the bid envelope will be returned to the Bidder unopened. It is the obligation of the bidder to check the Department Bid Express web site for addenda.
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PROPOSALS WILL BE CONSIDERED IRREGULAR AND WILL BE REJECTED BY THE DEPARTMENT IF THEY ARE DETERMINED TO CONTAIN A MATERIAL DEFECT.
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THE DEPARTMENT WILL DISQUALIFY A BIDDER AND REJECT A BID SUBMITTED BY THAT BIDDER IF THE BIDDER IS DETERMINED BY THE DEPARTMENT TO LACK RESPONSIBILITY. FACTORS DEMONSTRATING A LACK OF RESPONSIBILITY SHALL INCLUDE BUT NOT BE LIMITED TO:
1. Evidence of collusion among bidders.
2. Uncompleted work, which in the opinion of the Department, might hinder or prevent completion of additional work if awarded.
3. Failure to satisfy the pre-award requirements of the Disadvantaged Business Enterprise or Emerging Small Business Enterprise (DBE or ESBE) as specified in the Special Provisions for federally funded contracts.
4. Failure to satisfy the pre-award requirements of the Small Business Enterprise (SBE) as specified in the Special Provisions for wholly State funded contracts.
5. The bid is materially unbalanced.
6. Lack of competency or lack of adequate machinery, plant, or other equipment.
7. Unsatisfactory performance on previous or current contracts.
8. Questionable moral integrity as determined by the Attorney General of New Jersey or the Department.
9. Any other outward actions or lack of action that demonstrates the Bidder is not responsible.
10. Disqualification, suspension, or debarment of an individual, firm, partnership, corporation, or any combination as required by NJSA 16:44-8.1
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102.17 REJECTION OF ALL BIDS.
The Department may reject all bids when it is advisable to do so in the interest of the State or public.
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103.05 PERFORMANCE BOND AND PAYMENT BOND.
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REINSURANCE IS PROHIBITED PURSUANT TO NJAC 16:44-6.1(B)6.
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103.06 EXECUTION OF THE CONTRACT.
The successful Bidder shall properly and duly execute a Contract in accord with Contract Documents and return same, together with the Performance Bond and Payment Bond, within ten State Business Days of the date of Award or Conditional Award. The successful bidder shall also provide the Department, within the same ten State Business Day period, proof of a valid business registration with the Division of Revenue in the New Jersey Department of Treasury. The Contract will not be entered into by the Department unless the Bidder first provides proof of a valid business registration in compliance with N.J.S.A. 52:32-44 (P.L. 2001, c134 ). For FHWA funded projects, the successful bidder shall also provide proof of valid, current registration with the New Jersey Department of Labor, Division of Wage and Hour Compliance as required by “Public Works Contractor Registration Act,” N.J.S.A. 34:11-56.48 et seq. (P.L. 2003, c. 91). If said Contract is not executed by the Commissioner within 45 State Business Days following receipt from the Bidder of the executed Contract and Performance Bond and Payment Bond, the Bidder may within its discretion withdraw its bid without penalty; where the Bidder chooses not to withdraw prior to the Commisioner executing said Contract, the Bidder shall be deemed to have waived any claim for Additional Compensation or for an extension of time. The Contract shall not become effective until it has been fully executed by all parties.
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103.08 CONTRACT DOCUMENTS.
After Award, the successful bidder may request the number of sets of Plans specified below, without charge. One copy of Special Provisions and Addenda is furnished, without charge, with each set of the Plans. Additional sets or additional copies are available to subscribers through as specified in Subsection 102.03.
Table of Plans Furnished Without Charge
|Amount of Contract |Sets of Plans |
|For More Than |To and Including | |
|$ 0 |$ 500,000 |1 |
|500,000 |1,000,000 |2 |
|1,000,000 |5,000,000 |3 |
|5,000,000 |10,000,000 |4 |
|10,000,000 |-- |5 |
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104.01 INTENT.
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THE INTENT OF THE CONTRACT DOCUMENTS IS TO DESCRIBE A FUNCTIONALLY COMPLETE AND AESTHETICALLY ACCEPTABLE PROJECT TO BE CONSTRUCTED AND COMPLETED BY THE CONTRACTOR IN EVERY DETAIL ACCORDING TO THE CONTRACT DOCUMENTS. ANY WORK THAT MAY BE REASONABLY INFERRED FROM THE CONTRACT DOCUMENTS AS BEING REQUIRED TO PRODUCE THE INTENDED RESULT SHALL BE SUPPLIED WHETHER OR NOT SPECIFICALLY CALLED FOR. THE CONTRACTOR IS RESPONSIBLE TO PROVIDE SUCH ELEMENTS TO COMPLETE THE WORK UNDER THE PAY ITEMS OF THE CONTRACT FOR NO ADDITIONAL COMPENSATION AS PROVIDED UNDER SUBSECTION 109.02. HOWEVER, AS SPECIFIED IN THE RESPECTIVE SUBSECTIONS, ADJUSTMENTS MAY BE ALLOWED WHEN THE DEPARTMENT DETERMINES THERE IS A DISCREPANCY, ERROR, OMISSION, OR LATENT AMBIGUITY. IT IS UNDERSTOOD THAT ONLY THE BEST CONSTRUCTION PRACTICE IS TO PREVAIL AND ONLY MATERIALS AND WORKMANSHIP OF THE FIRST QUALITY ARE TO BE USED.
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BDC03s-06 dated april 24, 2003
THOSE PAY ITEMS LISTED BELOW SHALL BE CONSIDERED AS MAJOR PAY ITEMS EVEN THOUGH THEIR CONTRACT VALUE MAY NOT BE MORE THAN TEN PERCENT OF THE TOTAL CONTRACT PRICE:
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REPAIR OF CONCRETE DECK, TYPE B
REPAIR OF CONCRETE DECK, TYPE C
CONCRETE REPAIRS, TYPE D
CONCRETE REPAIRS, TYPE E
REPLACE RIVETS WITH HIGH STRENGTH BOLTS
REPAIR OF STRUCTURAL STEEL
FENDER PILE SPLICE
CONTROL HOUSE REPAIRS DUE TO WATER LEAKAGE
CLEANING, IF AND WHERE DIRECTED
RACEWAY CONDUCTORS, TERMINATIONS, AND BOXES
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IF AN ORDERED ALTERATION IN THE WORK PURSUANT TO SUBSECTION 104.02 MATERIALLY CHANGES THE CHARACTER OF THE WORK OF A PAY ITEM, AND IF THE CHANGE SUBSTANTIALLY INCREASES OR DECREASES THE ACTUAL UNIT COST OF SUCH CHANGED ITEM AS COMPARED TO THE ACTUAL OR ESTIMATED ACTUAL COST OF PERFORMING THE WORK OF SAID ITEM ACCORDING TO THE CONTRACT DOCUMENTS ORIGINALLY APPLICABLE THERETO, IN THE ABSENCE OF A SUPPLEMENTARY AGREEMENT OR UNPROTESTED CHANGE ORDER SPECIFYING THE COMPENSATION PAYABLE, AN ADJUSTMENT IN COMPENSATION THEREFORE WILL BE MADE ACCORDING TO THE FOLLOWING:
1. The basis of such adjustment in compensation will be the difference between the actual unit cost to perform the work of said item or portion thereof involved in the alteration as originally planned and the actual unit cost of performing the work of said item or portion thereof involved in the alteration, as changed.
104.11 Value Engineering
4. Conditions.
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THE PROPOSAL SHALL NOT CHANGE THE CONTRACT’S ORIGINAL DESIGN CRITERIA, MERELY ELIMINATE WORK, BE BASED ON AN UNKNOWN FACTOR, OR DELAY THE PROJECT.
All proposals for changes to bridges and structures shall conform to the current AASHTO Standard Specifications for Highway Bridges as modified by the NJDOT Design Manual for Bridges and Structures.
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105.03 PLANS AND SPECIFICATIONS.
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THE CONTRACT DOCUMENTS ARE ESSENTIAL PARTS OF THE CONTRACT, AND A REQUIREMENT OCCURRING IN ONE IS AS BINDING AS THOUGH OCCURRING IN ALL. ALL COMPONENTS ARE COMPLEMENTARY AND DESCRIBE AND PROVIDE FOR THE GENERAL COMPLETION OF THE PROJECT. THE CONTRACTOR SHALL KEEP ONE SET OF PLANS, SPECIAL PROVISIONS, ADDENDA, STANDARD SPECIFICATIONS, SUPPLEMENTAL SPECIFICATIONS, AND STANDARD DETAILS AVAILABLE ON THE PROJECT SITE AT ALL TIMES.
In case of discrepancy, calculated dimensions will govern over scaled dimensions; Plans will govern over Specifications; Contract Documents will govern over Working Drawings, Right-of-Way Plans will govern over Plans when setting monuments; Special Provisions will govern over Supplemental Specifications; and Supplemental Specifications will govern over Standard Specifications.
The Contractor shall not take advantage of any apparent discrepancy, error, omission, or patent ambiguity in the Contract Documents. In the event the Contractor discovers any discrepancy, error, omission; or patent ambiguity in the Contract Documents, or if there is any doubt or question as to the intent or meaning of the Contract Documents, the Contractor shall immediately notify the Resident Engineer in writing with sufficient detail. The Department will promptly make, in writing, such corrections and interpretations as deemed necessary. The Contractor shall not be relieved of the obligation of completing an item of Work because of any discrepancy, error, omission, or patent ambiguity, and shall complete the Work as directed with adjustments as specified in Section 104. The Contractor shall not commence with any changes to the Work as provided under the Contract Documents without written authorization from the Department.
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THOSE PROVISIONS SHALL NOT APPLY TO THE REVIEW AND APPROVAL OF THE DESIGN FOR PROPRIETARY WALLS, NOISE BARRIERS, TEMPORARY SHEETING, SHEETING LEFT IN PLACE, TEMPORARY STRUCTURES, COFFERDAMS, ERECTION PLANS, TRAFFIC CONTROL/STAGING PLANS AND PRECAST CONCRETE CULVERTS OR ANY OTHER ITEMS WHERE CONCEPTUAL PLANS WERE INCLUDED IN THE CONTRACT DOCUMENTS AND THE CONTRACTOR IS REQUIRED TO COMPLETE THE FINAL DESIGN PLANS.
The following is added to the eleventh paragraph:
THE DESIGN UNIT(S) SHALL BE AS DESIGNATED FOR EACH CONTRACT BY LETTER FROM THE DEPARTMENT.
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23. Exodermic Deck System
24. Steel Grid Flooring
25. Traffic and Barrier Gates
27. Fender System Repairs
28. Finger Joints
29. Conduit and Wiring System
30. Bridge Control System
31. Electrical Service Automatic Transfer Switch
32. Direct Drive Diesel and Temporary Span Motor Assembly
THE FOLLOWING IS ADDED TO THE END OF THE EIGHTEENTH PARAGRAPH:
9. Demolition and Erection Plans
10. Temporary Shielding Design and Details
11. Temporary Jacking System for Approach Spans Bearing Replacement
12. Cleaning and Painting Containment/Shielding Design and Details
The Contractor is cautioned that certain materials required for contract items may have an unusually long lead time for approval and/or procurement. The preparation of working drawings and other necessary approvals for these items, if required, shall be expedited so that the construction may proceed as planned. The Contractor shall account for the required lead times in the preparation of his original baseline progress schedule in accordance with Subsection 108.04. Materials with unusually long lead time may include, but are not limited to:
Warning Gates and Barrier Gates
Specialized concrete mix designs
Exodermic deck panels
Open Grid deck Panels
Bridge Control Console and Cabinets
DC Drive Cabinets and SCR Drive Cabinets
Structural Steel for Barrier Gate and Warning Gate platforms
THE FOLLOWING IS ADDED:
Project Sequencing and Advanced Materials Acquisition – The contractor is alerted to two key items of work that shall be completed prior to the end of the first winter outage of the bascule span, that is prior to March 1, 2007 – these work items are the installation of the two advance warning gates and two barrier gates and all four platforms for the barrier gates and warning gates and all the necessary electrical work for the full operation of the four gates to be completed prior to the opening of the span for normal operation on March 1, 2007. As such the contractor is required to begin the necessary work for submittals of RFI’s, shop and working drawings, catalog cuts, manufacturer data, necessary designs and calculations, etc., – for the gates and components and platforms and components as necessary, for the Engineer’s approval, upon AWARD of the contract, no later than three working days after Award. The Designer’s Construction Schedule has been prepared with the assumption that this necessary preparatory work for advance material acquisition will begin by September 5, 2006, contingent upon Award of the Contract on August 31, 2006. Appropriate adjustments to these dates will be made depending upon the actual Award date of the contract.
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105.07 PURCHASE OF CONTRACT DOCUMENTS.
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A. GENERAL. IT IS UNDERSTOOD AND AGREED THAT THE CONTRACTOR HAS CONSIDERED IN ITS PROPOSAL ALL OF THE PERMANENT AND TEMPORARY UTILITY FACILITIES IN THEIR PRESENT, NEW, OR RELOCATED POSITIONS TO THE EXTENT REQUIRED BY THE CONTRACT DOCUMENTS AND AS REVEALED BY ITS OWN INVESTIGATIONS; IS AWARE THAT UTILITY SERVICE DEMANDS, ADVERSE FIELD CONDITIONS AND EMERGENCIES MAY AFFECT THE UTILITY’S ABILITY TO COMPLY WITH THE PROPOSED SCHEDULES FOR UTILITY WORK; IS COGNIZANT OF THE LIMITED ABILITY OF THE DEPARTMENT TO CONTROL THE ACTIONS OF THE UTILITY(S), AND HAS MADE ALLOWANCES IN ITS PROPOSAL THAT IT IS NOT ENTITLED TO ANY ADDITIONAL COMPENSATION BY REASONS OF DELAYS, INCONVENIENCE OR DAMAGE SUSTAINED BY THE CONTRACTOR DUE TO ANY INTERFERENCE FROM UTILITY FACILITIES OR THE OPERATION OF MOVING OR INSTALLING THEM. SIMILARLY, THE CONTRACTOR IS DEEMED TO UNDERSTAND THAT ONLY LIMITED EXTENSIONS OF TIME MAY BE GRANTED AS SPECIFIED IN SUBSECTION 108.11.
The Contractor shall notify, in writing, the Utility(s) involved of the nature and scope of the Project, and of its operations that may affect their facilities or property. The notice shall include an inquiry for all information required to determine the location of the existing utility facilities and the Contractor shall also provide the portion of the approved Preliminary Schedule relative to that respective Utility. Two copies of such notices and the Utility’s responses shall be sent to the Resident Engineer prior to the start of Construction Operations. The Contractor shall also attend a Utility preconstruction conference prior to the start of Construction Operations.
The Contractor shall provide each Utility the portion of the approved Baseline CPM Schedule related to the respective Utility and any approved updates or revisions that affect that Utility.
Information on the Utility(s), including the work to be performed by the Utility(s) on the Project, will be provided in the Special Provisions.
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New Jersey Natural Gas
1415 Wyckoff Road
Wall, NJ 07719
Attn: Mr. Mark Kurilla
Tel: (973) 919-8158
Fax: (973) 919-7854
Electric
Jersey Central Power and Light
Electric Delivery
1 River Center
Building 3
331 Newman Springs Road
Red Bank, NJ 07701
Attn: Mr. William Uellner
Tel.: (973) 212-4216
Fax: (973) 695-5585
Sewer / Water
Brielle Municipal Authority – Water & Sewer
601 Union Lane
Brielle, NJ 08730
Attn: Mr. William Burkhardt
Tel: (732) 528-6600
Brielle Borough Engineer – Water & Sewer
Mr. Alan Hilla, Jr.
c/o Birdsall Engineering, Inc.
611 Industrial Way West
Eatontown, NJ 07724
Tel: (732) 380-1700 Ext. 1216
Fax: (732) 380-1701
Borough of Point Pleasant Beach – Water & Sewer
416 New Jersey Avenue
Point Pleasant, NJ 08742
Attn: Mr. Robert Meany; Mr. Michael Gardner; Ms. Christine Riehl
Tel: (732) 899-0705
Tel: (732) 899-3306
Tel: (732) 892-8770
Fax: (732) 899-8970
Cable Television
Comcast Communications
751 Brick Boulevard
Brick, NJ 08723
Attn: Mr. Andrew Cortes
Tel: (732) 299-2971
Fax: (732) 920-6017
Cablevision of Monmouth
1501 18th Avenue
Wall, NJ 07719
Attn: Mr. Paul Kostyz
Tel: (732) 681-8222 Ext. 3285
Telephone
Verizon-NJ, Inc.
900 Clinton Avenue, 1st Floor
Irvington, NJ 07111
Attn: Mr. Frank Antisell
(To be copied on all correspondence)
Tel.: 973-649-4058
Fax: 973-484-8748
Verizon-NJ, Inc.
5100 Belmar Boulevard
Farmingdale, NJ 07727
Attn: Mr. Warren Ryllo
Tel: (732) 751-8725
Nextel Communications, Inc.
210 Malapardis Road, Floor 1
Cedar Knolls, NJ 07927
Mr. Scott Hawkins
Tel.: 973-631-7551
Railroad
New Jersey Transit
1 Penn Plaza East
2nd Floor
Newark, NJ 07105
Attn: Mr. Charles Johnson
Tel: (973) 879-7132
Bidders are advised to verify the above information as its accuracy and completeness is not guaranteed by the Department.
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Electrical service outages during the rehabilitation of the bridge are to be requested by the Contractor. The Contractor shall provide written notice to Jersey Central Power and Light (JCPL) four (4) weeks before the anticipated outage is required.
The anticipated sequence of operations following such notice is as follows:
1. Contractor provides written notice to (JCPL) prior to outage. (Duration - 4 weeks)
2. (JCPL) shuts off electrical service feeding the Route 35 Bridge over the Manasquan River. (Duration – 2 weeks)
3. Contractor completes work on bridge requiring shutdown of electrical service.
4. Contractor provides written notice to (JCPL) to restore power. (Duration - 4 weeks)
5. (JCPL) turns on electrical service feeding the Route 35 Bridge over the Manasquan River. (Duration – 2 weeks)
The Contractor may perform other work at the site and cannot interfere with the electrical service, until the outage has taken place. No extension in time will be considered for delays if, in the opinion of the Engineer, the Contractor has interfered with the electrical service work or is otherwise responsible for such delays.
Jersey Central Power and Light Electric Delivery – Utility Pole Relocation:
Three utility poles in the vicinity of Route 35 and Euclid Avenue are to be relocated behind proposed guiderail. The Contractor shall provide written notice to Jersey Central Power and Light (JCPL) eight (8) weeks prior to the anticipated pole relocation is to occur. JCPL requires one (1) week to complete the relocations.
Verizon-NJ Phone Service – Service Connection to Bridge:
Phone service outages during the rehabilitation of the bridge are to be requested by the Contractor. The Contractor shall provide written notice to Verizon-NJ four (4) weeks before the anticipated outage is required.
The anticipated sequence of operations following such notice is as follows:
1. Contractor provides written notice to Verizon-NJ prior to outage. (Duration - 4 weeks)
2. Verizon-NJ, Inc shuts off phone service to the Route 35 Bridge over the Manasquan River.
3. Contractor completes work on bridge requiring shutdown of phone service.
4. Contractor provides written notice to Verizon-NJ to restore power. (Duration - 4 weeks)
5. Verizon-NJ restores phone service to the Route 35 Bridge over the Manasquan River. (Duration - 2 weeks)
The Contractor may perform other work at the site and cannot interfere with the phone service. No extension in time will be considered for delays if, in the opinion of the Engineer, the Contractor has interfered with the phone service work or is otherwise responsible for such delays.
New Jersey Natural Gas – Work in Proximity to Proposed Bulkhead:
New Jersey Natural Gas has an existing 8 inch gas distribution main in the vicinity of the proposed bulkhead adjacent to the northern abutment of the Manasquan River Bridge. The Utility does not anticipate impacts to their main, however, they require their staff to be present when the Contractor is to perform bulkhead construction within 10 feet of the main. The utility requires 10 working days notification prior to commencing work. No extension in time will be considered for delays if, in the opinion of the Engineer, the Contractor has interfered with the gas main or is otherwise responsible for such delays.
B. Existing Facilities. The Contractor shall not proceed with any excavation operations until it has determined the exact location of the existing utility facilities within the Project from examination of the Contract Documents and information provided in Subsection 102.06, through inquiries to the respective Utility(s), and through its own subsurface site investigations, including test pits. Test Pits shall be as specified in Subsection 207.04. The Contractor shall notify the Resident Engineer as specified in Subsection 105.03 if their examinations determine any conflicts to completing the Work.
The Contractor shall notify the Resident Engineer at least 10 State Business Days in advance of the excavation of any test pits, or other subsurface investigations. Bidders shall notify the Department in advance as specified in Subsection 102.06.
Electrical installations, including Intelligent Transportation Systems (ITS) facilities as specified in Section 706, of the Department constructed either before or as part of the Contract shall be considered a Utility, and all provisions of this Subsection and Division 700 shall be applicable.
Examination of Department documents available on existing electrical installations shall be as specified in Subsection 102.06. The Contractor may request markout for the fiber optic network of the Department ITS facilities. Markout will be provided within ten Working Days after the completed, written Traffic Operations Markout Form is received by the Traffic Operations location specified in the Special Provisions in this Subsection. The Contractor shall copy the Resident Engineer on the written request and shall maintain the markout until all operations in the vicinity of the ITS facilities are completed.
C. Regulations. The Contractor shall also comply with all other State and Federal rules, and regulations applicable to work on or in the proximity of utilities. Specific attention is made to:
1. The State’s Underground Facility Protection Act. The Contractor shall notify the State’s One Call System (1-800-272-1000) and identify itself as the State’s Contractor and specify the route and contract number of the Project before performing Work on the Project.
2. High voltage line requirements according to NJSA 34:6-47.1 to 47.9, 29 CFR 1926.550, and the Utility Accommodation Policy, NJSA 16:25. The Contractor shall obtain written approval from the Department of Labor, Office of Safety Compliance, and the respective Utility(s) if required, for any operations that do not provide the minimum clearances under these regulations. The Contractor shall be responsible for any proposed power outage or de-energization associated with their operations. A copy of the approvals shall be submitted to the Resident Engineer at least 5 State Business Days in advance of starting those operations.
D. Notices. The Contractor shall make a written request to the Resident Engineer at least 10 State Business Days in advance of the notice requirements provided in the Special Provisions for the Department to notify Utility(s) to proceed with the Utility(s) utility work. The Contractor shall be cognizant that where joint use poles or duct banks are used, the time frames for work performed by each user are cumulative. The Contractor shall guarantee the site availability for utility operations. The Department will notify the Utility(s) to proceed if in the Department’s opinion the site will be available for a particular item of utility work. The Contractor shall permit the Utility(s) or their agents access to their facilities at all times and shall cooperate with them in performing their work.
The Contractor shall cooperate with the Utility(s) concerned and shall notify them, through the Resident Engineer, not less than 10 State Business Days in advance of the time it proposes to construct any utility item or perform any work that may endanger or affect their facilities. The Contractor shall have the contractual obligation of coordinating its activities with those of the Utility(s). The Utility(s) shall be given the opportunity to inspect the actual material to be installed as well as the installation.
The Contractor shall provide 72 hour advance notice to the Resident Engineer of any meetings scheduled with Utility(s) and provide the Resident Engineer with a copy of any correspondence with the Utility(s).
The Contractor shall make separate written notifications, with a copy to the Resident Engineer, a minimum of 4 State Business Days prior to when work may impact or be adjacent to Department electrical installations. For ITS facilities, notification shall be to the Bureau of Traffic Operations at the location and telephone number provided in the Special Provisions. For all other electrical installations, notification shall be made to the Regional Bureau of Electrical Maintenance at the location and telephone number provided in the Special Provisions. No Department-owned installation shall be accessed, modified, removed, or disturbed in any manner, without first making such notifications and attending a meeting with the Department if requested.
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100 Daniels Way
Freehold, NJ 07728
Telephone: 732-308-4086
*****OR*****
1 Executive Campus-Route 70 West
Cherry Hill, NJ 08002-4123
856-486-6650
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Within two hours of any damage by the Contractor to the fiber optic network, the Contractor shall notify the Resident Engineer, in writing with a copy to the Traffic Operations contact specified in the Special Provisions, that the Contractor shall complete the repairs within 48 hours and have the repairs underway within 12 hours after the damage has occurred. If the written notice has not been received from the Contractor within two hours and/or the commencement of the repairs has not started within 12 hours, the Department may undertake and complete the repairs. The cost of repairs made by the Department for damages that are determined by the Resident Engineer to be the Contractor’s responsibility shall be deducted from subsequent estimates. If the Contractor does not complete the repairs within 48 hrs, damages for lost services will be assessed to the Contractor at a minimum of $1000 per hour, or increased based on costs calculated by the Department, and deducted from subsequent estimates.
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F. Railroads. In addition to the foregoing provisions, the following specific provisions relate to railroads only:
1. Railroad Traffic and Property. Where the Project includes work across, over, under, or adjacent to railroad tracks or railroad ROW, the Contractor shall safeguard the traffic, tracks, and appurtenances, and other property of the railroad that may be affected by its Work. The Contractor shall comply with the regulations of the railroad relating to its Work, shall keep tracks clear of obstructions, and shall provide barricades, warning signs, lights, or other safety devices as required by the railroad. Payment for such safety devices will be made as specified in Section 617. Prior to the commencement of any work within the railroad ROW or on railroad facilities, the Contractor shall obtain the railroad’s written approval of access, the method of construction, and the schedule of the Work. The Contractor shall provide a copy of the submittal and approval to the Resident Engineer.
Estimated railroad train schedules will be provided in the Special Provisions.
The safety and continuity of railroad operations shall be the first priority when working in proximity to the railroad. Railroad approval does not release the Contractor from responsibility or liability for any damage that the railroad may suffer, or for which the Contractor may be held liable, by the acts of the Contractor.
Fouling of railroad facilities’ track, power lines, and signal systems occurs when the railroad parameters for normal operations are jeopardized because obstructions are in close proximity to the facilities. The Contractor shall obtain from the railroad its fouling parameters for the work site and observe the railroad’s regulations concerning fouling. Construction equipment or material shall not be stored or operated within the fouling distance of the railroad facilities without written permission of the railroad, with a copy to the Resident Engineer.
The railroad may assign inspectors, engineers, or flagmen during the time the Contractor is engaged in work on railroad property for the general supervision of construction operations, to ensure adherence to the Contract Documents and applicable railroad requirements, and to ensure the use of approved construction methods.
If materials are to be hauled across the tracks of any railroad, the Contract Documents will provide for any new crossings required or for the use of any existing crossings. If the Contractor elects to use crossings other than those designated, it shall obtain written approval from the railroad with a copy of the approval to the Resident Engineer at least 10 State Business Days in advance.
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THE FOLLOWING IS ADDED AFTER THE LAST PARAGRAPH:
New Jersey Department of Transportation’s Route 70 Bridge over the Manasquan River Project is tentatively scheduled for construction from December 2005 through September 2010. This is a major bridge replacement project. The bridge is located west of the Route 35 Bridge over the Manasquan River. The Route 70 Bridge replacement is anticipated to be performed off-line with all four existing lanes open throughout construction. However there will be periods when the Route 70 mainline traffic may be impacted due to temporary lane closures. The State’s Contractor for the Route 35 Project over the Manasquan River shall coordinate with the State’s Resident Engineers for both Route 35 over the Manasquan River and Route 70 over the Manasquan River with regard to any full closure of Route 70, if any.
105.11 Construction Stakes, Lines, and Grades.
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the fifth paragraph is changed to:
THE CONTRACTOR SHALL COMPLETE ALL UTILITY WORK LAYOUTS REQUIRED AFTER APPROVAL OF THE INSURANCE CERTIFICATES AS SPECIFIED IN SUBSECTION 107.23 AND THE SAFETY AND HEALTH PROGRAM AS SPECIFIED IN SUBSECTION 107.10. THE CONTRACTOR SHALL NOTIFY THE UTILITY(S) AS SPECIFIED IN SUBSECTION 105.09.
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15.
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a Type A.
THE FIRST PARAGRAPH IS CHANGED TO:
TYPE A FIELD OFFICE SHALL BE OF WEATHERPROOF CONSTRUCTION LOCATED ADJACENT TO THE CONTRACTOR’S FIELD OFFICE HAVING A FLOOR AREA OF NOT LESS THAN 576 SQUARE FEET AND A CEILING HEIGHT OF NOT LESS THAN 7½ FEET, AND HAVING PARTITIONS AND DOORS PROVIDING THREE COMMUNICATING ROOMS, ONE WITH A FLOOR AREA OF NOT LESS THAN 288 SQUARE FEET AND TWO WITH A FLOOR AREA OF NOT LESS THAN 144 SQUARE FEET EACH.
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1) 6 MULTI-LINE TOUCH-TONE TELEPHONES AND 3 TELEPHONE LINES FOR USE WITH THE TELEPHONES INSTALLED AS DIRECTED AND OPERATIONAL IN THE FIELD OFFICE AND OTHER FACILITIES SPECIFIED.
a) 1 dedicated, operational telephone line(s) for Fax machines (s) and (3) dedicated, operational telephone line(s) for microcomputer system(s) modem use installed as directed in the Field Offices specified.
b) 6 portable hand held cellular phone(s). The cellular telephone plan shall provide for the anticipated usage of approximately 300 minutes per telephone per month. Each of the cellular phones shall have as a minimum the following features:
1) Home rate with no roaming charges within the entire state
2) 832 Channel Compatible
3) Mute Function
4) Back Light Display with Battery Saver
5) Signal Strength Indicator
6) Individual Call Length Timer
7) Full Lock Function
8) 30 Memory Number Feature
9) Low Battery Warning
10) 70 Minute Continuous Use
11) 12 hour Standby Mode
12) Alphanumeric Display
13) Transmission Power 0.6 Watt
14) Passive Repeating Antenna for Vehicle
15) Spare high capacity Battery Pack
16) Home Charging Station
17) Cigarette lighter power adapter /charger
18) AC charging station
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19)
20) Two Way Radio Capability
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c)
1) Lighted Alphanumeric Display
2) Tone and Vibrator Alert
3) High Sensitivity
4) Message Storage
5) Statewide Coverage
6) Exchange Local to Project
7) LCD Readout
d) 1 telephone answering machine or Voice Mail Service
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THE FIRST SENTENCE OF THE FIRST PARAGRAPH IS CHANGED TO:
(17) A MICROCOMPUTER SYSTEM COMPATIBLE WITH THE DEPARTMENT’S “ACES” SYSTEM, WHETHER PURCHASED NEW OR PREVIOUSLY USED.
THE FIFTH PARAGRAPH IS CHANGED TO:
THE MICROCOMPUTER SYSTEM (INCLUDING THE HARD DRIVE CONTAINING THE PROJECT DATA), MANUALS, INSTRUCTIONS, SOFTWARE, AND LITERATURE SHALL BE REMOVED AND RETAINED BY THE CONTRACTOR WHEN NO LONGER REQUIRED AS DETERMINED BY THE RESIDENT ENGINEER, EXCEPT FOR THE DATA CARTRIDGES AND DATA DISKETTES, AND THE HARD DRIVE CONTAINING THE PROJECT DATA, WHICH WILL BECOME THE PROPERTY OF THE STATE.
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THE MICROCOMPUTER SYSTEM SHALL INCLUDE THE FOLLOWING:
(a) 3 base computer system(s) having at minimum:
1) Pentium IV Processor at 3.5 GHz or faster, Intel processor with Hyper Threading technology, with 1024 MB RAM, 512 MB Video RAM, mouse, mouse pad, 200 Gigabyte hard drive or larger (must be designated as drive C:), one DVD (+/-) Writer Drive, one CD-R Recordable Drive, and one 3½-inch, 1.44 MB floppy diskette drive with multi-media card reader installed as the “A” drive. System must be USB 2.0 compactable.
2) 56K baud data/fax modem. (e.g., 3Com U.S. Robotics 56K Fax modem, 3Com U.S. Robotics Courier V.Everything/V.34 - 56K ITU / x2 Technology, or Hayes Accura 56K).
3) One wireless network card for each base computer system specified, when more than one base computer is specified.
4) One wireless Ethernet Hub Switch with appropriate number of ports and cables (e.g. Lynksys) and a print server.
5) One dedicated telephone line per computer to be used in conjunction with each of the microcomputer modem.
6) One high-speed broad band connection with a minimum speed of 3 Megabytes per second (mbps) with dynamic IP address per field office (DSL, Cable, etc.) for the duration of the project.
7) 19 inch or larger Flat Screen LCD monitor with tilt/swivel capabilities.
8) 250 Megabyte or larger Zip Drive internal or external with backup software for MS-Windows and DOS, and fifteen corresponding formatted data cartridges corresponding to the tape drive size (e.g., Iomega Zip Drive or equivalent).
9) 10 USB 1 GB Flash/Stick/Jump Memory Drives. (e.g. SanDisk Cruzer Micro 1 Gigabyte).
10) One Flatbed USB version 2.0 or greater Color Scanner. (e.g. H.P. or Cannon)
11) Uninterruptible power supply (UPS) - OMNI 1000 or approved equal (e.g., APC-1000 - American Power Corporation).
12) Surge protector for the entire computer workstation to be used in conjunction with the UPS (e.g., Zero Surge Power, Inc. - Point of Use - 2R-15 amp/120 volts).
13) Static mat, floor type, 4 by 5 feet or larger with grounding capabilities.
14) Computer workstation, printer stand, and/or table having both appropriate surface and chair height.
15) Five boxes of 3½-inch floppy diskettes that match the drive density of the 1.44 MB floppy diskette drive (ten per box).
16) 150 CD-R 700 MB (or larger) recordable CD’s compatible to the CD drive and 100 recordable DVD’s.
17) One floppy diskette holder (holds 50, 3½-inch floppy diskettes), and dust covers for the microcomputer, monitor, keyboard, and printer.
18) Two head cleaner kit for 3½-inch floppy diskette drive.
19) One can of compressed air and screen cleaning solution every other month of the duration of the project.
(b) One base printer having at minimum:
1) Color laser printer having HP PCL 5 emulation, with a minimum of 192 Megabytes of expanded memory, appropriate printer cable, and legal size paper tray (e.g., HP Color LaserJet 2500N or TN).
2) One set of appropriate printer toner cartridges every other month for the duration of the construction project.
3) One ten-ream carton of 8½" X 11" size paper (500 sheets per ream, weight: 2.2 ounces per square yard, color: white, grain: long, for laser printers and copiers) every two months for the duration of the construction project.
4) One ten-ream carton of legal size paper (500 sheets per ream, weight: 2.2 ounces per square yard, color: white, grain: long, for laser printers and copiers) every three months for the duration of the construction project.
5) 11 inch by 17 inch copy size capability and One ten-ream carton of 11" X 17" size paper (500 sheets per ream, weight: 2.2 ounces per square yard, color: white, grain: long, for laser printers and copiers) every four months for the duration of the construction project.
(c) One software package, on CD-ROM with documentation, including:
1) Microsoft Windows, latest version with future upgrades for the duration of the entire project.
2) Microsoft Office Professional latest version. Software package should contain the following: word processor, spreadsheet, and database.
3) Norton’s System Works for Windows, latest version, or compatible software package with future upgrades and latest virus patches.
4) Anti-Virus software, latest version with monthly updates for the duration of the entire project (e.g., McAfee Anti Virus, Dr. Solomon’s, or Norton’s Anti Virus).
5) Visio Professional Graphics Software for Windows, latest version.
6) One Primavera Project Planner for the Enterprise (P3E) or equivalent software, latest version with software updates for the duration of the entire project.
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1) Color Inkjet printer of current technology, with appropriate printer cable.
2) Ink cartridge replacements, one of each color, every other month for the duration of the construction project.
3) One 10-ream carton of 8½ X 11 inches size paper (500 sheets per ream, weight: 22 ounces per square yard, color: white, grain: long, for laser printers and copiers) every three months for the duration of the construction project.
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*****or*****
The Contractor shall only utilize equivalent or compatible software for a project, which has received written approval from the Department in accordance with the most current NJDOT Capital Program Management Construction Scheduling Standard Coding and Procedures for Designers and Contractors Manual. The approved equivalent/compatible software utilized shall not vary throughout the construction phase.
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(18) 1 TV/VCR (VIDEO CASSETTE RECORDER) COMBO WITH: 4-HEAD VCR, CRYSTAL-CLEAR-SLOW-MOTION, STILL FRAME, AND FRAME ADVANCE, AND INDEX SEARCH.
(19) 1 DVD Palmcorder with 50 Rewritable discs with cases and labels, two spare rechargeable batteries, carrying case, AC power adapter/charger, cigarette lighter power adapter, and lightweight tripod.
(20) Six (6) of each: hard hats (Orange in color, reflectorized) and safety vests (Orange in color, reflectorized, 360( high-visibility that meet ANSI/ISEA standards for Class 3 garments). It should be noted that safety vests are to be replaced as needed for the duration of the project.
(21) Six (6) sets: ear protection and eye protection, to be replaced as needed for the duration of the project
(22) Six (6) sets: rain gear with reflective sheeting
(23) Concrete testing equipment to include: Concrete receptacle (wheel barrow), square tipped shovel, concrete scoop, slump cone & base set (rod, slump cone, base and funnel), tamping rod (12 inches long, 3/8-inch diameter with hemispherical ends), tamping rod (24 inches long, 5/8-inch diameter with hemispherical ends), 12-inch ruler, Forney air meter (complete set) or equivalent, two concrete thermometers, sponge, long-handled round scrub brush, rubber or rawhide mallet (2.25 lb. +/- 0.50 lb.), pointed trowel, five-gallon plastic bucket, concrete cylinder curing items in accordance with this project’s applicable governing Specifications.
(24) Two (2) electronic Smart levels (4 or 6 feet long)
(25) Two (2) measuring wheels, with English measuring units (in feet)
(26) Two (2) 50-foot cloth tape measures
(27) One (1) 100-foot steel tape measure
(28) Ten (10) six-foot folding wood rules
(29) Two (2) asphalt thermometers
(30) One (1) digital infrared thermometer
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ANY DAMAGE TO THE ROADWAY DUE TO THE CONTRACTOR’S OPERATIONS SHALL BE REPAIRED AT NO ADDITIONAL COMPENSATION, EXCEPT AS SPECIFIED IN SUBSECTION 107.22. THE CONTRACTOR SHALL COMPLETE WITHIN 24 HOURS SPECIFIC REPAIRS DIRECTED BY THE DEPARTMENT, EXCEPT WHERE THE REQUIREMENTS ARE SPECIFIED BY A SUBSECTION. NOTHING IN THIS SUBSECTION SHALL BE CONSTRUED TO LIMIT OR CHANGE THE RISKS ASSUMED BY THE CONTRACTOR AS SPECIFIED IN MACROBUTTON HTMLRESANCHOR SUBSECTION 107.22.
THE sixth paragraph is changed to:
THE DEPARTMENT MAY DIRECT THE CONTRACTOR TO CONSTRUCT BITUMINOUS CONCRETE PATCH AS SPECIFIED IN SECTION 402 TO MAINTAIN SECTIONS OF TRAVELED WAY AND SHOULDERS IN A SMOOTH RIDING CONDITION AT ALL TIMES INCLUDING SEASONAL SHUTDOWNS. PAYMENT FOR BITUMINOUS CONCRETE PATCH WILL BE MADE AS SPECIFIED IN SECTION 402 EXCEPT FOR THOSE AREAS THAT ARE DAMAGED OR CREATED BY THE CONTRACTOR’S OPERATIONS.
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IF THE ENGINEER DETERMINES THAT THE WORK IS SUBSTANTIALLY COMPLETE, THE ENGINEER WILL THEN PREPARE A LETTER WHICH STATES THE DATE OF SUBSTANTIAL COMPLETION AND ESTABLISHES A REASONABLE TIME WITHIN WHICH THE CONTRACTOR SHALL PERFORM THE FINAL CLEANUP, AND REPAIR UNACCEPTABLE WORK, WHICH TIME MAY BE PRIOR TO CONTRACT TIME AS MODIFIED.
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106.03 MATERIALS, INSPECTIONS, TESTS, AND SAMPLES.
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106.03 MATERIALS, INSPECTIONS, TESTS, SAMPLES AND CERTIFIED TRAINING.
B. Sampling and Field Testing of Soil Aggregates.
this sixth paragraph is changed to:
SAMPLING AND TESTING OF AGGREGATES BY THE DEPARTMENT THAT MEET THE SPECIFICATIONS AND ARE USED IN THE WORK WILL BE PERFORMED WITHOUT COST TO THE CONTRACTOR.
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D. SHARING OF PAY-ADJUSTMENTS FOR PORTLAND CEMENT CONCRETE. POSITIVE AND NEGATIVE PAY-ADJUSTMENTS, AS DEFINED IN SUBSECTION 914.02, SUBPART E, ARE AWARDED TO ENCOURAGE HIGH QUALITY CONSTRUCTION AND, WHEN NECESSARY, TO RECOUP THE ANTICIPATED EXTRA COSTS TO THE DEPARTMENT RESULTING FROM POOR QUALITY CONSTRUCTION. THE MANNER IN WHICH POSITIVE AND NEGATIVE PAY-ADJUSTMENTS ARE TO BE SHARED BY THE PRIME CONTRACTOR AND SUBCONTRACTORS OR PRODUCERS IS TO BE NEGOTIATED BY THE AFFECTED PARTIES. A LETTER SIGNED BY BOTH PARTIES, STATING THAT AN AGREEMENT HAS BEEN REACHED BETWEEN THE PARTIES SHALL BE PROVIDED TO THE ENGINEER BEFORE COMMENCEMENT OF WORK. NOTHING CONTAINED HEREIN SHALL CREATE RIGHT OF ACTION EITHER IN LAW OR EQUITY AGAINST THE DEPARTMENT.
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THE CONTRACTOR SHALL ANNUALLY PAY ALL FEES NECESSARY TO PROCURE AND MAINTAIN A UNIFORM CODE TYPE FOUR FIRE PERMIT ACCORDING TO REGULATIONS OF THE NEW JERSEY DEPARTMENT OF COMMUNITY AFFAIRS. ADDITIONAL INFORMATION CONCERNING THE PERMIT FEES AND PROCESSING OF THE APPLICATION MAY BE OBTAINED BY CONTACTING THE BUREAU OF MATERIALS.
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b.
THE FOLLOWING is added:
(19) HANDS-FREE HEADSET
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THE FIRST SENTENCE of subpart z. is CHANGED TO:
EQUIPMENT AND TEST APPARATUS CONFORMING TO THAT LISTED IN AASHTO T 310 WHEN THE PAY ITEM “NUCLEAR DENSITY GAUGE” APPEARS IN THE PROPOSAL.
Subpart (1) is changed to:
(1) CONFORMANCE TO AASHTO T 310,
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the entire part aa text IS changed to:
AA MICROCOMPUTER WORKSTATION HARDWARE AND SOFTWARE REQUIREMENTS AS INDICATED. THE MICROCOMPUTER SYSTEM SHALL INCLUDE THE FOLLOWING:
(1) One base computer system(s) having at minimum:
a) Pentium IV Processor at 3.5 GHz or faster, Intel processor with Hyper Threading technology, with 1024 MB RAM, 512 MB Video RAM, mouse, mouse pad, 200 Gigabyte hard drive or larger (must be designated as drive C:), one DVD (+/-) Writer Drive, one CD-R Recordable Drive, and one 3½-inch, 1.44 MB floppy diskette drive with multi-media card reader installed as the “A” drive. System must be USB 2.0 compactable.
b) 56K baud data/fax modem. (e.g., 3Com U.S. Robotics 56K Fax modem, 3Com U.S. Robotics Courier V.Everything/V.34 - 56K ITU / x2 Technology, or Hayes Accura 56K).
c) One wireless network card for each base computer system specified, when more than one base computer is specified.
d) One wireless Ethernet Hub Switch with appropriate number of ports and cables (e.g. Lynksys) and a print server.
e) One dedicated telephone line per computer to be used in conjunction with each of the microcomputer modem.
f) One high-speed broad band connection with a minimum speed of 3 Megabytes per second (mbps) with dynamic IP address per field office (DSL, Cable, etc.) for the duration of the project.
g) 19 inch or larger Flat Screen LCD monitor with tilt/swivel capabilities.
h) 250 Megabyte or larger Zip Drive internal or external with backup software for MS-Windows and DOS, and fifteen corresponding formatted data cartridges corresponding to the tape drive size (e.g., Iomega Zip Drive or equivalent).
i) 10 USB 1 GB Flash/Stick/Jump Memory Drives. (e.g. SanDisk Cruzer Micro 1 Gigabyte).
j) One Flatbed USB version 2.0 or greater Color Scanner. (e.g. H.P. or Cannon)
k) Uninterruptible power supply (UPS) - OMNI 1000 or approved equal (e.g., APC-1000 - American Power Corporation).
l) Surge protector for the entire computer workstation to be used in conjunction with the UPS (e.g., Zero Surge Power, Inc. - Point of Use - 2R-15 amp/120 volts).
m) Static mat, floor type, 4 by 5 feet or larger with grounding capabilities.
n) Computer workstation, printer stand, and/or table having both appropriate surface and chair height.
o) Five boxes of 3½-inch floppy diskettes that match the drive density of the 1.44 MB floppy diskette drive (ten per box).
p) 150 CD-R 700 MB (or larger) recordable CD’s compatible to the CD drive and 100 recordable DVD’s.
q) One floppy diskette holder (holds 50, 3½-inch floppy diskettes), and dust covers for the microcomputer, monitor, keyboard, and printer.
r) Two head cleaner kit for 3½-inch floppy diskette drive.
s) One can of compressed air and screen cleaning solution every other month of the duration of the project.
(2) One base printer having at minimum:
a) Color laser printer having HP PCL 5 emulation, with a minimum of 192 Megabytes of expanded memory, appropriate printer cable, and legal size paper tray (e.g., HP Color LaserJet 2500N or TN).
b) One set of appropriate printer toner cartridges every other month for the duration of the construction project.
c) One ten-ream carton of 8½" X 11" size paper (500 sheets per ream, weight: 2.2 ounces per square yard, color: white, grain: long, for laser printers and copiers) every two months for the duration of the construction project.
d) One ten-ream carton of legal size paper (500 sheets per ream, weight: 2.2 ounces per square yard, color: white, grain: long, for laser printers and copiers) every three months for the duration of the construction project.
(3) One software package, on CD-ROM with documentation, including:
a) Microsoft Windows, latest version with future upgrades for the duration of the entire project.
b) Microsoft Office Professional latest version. Software package should contain the following: word processor, spreadsheet, and database.
c) Norton’s System Works for Windows, latest version, or compatible software package with future upgrades and latest virus patches.
d) Anti-Virus software, latest version with monthly updates for the duration of the entire project (e.g., McAfee Anti Virus, Dr. Solomon’s, or Norton’s Anti Virus).
e) Visio Professional Graphics Software for Windows, latest version.
Hardware and software shall be acceptable to the Regional Construction and Resident Engineers before purchase/installation. All software shall be compatible with the computer’s operating system.
The microcomputer system, whether purchased new or previously used, shall be installed in the materials field laboratory.
At the time of installation, the Contractor shall ensure that the system is fully operational and meets all Department requirements. All software listed above shall be installed by the Contractor and maintained in the materials field laboratory. The Contractor shall configure the software to operate with the hardware provided. Any accessories for the microcomputer shall be compatible with the microcomputer.
The Contractor will not be permitted to use this microcomputer system at any time. It is being supplied solely for the Department’s use.
The Contractor shall forward all manuals, instructions, software, and literature received with the microcomputer system to the Resident Engineer. The Contractor is responsible for maintaining the microcomputer system in good working condition. Any part of the microcomputer system that becomes inoperable or defective, during the duration of the construction project, shall be replaced by the Contractor within 48 hours.
The microcomputer system (including the hard drive containing the project data), manuals, instructions, software, and literature shall be removed and retained by the Contractor when no longer required as determined by the Resident Engineer, except for the data cartridges and data diskettes, and the hard drive containing the project data, which will become the property of the State.
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SETTING UP THE MATERIALS FIELD LABORATORY SHALL CONSIST OF FURNISHING THE LABORATORY AND ENCLOSURE COMPLETE WITH FURNITURE, EQUIPMENT, ELECTRICITY, WATER, HEATING, AIR-CONDITIONING, INSTALLATION AND ACTIVATION OF TELEPHONE LINES, TELEPHONE SETS (TOUCH TONE AND CELLULAR), PAGER UNITS, SANITARY FACILITIES, AND LAVATORY SUPPLIES.
Maintenance of the materials field laboratory, for the time required, shall consist of maintaining the furniture, equipment, and utilities which includes the cost of telephone fixed monthly service charges, cellular phone fixed monthly service charges for the plan specified and pager services, providing lavatory supplies, janitorial and waste disposal services weekly, restocking of the first aid box, and snow removal services. Maintenance of the materials field laboratory shall also include monthly rent.
Payment for nuclear density gauge will be made by the number of units supplied.
Payment for setting up the materials field laboratory will be made by the number of units.
Payment for the maintenance of the materials field laboratory will be made for each month or fraction thereof that the materials field laboratory is required, except that payment will not be made for any month or fraction thereof in which the Contractor is assessed liquidated damages according to Subsection 108.16.
Payment will be made under:
Pay Item Pay Unit
NUCLEAR DENSITY GAUGE UNIT
MATERIALS FIELD LABORATORY SET-UP UNIT
MATERIALS FIELD LABORATORY MAINTENANCE MONTH
PAYMENT FOR TELEPHONE SERVICE WILL BE MADE ACCORDING TO SUBSECTION 105.15.
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MATERIALS SHALL BE STORED TO ENSURE THE PRESERVATION OF THEIR QUALITY AND FITNESS. STORED MATERIALS, EVEN THOUGH APPROVED BEFORE STORAGE, MAY AGAIN BE INSPECTED BEFORE THEIR USE ON THE PROJECT. STORED MATERIALS SHALL BE LOCATED SO AS TO FACILITATE THEIR PROMPT INSPECTION. WITH THE APPROVAL OF THE DEPARTMENT, PORTIONS OF THE ROW MAY BE USED FOR STORAGE PURPOSES AND FOR THE PLACING OF THE CONTRACTOR’S PLANT AND EQUIPMENT, BUT ANY ADDITIONAL SPACE MUST BE PROVIDED BY THE CONTRACTOR AT THE CONTRACTOR’S EXPENSE. EQUIPMENT AND MATERIALS SHALL BE PLACED BEHIND BARRIERS OR CRASH CUSHIONS, OR STORED MORE THAN 30 FEET FROM THE TRAVELED WAY. THE BARRIERS AND CRASH CUSHIONS MUST BE APPROVED BEFORE INSTALLATION. FURNISHING, PLACING, AND REMOVING THE BARRIERS AND CRASH CUSHIONS SHALL BE AT NO ADDITIONAL COMPENSATION. NO MATERIALS SHALL BE STORED WITHIN RESTRICTED AREAS NOTED ON THE PLANS. NO MATERIALS SHALL BE STORED WITHIN 10 FEET, PLUS THE EXTENDED BOOM LENGTH OF THE LARGEST CRANE ON SITE, OF OVERHEAD HIGH VOLTAGE POWER LINES. THE HIGH VOLTAGE POWER LINE IS DEFINED AS AN AERIAL POWER LINE HAVING A VOLTAGE DIFFERENTIAL IN EXCESS OF 750 VOLTS BETWEEN ANY PAIRS OF CONDUCTORS OR BETWEEN ANY CONDUCTOR AND GROUND. THE CONTRACTOR SHALL BE RESPONSIBLE FOR ANY POWER OUTAGE OR DE-ENERGIZATION ASSOCIATED WITH THE CONTRACTOR’S ACTIVITY IN THE VICINITY OF THE POWER LINES. PRIVATE PROPERTY SHALL NOT BE USED FOR STORAGE PURPOSES WITHOUT WRITTEN PERMISSION OF THE OWNER OR LESSEE, AND ANY OTHER APPROVALS, INCLUDING THOSE AS SPECIFIED IN SUBSECTION 107.05. COPIES OF SUCH WRITTEN PERMISSION SHALL BE FURNISHED TO THE RESIDENT ENGINEER BEFORE STORAGE. STORAGE SITES SHALL BE RESTORED TO THEIR ORIGINAL CONDITION AT NO ADDITIONAL COMPENSATION.
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THE MONTHLY FUEL PRICE INDEX WILL BE POSTED EVERY MONTH ON THE DEPARTMENT’S WEB SITE: WWW.STATE.NJ.US/TRANSPORTATION/ENG/CCEPM/PRICEINDEX.SHTM.
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THE BASIC FUEL PRICE INDEX WILL BE THE PREVIOUS MONTH’S FUEL PRICE INDEX BEFORE RECEIPT OF BIDS.
The eighth PARAGRAPH IS deleted:
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107.01 LEGAL JURISDICTION.
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1. APPLICABLE LAW. THIS CONTRACT SHALL BE CONSTRUED AND SHALL BE GOVERNED ACCORDING TO THE CONSTITUTION AND LAWS OF THIS STATE.
2. Sovereign Immunity. The State by entering into this Contract does not waive its Sovereign Immunity, except as provided by the New Jersey Contractual Liability Act, NJSA 59:13-1 et seq. The rights or benefits provided the Contractor in this Contract which exceed those provided under the Act are contractual in nature and shall not be deemed to expand the waiver of Sovereign Immunity as set forth in that Act.
3. Litigation of Claims by Contractor. The Contractual Claims Resolution Process is not an administrative procedure but is contractual in nature, intended to review properly filed and documented claims. Pursuant to N.J.C.A. 16:45-1.3, exhaustion of the Claims Resolution Process as set forth under the Specifications is not a prerequisite to the filing of a legal action against the Department or State. The Contractor, however, must fully comply with all of the terms and conditions of the Contractual Liability Act, N.J.S.A. 59:13-1 et seq. prior to commencing a legal action. Therefore, where a Contractor brings a legal action, arising out of a Contract, against the Department or State or any officials or employees, thereof, arising out of or related, directly or indirectly, to a claim pending against the Department; the Contractual Claims Resolution Process, at any step, shall terminate as to that claim(s) or related claims being litigated, no matter which level of review the claim may be at when the legal action is filed. Furthermore, once the Contractor files a legal action any claim(s), related to that legal action will no longer qualify to be reviewed by the Claims Committee or to have the same claim(s) resolved under the Non-Binding Mediation Procedure or at any other Level of review. Such claim(s) will, thereafter, be resolved under the legal action subject to the provisions of the Contractual Liability Act, N.J.S.A. 59:13-1 et seq. unless and until the legal action is dismissed with or without prejudice. The Contractor may submit to the Department for processing through the various steps of the Contractual Claims Resolution Process any claims that are unrelated to the pending litigation subject to the terms of the Specifications and the Contractual Liability Act N.J.S.A. 59:13-1 et seq.
4. Completion of the Contract. The Completion of the Contract shall control as to any issue that may arise regarding the particular point in time when a Contractor may be barred from recovering against the State as provided under N.J.S.A. 59:13-5 et seq. The Contractual Claims Resolution Process and the various steps thereof may continue beyond the Completion of the Contract; however, the Contractual Claims Resolution Process will not in any manner, expressed or implied, extend any statute of limitation that may apply as to a claim. The Contractor by entering into the Contract with the Department agrees no further notice to the Contractor regarding the provisions stated in this Section are required. The Contractor also agrees to be responsible for compliance with all statutes of limitation and compliance with the various provisions of the Contractual Liability Act, N.J.S.A. 59:13-1 et seq.
5. Subcontractor(s). Pursuant to Subsection 108.02, the Department will not process or review any claims submitted by a subcontractor(s) or supplier(s) at any tier. All claims submitted by the Contractor must be an obligation or liability of the Contractor and cannot be merely a pass through of a claim by a subcontractor or by a supplier.
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107.02 NOTICE OF CLAIM AND THE CONTRACTUAL CLAIM RESOLUTION PROCESS.
1. Notice.
a. Obligations. The various notice provisions set forth in this Contract are contractual obligations assumed by the Contractor by the act of executing the Contract. The Contractor shall be responsible to notify the Department in writing within the time frame as may be mandated in an applicable Subsection of the Specifications as well as within 90 days of any situation or occurrence which may potentially result in or be the basis of a belief that additional compensation or an extension of time is due from the State, except where permission to file a “late notice of claim” has been obtained by the Contractor from the Superior Court in accordance with N.J.S.A. 59:13-6. The Department is not authorized to expand, reduce or waive either the contractual or statutory time limitations within which a notice of claim is to be filed with the Department. Any required notice shall be given only on the Contractual Notice Form provided by the Department. Submission of a Contractual Notice Form is required in order to comply with the notice requirements of the New Jersey Contractual Liability Act, N.J.S.A. 59:13-5 et seq., provided such notices are given within the time limits established by that Act. The Contractor, by executing the Contract, agrees that the only evidence of compliance with the notice provisions of the Contractual Liability Act, N.J.S.A. 59:13-5 et seq., and the Specifications shall be the filing of a fully completed (except that the amount of the claim need not be stated when unknown) Contractual Notice Form with the Department, and that no other documents sent or delivered to the Department or any of its officers or employees shall satisfy the statutory and/or contractual notice requirements.
b. Time. The Contractor, by the act of executing the Contract, acknowledges that it will be forever barred from recovering against the State if it fails to give timely notice in accordance with N.J.S.A. 59:13-5 et seq., on the Contractual Notice Form required under this Subsection of any happening of an event, thing, or occurrence or of an act or failure to act, by the Department and that the Contractor is solely responsible for complying with the various notice requirements and the timeliness of a claim as set forth under the Contractual Liability Act, N.J.S.A. 59:13-5 et seq. and the Specifications.
c. Notice Form. The Contractual Notice Form shall be completed in its entirety for each and every claim and shall be signed by an authorized representative of the Contractor. Any Contractual Notice Form filed which does not provide all of the minimum information listed in this Subsection will be considered incomplete for the purpose of processing the claim under the Contractual Claim Resolution Process and no formal discussions or meetings concerning a claim filed on an incomplete Form will take place. A Contractual Notice Form which identifies the amount of the claim as being unknown may be considered by the Department as only satisfying the notice requirements as set forth under the Contractual Liability Act, N.J.S.A. 59:13-5 et seq., as long as the notice of claim is timely filed and provides all of the other minimum information on or attached to a properly executed Contractual Notice Form. However, for any claim requesting Additional Compensation, it shall not be sufficient to begin the Claim Resolution Process until the exact amount is provided according to 3.j. below. The Contractor’s act of executing the Contract shall be construed to be an acknowledgment by the Contractor that it understands that the processing of a claim by the Department at any step of the Contractual Claims Resolution Process shall not constitute a waiver by the State of any defense that a claim was filed out of time and is thereby barred under the terms of the Contractual Liability Act or of any defense that there is no merit to the “claim being asserted by the Contractor”.
2. Steps of Review. The Contractual Claim Resolution Process is sequential in nature and is composed of the following steps:
Step I: Review by the Resident Engineer;
Step II: Review by the Regional Dispute Board;
Step III: Review by the Department Claims Committee;
Step IV: Non-Binding Mediation.
Processing through the steps is subject to the following conditions:
a. No claim will be accorded a particular level of review unless and until the claim has been reviewed at the preceding step. Additionally, there will be no further review of the claim, unless and until the Contractor provides, in writing, that the decision of a review step within the specified timeframe is unacceptable and further requests that the claim be forwarded to the next step. Absent the written submittal of this information the claim will be considered withdrawn from the Contractual Claim Resolution Process. If at any step in the process, a claim is resolved, the Contractor must sign an unconditional release, furnished by the Department, as to any and all matters arising from the claim.
b. In order to begin the Contractual Claim Resolution Process the Contractor must state in writing that all documentation in support of the claim, as required under this Subsection, has been provided to the Department as part of or attached to the contractually required Contractual Notice Form and that the Contractor has requested that the review process, as outlined above, begin. The Resident Engineer will take no formal action until this notification is received and the Resident Engineer independently determines that the Contractor has in fact satisfied the requirements of this Subsection. If the documentation submitted by the Contractor is determined to be incomplete, the Resident Engineer will notify the Contractor that the review process cannot begin and include a list of missing components required to start the process. When the additional material is submitted, the Contractor is required to again notify the Resident Engineer in writing that all documentation in support of the claim has been provided and the Contractual Claim Resolution Process should begin. The Contractor shall be limited to the documentation provided to the Resident Engineer at the beginning of Step I, in support of a claim, throughout all steps of the Claim Resolution Process. The submission of additional information by the Contractor at any step beyond Step I, shall be cause for the claim to revert back to Step I for review at each and every Step. The Resident Engineer will provide written notice to the Contractor when Step I was begun.
c. When the value of the claim submitted by the Contractor is $20,000 or less, the Step II review will be the final step in the Contractual Claim Resolution Process. In such a case, the decision of the Regional Dispute Board will be final and there will be no further contractual review.
d. Where there has been a determination, at both Step I and Step II, that the specifications do not provide a contractual basis for the resolution of the claim submitted by the Contractor or that the Notice of Claim was filed late without obtaining permission of the Superior Court, the Department reserves the right to conclude the Contractual Claim Resolution Process at the end of the Step II review. In such instance, the Secretary of the Department Claims Committee will provide the Contractor with the reason(s) for the no further review determination and rejection of the claim. However, where the Claims Committee does review a claim, there shall not be deemed a waiver by the Department of any defense that the Notice was filed late or that there does not exists a contractual basis for resolution.
3. Information Required. As a minimum, all of the following information must accompany each claim and be incorporated into or attached to the contractually required Contractual Notice Form:
a. A detailed factual statement of the claim providing all necessary dates, locations, and items of work affected by the claim.
b. The date on which facts arose that gave rise to the claim.
c. A copy of any notice given to the Department pursuant to any other Subsection of the Contract which relates to the matter giving rise to the claim.
d. The name, function, and activity of each State individual, official, or employee involved in or knowledgeable about the claim.
e. The specific provisions of the Contract which support or mitigate against the claim and a statement of the reasons why such provisions support or mitigate against the claim.
f. If the claim relates to a decision of the Department which the Contract leaves to the Department's discretion or as to which the Contract provides that the Department's decision is final, the Contractor shall set out in detail all facts supporting its contention that the decision of the Department was fraudulent, arbitrary or capricious.
g. The identification of any documents and the substance of any oral communications relating to such claim attaching same to the Form.
h. A statement as to whether the additional compensation or extension of contract time sought is based on the operation of the provisions of the Contract or an alleged breach of contract.
i. If an extension of contract time is sought, the specific days sought and the basis for such claim, supported by the Contractor’s approved baseline progress schedule and updates, as well as a fragment, which will include a time impact evaluation, depicting the delay according to Subsection 108.04.
j. If additional compensation is sought, the exact amount sought and a breakdown of that amount into the following categories:
(1) Direct Labor
(2) Direct Materials
(3) Direct Overhead as specified in Subsections 109.03 and 109.04.
(4) Subcontractor's Work
(5) Other categories as specified by the Contractor.
(6) The basis and manner of the Contractor’s calculations of the additional compensation claimed.
The Department will not determine liability separate and apart from damages. The Contractual Claims Resolution Process shall not be bifurcated. The Department shall review liability and damage valuation issues at the same time.
4. The Procedures for the Process.
a. Step I, Resident Engineer Review. The Resident Engineer will render a written decision regarding the claim presented within 30 State Business Days of the Resident Engineer’s determination that the information provided by the Contractor on the Contractual Notice Form in support of the claim satisfied the requirements to begin Step I. This time limit may be extended by mutual agreement of the parties. Within 15 State Business Days of the receipt of the decision by the Resident Engineer, the Contractor shall either accept or reject the decision in writing; or upon failure to complete this, the claim will be considered withdrawn from the Contractual Claim Resolution Process and there will be no further review of the claim. If the Contractor accepts the decision, such acceptance shall include execution of an unconditional release furnished by the Department effective upon payment.
b. Step II, Regional Dispute Board Review. If the Contractor provides a written rejection of the Resident Engineer’s decision and a request to forward the claim to Step II, the Resident Engineer will forward the claim and supporting information previously submitted by the Contractor to the Regional Dispute Board within five State Business Days. The Regional Dispute Board will schedule and hold a meeting to review the claim with the Contractor within 30 State Business Days of receipt of the said claim information from the Resident Engineer. This time limit may be extended by mutual agreement of the parties. The Regional Dispute Board will issue a written decision regarding the claim within 20 State Business Days of the meeting.
Within 15 State Business Days of receipt of the Regional Dispute Board decision, the Contractor shall either accept or reject it in writing; or upon failure to complete this, the claim will be considered withdrawn and the Contractual Claim Resolution Process shall be considered to be concluded for that particular claim. If the Contractor accepts the decision, such acceptance shall include execution of an unconditional release furnished by the Department effective upon payment.
The Director, Construction Services and Materials, may request an informal meeting with the Contractor to discuss the then pending claim(s) after the Step II decision has been issued and sent to the Contractor, but prior to the matter being reviewed at the next step, subject to the mutual consent of the Contractor and the Department.
c. Step III, Claims Committee Review. A written request for a Step III review of the claim is to be made to the Secretary of the Department Claims Committee, P.O. Box 600, Trenton, New Jersey 08625-0600 with a copy to the Director, Construction Services & Materials. The Contractor may request that the Department Claims Committee immediately review claims, which are unresolved after review by the Regional Dispute Board,, when the following conditions are met:
1. A claim or the combination of claims exceed $250,000; or
2. It is mutually agreed to by the Contractor and the Department.
However, when a project becomes 75 percent complete by contract time or dollar amount, which ever first occurs, claims that are unresolved at Step II will be reviewed at a single session of the Department Claims Committee after the Completion of the Work.
Additionally, the Contractor may request at the time of issuance of the Final Certificate that all unresolved claims, with the exception of the exclusionary cases as provided for in this Subsection, that have gone through the Steps I and II of the Contractual Claim Resolution Process, and which have not been presented at Step III of the Contractual Claim Resolution Process, be reviewed by the Department Claims Committee as provided for in this Subsection. The Contractor's written request must accompany its exceptions to the Final Certificate, with a copy sent to the Secretary of the Department Claims Committee and shall be made no later than 30 State Business Days after the issuance of the Final Certificate.
The Secretary of the Department Claims Committee will schedule a Claims Committee meeting with representatives of the Contractor and the Region, to be held within 45 State Business Days of the receipt of the claim information. This time limit may be extended by mutual agreement of the parties. The Department Claims Committee will notify the Contractor in writing of its decision on the claim(s) within 45 State Business Days of the meeting, stipulating the terms of any resolution of the claims. If the Department Claims Committee determines after review of the claims that no resolution and no further payment is warranted, it shall notify the Contractor in writing of its decision. Within 15 State Business Days of the receipt of the Department Claims Committee decision, the Contractor shall either accept or reject it in writing, or upon failure to complete this, the claim will be considered withdrawn and the Contractual Claim Resolution Process shall be considered to be concluded for that particular claim. If the Contractor accepts the decision, such acceptance shall include execution of an unconditional release furnished by the Department effective upon payment. If the Contractor rejects the decision, there will be no further review of the claim unless the Contractor submits a written request for the utilization of Non-Binding Mediation.
d. Step IV, Non-Binding Mediation.
(1) Conditions. The Contractor may request at any time during the Project, but no later than 30 State Business Days after issuance of the Final Certificate, that any claim unresolved by the Department Claims Committee be elevated to Step IV. The request must be in writing to the Secretary, Department Claims Committee, P.O. Box 600, Trenton, New Jersey 08625-0600. No claim will be elevated to Step IV unless all of the following conditions are satisfied:
a. The claim has been reviewed by the Department Claims Committee.
b. The Contractor has escrowed its bid preparation documents as required under Subsection 103.06 and the documents are still being held in escrow.
c. The Contractor has entered into a Non-Evidential agreement to the effect that any statement or information provided during the Non-Binding Mediation proceedings shall not be evidential in any legal proceeding unless obtained by other discoverable means.
d. The Contractor has entered into a cost sharing agreement to equally share the cost of using Non-Binding Mediation in accord with Department issued forms.
e. The utilization of Non-Binding Mediation has been mutually agreed to by the Department and the Contractor; and
f. Prior to the commencement of the Non-Binding Mediation the parties shall confer with one another for the purpose of resolving the format of presenting the claim summary, supporting information, opening statements, and responses.
Failure by the Contractor to request Non-Binding Mediation within the required time period shall constitute a waiver by the Contractor of any utilization of the Non-Binding Mediation Step.
(2) Forms. Where the Contractor requests that Non-Binding Mediation be conducted, the Department will forward to the Contractor the required Non–Evidential and cost sharing agreement forms which shall be executed by the Contractor and returned to the Department within ten State Business Days. The failure by the Contractor to return the fully executed Non-Evidential and cost sharing agreements to the Department within the ten-day period shall constitute a waiver by the Contractor of the availability of Step IV.
(3) Mediator. The Department will select the Mediator to be utilized for the Non-Binding Mediation from a list of candidates submitted by the Contractor. The Contractor shall submit the names of six proposed Mediators, along with a biographical background listing the experience and qualifications of each candidate. Candidates may be from the same employment category or disciplines, such as construction, mediation, partnering facilitation, consulting engineer, attorney, judiciary (retired), accountant, architect, etc.
A candidate may have been used for mediation purposes for this Project or another project but shall not have any other relationships with either the Department or the Contractor for a period of two years preceding the request for Step IV. If the Department determines that none of the candidates submitted are acceptable, the Department will request and the Contractor shall submit four additional Mediator candidates. The Contractor shall submit this additional list within five State Business Days of the receipt of the written request. Upon mutual agreement, the Mediator can be an individual proposed by the Department.
(4) Escrow Documents. Once the Contractor has fully executed the required Non-Evidential and cost sharing agreements, its escrowed bid documents will be released upon request of the Department Claims Committee Chairperson solely for the exclusive use of the Mediator, the Department’s selected Negotiator(s), the Department Regional Representative(s) and the Contractor Representative(s) participating in the Mediation session. These documents will be used by the Department as part of the Contractual Claims Resolution Process only to resolve the pending claims except it may seek such documents through the discovery process in the event mediation is not successful and litigation ensues.
(5) Meeting. The Secretary of the Department Claims Committee will schedule a meeting for the Non-Binding Mediation of the submitted claims to be held within 30 State Business Days of the return of the executed Non-Evidential and cost sharing agreements. The meeting time limit may be extended by mutual agreement of the parties. The Secretary of the Department Claims Committee will issue the recommendations of the Department’s Negotiator to the Commissioner for action within 15 State Business Days of the Non Binding Mediation session. The Commissioner, or their designee, will accept, reject, or modify the recommendation of the Department Negotiator and notify the Contractor of the decision within 15 State Business Days.
(6) Decision. The Contractor shall accept or reject the decision within 15 State Business Days of notification of the Commissioner's decision. If the Contractor accepts the decision of the Commissioner, or their designee, such acceptance shall be in writing and include execution of an unconditional release furnished by the Department effective upon payment. If the Contractor fails to accept or reject the Commissioner’s decision within 15 State Business Days, the decision of the Commissioner will be withdrawn and the Contractual Claims Resolution Process shall be deemed concluded as to that particular claim under review.
After submission of the recommendation to the Commissioner, the bid documents released from escrow will be returned to the escrow agent for continued escrow in the designated repository
107.10 Sanitary Health and Safety Provisions.
THE FOLLOWING IS ADDED AT THE END OF THE SECTION:
The Contractor shall address the following items of work in accordance with these Special Provisions:
1. Asbestos abatement related to removal/encapsulation of window caulking, and associated demolition of asbestos containing wallboard.
2. Removal, temporary storage (if required and approved by the Resident Engineer), and disposal of lead-contaminated soil.
3. Lead based paint removal and disposal.
The Contractor shall also submit a separate Lead Health and Safety Plan as required in Subsection 514.13
107.11 Public Convenience and Safety.
THE FOLLOWING IS ADDED AT THE END OF THE SECTION:
The Contractor is cautioned that there is a significant amount of bicycle traffic utilizing the bridge, not only in the peak summer months, but also throughout the year. Additionally there is a motorized wheelchair-bound individual that traverses the bridge several times a week. As such, the Contractor is to exercise extreme caution in maintaining the safety of the afore-mentioned public while they utilize the bridge and/or roadway sidewalks within the limits of the project.
107.13 Construction over or Adjacent to Navigable Waters.
THE FOLLOWING IS ADDED:
The Department has obtained permission from the US Coast Guard (USCG) to limit operation of the bridge during construction for a total of the three winters (2006-07, 2007-08, 2008-09), beginning November 1 and ending March 1, each construction year. The anticipated closure of the bridge operations will be limited to six (6) days each week, (i.e Monday through Saturday) for the entire 24 hours each day. The specific restrictions are as follows:
▪ Period of Restricted Openings: November 1 to March 1 (years of 2006, 2007, 2008, and 2009)
1. Openings on Sundays only, as scheduled at 9:00 AM, 11:00 AM, 1:00 PM, and 3:00 PM
2. Double leaf openings (whole bridge) from November 1 to December 15 (end date can be shifted if needed)
3. Single leaf openings (half the bridge) from December 16 to March 1
4. Special openings for Atlantic City Boat Show – both leaves (out and in) – dates to be defined [typically out during the last week of January and returning in the second week of February]
5. Special openings for New York City Boat Show – both leaves (out and in) – dates to be defined [typically out the third week of December and returning in the second week of January]
▪ Accommodations for Boats arriving on days other than Sunday, or as needed:
1. Boat slips will be available at the Brielle Marine Basin (5 slips available that can accommodate boats up to 60 feet long)
2. The Contractor will provide vessels with the temporary use of boat slips in accordance with Section 624.
A 4-hour notification will be required by the boaters requesting bridge openings, on these Sundays. During this period (November 1 through March 1) the Contractor shall be held responsible for the operation of the bascule span. The navigational channel shall remain open to vessels less than thirty (30) feet tall to pass through unrestricted at all times, but need not open to taller vessels requiring an opening except on these Sundays.
The specific opening dates and times for the Atlantic City and New York City Boat Shows shall be coordinated with Richard King of Garden State Yacht Sales at 732-892-4222.
The Contractor may be allowed to request closure of the bridge (to navigational traffic requiring openings) only during the period noted above, however the channel closures must be coordinated and approved by the U. S. Coast Guard, Fifth Coast Guard District, Portsmouth, Virginia. Boat traffic that needs to pass under the bascule span, NOT requiring a bridge opening shall NOT be obstructed from passing through, as a result of ANY Contractor operation. The Contractor shall submit his plan and schedule of operation for approval at least 30 days prior to commencement of work in the waterway. Two copies of such information shall be submitted concurrently to the Resident Engineer, the Commander (obr), Fifth Coast Guard District, 431 Crawford Street, Portsmouth, Virginia 23704-5004. The information shall include a sketch of the waterway; the bridge; the location of any restrictions that will be placed in the waterway such as barges, anchors, and anchor lines; the location and height above mean high water and detailed description of any scaffolding, or netting; detailed description indicating the placement, type and dimension of any cofferdams if used, with the method of screening silt from dewatering operations; and a project set of dates and length of time each operation will take. The schedule should also include the hours of operation and whether or not the equipment will be removed at night. No deviation from the approved plan and schedule of operation may be made unless the modification has previously been submitted and approved by the Coast Guard. The Contractor shall comply with all provisions of the Navigation Rules International – Inland, available from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. The Contractor shall submit to the Resident Engineer a copy of all correspondence between the Coast Guard and himself.
During the progress of work, while the channel is in operation, should any material, machinery, or equipment be lost, dumped, thrown overboard, sunk or misplaced which may be dangerous to or obstruct navigation, immediate notice shall be given to the Coast Guard and the object removed with the utmost dispatch. Until removal can be effected, the objects shall be properly marked in order to protect navigation. Notice to the Coast Guard shall give a description and location of any such object and the action taken or being taken to protect navigation.
Except as noted above, at no time during the work will the waterway be closed to navigation without prior approval from the Coast Guard. While the channel is in operation, all restrictions placed on the waterway shall be able to clear the channel within one hour’s notice. Floating work equipment (barges, etc.) must be moved out of the navigable channel during darkness after work hours. No existing bridge navigation lights shall be impaired or blocked during darkness or periods of reduced visibility.
Except as shown on the plans, no dredging, excavation, filling, rip-rap, or other work affecting the bottom, shall be done in conjunction with this work. It shall be the responsibility of the Contractor to insure that channel depths are not affected by the work. Should it be suspected that the channel depths may have been impaired or that an obstruction may exist from the work, the Contractor shall, upon request of the Coast Guard or Corps of Engineers, provide the necessary equipment and personnel to undertake a survey to determine the presence of an obstruction, objects, or silting that may have occurred during construction. The cost of this work shall be borne by the Contractor.
The construction of falsework, cofferdams, or other obstructions, if required, shall be in accordance with plans submitted to and approved by the Commander, Fifth Coast Guard District, prior to construction of the bridge. All work shall be so conducted that the free navigation of the waterway is not unreasonably interfered with and the present navigable depths are not impaired. Timely notice of any and all events that may affect navigation shall be given to the District Commander during construction of the bridge. The channel or channels through the structure shall be promptly cleared of all obstructions placed therein or caused by the construction of the bridge to the satisfaction of the District Commander, when in the judgment of the District Commander the construction work has reached a point where such action should be taken, but in no case later than 90 days after the bridge has been opened to traffic.
Spillage of oil and hazardous substances is specifically prohibited by Section 311 of the Federal Water Pollution Control Act, and amended in 1972. Measures including proper maintenance of construction equipment; arrangement of the fuel handling areas so as to permit spills to be contained before reaching a waterway; instructing personnel not to dispose of oil or other such materials into drains or into a waterway directly, as well as other procedures should be planned to prevent spillage. If any oil or other hazardous material is spilled into the waterway, the U.S. Coast Guard shall be notified immediately at 800-424-8802. A supply of hay, straw or other absorbent shall be retained so that it may be rapidly deployed to soak up any possible spillage, pending Coast Guard arrival on the scene. Use of emulsifiers or chemical dispersants is a violation of federal law and is prohibited.
During the period that the channel is in operation, placement of construction equipment in the navigational channel shall be done so as to provide a minimum horizontal clearance of 25 feet. All construction equipment placed in the waterway during periods of darkness or reduced visibility shall be lighted in accordance with the provision as outlined in the Navigation Rules International-Inland COMDTINST M16672.2D and as directed by the Coast Guard or the Resident Engineer. All anchor lines (if used) must be marked by anchor buoys, which preferably should be lighted. Floating work equipment must be moved out of navigable channel during darkness after work hours. Anchors, anchor lines, and buoys shall be so located as not to hazard transits of the waterway and so they will not infringe on the navigational channel. Floating equipment shall have a radiotelephone capable of operation from its main control station in accordance with Part 26 of Title 33, Code of Federal Regulations and shall be monitored during all periods the floating equipment is on station.
If during the periods of construction, permanent lighting cannot be maintained operable, the fenders of each pier shall be marked with a battery or power operated quick flashing white light of not less than 60 flashes per minute and visible for a range of 2,000 yards on 90% of the nights of the year. Generally, a lamp of 20-candle power will meet these requirements. If necessary to obtain coverage required, a light or lights on the upstream and downstream sides shall be installed. The piers shall be so marked until the construction has been completed and permanent navigational lighting has been reinstalled and determined to be operating satisfactorily. Written approval from the Coast Guard of temporary lighting during periods of construction is required.
Compliance with the requirements stated herein does not relieve the Contractor of the obligation or responsibility for compliance with the provisions of any other law or regulation as may be under the jurisdiction of the State of New Jersey, or any other federal, state or local authority having cognizance of any aspect of the location, construction or maintenance of said bridge.
Time restrictions for the navigational traffic shutdown shall be strictly adhered to. Any request for a minor extension (not to exceed one week) of the closure dates stated above shall be forwarded in a timely manner to the Coast Guard Bridge Administration Office for approval. However, this approval by the USCG and/or NJDOT is not guaranteed. It is advised that the Coast Guard may levy monetary civil penalties for violations of bridge regulations and statutes. Should the Contractor fail to comply with any of the aforementioned requirements and should the Federal Government be required to take action for the protection of navigation, the Government reserves the right to recover costs for any such action from the Contractor.
The office of the Bridge Administrator, Fifth Coast Guard District, shall be notified immediately upon completion of the project.
No dredging will be permitted in the waterway, anywhere under any of the bridge spans, for any reason whatsoever.
The Contractor is cautioned that several fishing boats and large charter vessels, owned and operated by a marina nearby (Bogan’s Basin) use the waterway, all year round, and generally under Span 3 (from the north) and may not necessarily require bridge openings. These boats and vessels are docked in the immediate vicinity of the bridge along the east and west sides adjacent to Bridge Piers 2N, 3N, and 4N. A typical representative schedule of the fishing boats and charter vessels is provided herewith for the Contractor’s information only, as supplied to the designer by the marina owner. These schedules are not guaranteed by the State or its representatives and it is the Contractor’s sole responsibility to verify this information and coordinate the with the marina owners. The Contractor shall take all appropriate precautions to keep the waterway under Span 3N totally unobstructed during the entire construction period, so as not to impede normal boating operations in any way.
Departure from Marina Arrival at Marina
7:30 AM 4:00 PM
8:00 AM 12:00 PM
2:00 PM 6:30 PM
7:30 AM 3:00 PM
7:30 PM 4:00 AM
6:00 AM 2:00 PM
7:00 AM 3:00 PM
8:00 AM 4:00 PM
6:00 PM 4:00 PM
8:00 PM 6:00 PM
1:00 AM 7:00 PM
5:00 AM 5:00 PM
The above schedule is NOT all inclusive and is meant to only alert the Contractor of the busy nature of the marina that essentially operates nearly 24 hours a day. The heaviest season is the beginning of May through the end of November. The basin’s entire fleet operates on a daily schedule December through April.
See Section 108.16 for liquidated damages. For bridge operations and maintenance during construction, see Section 536.
107.22 Risks Assumed by the Contractor.
BDC02s-03 dated may 24, 2002
1. RISKS OF LOSS OR DAMAGE TO THE PERMANENT CONSTRUCTION. UNTIL ACCEPTANCE, AND WITHIN THE LIMITS OF THE PROJECT’S WORK, THE CONTRACTOR SHALL BEAR THE RISK OF ALL LOSS OR DAMAGE TO ALL PERMANENT CONSTRUCTION AND TEMPORARY CONSTRUCTION PERFORMED UNDER THIS CONTRACT AND TO MATERIALS, WHETHER OR NOT IT HAS RECEIVED PAYMENT FOR SUCH CONSTRUCTION OR MATERIALS UNDER SUBSECTION 109.05, 109.06, OR 109.07, EXCEPT PAYMENT WILL BE MADE TO THE CONTRACTOR FOR THE REPAIR OR REPLACEMENT OF ANY PERMANENT ELEMENT OF THE CONSTRUCTION WHICH HAS NOT BEEN ACCEPTED BY THE DEPARTMENT, IF THE ELEMENT OF THE WORK DAMAGED IS COMPLETED TO THE STAGE OF SERVING ITS INTENDED FUNCTION AND IS SUBSEQUENTLY DAMAGED BY ACCIDENT BY PUBLIC TRAFFIC. IN ORDER TO RECEIVE PAYMENT, THE CONTRACTOR MUST SUPPLY SATISFACTORY EVIDENCE THAT SUCH DAMAGE WAS CAUSED BY A PUBLIC TRAFFIC ACCIDENT WHICH WAS NOT CAUSED BY VANDALISM OR BY THE EQUIPMENT OF THE CONTRACTOR OR ANY OF ITS SUBCONTRACTORS OR SUPPLIERS. SATISFACTORY EVIDENCE SHALL GENERALLY BE LIMITED TO: ACCIDENT REPORTS FILED WITH THE DIVISION OF MOTOR VEHICLES, POLICE AGENCIES OR INSURANCE COMPANIES; STATEMENTS BY RELIABLE, UNBIASED EYE WITNESSES; IDENTIFICATION OF THE VEHICLE INVOLVED IN THE ACCIDENT. PHYSICAL EVIDENCE THAT THE DAMAGE WAS CAUSED BY A MOTOR VEHICLE (SUCH AS TIRE MARKS OR BROKEN HEADLIGHT GLASS) WILL NOT BE SUFFICIENT UNLESS IT CAN BE CLEARLY SHOWN THAT THE DAMAGE WAS NOT CAUSED BY THE CONTRACTOR’S VEHICLES OR BY VANDALISM. THE CONTRACTOR SHALL TAKE EVERY PRECAUTION, AS ALLOWED BY THE CONTRACT AGAINST INJURY OR DAMAGE TO ANY PART OF THE CONSTRUCTION OR TO MATERIALS BY THE ACTION OF THE ELEMENTS, THE TRAVELING PUBLIC, VANDALISM, OR FROM ANY OTHER CAUSE, WHETHER ARISING FROM THE EXECUTION OR THE NON-EXECUTION OF THE WORK. THE CONTRACTOR SHALL PROMPTLY REPAIR, REPLACE, AND MAKE GOOD ANY SUCH DAMAGE OR LOSS WITHOUT COST TO THE DEPARTMENT. THE CONTRACTOR SHALL NOT BEAR SUCH RISK OF LOSS OR DAMAGE, WHICH ARISES FROM ACTS OF WAR OR FLOODS, TIDAL WAVES, EARTHQUAKES, CYCLONES, TORNADOES, HURRICANES, OR OTHER CATACLYSMIC NATURAL PHENOMENON UNLESS SUCH LOSS OR DAMAGE IS COVERED BY INSURANCE.
107.23 Insurance.
INCLUDE THE FOLLOWING WHEN RAILROAD INSURANCE IS REQUIRED.
6.
Insurance coverage shall be procured and maintained for the following railroad(s):
include THE APPROPRIATE RAILROAD(S).
It is estimated that 10 percent of the Project cost is located within or adjacent to the railroad right-of-way.
107.28 Environmental Protection.
THE FOLLOWING IS ADDED AT THE END OF THE SECTION:
The following time restrictions shall be complied with during the entire duration of the construction of the project:
▪ No in-water work will be allowed between January 1 through June 30 – work includes installation of riprap channel protection around the two piers as designated in the plans, fender repairs and installation of the northern bulkhead repairs.
▪ No bridge demolition or roadway excavation/demolition work at the southern end of the bridge will be allowed between April 1 to September 30 within the buffer zone for night heron roosting as indicated on the plans – specifically deck demolition, railing removal, sidewalk demolition, excavation of the existing approach pavement, guide rail removal, contaminated soil removal under the south end span, cleaning and painting activities, bearing jacking work - any of these activities that occur inside of the buffer zone shall be scheduled outside of the time restrictions. The construction schedule for the staging of the work has considered these restrictions.
SECTION 108 – PROSECUTION AND PROGRESS
108.02 SUBCONTRACTING.
listed below are typical “SPECIALITY ITEMS”.
Span Balancing – (initial, intermediate ones [one each after Stage I, Stage II, Stage III, and Stage IV] and Final).
Remove Asbestos walls in machinery room.
CHECK WITH GEOTECHnical engineering.
*****OR*****
*****OR*****
list additional “specialty items”
BDC03s-16 dated november 21, 2003
THE CONTRACTOR SHALL ALSO ATTACH TO THAT FORM (APPLICATION FOR SUBCONTRACTING FORM) PROOF OF THE SUBCONTRACTOR’S VALID, CURRENT REGISTRATION WITH THE NEW JERSEY DEPARTMENT OF LABOR, DIVISION OF WAGE AND HOUR COMPLIANCE AS REQUIRED BY “PUBLIC WORKS CONTRACTOR REGISTRATION ACT,” N.J.S.A. 34:11-56.48 ET SEQ. (P.L. 2003, C. 91). PURSUANT TO P.L. 2003, C. 91, THE DEPARTMENT WILL NOT CONSENT TO THE PROPOSED SUBCONTRACTING, AND THE SUBCONTRACTOR SHALL NOT PERFORM ANY WORK UNDER THE CONTRACT, UNLESS THE CONTRACTOR FIRST PROVIDES THE REQUIRED PROOF OF THE SUBCONTRACTOR’S VALID, CURRENT REGISTRATION WITH THE NEW JERSEY DEPARTMENT OF LABOR, DIVISION OF WAGE AND HOUR COMPLIANCE AS REQUIRED BY “PUBLIC WORKS CONTRACTOR REGISTRATION ACT.” THE CONTRACTOR SHALL ENSURE FULL COMPLIANCE WITH THE PUBLIC WORKS CONTRACTOR REGISTRATION REQUIREMENTS BY THEIR SUBCONTRACTORS.
108.03 Commencement of Work.
BDC01s-12 dated february 27, 2002
CONSTRUCTION OPERATIONS SHALL NOT BEGIN UNTIL THE CONTRACTOR HAS SUPPLIED, AND THE ENGINEER HAS ACCEPTED, THE PRELIMINARY SCHEDULE AND OTHER CERTIFICATIONS, FORMS, SCHEDULES, AND ANY OTHER INFORMATION REQUIRED BY THE CONTRACT DOCUMENTS, AND UNTIL THE CONTRACTOR HAS ESTABLISHED A FIELD OFFICE AS REQUIRED BY SUBSECTION 105.15.
108.04 Progress Schedule and Prosecution of the Work.
BDC01s-12 dated february 27, 2002
IN SCHEDULING AND EXECUTING THE WORK, THE FOLLOWING SHALL BE COMPLIED WITH:
1. Progress Schedules. The progress schedule shall conform to and incorporate the following requirements:
a. General.
(1) The work shall be monitored by a detailed CPM schedule. The CPM schedule shall be developed utilizing the most current NJDOT Capital Program Management Construction Scheduling Standard Coding and Procedures for Designers and Contractors Manual and the NJDOT Primavera template project containing the latest standard coding. The manual and template are available from the Bureau of Quality Management Services.
The CPM schedule shall consist of diagrams and accompanying mathematical analyses. The scheduling of submittals, procurement, construction, and all else necessary to complete the Work as described in the Contract Documents, is the responsibility of the Contractor. The requirement for the CPM schedule is included to ensure adequate planning and execution of the Work and to assist the Department in appraising the reasonableness of the proposed schedule, as well as its compliance with Contract requirements.
The CPM schedule is the Contractor’s committed plan to complete all work within the allotted time. The Contractor assumes full responsibility for the prosecution of the Work as shown. The CPM schedule shall be based on and derived from detailed schedules used to complete all Contract activities.
(2) No claim for extension of time due to extra work or any other type of delay will be considered unless the baseline schedule has been approved and monthly updates are current and submitted within the time limits stated.
(3) No claim for additional compensation as specified in Subsection 109.04 will be considered unless the baseline schedule has been approved and monthly updates are current and submitted within the time limits stated.
(4) The CPM preliminary, baseline, and updated schedules shall be submitted in electronic format on a floppy diskette or compact disk, in addition to the required number of copies specified in b. (1) and b. (2) below.
(5) Once the CPM baseline schedule has been approved, the Contractor shall not deviate therefrom without first notifying the Engineer in writing and schedule is updated in accordance with 1.h. and 1.i. below.
b. Submittals. The CPM schedule shall consist of the following two distinct initial submittals:
(1) Preliminary Schedule. No later than 10 State Business Days after execution of the Contract, the Contractor shall submit to the Engineer for review and approval or rejection and return a preliminary schedule. The Contractor shall submit six copies of:
(a) A CPM time-scaled diagram defining the Contractor’s planned activities during the first 90 Calendar Days. For projects with a construction cost over $ 40 million, a CPM time-scaled diagram defining the Contractor’s planned activities during the first 120 Calendar Days.
(b) A summary network for the remainder of the Contract time. The preliminary schedule shall indicate all milestone activities expected to be completed or partially completed before submission and approval of the CPM baseline schedule as specified in b. (2) below.
I All multiple shifts per day and anticipated production rates shall be detailed in the Contractor’s narrative accompanying the preliminary schedule.
(d) The Work shall not begin until the preliminary schedule has been approved. Five State Business Days will be required for review and approval or rejection and return of the preliminary schedule.
(2) Baseline CPM Schedule. In accordance with the time frames listed below, the Contractor shall submit six copies of the Baseline CPM Schedule documents depicting the Contractor’s work plan for the entire Contract.
|Project Construction Cost |Time Frame After Approval of Preliminary |
|($ million) |Schedule for Submission of the Baseline CPM |
| |Schedule |
| |(State Business Days) |
|< 5 |10 |
|5 - 15 |15 |
|15 – 40 |20 |
|> 40 |30 |
The Contractor shall submit to the Engineer for review and approval or rejection and return:
(a) Computer generated tabular schedule and logic reports in accordance with 1.e. below.
(b) Time-scaled computer generated Layout Output in conformance with 1.f. below.
I A written narrative explaining the schedule and the Contractor’s general approach for achieving Substantial Completion and the date of Completion as specified in Subsection 108.10 of these Special Provisions. Multiple shifts per day and anticipated production rates shall be detailed in the Contractor’s narrative accompanying the Baseline CPM Schedule.
(d) Electronic version as specified in 1.a. (4) above.
c. CPM Schedule Requirements for the Baseline and Updates.
(1) The CPM schedule and updates shall contain the following:
(a) The order in which the Contractor proposes to prosecute the Work; the starting dates of the various work stages, operations, and principal items of work including procurement of materials and plant, and the contemplated dates for completing the same.
(b) List dates for all required submissions.
I A clear outline of the intended maintenance of traffic.
(d) The locations and timeframes for the installation of temporary and permanent soil erosion and sediment control measures to be installed.
(e) All unusual requirements specific to the project included in the Contract Documents or as deemed appropriate for the project.
(f) Special consideration to sensitive areas such as wetlands, floodplains, waterways, and parklands to ensure that appropriate staging and seasonal constraints are considered in order to maximize the effectiveness of the soil erosion and sediment controls.
(g) The time frames when work is restricted in sensitive areas as reflected in present and future permits as anticipated or known.
(h) Updates to reflect permit conditions if changed.
(i) Include a detailed, step-by-step outline of any clean-up operations regarding contaminated material.
(j) The work of the Contractor, subcontractors, suppliers, the Department, permitting agencies, utility companies, and all others that affect progress shall be shown and identified on the schedule by responsibility codes.
the designer shall Insert the number of State Business Days (Sbd) that they will require to review certify/approve or reject working drawings. It is suggested that twentY Sbds be used for the “certification” process and thirty Sbds be used for the “approval” process. based on specific project charactoristics,the suggested time frames may be increased or decreased. However, any increase must be justified by the designer and approved by the project manager.
(l) Traffic staging, delivery of Department – furnished labor/equipment, project phasing, right-of-way availability dates, and any other requirements specified in Divisions 200 through 900 shall be shown.
(m) The CPM schedule shall contain sufficient activities to adequately depict the Work, and will be subject to the review and approval of the Engineer.
(n) The logic and activity time durations established by the Contractor shall be consistent with the Contract Documents and be reflective of proper coordination between trades.
(2) The CPM schedule shall operate as follows:
(a) The CPM schedule shall be of the precedence type.
(b) One activity for each discrete component part of each Pay Item scheduled in the Proposal. The Engineer may allow grouping of similar Pay Items into one activity. No work activity shall have a duration greater than 30 Calendar Days, except as approved by the Engineer. The activities shall be consistent with the Work Breakdown Structure (WBS), and shall also include discrete component parts of the Contractor’s submittal preparation, Department approval, procurement, and construction work activities with sufficient detail such that all the relationships with all direct and non-direct parties to the Work are shown.
I The system shall be based upon network diagrams and accompanying mathematical tabulations as described hereinafter. Diagrams shall show the order and interdependence of activities and the sequence and quantities in which work is to be accomplished. The basic concept of network scheduling shall be followed to show how the start of a given activity is dependent on the completion of preceding activities and how its completion may affect the start of subsequent activities. The critical path shall be distinguished from other paths on the network.
(d) The completion date of the CPM schedule shall be the date of Completion specified in Subsection 108.10 of these Special Provisions, except as specified in Subsection 108.04 subpart 5, which shall be input as a Finish Milestone with a Late Finish Constraint. All Intermediate Milestones required in the Contract shall be shown in proper logical sequence and input as a “Start-no-Earlier-Than” constraint for entrance into an area or start activity or a “Finish-no-Later-Than” constraint date for completions.
(e) Activities shall be described such that the Work is readily identifiable for assessment of start and completion, as well as intermediate status. Descriptions shall utilize activity codes for physical locations at each stage such as distance-markers, structures, and elevations where possible to define the Work. Activity descriptions of “Start,” “Continue,” “Completion,” “X percent,” “Y percent,” “Z percent” or similar nonspecific descriptions will not be allowed.
(f) The CPM schedule shall be calculated in Working Days. The Working Day to calendar date correlation shall be based upon the Contractors proposed work week with adequate allowance for weekends, legal holidays and any special requirements of the Contract. Activities shall indicate the calendar being used. Durations for activities shall not be less than one workday. Multiple shifts per day and anticipated production rates shall be detailed in the Contractor’s narrative accompanying the baseline schedule and subsequent updates.
(g) Constraint dates are permitted only on milestone activities, unless otherwise approved by the Engineer.
(h) All activities with the exception of the Project Start Milestone and Project Completion Milestone shall have predecessors and successors. The start of an activity shall have a Start-to-Start or Finish-to-Start relationship with preceding activities. The completion of an activity shall have a Finish-to-Start or Finish-to-Finish relationship with a succeeding activity. Start-to-Finish relationships are not acceptable.
(i) CPM schedules, which have been resource leveled, are permissible, provided the effects of leveling are incorporated in the schedule using “Start-no-Earlier-Than” date constraints.
d. Computer Program Requirements. The computer program requirements shall be the same as that specified in Subsection 105.15 subpart 1.e. of these Special Provisions.
e. Tabular Reports.
(1) CPM schedule reports shall be provided for the following sort orders:
(a) Total float, then early start for activities with float less than 20 days.
(b) Grouped by responsibility, then by early start.
I Grouped by WBS, area, then sorted by early start.
(2) The minimum activity information required for each of the above reports in (1), shall include the following:
(a) A unique activity ID for each activity.
(b) A description of the Work represented by the activity.
I Location code identification.
(d) Work responsibility code identification.
(e) Original activity duration and remaining activity duration in Working Days.
(f) Early and late, start and finish dates calculated according to CPM principles.
(g) Total float.
(h) Historical (actual) dates for activities completed or underway shall replace the appropriate calculated dates.
(i) Stages.
(j) Calendar used for each activity.
f. CPM Time-Scaled Layout Output.
(1) The network displayed on the schedule diagram shall depict the exact detail of the CPM schedule reports.
(2) The network diagram shall be of the precedence type and drawn by using early dates.
(3) The layout output shall be time-scaled. The length of the activity representation shall be proportional to the activity duration.
(4) The activity display shall include the:
(a) Activity description.
(b) Activity identification.
I Activity original duration and remaining duration.
(d) Activities coded by area, responsibility, and WBS.
(e) Activity total float.
(f) Activities early start dates.
(g) Activities finish dates.
(5) The activities, which are displayed on the network diagram, shall be grouped by WBS and sorted by area. The title of these components shall appear on the left-hand side of the plot.
(6) The critical path shall be identified on the plot.
(7) Vertical lines indicating the start and the end of each month shall be shown.
(8) The data date shall be indicated on the plot in the activity display and in the title at the top or bottom of the plot.
(9) Completed activities shall be indicated on the plot.
(10) The Contract title shall be displayed on the plot.
(11) A legend shall be provided which indicates the various symbols used and their meanings.
(12) Milestone Activity shall be indicated by a prominent symbol.
(13) Different line types shall indicate the critical path and completed Milestone and activities.
g. Review and Approval. The Engineer will review a submitted preliminary schedule for approval or rejection within five State Business Days of receipt and will thereafter return same to the party having submitted it. There will, in turn, be allotted ten State Business Days for review and approval or rejection by the Engineer of the submitted baseline schedule, which will thereafter be returned to the party having submitted it. The Engineer will review revised preliminary or revised baseline submittals within five State Business Days of receipt. The time periods set forth in this paragraph are provided for scheduling purposes only. The Department reserves the right to enlarge such time periods for review by a reasonable amount of time where circumstances necessitate, within the sole discretion of the Engineer.
h. Updating and Revisions.
(1) Within ten State Business Days after review by the Engineer, all preliminary and baseline schedules that are not approved shall be revised and resubmitted by the Contractor until the Engineer’s approval is received.
(2) The Contractor shall update the CPM schedule monthly whether or not the Engineer has accepted the schedule, to reflect actual activity progress. The update shall include the historical record of actual start and actual finish dates for activities in progress, or completed, and the remaining duration based on the amount of workdays required to complete the activity.
(3) Monthly progress meetings shall be held. The updated CPM schedule shall be the basis for the monthly progress review meetings. Activity progress shall be prepared in advance of the meeting. At this meeting, attended by the Engineer, all progress during the calendar month shall be presented and reviewed for incorporation into the schedule by the Contractor. Within a period of ten State Business Days from the date of this progress meeting, the Contractor shall submit the schedule update to the Engineer with the agreed upon changes.
(4) The monthly schedule update submission shall consist of three copies of electronic format on floppy diskettes or compact disks and three copies of the following:
(a) Updated CPM schedule reports (see Item e. above).
(b) Layout output. (See item f. above).
I CPM progress narrative.
The CPM progress narrative report submitted as part of the update analysis shall include, but not be limited to, the:
1. Description of schedule status.
2. Discussion of current and anticipated delaying problem areas and their estimated impact.
3. Schedule slippage, pay revisions, and/or progress along the critical path in terms of days ahead or behind the allowable dates, and if the Work is behind schedule, progress along other paths with negative float. This shall be in addition to and not a substitute for requirements in Subsection 108.11.
4. Logic changes and an explanation of the revisions. Revisions to activities not worked on during the period, including changes in duration, or revisions to activity relationships are to be considered logic revisions. Out-of-sequence activities are not acceptable and shall be corrected in logic revisions prior to submission to the Department.
(5) When, in the Engineer’s opinion, the CPM schedule fails to reflect the Contractor’s actual plan and method of operation, or the Contractor’s completion date as indicated by the CPM is more than one month behind the Contract completion date, the Engineer may require the Contractor to submit for review within ten State Business Days, a recovery plan for completion of the remaining work within the Contract completion date. A recovery plan shall include, but not be limited to, a revised CPM schedule and additional manpower and equipment that shall be utilized to complete the project by the date of Completion.
(6) When the Contractor adds activities that are not Extra Work Items to the CPM schedule, they shall be added in a method that completion dates of any succeeding baseline activities are not affected. All revisions shall be submitted to the Engineer for approval before incorporation into the CPM schedule.
(7) The Engineer shall have the right, within its sole discretion, to prepare its own update(s) or revision(s) to the baseline schedule in the event of a dispute between the parties regarding the appropriateness of the submitted revision(s) or updates to the baseline schedule or by reason of a failure on the part of the Contractor to prepare same, which update(s) or revision(s) may reflect what the Engineer has determined to be the actual status of the project progress, actual sequencing of the Work and appropriate scheduling logic required under this Subsection. The Engineer may thereupon rely on its own revision(s) or update(s) of the baseline schedule in the administration of the project, review of claims and/or the imposition of liquidated damages.
i. Changes and Delays. To ensure that the CPM schedule continues to accurately reflect the Contractor’s plan for the Work and that it incorporates the impact of all changes and delays as soon as the Work scope can be defined, the Contractor shall use the following procedure to incorporate changes and delays.
When Extra Work or a change is proposed or claimed, the Contractor shall submit a Time Impact Evaluation form. Each Time Impact Evaluation must identify in a CPM fragnet sketch, additional work required as a result of the proposal and its interrelationship to the CPM schedule. Each change or delay shall be represented by adding a new activity or activities. These activities shall be clearly identified. This sketch shall show all activities, logic revisions, duration changes, and new activities with all the predecessors and successors. The Time Impact Evaluation form shall also include any associated cost changes for performing the Work in question. Upon the Engineer’s approval of the Time Impact Evaluation, the Contractor shall incorporate the fragnet’s illustrating the influence of changes and delays into the baseline schedule and the working schedule in the next schedule update. An extension of time may only be considered when the Time Impacted scheduled completion date exceeds the date of Completion. For cases where the Contractor is behind schedule, an extension will be granted for only the amount of time that the Department is responsible as supported by a Time Impact Evaluation. In the event of a dispute, the Engineer may prepare an update, which is believed to be the true impact on the project. No additional compensation will be paid to the Contractor for preparing these revisions. Any request for extension of time shall be verified by CPM analysis and shall be in accordance with Subsection 108.11. Compensation for additional expense to the Contractor and allowance of additional time for completion of the Work shall be as set forth in a Construction Order in accordance with Subsections 108.11 and 109.03.
2. Staging. The Contractor shall schedule the Work using such procedures and staging as may be specified in the Contract Documents. Work designated as part of separate stages may be performed simultaneously where provided by the Contract Documents or where approved.
When the Contract Documents provide for staging or specific procedures, the Contractor may present, for written approval of the Engineer, a detailed, written alternate staging plan or procedure which incorporates the requirements of the Department. If the Contractor proposes an alternate-staging plan, two CPM schedules shall be submitted, one based on the original staging and one based on the Contractor’s alternate staging. As a condition of the Engineer’s reviewing of the alternate staging plan or procedure, the Contractor agrees that it is not entitled to additional Contract Time or compensation arising from possible delays to construction due to the time spent in reviewing the Contractor’s staging plan or procedure, regardless of whether the Department accepts or rejects it. The Engineer will review and approve or reject and or return, with comments, the staging plan within ten State Business Days. If such staging plan or alternate procedure is approved in writing, the Contractor shall then finalize the progress schedule consistent with the alternate approved staging.
3. Prosecution of the Work.
a. At or prior to the preconstruction conference, the Contractor shall furnish the name and location of the solid waste facilities to be utilized as well as the fee structure of each of the facilities. Failure to provide such information shall make the Contractor ineligible for adjusted compensation as provided for in Subsection 104.07.
b. The Contractor shall provide sufficient materials, equipment, and labor to guarantee the Completion of the Project in accordance with the Contract Documents and within the time set forth under Subsection 108.10.
c. The Contractor shall supply the Engineer with a weekly work schedule indicating the Contractor’s planned work, the subcontractor’s planned work, the dates when materials and submissions are to be delivered, and a forecast of lane closings.
d. The Contractor shall notify the Engineer, in writing, prior to discontinuing work for any reason and at least 24 hours in advance of resuming operations.
e. The Contractor shall arrange and prosecute the Work so that each successive construction operation at each location shall follow the preceding operation as closely as the requirements of the various types of construction permit.
f. Underground structures for traffic signals, except for pressure detector installations shall be constructed prior to completion of the intersecting road.
g. Work which closes or alters the use of existing roadways shall not be undertaken until adequate provisions, conforming to the requirements of Section 617, have been made by the Contractor and approved.
h. The Engineer may revise stage construction and maintenance of traffic, if deemed necessary, by the Engineer due to unforeseen circumstances that may arise during construction.
i. When possible, the construction of subsurface structures adjacent to traffic shall be performed while traffic is being diverted from such areas. If traffic must be maintained in such areas, the Work shall be done expeditiously in stages, as approved, and with minimum interference with traffic.
j. Subsurface structure excavation adjacent to traffic shall not remain open overnight unless adequately protected by approved safety devices.
k. The Contractor shall proceed with the Work of demolition of the various buildings that are identified with a demolition number as and when they become available for demolition. If any of the buildings to be demolished is not available for demolition at the time the Contractor begins work on the Project, the Contractor shall temporarily defer its work in the vicinity of the building and complete the Work when the building is made available for demolition.
l. Operations adjacent to traffic shall be confined to only one side of the traffic at any one time unless otherwise specified in the Contract Documents.
m. Concrete curbs constructed adjacent to flexible base and surface courses shall be completed, cured, and backfilled before the flexible base and surface courses are constructed.
n. Bituminous paving operations shall be staged to progress up to the bottom of the surface course. The top layer of the bituminous concrete surface course for the full width of the traveled way, shoulder, and auxiliary lanes shall be paved as a single stage of construction and as the final paving operation.
4. Acceleration and Default. If, in the opinion of the Engineer, the Contractor falls behind its baseline schedule, and cannot complete the Work within the time prescribed under Subsection 108.10, as modified pursuant to Subsection 108.11, the Contractor shall take such steps as may be necessary to improve its progress. The Engineer may require the Contractor to increase the number of shifts, begin overtime operations, work extra days including weekends and holidays, or supplement its construction plant and to submit for approval such supplementary schedule or schedules, as may be deemed necessary to demonstrate the manner in which the agreed rate of progress shall be regained, all at no cost to the State.
Failure of the Contractor to comply with the requirements of the Engineer under this Subheading is grounds for the determination that the Contractor is not prosecuting the Work with such diligence as to ensure Completion within the time specified. Upon such determination, the Engineer may terminate the Contractor’s right to proceed with the Work or any separate part thereof in accordance with Subsection 108.17.
5. Intent, Responsibility, and Time. Scheduling of construction shall be the responsibility of the Contractor. The Contractor’s shall determine the most feasible order of work commensurate with the Contractor’s abilities and the Contract Documents. The CPM schedule will be used for determining extensions or reductions of Contract Time pursuant to Subsection 108.11.
It is not intended that the Engineer, by approving the CPM schedule, agrees that it is reasonable in any or all respects or that following the CPM schedule can result in timely completion of the Project. The progress schedule is not a part of the Contract.
If, in the preparation of the CPM schedule, the Contractor reflects a completion date different than that specified under Subsection 108.10, this in no way voids the date set therein. The date as specified in that Subsection governs. Where the CPM schedule reflects a completion date earlier than that specified as the Contract Time, the Engineer may approve such schedule with the Contractor specifically understanding that no claim for additional Contract Time or compensation shall be brought against the State as the result of failure to complete the Work by the earlier date shown on the CPM schedule.
6. Payment. Payment for the accepted progress schedule will be made on a lump sum basis for the costs for schedule preparation, maintenance, updating, facilities, personnel, computer hardware and software requirements, schedule submittals and reproduction as specified. Twenty-five percent of the lump sum bid will be paid upon approval of the baseline submission, and the balance paid on approval of updates at a prorated sum based upon the number of anticipated updates to be submitted during the Contract Time.
Payment will be made under:
Pay Item Pay Unit
PROGRESS SCHEDULE LUMP SUM
108.05 MOBILIZATION.
BDC01s-12 dated february 27, 2002
MOBILIZATION SHALL CONSIST OF THE PREPARATORY WORK AND OPERATIONS NECESSARY FOR THE MOVEMENT OF PERSONNEL, EQUIPMENT, SUPPLIES, AND INCIDENTALS TO THE PROJECT SITE, AND OTHER WORK PERFORMED OR COSTS INCURRED PRIOR TO BEGINNING WORK.
Payment for mobilization will be made on a lump sum basis regardless of the fact that the Contractor may have, for any reason, shut down its work on the Project or moved equipment away from the Project and back again.
Payment will be made in accordance with the following schedule:
1. When five percent of the Work is completed and the Baseline Progress Schedule is approved by the Engineer, 25 percent of the lump sum bid for mobilization or 2.5 percent of the Total Contract Price, whichever is less, will be paid.
2. When ten percent of the Work is completed and all required CPM Progress Schedule Updates are approved by the Engineer, 50 percent of the lump sum bid for mobilization or five percent of the Total Contract Price, whichever is less, will be paid.
3. When 15 percent of the Work is completed and all required CPM Progress Schedule Updates are approved by the Engineer, 75 percent of the lump sum bid for mobilization or 7.5 percent of the Total Contract Price, whichever is less, will be paid.
4. When 20 percent of the Work is completed and all required CPM Progress Schedule Updates are approved by the Engineer, 100 percent of the lump sum bid for mobilization or ten percent of the Total Contract Price, whichever is less, will be paid.
5. When all Work on the Project is complete, payment for the lump sum bid for mobilization in excess of ten percent of the Total Contract Price will be made.
6. The percentage of Work completed shall be the total of payments earned compared to the Total Contract Price. The total of payments earned excludes the amount paid for this item and the amount paid for materials furnished but not incorporated into the Work in accordance with Subsection 109.06, as shown on the monthly estimates of the approximate quantities of Work performed, prepared in accordance with Subsection 109.05.
7. No payment will be made for mobilization until a Baseline Schedule is approved, except when all Work on the Project is complete, then 50 percent of the lump sum bid for mobilization will be paid and no further payment(s) will be made for the lump sum bid for mobilization.
Payment will be made under:
Pay Item Pay Unit
MOBILIZATION LUMP SUM
WHEN MOBILIZATION IS NOT A PAY ITEM, ALL COSTS FOR THE WORK SHALL BE INCLUDED IN THE PRICES BID FOR VARIOUS PAY ITEMS SCHEDULED IN THE PROPOSAL.
108.06 Limitations of Operations.
the FIRST SENTENCE OF THE FIRST PARAGRAPH is DELETED AND the FOLLOWING IS INSERTED IN ITS PLACE:
THE CONTRACTOR SHALL CONDUCT THE WORK AT ALL TIMES IN SUCH A MANNER AND SUCH SEQUENCE THAT SHALL ENSURE THE LEAST INTERFERENCE WITH VEHICULAR AS WELL AS MARINE TRAFFIC. THE CONTRACTOR SHALL BE AWARE THAT THERE IS A NOISE ORDINANCE IN BRIELLE BOROUGH THAT RESTRICTS CONSTRUCTION WORK NOISE AT NIGHT. NIGHT WORK IS EXPECTED IN PRE-STAGE I, STAGE IIB AND IIIB AND MAY OCCUR IN OTHER STAGES. BRIELLE BOROUGH AND POINT PLEASANT BEACH BOROUGH ARE AWARE OF THE REQUIRED WORK AND HAVE AGREED TO COOPERATE WITH THE DEPARTMENT AND CONTRACTOR TO COMPLETE THIS WORK. TO COORDINATE THIS NIGHT TIME WORK WITH BRIELLE BOROUGH, THE CONTRACTOR SHALL CONTACT THE BRIELLE POLICE DEPARTMENT AT 732.528.5050. TO COORDINATE NIGHT-TIME WORK WITH POINT PLEASANT BEACH BOROUGH, THE CONTRACTOR SHALL CONTACT THE POINT PLEASANT BEACH POLICE DEPARTMENT AT 732.892.0500.
108.08 Working Site.
THE FOLLOWING IS ADDED AT THE END OF THE SECOND PARAGRAPH:
At the Resident Engineer’s discretion and prior permission, ONLY areas of the deck designated to be demolished within the Stage construction regions may be allowed for TEMPORARY storage of certain items, if in the Resident’s opinion, these are construed as being necessary for a particular construction operation that is to be done within time constraints imposed by the contract documents.
NJDOT or its representatives make no guarantee as to the capacity of the existing structure for use as access to the construction or support for construction equipment. The Contractor should, at his own expense perform all necessary stress analyses to determine the structures capacity, prior to imposing any construction loads.
The Contractor is cautioned that there is a busy marina in the immediate vicinity of the bridge site at the north end (Bogan’s Basin), which operates several large charter vessels throughout the year. Several of these large charter boats are docked in the very close vicinity at the northeast and northwest corners. The area under and adjacent to the north end span is occupied by numerous private vehicles parked under the bridge and adjacent to the work site. Any Contractor operations shall take extreme care and caution to prevent any type of potential conflicts with either the vessels or vehicles or personnel or public utilizing any of these afore-mentioned areas. The work in this area impacting vehicular and fishing vessel parking may only be performed between November 1 and November 30, of each construction year. Details of work items and associated timing restrictions in Spans 1, 2, and 3 are listed in Section 108.12. Coordination with the owners of Bogan’s basin is required prior to any activities impacting the parking areas, boat docking facilities and any obstructions to the sailing path of their boats in the three northern end spans (Spans 1, 2, and 3).
Contact information: Bogan’s Basin William H. Bogan, Sr. Phone 732–528-3377
732–892-3377
Captain Sharon Bogan Phone 732–528-8673
Captain Tony Bogan Phone 732–528-8673
108.09 Unusual Site Conditions.
THE FOLLOWING IS ADDED AT THE END OF THE SECTION:
The existing deck concrete strength is unknown and assumed to be 3000 psi. This information is being provided for informational purposes only and in no way guarantees or represents the actual concrete strength that may be encountered along the length of and across the width of the bridge and sidewalks. There shall be no claims for time extension or any additional compensation for removal of the deck concrete owing to any variation in the existing concrete strength, regardless of the amount of variation, from these values known to the designer.
All work under the Contract shall be performed and completed in accordance with the following schedule:
Platforms and Gates for the Barrier Gates and Traffic Gates, both north bound and south bound shall be completed and fully operational prior to March 1, 2007.
Stage 1: All work required for the completion of Pre-Stage 1, Stage 1, and shifting of traffic into the Stage 2 lane configuration shall be completed prior to June 14, 2007.
Stage 2: All work required for the completion of Stage 2 and shifting of traffic into the Stage 3 lane configuration shall be completed prior to December 26, 2007.
Stage 3: All work required for the completion of Stage 3 and shifting of traffic into the Stage 4 lane configuration shall be completed prior to September 30, 2008.
Stage 4: All work required for the completion of Stage 4 and shifting of traffic into the standard operating lane configuration shall be completed prior to April 30, 2009.
Final: All work on the project shall be completed prior to June 30, 2009.
If the Contractor fails to complete fully, entirely and in conformity with the provisions of the Contract, the Project and each and every part and appurtenance thereof, within the time stated above, or any portion for which a completion date is stipulated within such further time as may have been granted in accordance with the provisions of the Contract, then the Contractor shall and hereby agrees to pay the Department for each and every calendar day that he is in default on time to complete such portion of the work for which a completion date is stipulated or to complete the entire Project, the following amount:
Platforms and Gates Operational Three Thousand, Two Hundred Dollars ($3,200.00) per calendar day.
Stage 1: Three Thousand, Two Hundred Dollars ($3,200.00) per calendar day.
Stage 2: Three Thousand, Two Hundred Dollars ($3,200.00) per calendar day.
Stage 3: Three Thousand, Two Hundred Dollars ($3,200.00) per calendar day.
Stage 4: Two Thousand, Three Hundred Dollars ($2,300.00) per calendar day.
Final: One Thousand, Nine Hundred Dollars ($1,900.00) per calendar day.
Which said amount per calendar day is agreed upon by the parties hereto to be liquidated damages and not a penalty.
108.10 Time of Completion.
BDC03s-06 dated april 24, 2003
A.
B. The entire Work of the Project shall be completed on or before June 30, 2009.
*****OR*****
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A. BASIS FOR ADJUSTMENT. EXTENSIONS OR REDUCTIONS TO THE CONTRACT TIME MAY BE PROVIDED BY CONSTRUCTION ORDER, HOWEVER, SUCH EXTENSIONS OR REDUCTIONS WILL BE ALLOWED ONLY TO THE EXTENT THAT THE INCREASE OR DECREASE IN THE WORK OR DELAYS OF THE TYPES INDICATED BELOW AFFECT THE CRITICAL PATH OF THE CURRENT APPROVED PROGRESS SCHEDULE UPDATE AND THE COMPLETION OF THE WORK AND/OR SUBSTANTIAL COMPLETION DATES PROVIDED IN SUBSECTION 108.10. HOWEVER, WHEN THE FINISH MILESTONE(S) FOR THE SUBSTANTIAL COMPLETION DATE OR COMPLETION OF THE WORK DATE IDENTIFIED ON THE CURRENT APPROVED SCHEDULE IS A DATE OR DATES PRIOR IN TIME TO THE DATES SPECIFIED IN THE CONTRACT, THE DEPARTMENT WILL CONSIDER THE TIME BETWEEN THE DATES PROJECTED IN THE SCHEDULE AND THAT IN THE CONTRACT AS CONSTITUTING FLOAT IN THE SCHEDULE WHICH SHALL OFFSET THE AMOUNT OF ALLOWABLE DELAY CONTRIBUTABLE TO THE ACTIONS OF THE DEPARTMENT, THIRD PARTIES, OR THE CONTRACTOR, OR CAUSED BY A COMBINATION OF THOSE FACTORS, AND OTHER FACTORS BEYOND THE CONTROL OF THE CONTRACTOR AS DETERMINED BY THE DEPARTMENT WHICH EVER FIRST OCCURS.
An extension will also provide only for those Working Days adversely impacted where operations were on an approved schedule, including all shifts of Work. No extension can be requested unless all submittals and approvals have been completed as specified in Subsection 108.04.
The Contractor may be granted an extension of Contract Time and not be assessed liquidated damages for any portion of the delay beyond the Completion of the Work and/or Substantial Completion Dates as specified in Subsection 108.10 caused by reasons beyond the control and without the fault or negligence of the Contractor, and subject to all due diligence by the Contractor to avoid and mitigate the delay. Reasons may include, but are not restricted to, those provided for in the Specifications and the following:
1. acts of civil or military authorities, terrorism, war, or riot;
2. fire;
3. floods, tidal waves, earthquakes, cyclones, tornadoes, hurricanes, sustained severe winds exceeding 75 mph, or other cataclysmic natural phenomenon (except on working day contracts);
4. Extreme Weather Conditions (subject to Item 1 of subpart B) (except on working day contracts);
5. epidemics or quarantine restrictions;
6. strikes or labor disputes beyond the control of the Contractor that prevent work on the construction operations that are critical to the completion of the Project;
7. shortages of materials (subject to Item 2 of subpart B) or freight embargoes;
8. acts of the State in its sovereign capacity;
9. court orders or injunctions;
10. discovery of Regulated Hazardous Waste;
11. acts by others consistent with Subsections 105.10 and 107.09;
12. failure of the Engineer to furnish interpretations of the Contract Documents (subject to Item 3 of subpart B).
Unless specifically provided for in the Specifications or where the delay is caused by the negligence, bad faith, active interference, or other tortuous conduct of the Department or its employees, the Contractor shall not make any claim for damages or Additional Compensation for any delay, and agrees that any such delay shall be fully compensated for by an extension of Contract Time if granted. In such a case where the delay is shown by the Contractor to have been caused by such tortuous conduct of the Department or its employees, the Contractor’s remedy for Additional Compensation shall be as specified in Subsection 109.04. Negligence of consultants, other contractors, Utility(s), other public entities or any other person or entity, shall not be imputed to the Department. The Contractor shall not be entitled to Additional Compensation or an extension of Contract Time for any delay contemplated or that which should have been contemplated by the Contractor at the time the Contract was awarded.
Extensions of Contract Time will not be granted due to delays caused by, or in any way related to, the financial condition of the Contractor, subcontractors, sub-subcontractors, material, personnel, fabricators, or suppliers. The Contractor and its surety assume full responsibility for ensuring that the financial condition of any of the above does not delay completion of the Contract.
If the Work required is reduced or altered so that the time required for Completion is reduced, the Department may reduce the Contract Time as specified in Subsection 108.10. The Engineer will evaluate the facts and the extent of the reduction. The Department’s findings thereon will be final and conclusive.
The Contractor or surety is not relieved of liability for liquidated damages for any period of delay in completion in excess of that expressly provided for in this Subsection.
B. Requests for Extensions. Request for extension of Contract Time will not be evaluated or granted unless they meet the provisions of A. above and the Contractor has notified the Resident Engineer in writing of the causes of delay within 15 State Business Days from the beginning of any such delay on forms provided by the Department. The effect of the delay on the Progress Schedule shall be documented by the Contractor as specified in Subsection 108.04. The Department will evaluate the facts and the extent of the delay, and the Department’s findings will be final and conclusive. Request for extensions shall also be based on the following:
1. If the Contractor submits daily documentation of such conditions, Extensions of Contract Time for Extreme Weather Conditions may be granted according to the following:
a. The specified completion dates anticipate that the number of total Working Days available for Construction Operations, subject to the requirements of the Contract Documents, during the period of April through November inclusive is at least 145 for road and bridge work.
THE DESIGNER SHALL INSERT THE NUMBER OF WORKING DAYS THAT ARE ANTICIPATED DURING THE WINTER SEASON FOR ROAD AND BRIDGE WORK. THIS SHOULD BE BASED ON ITEMS OF WORK ON THE CRITICAL PATH for the months of december through march inclusive. The designer shall provide a separate clause and specific days for the schedule if more than one winter season is proposed. If the completion date is based on an accelerated schedule that requires more than the 145 days alloted in the Construction scheduling manual, then the designer must also revise part b. above and the definition of working day accordingly.
c. When the actual number of Working Days available for Construction Operations is less than the anticipated number provided for in the Special Provisions, an extension of one day for each day less may be allowed.
2. Extensions of Contract Time will not be granted for a delay caused by a shortage of materials unless the Contractor furnishes the following:
a. Documentary proof that it has diligently made every effort to obtain such materials from all known sources within reasonable distance from the Work.
b. Proof that the inability to obtain such materials when originally planned, could not be compensated for by revising the sequence of the Contractor’s operations. The term “shortage of materials” applies only to raw and fabricated materials, articles, parts, or equipment which are standard items and does not apply to materials, parts, articles, or equipment which are processed, made, constructed, fabricated, or manufactured to meet the specific requirements of the Contract. Only the physical shortage of materials and not the cost of materials will be considered.
3. Extensions of Contract Time will not be granted for failure of the Engineer to furnish interpretations of the Contract Documents unless such request for an interpretation of the Contract Documents is reasonable and made in good faith, and the failure to respond was palpably unwarranted and was furnished more than 20 State Business Days after the written request was received by the Resident Engineer.
4. Extension of Contract Time for utility work delays will only be granted when the Utility does not complete their work within an additional 30% of the estimated durations for the Utility as specified in Subsection 105.09. A day for day extension will be allowed for each day extended beyond the 30% time that the Critical Path is affected.
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BDC01s-11 dated march 8, 2002
108.12 RIGHT-OF-WAY INFORMATION AND DELAYS.
THE FOLLOWING IS ADDED:
THE CONTRACTOR SHALL OBTAIN FROM THE ENGINEER ALL INFORMATION REGARDING ROW PARCELS AND EASEMENTS ACQUIRED FOR THE PROJECT AS WELL AS THE NATURE AND TYPE OF TITLE ACQUIRED. THE CONTRACTOR SHALL MAKE PERIODIC REQUESTS FOR UPDATES TO THIS INFORMATION DURING THE COURSE OF THE CONTRACT.
The Contractor shall not enter an Easement until the Resident Engineer provides written notice to the property owner. The Contractor shall provide written notice to the Resident Engineer, 30 calendar days prior to entering a particular Easement or right, which is lesser than a fee interest. The Contractor shall make no claim for delays by reason that entry upon an Easement or right which is lesser than a fee interest is conditioned upon notice or is limited in duration; the Contractor is required to schedule accordingly and take such limitations into account when planning performance of the work.
Temporary Easements and/or temporary construction rights will in most cases contain a limitation as to the length of time that they are extant. The Contractor shall schedule the Work pursuant to Subsection 108.04 so as to accommodate the particular time limitations of an Easement or right which is lesser than a fee interest as reflected on the R.O.W. plans. The Contractor shall provide a written request to the Engineer that the Department procure an extension from the owner of a particular temporary easement or right, which is lesser than a fee simple interest, so as to enable the Contractor to continue occupancy of or re-enter same in the future, beyond the initial time period set forth in the respective property description prior to the expiration thereof.
Where the Contractor fails to complete the work within an area of a temporary easement or right lesser than a fee interest during the time allowed under the property description, by reason of the Contractor’s own fault; the Contractor shall reimburse the State for the sum payable to the owner of the underlying fee interest for the extended period of occupancy use. The Resident Engineer may deduct an amount equal to such payments from the monthly estimate of the Work performed after providing 30 day written notice to the Contractor of such action, including a breakdown of the costs sought or to be sought by reason of the delay in timely vacating a temporary easement or right lesser than a fee interest.
Painting operations in Spans 1, 2, and 3 shall preferably be performed between November 1 and November 30, with coordination and prior approval of the Engineer and marina owners. However, as long as the minimum required vertical Underclearance in Span 1 (16 feet minimum, approximately 18 feet existing) is maintained, and approved, proper protection and containment are provided, painting in Span 1 outside of November MAY be allowed during the month of October, or December through March. The same restrictions apply to painting in Spans 2 and 3, except that 26 feet vertical underclearance (at high tide) shall be maintained under Span 3. No barges or any other equipment may be placed in the waterway in Spans 2 or 3 that would restrict movement of any of the marina vessels.
complete and include THE FOLLOWING WHEN RoW HAS NOT BEEN SECURED before THE SCHEDULED ADVERTISING DATE.
Properties and Vacation/Availability Dates
|Demolition and/ or Parcel No. |Approximate Baseline Station |Offset/Direction |Date |
list unsecured row.
| | | | |
THE FOLLOWING IS ADDED AT THE END OF THE SECTION:
Based on information provided by the marina owners at the north end of the bridge, and to minimize impacts to their routine activities, the following timing restrictions apply to these following specific work items. These restrictions have been taken into account in the designer’s construction schedule;
1. Removal and disposal of the contaminated soil and slope protection work at the northern end under Span 1, as shown in the plans – November 1 to November 30.
2. Construction of the new bulkhead in front of the existing northern bulkhead, Span 2 – November 1 to November 30. However these two items MAY NOT BE SCHEDULED IN THE SAME PERIOD, so as to not impact the parking area underneath Span 1.
108.16 Failure to Complete on Time.
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108.16 LIQUIDATED DAMAGES AND INCENTIVE PAYMENTS FOR EARLY COMPLETION.
A. Liquidated Damages. The Contractor and the Department recognize that delay in Completion results in damages to the State in terms of the effect of the delay on the use of the Project, upon the public convenience and economic development of the State, and also results in additional costs to the State for engineering, inspection, and administration of the Contract. Because it is difficult or impossible to accurately estimate the damages incurred; therefore, the parties agree that if the Contractor fails to complete the Contract within the time stated in these Special Provisions, or within such further time as may have been granted in according to the provisions of the Contract, the Contractor shall pay the State liquidated damages according to those provided in the Special Provisions. Such liquidated damages shall be paid for each and every day, as hereinafter defined, that the Contractor is in default to complete the Contract.
the designer shall develop the road user costs based on Road User Cost Manual and contact the Quality Assurance Unit to obtain the construction engineering costs prior to the final Design submission.
include the following WHEN COMPLETION DATEs are IN CALENDaR DAYS, OR a specific date is required. if required, Other interim requirements would be added before substantial completion.
1.
2. For each Calendar Day that the Contractor fails to complete the Work as specified in Subpart A of Subsection 108.10 of these Special Provisions, for work related to Navigational channel closure and overruns of the specified navigational channel closure period, the Contractor shall pay liquidated damages consisting of Road User Costs and Construction Engineering Costs to the State in the amount of $4,800 and civil penalty imposed by the U.S. Coast Guard, in the amount of $15,000 per day in the year 2006, $20,000 per day in 2007, and $25,000 per day in 2008 and beyond. For each occurrence that the Contractor fails to provide scheduled bridge openings on Sundays, for the period between November 1 through March 1, each season throughout the construction duration, as described under Section 107.13, the Contractor shall pay liquidated damages consisting of Road User Costs and Consulting Engineering Costs to the State in the amount of $4,800 and USCG civil penalties in the amount of $15,000 per day in 2006, $20,000 per day in 2007, and $25,000 per day in 2008 and beyond, and also $5,400 per every offense for mobilizing the State’s forces and equipment.
3. For each Calendar Day that the Contractor fails to complete the entire Work of the Project as specified in Subpart B of Subsection 108.10 of these Special Provisions, for Completion of the Work, the Contractor shall pay liquidated damages consisting of Construction Engineering Costs to the State in the amount of $3,100, provided that the Work as specified for Substantial Completion is actually completed.
include the following WHEN a number of working DAYS
B. Incentive Payment for Early Completion. As provided for in the Special Provisions.
the designer shall contact the Quality Assurance Unit to obtain specification prior to the final Design submission.
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EXCEPT AS SPECIFICALLY EXCLUDED IN THE SPECIAL PROVISIONS, A LANE OCCUPANCY CHARGE WILL BE COLLECTED BY DEDUCTING THE APPROPRIATE CHARGE, CALCULATED ACCORDING TO THIS SUBSECTION, FROM THE MONTHLY ESTIMATE, WHENEVER A LANE OR LANES ARE NOT PROMPTLY MADE AVAILABLE TO THE TRAVELING PUBLIC DURING THE LANE CLOSURE LIMITS FOR THE FOLLOWING REASONS: EQUIPMENT BREAKDOWNS; NON-EXTREME WEATHER RELATED CAUSES; LATE START OF WORK; SHORTAGE OF LABOR, MATERIALS, FUEL, MACHINERY OR EQUIPMENT OR BY REASON OF THE CONTRACTOR’S NEGLIGENCE OR FAULT OR THAT OF ITS WORKERS, EMPLOYEES, SUBCONTRACTORS OR SUPPLIERS. THIS CHARGE WILL BE COLLECTED FOR THAT PERIOD OF TIME EACH LANE IS UNAVAILABLE TO THE TRAVELING PUBLIC BEYOND THE LANE CLOSURE LIMITS. THIS CHARGE WILL BE CALCULATED BY MULTIPLYING THE LENGTH OF TIME OF THE DELAYED OPENING, IN MINUTES, BY THE RATE OF $10 PER MINUTE PER LANE, UNLESS OTHERWISE SET FORTH IN THE SPECIAL PROVISIONS.
THE third PARAGRAPH IS CHANGED TO:
THE TOTAL AMOUNT OF THE LANE OCCUPANCY CHARGE COLLECTED FROM A CONTRACTOR SHALL NOT EXCEED $10,000.00 PER DAY.
THE fourth PARAGRAPH IS CHANGED TO:
THE RESIDENT ENGINEER WILL KEEP RECORD OF EACH OCCURRENCE AS WELL AS THE CUMULATIVE AMOUNT OF TIME THAT A LANE IS KEPT CLOSED BEYOND THE LANE CLOSURE LIMITS. AFTER EACH OCCURRENCE THE CONTRACTOR WILL BE NOTIFIED. FOR EVERY THREE SUCH OCCURRENCES, ONE DAY WILL BE DEDUCTED FROM THE SUBSTANTIAL COMPLETION DATE OR DAYS. FOR EVERY 60 MINUTES OF LANE CLOSURES RECORDED BEYOND THE LANE CLOSURE LIMITS, ONE ADDITIONAL DAY WILL BE DEDUCTED FROM THE SUBSTANTIAL COMPLETION DATE OR DAYS. THE SUBSTANTIAL COMPLETION DATE OR DAYS WILL BE RE-ESTABLISHED. THE CONTRACTOR WILL BE NOTIFIED OF SUCH ACTION, AND THE CONTRACTOR SHALL NOT MAKE ANY CLAIM AGAINST THE DEPARTMENT AS A RESULT OF SUCH ACTION. THE RESIDENT ENGINEER ALSO RESERVES THE RIGHT TO SUSPEND ALL WORK UNTIL THE NEXT ALLOWABLE LANE CLOSURE TIME PERIOD, WHERE THE CONTRACTOR EXCEEDS THE LANE CLOSURE LIMITS. BEFORE DEDUCTION OF ANY CHARGE FROM A MONTHLY ESTIMATE FOR OCCUPANCY OF A LANE BEYOND THE ALLOWABLE LANE CLOSURE HOURS, THE DEPARTMENT WILL PROVIDE THE CONTRACTOR WITH A STATEMENT OF THE CHARGES TO BE COLLECTED AND THE SUPPORTING CALCULATIONS.
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THE RATE OR RATES TO BE APPLIED IN THE CALCULATION OF A LANE OCCUPANCY CHARGE SHALL BE IN ACCORDANCE WITH THE FOLLOWING:
|Description |Rate per Minute |
Overrun of “One Lane Maintained” Time Limits - $10/minute
include appropriate information.
| | |
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108.20 ITS OCCUPANCY CHARGES.
For projects where there is proposed work on existing ITS facilities, the designer shall contact the respective traffic operations center for a determination if that work will require limitations to when that work can be completed and whether the limitations apply to all its facilities or only the fiber optic network. this clause isn’t required when there is only work in the vicinity of Its facilities, which is covered by subsection 105.09. the designer shall include Any time frame limitations on the plan sheet with the general its notes and include the following
109.01 MEASUREMENT OF QUANTITIES.
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TYPE 2 PAY ITEMS CHARGE PER UNIT OF MEASURE
SAWCUT GROOVED DECK SURFACE $0.06 per square foot
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THE “BASIS OF PAYMENT” CLAUSE IN THE SPECIFICATIONS RELATING TO ANY PAY ITEM IN THE PROPOSAL ENCOMPASSES ALL COMPENSATION FOR WORK TO COMPLETE THAT PAY ITEM AND NO OTHER PAY ITEM. ALL ELEMENTS OF THE WORK RELATED TO THAT PAY ITEM WILL NOT BE MEASURED OR PAID FOR UNDER ANY OTHER PAY ITEM IN THE CONTRACT DOCUMENTS UNLESS IT IS STATED IN THE “BASIS OF PAYMENT” CLAUSE FOR THAT PAY ITEM THAT A PORTION OF THE WORK WILL BE PAID FOR UNDER ANOTHER SECTION OR SUBSECTION OF THE SPECIFICATIONS.
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WHEN THE DEPARTMENT HAS DIRECTED THE CONTRACTOR TO DO WORK ON A FORCE ACCOUNT BASIS IT WILL BE COMPENSATED AS SPECIFIED IN THIS SUBSECTION.
The total direct costs for labor, materials, equipment, bonds, insurance, and tax as provided below, together with applicable markups constitute full compensation for all direct and indirect costs (including overhead and profit), and are deemed to include all items of expense not specifically designated. Any adjustments to Performance Bond and Payment Bond will be made as specified in Subsection 103.05. Force Account payments will be adjusted for those costs incurred determined to be the fault of the Contractor. The Force Account payment will be further adjusted where the Contractor’s prices in its Proposal for any affected original items of work did not properly include all the costs to complete the affected work as originally provided in the Contract Documents.
When Work that is paid on a Force Account basis is performed by forces other than the Contractor’s organization, the Contractor shall reach an agreement with such other forces as to the distribution of payments made by the State for such Work, with a copy of all such completely executed agreements to the Resident Engineer. Additional payment will not be made for any reason due to the performance of the Work by a subcontractor or other forces, or for costs outside that covered by the agreement.
It is understood that a Contractor’s remedy for Additional Compensation for Extra Work or for any other reason as specified in these Specifications, when an action is brought before the Superior Court as specified in the Contractual Liability Act, NJSA 59:12-1 et seq., shall not exceed the amount that would be specified in these provisions had a Force Account been carried out. However, damages sought by the Contractor in a court proceeding shall be limited to actual additional costs incurred by the Contractor resulting directly from the Extra Work or by other reason specifically permitted under the terms of the Specifications as specified in the Contractual Liability Act. As a condition predicate to seeking Additional Compensation under the claims process or in the Superior Court, the Contractor shall have the burden of proof to demonstrate compliance with the requirements of this Subsection and other applicable Subsections, and shall have kept all records required under this Subsection even if the Department has not directed that the Contractor do such Work on a Force Account basis.
Force Account payment will be limited to the following:
1. Labor.
THE first PARAGRAPH is CHANGED TO:
FOR ALL NECESSARY DIRECT LABOR AND FOREMEN IN DIRECT CHARGE OF THE SPECIFIC OPERATIONS, WHETHER THE EMPLOYER IS THE CONTRACTOR, SUBCONTRACTOR, OR ANOTHER, THE CONTRACTOR SHALL RECEIVE THE RATE OF WAGE (OR SCALE) ACTUALLY PAID AS SHOWN IN ITS CERTIFIED PAYROLLS FOR EACH AND EVERY HOUR THAT SAID LABOR AND FOREMEN ARE ACTUALLY ENGAGED IN SUCH WORK.
For specific extraordinary operations the Department may allow supervising or other special type employees to be considered direct labor, but only that time in direct labor or direct charge to complete the specific construction operations.
2. Bond, Insurance, and Tax.
the entire text is changed to:
FOR BOND PREMIUMS; PROPERTY DAMAGE, LIABILITY, AND WORKERS COMPENSATION INSURANCE PREMIUMS; UNEMPLOYMENT INSURANCE CONTRIBUTIONS; AND SOCIAL SECURITY TAXES ON THE FORCE ACCOUNT WORK, THE CONTRACTOR SHALL RECEIVE THE ACTUAL INCREMENTAL COST THEREOF, NECESSARILY AND DIRECTLY RESULTING FROM THE FORCE ACCOUNT WORK. FOR PAYMENT, THE CONTRACTOR SHALL FURNISH SATISFACTORY EVIDENCE OF THE RATE OR RATES PAID FOR SUCH BOND, INSURANCE, AND TAX.
Payment for Performance Bond and Payment Bond adjustments will be as specified in Subsection 103.05.
4. Equipment and Plant.
a. Contractor Owned Equipment and Plant.
THE second and third PARAGRAPH are CHANGED TO:
THE BLUE BOOK WILL BE USED IN THE FOLLOWING MANNER:
(1) The estimated “rental” hourly rate will be determined by dividing the monthly rate by 176 and then applying a 20% reduction factor. The weekly, hourly, and daily rates will not be used.
(2) The estimated operating costs per hour will be the Blue Book rates.
(3) The number of hours to be paid for will be the number of hours that the equipment or plant is actually used on a specific Force Account activity each day, as presented in Daily Equipment Work Sheets, received from the Contractor and verified by the Department.
(4) The current revisions will be used in establishing rates. The current revision applicable to specific Force Account work is as of the first day of work performed on that Force Account work and that rate applies throughout the next six months of the period the Force Account work is being performed. The rates will be adjusted for each six-month period thereafter.
(5) Area adjustment will not be made. Equipment life adjustment will be made in according to the rate adjustment tables.
(6) Overtime shall be charged at the same rate indicated in Item (1) and (2) above.
(7) Idle time for equipment will not be paid for, except where the equipment has been held on the Project site on a standby basis at the request of the Engineer and, but for this request, would have left the Project site. Such payment will be made at one-half the rate established in Item (1) above and will be limited to the total hours worked for any Force Account activity on that particular day.
(8) The rates established above include the cost of fuel, oil, lubrication, supplies, small tools, necessary attachments, repairs, overhaul and maintenance of any kind, depreciation, storage, overhead, profits, insurance, all costs (including labor and equipment) of moving equipment or plant to, on, and away from the site, and all incidentals.
(9) Operator costs will be paid only as provided in Subheading 1 above.
All equipment shall, in the opinion of the Department, be in good operating condition. The State will not provide payment of any type for equipment that is determined to be unsuitable by the Department for the Force Account Work or that is inoperable during periods of breakdown or repair. Equipment used by the Contractor shall be specifically described and be of suitable size and suitable capacity required for the work to be performed. In the event the Contractor elects to use equipment of a higher rental value than that suitable for the Work, payment will be made at the rate applicable to the suitable equipment. The equipment actually used and the suitable equipment paid for will be made a part of the record for Force Account work. If there is a differential in the rate of pay of the operator of oversize or higher rate equipment, the rate paid for the operator will be that for the suitable equipment.
b. Rented Equipment and Plant.
the entire text is changed to:
IN THE EVENT THAT THE CONTRACTOR DOES NOT OWN A SPECIFIC TYPE OF EQUIPMENT OR PLANT AND MUST OBTAIN IT BY RENTAL, THE CONTRACTOR SHALL INFORM THE RESIDENT ENGINEER OF THE NEED TO RENT THE EQUIPMENT AND OF THE RENTAL RATE FOR THAT EQUIPMENT PRIOR TO USING IT ON THE WORK. THE CONTRACTOR WILL BE PAID THE ACTUAL RENTAL FOR THE EQUIPMENT AS SPECIFIED IN THE RENTAL AGREEMENTS FOR THE TIME THAT THE EQUIPMENT IS ACTUALLY USED TO ACCOMPLISH THE WORK, PROVIDED THAT RATE IS REASONABLE, PLUS THE COST OF MOVING THE EQUIPMENT TO, ON, AND AWAY FROM THE PROJECT SITE. THE CONTRACTOR SHALL PROVIDE THE RESIDENT ENGINEER A COPY OF THE FULLY EXECUTED RENTAL AGREEMENT, AND A PAID RECEIPT OR CANCELED CHECK FOR THE RENTAL EXPENSE INCURRED.
If the rental agreement does not cover operating costs, the Contractor shall be entitled to the rate established in Subheading 4.a. above for each hour that piece of rental equipment is actually operational.
The State will not provide payment of any cost incurred due to equipment that is determined to be unsuitable by the Department for the Force Account Work or that is inoperable during periods of breakdown or repair.
5. Profit.
the entire text is changed to:
PROFIT SHALL BE COMPUTED AT TEN PERCENT OF THE FOLLOWING:
a. Total material cost excluding transportation, shipping & handling.
b. Total direct labor cost (actual hours worked multiplied by the regular hourly rate).
c. Total fringe benefits on total direct labor cost as computed above.
6. Overhead.
the entire text is changed to:
ANY AND ALL OVERHEAD FOR THE CONTRACTOR IS DEFINED TO INCLUDE THE FOLLOWING:
a. All salaries and expenses of executive officers, supervising officers, or supervising employees, except as provided for under Subheading 1 above;
b. All clerical or stenographic employees;
c. All charges for minor equipment, such as small tools, including shovels, picks, axes, saws, bars, sledges, lanterns, jacks, cables, pails, wrenches, and other miscellaneous supplies and services; and
d. All drafting room accessories such as paper, tracing cloth, and blueprinting.
Any and all overhead costs of the Contractor for Force Account work shall be computed at 15 percent of the following:
a. Total material cost excluding transportation, shipping & handling.
b. Total direct labor cost (actual hours worked multiplied by the regular hourly rate), except for the direct labor cost of any supervisory or special employees allowed under Subheading 1. above.
c. Specific extraordinary overhead expenses, required specifically for the Force Account, may be allowed if approved by the Department prior to incurring any cost. In such instances, the Contractor will be paid only the reasonable costs of such extraordinary overhead expenses.
d. Total fringe benefits on total direct labor cost as computed above.
The Contractor will be allowed an additional five percent for overhead on the total amount of all work performed by the subcontractors.
THE FOLLOWING IS ADDED:
8. RESPONSIBILITY.
Where work is performed under a Force Account, responsibility of such work shall remain that of the Contractor. The Department will determine if the Work is eligible for payment.
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WHEN THE DEPARTMENT HAS APPROVED AN ADJUSTMENT FOR ADDITIONAL COMPENSATION DUE TO A DELAY, THE CONTRACTOR WILL BE PAID ITS EXPENSES DURING THAT PERIOD OF DELAY BY CHANGE ORDER IN THE FOLLOWING MANNER:
2. Bond, Insurance, and Tax.
the entire text is changed to:
FOR BOND PREMIUMS; PROPERTY DAMAGE, LIABILITY, AND, WORKERS COMPENSATION INSURANCE PREMIUMS; UNEMPLOYMENT INSURANCE CONTRIBUTIONS; AND SOCIAL SECURITY TAXES DURING THE PERIOD OF DELAY, THE CONTRACTOR IS TO RECEIVE THE ACTUAL INCREMENTAL COST THEREOF, NECESSARILY AND DIRECTLY RESULTING FROM THE DELAY. FOR PAYMENT, THE CONTRACTOR SHALL FURNISH SATISFACTORY EVIDENCE OF THE RATE OR RATES PAID FOR SUCH BOND, INSURANCE, AND TAX.
Payment for Performance Bond and Payment Bond adjustments will be as provided in Subsection 103.05.
3. Equipment.
the first paragraph is changed to:
FOR ANY IDLE MACHINERY OR SPECIAL EQUIPMENT OTHER THAN SMALL TOOLS WHICH MUST REMAIN ON THE PROJECT SITE, WITH APPROVAL OF THE DEPARTMENT, DURING DELAYS OF SPECIFIC OPERATIONS, THE CONTRACTOR IS TO RECEIVE COMPENSATION AT ONE-HALF THE RATE CALCULATED PURSUANT TO SUBHEADING 4 OF THE FIFTH PARAGRAPH OF SUBSECTION 109.03. SHOULD THE DEPARTMENT DETERMINE THAT IT IS NOT NECESSARY FOR MACHINERY OR EQUIPMENT TO REMAIN ON THE PROJECT DURING DELAYS, THE CONTRACTOR IS TO RECEIVE TRANSPORTATION COSTS TO REMOVE THE MACHINERY OR EQUIPMENT AND RETURN IT TO THE PROJECT AT THE END OF THE DELAY PERIOD.
4. Miscellaneous.
the subpart Heading is changed to:
4. OVERHEAD.
6. Records.
THE second and third PARAGRAPHS are CHANGED TO:
THE DEPARTMENT’S RECORDS WILL BE COMPARED WITH COMPLETED DAILY REPORTS FURNISHED BY THE CONTRACTOR AND ANY NECESSARY ADJUSTMENTS WILL BE MADE. WHEN THESE DAILY REPORTS ARE AGREED UPON AND SIGNED BY BOTH PARTIES, SAID REPORTS BECOME THE BASIS OF PAYMENT FOR THE EXPENSES INCURRED, BUT DO NOT PRECLUDE SUBSEQUENT ADJUSTMENT BASED ON A LATER AUDIT BY THE DEPARTMENT.
The Contractor’s cost records pertaining to expenses under this Subsection shall be open to inspection or audit by the Department during the life of the Contract and for a period of not less than three years after Acceptance thereof, and the Contractor shall retain such records for that period. Where payment for equipment or labor is based on the cost thereof to forces other than the Contractor, the Contractor shall make every reasonable effort to ensure that the cost records of such other forces are open to inspection and audit by the Department on the same terms and conditions as the cost records of the Contractor. Payment for such cost may be deleted if the records of such third parties are not made available to the Department. If an audit is to be commenced more than 60 days after Acceptance, the Contractor is to be provided with a reasonable notice of the time when such audit is to begin. In case all or a part of such records are not made so available, the Contractor understands and agrees that any items not supported by reason of such unavailability of the records will not be allowed, or if payment therefore has already been made, the Contractor shall refund to the Department the amount so disallowed.
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1. EACH SUBCONTRACTOR OR SUPPLIER HAS BEEN PAID ANY AMOUNT DUE FROM ANY PREVIOUS PROGRESS PAYMENT AND SHALL BE PAID ANY AMOUNT DUE FROM THE CURRENT PROGRESS PAYMENT AND NO RETAINAGE IS BEING WITHHELD FROM ANY SUBCONTRACTOR ON FEDERALLY FUNDED PROJECTS; OR
THE SEVENTH PARAGRAPH IS CHANGED TO:
FROM THE TOTAL AMOUNTS ASCERTAINED AS PAYABLE, EXCLUDING SUBCONTRACTED WORK ON FEDERALLY FUNDED PROJECTS, AN AMOUNT EQUIVALENT TO TWO PERCENT OF THE AMOUNT DUE ON THE TOTAL ADJUSTED CONTRACT PRICE WILL BE DEDUCTED AND RETAINED PENDING SUBSTANTIAL COMPLETION. ANY AMOUNTS PAID TO THE CONTRACTOR IN THE FORM OF INCENTIVE PAYMENTS FOR EARLY COMPLETION AND POSITIVE PAY ADJUSTMENTS WILL NOT BE INCLUDED IN THE ADJUSTED CONTRACT PRICE WHEN CALCULATING RETAINAGE.
109.06 Materials Payments.
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109.06 MATERIALS PAYMENTS AND STORAGE.
THE first PARAGRAPH IS CHANGED TO:
THE MONTHLY ESTIMATES AND PAYMENTS MADE ON ACCOUNT THEREOF MAY ALSO INCLUDE, WHEN AUTHORIZED BY THE DEPARTMENT, AN AMOUNT EQUAL TO THE ACTUAL COST OF MATERIALS FURNISHED BUT NOT INCORPORATED INTO THE WORK, PROVIDED, HOWEVER, THAT SUCH AMOUNT DOES NOT EXCEED 85 PERCENT OF THE CONTRACT PRICE FOR THE PAY ITEM INTO WHICH THE MATERIAL IS TO BE INCORPORATED, AND THE QUANTITY ALLOWED DOES NOT EXCEED THE CORRESPONDING QUANTITY ESTIMATED IN THE CONTRACT DOCUMENTS. ADVANCE PAYMENT WILL ONLY BE FOR THAT PORTION OF THE PRICE IN THE PROPOSAL RELATED TO THE MATERIALS AND ANY COSTS FOR STORAGE AT THE FACILITY OF MANUFACTURE. ANY TAXES LEVIED BY ANY GOVERNMENT AGAINST THE MATERIALS SHALL BE BORNE BY THE CONTRACTOR. BEFORE INCLUDING PAYMENTS FOR SUCH MATERIALS IN AN ESTIMATE, THE DEPARTMENT MUST BE SATISFIED THAT:
1. The materials have been properly stored and protected along or upon the Project site or have been stored and protected at locations owned or leased by the Contractor or the Department within the State, except that structural steel, prestressed concrete beams, and other large items not suitable for storage on or near the site, may be stored outside the State with the approval of the Department; and
2. The materials have been inspected and appear to be acceptable based upon available supplier’s certification and/or materials test reports; and
3. The Contractor has provided the Resident Engineer with an paid invoice or paid bill of sale for the materials and a fully executed Department form “Release of Liens for Materials Stored for Incorporation in Department of Transportation Project” including the transfer of ownership to the Department; and
4. The materials are clearly identified in large letters as being without encumbrances and for use solely on the Project, and if stored on property not belonging to the State or at the facility of manufacture, are fenced in with access limited to the State and the Contractor; and
5. When such materials are stored in a leased area, the lease is made out to the Contractor and provides that it shall be canceled only with the written permission of the Department.
the fourth PARAGRAPH IS deletED:
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1. EACH SUBCONTRACTOR OR SUPPLIER HAS BEEN PROMPTLY PAID ANY AMOUNT DUE FROM ANY PREVIOUS PROGRESS PAYMENT AND SHALL BE PAID ANY AMOUNT DUE FROM THE CURRENT PROGRESS PAYMENT, INCLUDING ALL RETAINAGE WITHHELD FROM THE SUBCONTRACTOR OR SUPPLIER, WITHIN 14 DAYS OF THE RECEIPT BY THE CONTRACTOR OF PAYMENT FROM THE DEPARTMENT; OR
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IN THE FIRST ESTIMATE FOLLOWING SUBSTANTIAL COMPLETION, THE DEPARTMENT WILL REDUCE RETAINAGE TO ONE PERCENT OF THE TOTAL ADJUSTED CONTRACT PRICE EXCLUDING SUBCONTRACTED WORK ON FEDERALLY FUNDED PROJECTS, UNLESS IT HAS BEEN DETERMINED BY THE COMMISSIONER THAT THE PUBLIC INTEREST REQUIRES THE WITHHOLDING OF ADDITIONAL RETAINAGE. IF RETAINAGE IS HELD IN CASH WITHHOLDINGS, THE REDUCTION IS TO BE ACCOMPLISHED BY PAYMENT UNDER THE NEXT PARTIAL PAYMENT. IF RETAINAGE IS HELD IN BONDS, THE DEPARTMENT WILL AUTHORIZE A REDUCTION IN THE ESCROW ACCOUNT.
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ALL MONIES RETAINED SUBSEQUENT TO THE FIRST ESTIMATE FOLLOWING SUBSTANTIAL COMPLETION MAY BE RELEASED AS SPECIFIED IN SUBSECTION 109.11.
109.09 Payment Following Acceptance.
BDC02s-22 dated december 17, 2003
ALL PARTIAL PAYMENTS BY MONTHLY ESTIMATE WILL BE PROCESSED PRIOR TO ACCEPTANCE. FINAL PAYMENT WILL BE MADE AS SPECIFIED IN SUBSECTION 109.11.
109.10 As-Built Quantities.
BDC02s-22 dated december 17, 2003
THE RESIDENT ENGINEER MAY FROM TIME TO TIME, BEFORE SUBSTANTIAL COMPLETION, PREPARE AS-BUILT QUANTITIES AND INCORPORATE THESE QUANTITIES INTO MONTHLY ESTIMATE CERTIFICATES THROUGH AN APPROPRIATE FIELD ORDER OR CHANGE ORDER. SUCH INTERIM AS-BUILT QUANTITIES ARE SUBJECT TO RECALCULATION IN COMPLETION OF THE FINAL CERTIFICATE.
The third paragraph is deleted.
109.11 FINAL PAYMENT AND CLAIMS.
BDC02s-22 dated december 17, 2003
1. FINAL CERTIFICATE. ALL PRIOR ESTIMATES AND PAYMENTS MADE BY THE DEPARTMENT ARE SUBJECT TO CORRECTION IN THE FINAL CERTIFICATE, WHICH WILL BE COMPLETED AS FOLLOWS:
a. After Acceptance is completed as specified in Subsection 105.23 and the As-Built quantities finalized, the Department will make an estimate of the total amount of Work done under the Contract, and prepare and issue the Final Certificate to the Contractor.
b. Within 30 State Business Days after said Final Certificate has been issued to the Contractor, the Contractor shall submit to the Department either a written acceptance of the Final Certificate without exception together with an executed release in the form provided with the Final Certificate or a written acceptance of the Final Certificate with a reservation of specific claims, but otherwise releasing all claims not specifically reserved, by executing a conditional release in the form provided with the Final Certificate. The Contractor’s failure to submit any written acceptance or acceptance with reservation within said 30 days will be construed by the Department as an acceptance by the Contractor of the Final Certificate without exception or reservation of Claims.
c. Upon receipt of the Contractor’s written acceptance of the Final Certificate with unconditional or conditional release, or when the Contractor fails to provide any written acceptance of the Final Certificate within 30 State Business Days of issuance, the Department will pay the entire sum due thereunder as provided by the New Jersey Prompt Payment Act NJSA 52:32-32 et seq., provided the Final Certificate indicates a payment is due the Contractor. However, where the Final Certificate indicates a Credit (payment) is due the Department, the Contractor shall remit said Credit (payment) to the Department in the amount set forth in the Final Certificate.
d. If the Contractor fails to remit the Credit (payment) due the Department, as indicated on the Final Certificate, within 30 State Business Days of issuance of the Final Certificate, the Department may pursue all legal means available to recover the amount due the State, including but not limited to, deducting the amount from payment due the Contractor on this or other Department Contracts or from retainage and/or the sale of bonds held in lieu of retainage for the Contract or for other Contracts, even where the credit is being contested by the Contractor.
Neither the failure of the Contractor to accept the tendered Final Payment nor the failure of the Contractor to remit the credit (payment) due the Department shall affect when the “Completion of the Contract” shall be deemed to have occurred for any reason. Where there is a remaining monetary balance due to the Contractor by the Department, Final Payment will be made after the “Completion of the Contract”. Retainage shall be released to the Contractor upon completion of the contract unless a credit (payment) is due to the Department, which shall be deducted or adjusted in accord with the Specifications.
2. Conditions for Claims. Conditional acceptance of the Final Certificate will be permitted only where all of the following are met:
a. When the Contractor submits a Release conditioned with exception or reservation, the release shall state the specific monetary amounts and category of the claims being reserved. The Contractor acknowledges, by the act of executing the contract, that the failure to state specific monetary amounts and specific categories shall result in a waiver of such claims lacking as to amounts or specific categories thereof. The Contractor may reserve only those claims properly filed with the Department pursuant to Subsection 107.02 and not previously resolved. The Contractor waives all claims for which the required notice has not been filed with the Department.
b. The Contractor further understands and agrees, by the act of executing the Contract that neither the procedures established under this Subsection nor the review of claims by the Department pursuant hereto shall in any way modify the requirements applicable to the filing of a Contractual Notice Form or the filing of a suit pursuant to the provisions of N.J.S.A. 59:13-1 et seq. .
c. If the Contractor conditions its acceptance of the Final Certificate by reserving particular claims, the Contractor shall at the same time state in writing whether it would like to submit its reserved claims for review by the Department Claims Committee. Only those claims properly reserved, as provided for in Subsection 107.02, and which are unresolved after completing Steps I and II of the Contractual Claim Resolution Process for the resolution of contract claims, are eligible for review by the Department Claims Committee to the extent provided in that Subsection. If the Contractor states that it does not want Department Claims Committee review of the reserved claims or if it fails to request Department Claims Committee review of reserved claims when it conditions its acceptance of the Final Certificate or if it files suit in a court of law regarding those claims, the Contractor shall be deemed to have waived any ability to have its reserved claims reviewed by the Department Claims Committee.
d. If the Contractor requests review of its reserved claims when it conditions its acceptance of the Final Certificate, it shall send at the same time a copy of its request for review to the Secretary of the Department Claims Committee, PO Box 600, Trenton, NJ 08625-0600. Department Claims Committee review will then take place according to Subsection 107.02.
e. At the election of the Contractor upon completion of the Contract, claims that are unresolved after review by the Department Claims Committee may be submitted to Non-Binding Mediation according to Subsection 107.02.
f. Interest shall neither be paid nor shall it accrue upon the amount of any additional compensation paid in resolution or settlement of a claim resolved through the various steps of the Contractual Claims Resolution Process.
DIVISION 200 – EARTHWORK
SECTION 201 – CLEARING SITE
201.01 DESCRIPTION.
THE FIRST PARAGRAPH IS DELETED AND REPLACED WITH THE FOLLOWING:
This work shall consist of clearing of the site; removal of bridges, footings, and other structures; removal of pipe, inlets, and manholes; removal of sidewalks, driveways, curbs, gutters, fences, riprap and concrete pylons; also included are trees and shrubs at the toe of slope at the southwest bridge corner, at the beginning of the South Abutment Construction Access Driveway, as directed by the Engineer, relocation of utility lines in conflict; removal of existing electrical and mechanical material and equipment; removal of electrical materials, salvaging of removed, above-ground electrical material; removal and resetting of existing traffic signs; removal of two existing traffic signal poles and foundations; and demolition of building components, except for items which are to be removed according to the work of other Sections.
201.03 Clearing Site.
THE LAST SENTENCE IS DELETED AND REPLACED WITH THE FOLLOWING:
Street, road and traffic signs shall be removed and shall be reset at the exact locations or where shown on the plans and in the manner acceptable to the public authorities having jurisdiction thereof.
201.04 Removal of Bridges, Culverts, and Other Structures.
include THE FOLLOWING FOR DECK AND/OR BEAM ENCASEMENT REMOVAL WHEn THE REMAINDER OF EXISTING SUPERSTRUCTURE IS TO REMAIN. this is not applicable to stage demolition where the entire structure is to be removed.
THE WORK TO BE PERFORMED UNDER THIS CONTRACT INCLUDES REMOVAL AND DISPOSAL OF REINFORCED CONCRETE BRIDGE DECKS, STEEL GRID DECK, PURLINS AND STRINGERS, BEARINGS, SIDEWALKS, CURBS, PARAPETS, DECK JOINTS, RAILINGS, FENCING, GUIDE RAILS, SCUPPERS, DOWNSPOUTS AND PIPING, TIMBER MEMBERS FROM FENDER SYSTEM, WARNING GATES, BARRIER GATES, AND MISCELLANEOUS CONTROL HOUSE COMPONENTS, AS SHOWN ON THE PLANS AND AS DIRECTED BY THE ENGINEER. THIS WORK SHALL ALSO INCLUDE REMOVAL AND PROPER DISPOSAL OF ALL MECHANICAL AND ELECTRICAL EQUIPMENT FROM BASCULE SPAN BEING REPLACED OR ELIMINATED.
The equipment listed below is permitted subject to the following applicable restrictions:
1. Pneumatic or Electric Equivalent Hand Operated Hammers.
a. Up to 90-pound hammers exclusive of the bit may be used for deck removal not closer than 6 inches to structural members. This hammer may also be used for removal of barriers, sidewalks, curbs, and parapets not closer than 6 inches from structural members. Only chisel point bits will be permitted. Structural members are defined as girders, floorbeams, stringers, diaphragms, or cross frames.
b. Up to 30-pound hammers exclusive of bit may be used for removal of concrete within 6 inches of structural members.
2. Saw Cutters.
a. Vermeer concrete cutters or cutting saws may be used to cut within 6 inches adjacent to structural members.
b. If water is used in conjunction with cutting operations, shielding beneath the operation shall prevent water leakage. Water shall be disposed by an approved method. The disposal method shall be submitted by the Contractor for approval by the Engineer.
3. Hydraulic Breakers. Hydraulic breakers, such as, but not limited to, Tramac or other ram-hoe type breakers, are permitted for removal of substructure concrete. For deck concrete removal, such equipment is permitted subject to the following restrictions:
a. The girders shall be analyzed to determine if induced stresses may be harmful.
b. The centerline and limits of the top flange of girders shall be delineated before starting the equipment operation.
c. The equipment shall not be used directly over the top of girders nor in overhang areas. Concrete removal in these areas shall be performed by jackhammers.
d. Pulling and twisting of the reinforcement steel is prohibited.
e. Any damage to existing reinforcement, shear studs, structural steel, or any other structural components that are to remain shall be repaired at no cost to the State.
4. Hydraulic Splitters. Hydraulic splitters such as Darda hydraulic splitters are permitted subject to approval.
5. Other Equipment. Equipment not specifically approved in this Section may be used only with written approval.
The sequence of removal shall be coordinated with the operations of the utility company to protect and maintain its facilities.
During removal operations, the Contractor shall take all necessary precautions so as not to damage the structural members scheduled to remain. All damage done to the existing structural members scheduled to remain shall be repaired. The repair procedure shall be as follows:
1. Steel Stringers, Floorbeams, Cross Frames, and Diaphragms.
a. Repair procedures to tensile components shall conform to ASTM A 6/A 6M and the following:
1) Gouges up to 120 mils shall be removed by grinding flush in the direction of principal stress.
2) Gouges deeper than 120 mils shall be removed first by grinding; then, weld metal shall be deposited and ground flush with the surface of the metal in the direction of principal stress. Welding shall be done using low hydrogen electrodes conforming to current AWS Specifications A5.1 and A5.5. The electrodes shall be protected from moisture during storage.
3) Kinks and deformations shall be repaired by flame straightening or a combination of flame straightening and jacking. Flame straightening shall be done by personnel approved by the Department with a minimum of three years of prior documented experience.
b. Repair procedures to compression components shall conform to the following:
1) Where more than five percent of the cross-sectional area of the member is damaged due to removal operations, the Contractor shall submit a repair procedure for approval.
2) Kinks and deformations shall be repaired as outlined in 2.a (3) above.
Existing top flanges of beams exposed by removal operations shall be cleaned and painted with a prime coat of paint according to Subsection 514.07, Subpart B.
include PROVISIONS FOR SALVAGE IF REQUESTED BY THE Project manager.
SPECIAL PROTECTIVE SYSTEMS FOR THE REMOVAL OF BRIDGES, CULVERTS, AND OTHER STRUCTURES SHALL BE AS FOLLOWS:
1. Temporary Shielding. Temporary shielding for demolition and new construction shall include furnishing, installing, and removing a structural framing and barrier system. The system shall be supported from girders to provide an adequate and substantial temporary shielding system to protect vehicular, pedestrian, and railroad traffic from falling construction materials or other objects. The barrier system shall remain in place during the time that construction work is performed and until the work is completed and accepted.
For deck replacement or new deck work, the temporary shielding shall seal the underside of deck and extend outside of the fascia stringers to enclose the soffits and parapets.
For parapet removal and replacement or new parapet construction, an outrigging type of temporary shielding, which encloses the soffit and parapet, shall be used.
The Contractor shall submit for approval detailed working drawings showing all elements of the temporary shielding system, including bonding and grounding over electrified rail lines, design calculations, and the sequence of operations thereof, signed and sealed by a Professional Engineer licensed in the State. Should the Contractor’s operation or construction staging require it to install and remove the shielding more than once, no additional payment will be made.
The traffic lanes and pedestrian areas below the areas where temporary shielding is being installed shall be closed, in accordance with the requirements of Section 617.
The temporary shielding shall be designed to withstand a load of at least 0.8 psi or greater if heavier loads are anticipated and shall prevent small particles and dust from falling through.
Bolted connections or welding between temporary shielding and bottom flanges of the beams shall not be permitted. Any materials dropped on the temporary shielding shall not be allowed to accumulate and shall be removed promptly.
The selection of sizes, materials, their arrangements, and details shall be the Contractor’s option and responsibility, but subject to approval by the Engineer.
In no case shall the temporary shielding reduce the existing vertical underclearance of the bridges to less than 14 feet – 9 inches, over roadways (except as noted in the next paragraph). If any existing vertical underclearance is less than these values, it shall be maintained without any further reduction.
Under all the existing spans that span over the waterway the existing vertical underclearance shall be maintained without exception, particularly under the bascule span and the three spans north of the bascule span (spans 3, 4, and 5). Under the northern most span (Span 1), there is an access road for the adjacent marina, and the area under this span is also utilized as a parking lot for the tourists/fishermen that access the charter boat from the marina. Existing clearance to the superstructure, and existing access and parking areas shall be maintained here throughout the construction, with shielding in place.
The Contractor shall obtain the Engineer’s approval of the method, design, and details of the temporary shielding system that the Contractor intends to use for the protection of traffic. No construction work shall be performed above traffic before such approval.
All necessary efforts must be taken to prevent debris from falling into the waterway. Any debris falling into the waterway shall immediately be removed at the Contractor’s expense. If found to be required, in areas other than covered by the pay limits identified on the plans, the cost of providing temporary shielding such as tarpaulin or an approved equal, shall be included in the item “Clearing Site, Bridge”.
All electrical and mechanical components shall be protected from falling construction materials/objects throughout construction.
INCLUDE THE FOLLOWING IF SHIELDING IS REQUIRED OVER ELECTRIFIED RAIL LINES.
THE TITLE IS DELETED AND REPLACED WITH THE FOLLOWING:
201.06 Removal of Sidewalks, Driveways, Curbs, Pylons, and Gutters.
THE FIRST SENTENCE IS DELETED AND REPLACED WITH THE FOLLOWING:
Concrete sidewalks, driveways, vertical curbs, sloping curbs, barrier curbs, pylons, and gutters, designated for removal, shall be disposed of according to Subsection 201.10.
201.09 Demolition of Buildings.
include the following for demolition contracts AND/OR
201.09 DEMOLITION OF BUILDINGS.
THE FOLLOWING IS ADDED:
6. ASBESTOS REMOVAL.
Removal of caulk and wallboard containing asbestos in the bridge control towers is required. A full specification is included as Appendix A to these Special Provisions.
THE FOLLOWING IS ADDED:
201.10 DISPOSAL OF MATERIALS AND DEBRIS.
The Resident Engineer will be immediately notified of any oil spill. The spill will be contained and removed immediately utilizing an Oil Emergency Spill Kit. The Contractor will furnish two complete kits. The kits shall be maintained in an accessible, secure location on the project site at all times as directed by the Engineer. Soiled, used or otherwise damaged items of the kits will be replaced. Disposal of kit items and spill material will be according to Subsection 202.13. Each kit will contain the following items:
(1) 55 Gallon 16 Gauge Drum, SPE. Approximately 53 gallons.
(60) 20” x 16” Oil-Only Absorbent Pads
(10) 5” x 10’ Oil-Only Absorbent Booms
(10) 3” x 10’ Oil-Only Absorbent Booms
(20) Temporary Disposal Bags and Ties
(1) Emergency Response Guide Book
(1) Instruction Manual
(1) Wheeled container to accommodate the above items
Disposal of Contaminated Soil and Disposal of Contaminated Soil, Hazardous. This work shall include the loading and off-site transport, and disposal of Contaminated Soil and Contaminated Soil, Hazardous (also known as Regulated Waste and Regulated Waste, Hazardous) designated by the Engineer as excess, unusable or unsuitable material to the project. The disposal, recycling or treatment of Contaminated Soil and Contaminated Soil, Hazardous shall be in accordance with these specifications, the Material Handling Plan, Federal and State laws, rules, and regulations and local laws, and the waste management plan of the district of origin. The references to Contaminated Soil hereinafter shall mean Contaminated Soil and Contaminated Soil, Hazardous as appropriate.
Construction Requirements. The Contractor shall provide all labor, equipment and materials needed to load, transport and dispose/recycle of Contaminated Soil in a manner protective of human health and the environment. All work in and with Contaminated Soil shall be performed in accordance with Subsection 202.04 Management of Contaminated Soil and applicable Federal, State and Local regulations.
Transport and Disposal of Contaminated Soil. The Contractor shall provide all personnel, material and equipment needed to transport and dispose/recycle all Contaminated Soil generated on the project in accordance with Federal and State laws, rules, and regulations and local laws, the waste management plan of the district of origin.
The Contractor shall be solely responsible for locating and contracting with appropriate hauler(s) and disposal facility(ies) for the Contaminated Soil directed to be removed in accordance with Federal and State laws, rules and regulations and local laws. The Contractor shall prepare and submit all documentation to obtain all Federal, State or local approvals and fees necessary for disposing of Contaminated Soil. The Contractor shall ensure that the waste disposal facility(ies) proposed for receipt of the material is (are) properly permitted to accept the classification of Contaminated Soil.
The Contractor shall submit to the Engineer, results of waste sampling and analysis, waste facility applications and acceptance documentation, and fee payment requirements at least two weeks prior to planned removal of Contaminated Soil. The Contractor shall submit to the Engineer a bill of lading (for ID-27 waste) or a hazardous waste manifest (for hazardous waste) for each truckload of Contaminated Soil removed from the site. The bill of landing and/or waste manifest form shall present the following information:
1. Transport subcontractor name, address, permit number and phone number.
2. Type and quantity of waste removed.
3. Weight of vehicle with weigh slip.
4. Recycling or disposal facility name, address, permit number, and telephone number.
5. Date removed from site.
6. Signature of transport vehicle operator.
7. Waste manifest number.
A representative of the Engineer will sign all waste manifests and/or bill of lading as the generator of the waste. The Contractor shall submit to the Engineer a copy of all waste manifests of Contaminated Soil by the end of the day that the truck leaves the site.
All vehicles leaving the site with Contaminated Soil shall be inspected by the Contractor to ensure that no excess soil adheres to the wheels or under carriage of the vehicles, and securely covered and equipped to prevent leakage of water. In the event of leakage of soil or water to the public roads, the Contractor shall immediately clean the road to restore it to the original condition and immediately notify the Engineer.
The licensed hauler shall transport the Contaminated Soil to the disposal/recycling facility with no unauthorized stops in between, except as required by regulatory authority. The hauler shall use appropriate vehicles and operating practices to prevent spillage from occurring during transport. Contaminated Soil shall not be transported over public roads if they contain free liquid or are sufficiently wet to be potentially flowable during transport.
The Contractor shall obtain appropriate documentation of disposal facility acceptance of the Contaminated Soil and provide a copy of the documentation, including the weight ticket slips, to the Engineer and the County of origin within ten working days of waste acceptance at the disposal facility.
Should any problems arise regarding the facility chosen to accept the Contaminated Soil for off-site management that would require the return of waste, or should such facility have violated any environmental regulation which may result in any regulatory enforcement action, the Contractor shall immediately notify the Engineer in writing of such a situation. The Contractor shall propose an alternate disposal facility, and obtain the written approval of the Engineer for off-site management at such facility.
The disposal of all Contaminated Soil shall be in accordance with the Material Handling Plan, Federal and State laws, rules and regulations and local laws and the waste management plan of the district of origin.
The NJDOT will provide the Contractor with a USEPA Hazardous Waste Identification Number for the project containing Hazardous Waste.
201.11 Method of Measurement.
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EXCAVATION OR THE USE OF ANY TYPE OF SHEETING THAT IS REQUIRED FOR THE REMOVAL OF THE STRUCTURE, OR WHEN SUCH SHEETING IS TO REMAIN FOR PLANNED NEW CONSTRUCTION THAT IS AT THE SAME LOCATION OF THE REMOVAL, WILL NOT BE MEASURED. PAYMENT SHALL BE INCLUDED IN THE BID PRICE FOR “CLEARING SITE, BRIDGE (STR. NO. 1506-152)”.
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Disposal of Contaminated Soil, Hazardous, which includes the off-site transport and the disposal of Contaminated Soil, classified as hazardous waste shall be measured by the ton. This will be verified by using certified weigh tickets.
Post Excavation Soil Sampling and Analysis will be measured by the unit. Each unit will include all costs associated with planning, collecting, analyzing, and processing individual waste characterization samples as needed by regulatory authority and/or disposal/recycling facility to classify Contaminated Soils and obtain regulatory and/or facility approval for acceptance.
Oil Emergency Spill kit shall be measured as unit.
201.12 Basis of Payment.
BDC03s-06 dated april 24, 2003
BASIS OF PAYMENT.
Payment will be made under:
Pay Item Pay Unit
disposing of contaminated soil, hazardous ton
OIL-ONLY EMERGENCY SPILL KIT, UP TO 53 GALLONS UNIT
SEPARATE PAYMENT WILL NOT BE MADE FOR MOBILIZING, PREPARING PERIODIC REPORTS, OR PLANNING SPECIAL HANDLING AND PLACEMENT OF CONTAMINATED SOIL IN A MANNER PROTECTIVE OF HUMAN HEALTH AND THE ENVIRONMENT. ALL COSTS ASSOCIATED WITH LABOR, EQUIPMENT, AND MATERIALS NEEDED FOR SPECIAL HANDLING AND PLACEMENT OF CONTAMINATED SOIL SHALL BE INCLUDED IN THE APPLICABLE EXCAVATION PAY ITEMS.
No extra payment will be made for replenishment Oil Emergency Spill Kit items after use or for disposal of spilled materials. Separate payment will not be made for the cleanup of spilled materials.
THE SECOND PARAGRAPH is CHANGED TO:
PAYMENT FOR THE PAY ITEM “CLEARING SITE” IN EXCESS OF $250,000 WILL NOT BE MADE UNTIL COMPLETION.
INCLUDE PROVISIONS FOR PARTIAL PAYMENTS, IF REQUIRED, when REMOVAL OF THE BRIDGE OR STRUCTURE IS SCHEDULED IN STAGES.
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A RIVER BOTTOM SURVEY SHALL BE CONDUCTED BY THE CONTRACTOR PRIOR TO AND AFTER CONSTRUCTION. THIS SURVEY SHALL BE CONDUCTED AND CERTIFIED BY A PE DIVER, UTILIZING A PERMANENT POINT ON THE BRIDGE, AND SHOWING THE STREAMBED ALONG THE BRIDGE FASCIAS AND LONGITUDINAL CENTERLINE, WITH SOUNDINGS ON A 10-FOOT GRID AND AT EACH SUBSTRUCTURE UNIT, SOUNDINGS SHALL EXTEND TO 150 FEET FROM EACH FASCIA. THE SOUNDINGS SHALL INCLUDE THE EXISTING BULKHEAD ALONG THE NORTHERN SHORE WITHIN THESE LIMITS AND WITHIN THE BERTHS, ALONG THE LENGTH OF THE BULKHEAD, TO ADEQUATELY COVER THE MARINA PROPERTY. THE SURVEY REPORT SHALL BE SUBMITTED TO THE RESIDENT ENGINEER TO KEEP ON FILE. PAYMENT FOR THIS SURVEY SHALL BE INCIDENTAL AND INCLUDED UNDER THE LUMP SUM ITEM, CLEARING SITE, BRIDGE.
Payment for the Pay Item “Clearing Site, Bridge (Str. No. 1506-152)” in excess of $1,000,000 will not be made until Substantial Completion.
Thirty percent of the Bid Price (or $300,000, whichever is less) upon acceptance of Stage I demolition
Thirty five percent of the Bid Price (or $350,000, whichever is less) upon acceptance of Stage II demolition
Thirty five percent of the Bid Price (or $350,000, whichever is less) upon acceptance of Stage III demolition
SECTION 202 – ROADWAY EXCAVATION
202.02 CLASSIFICATION.
provide CLASSIFICATION OF REGULATED WASTE as required.
D.
202.04 Excavation.
THE FOLLOWING IS ADDED:
1. MANAGEMENT OF CONTAMINATED SOIL
Preliminary analysis has identified areas of contaminated soil within and adjacent to planned excavation areas. Excavation in areas containing one or more contaminants exceeding New Jersey Department of Environmental Protection (NJDEP) soil cleanup criteria, as identified in the construction documents, as directed by the Engineer, or as determined by the Contractor and approved by the Engineer, shall be performed in accordance with applicable Federal and State law, rules and regulations; The Contractor’s Site Specific Health and Safety Plan (HASP); the specifications and the direction of the Engineer.
a. Requirements and Methods for Excavation and Management of Contaminated Soil
Description. The work shall include the excavation, handling, stockpiling, sampling, and analysis for disposal, reuse on-site and disposal, recycling or treatment of Contaminated Soil except as provided for in Subsection 202.13. The disposal of Contaminated Soil shall comply with the plan, specifications, Federal, State and local law, rules, and regulations, the waste management plan of the district of origin, and Subsection 202.13. The term ‘Contaminated Soil’ as used shall mean Contaminated Soil and Contaminated Soil, Hazardous as appropriate.
Construction Requirements. The Contractor shall provide all personnel, materials and equipment needed to undertake excavation as required to complete the work in a safe manner that is protective of human health and the environment. Excavation of Contaminated Soil shall be performed with equipment of suitable size and compatible with site conditions. All equipment shall comply with and shall be operated in accordance with all applicable regulations. Excavation of Contaminated Soil shall be to the limits shown on the plans and no further, unless directed by the Engineer.
The Contractor shall handle all excavated material in a manner that protects site personnel, the public, and the environment in accordance with all applicable federal, state, and local laws and regulations. Prior to any excavation of Contaminated Soil the Contractor shall develop a Site-Specific Health and Safety Plan (HASP) in accordance with 29 CFR 1910, 29 CFR 1926 and the Site Specific Health and Safety Requirements specified herein.
Environmental Sampling and Testing. The Contractor shall provide all personnel, materials, and equipment needed to properly characterize excavated Contaminated Soil material as required for disposal/recycling facility approval. The Contractor shall submit as part of the Material Handling Plan described herein, a sampling analysis section for characterizing the Contaminated Soil for off-site disposal in accordance with applicable Federal, State and Local laws, rules and regulations: or according to the disposal facility accepting the waste.
The Contractor shall submit as part of the sampling and analysis section, the name, address and telephone number of the contact for the Contractor’s proposed environmental laboratory and the name and experience of the proposed environmental sampling technician. The use of a proposed environmental laboratory and proposed environmental sampling technician are subject to review and acceptance by the Engineer.
The Contractor shall provide all personnel, equipment and ancillary services required to collect, transport and analyze environmental samples required for proper characterization of the material. All sampling, testing, and inspections conducted in areas containing potential Contaminated Soil shall be performed in accordance with the site-specific HASP in Subsection 202.04.
All sampling, testing, and data management procedures shall comply with current versions of the NJDEP Field Sampling Procedures Manual, NJDEP Technical Requirements for Site Remediation, NJDEP Management of Excavated Soils Guidelines, Appendix 1 of the NJDEP Waste Classification Form and EPA requirements.
Where required by the Contractor’s disposal facility, the Contractor shall collect and analyze for additional parameters necessary for off-site disposal.
Stockpiling Contaminated Soil. The Contractor shall provide all personnel, materials and equipment needed to properly store (and dewater, if necessary) Contaminated Soil in temporary stockpiles. If needed, any temporary stockpile(s) shall be located at area(s) within the project limits selected by the Contractor and approved by the Resident Engineer. Contaminated Soil, not suitable for construction activities and/or reuse, shall not be stockpiled for more than 180 days. Contaminated Soil subsequently classified as hazardous shall be properly stage and removed within 90 days of excavation.
Stockpiles shall only be placed on dry areas on a layer of minimum 10mils thick PVC sheeting or similar, as approved by the Engineer and contained with hay bales or silt fence placed continuously at the perimeter of the stockpile(s). All joints in the underlying PVC sheeting shall overlap with a minimum of 12 inches at the ends. Stockpile shall be constructed so that heights shall not exceed 15 feet, nor with sideslopes steeper than one vertical and two horizontal. The Contractor shall segregate material of differing types and degrees of contamination so as to prevent cross-contamination of uncontaminated material.
The Contractor shall provide protection for the Contaminated Soil stockpile to prevent the run-on of tormwater, migration of contaminants, dusting, erosion, and unauthorized contact. Stockpiles shall be covered with PVC sheeting of the same thickness. The sheeting shall be secured in place with tie downs and/or heavy objects such as concrete blocks at the end of each workday and during adverse weather conditions. All joints in the cover shall have a minimum 300 millimeters overlap and securing materials shall be placed along the joints such that the cover will not be opened by wind action.
The Contractor shall be responsible for the proper protection and maintenance for the Contaminated Soil stockpile and embankment until completion of the work and acceptance by the Engineer. The Contractor shall maintain the sheeting as needed to repair damage and replace displaced cover sheeting. At the direction of the Engineer, the Contractor shall remedy any observed deficiencies in the cover and sediment barrier surrounding the temporary stockpile or embankment as soon as practicable, including but not limited to the removal and disposal of accumulated sediments behind the sediment barrier, to maintain satisfactory protection, and as otherwise needed to prevent contamination migration or exposure.
Drainage shall be controlled with hay bales, placed continuously at the perimeter of the stockpile(s), PVC cover and silt fence such that run-on and run-off from the Contaminated Soil stockpile(s) are mitigated. Decant from the dewatering of sediments shall be in accordance with the Pollution Prevention and Control Plan (described herein Subsection 212.06).
Soil/Sediment Usage Tracking Log. The Contractor shall monitor and record on Daily Soil/Sediment Tracking Logs the source location, type, quantity, and characteristics of Contaminated Soil excavated, stockpiled, and. The Contractor shall submit a Daily Soil/Sediment Tracking Log to the Engineer for each workday involving excavation, stockpiling, transport, and disposal of Contaminated Soil. The Daily Soil Tracking Log shall contain, at a minimum, the following information:
(1) Date,
(2) Location(s) of excavation and placement of material,
(3) Volume of Contaminated Soil removed, and
(4) Name(s) and signature(s) of the Contractor representative(s) responsible for preparing and executing the Usage Tracking Log.
Copies of Daily Soil/Sediment Tracking Logs shall be submitted to the Engineer on a weekly basis. The Engineer will not approve any progress payment invoice if the required Daily Soil/Sediment Tracking logs have not been submitted.
2. Site-Specific Health And Safety Requirements
Background Environmental Information. The documentation and environmental information provided by the NJDOT is for information purposes only. The Contractor is responsible for appropriate interpretation of the information. The Contractor shall perform a hazard assessment of each proposed work task and make an independent evaluation regarding the appropriate level of health and safety requirements.
Description. This work shall consist of the Contractor preparing, submitting, and implementing a Site-Specific Health and Safety Plan (HASP) in accordance with all applicable health and safety requirements for work in and with contaminated soil, sediment, and water. The Engineer shall review all submittals for compliance with the health and safety requirements. Excavation shall not be commenced until the Engineer’s review has been completed as evidenced by written comment and acceptance as to completeness and compliance with these specifications. The Engineer will not approve the plan. However, acceptance of the plan by the Engineer implies only that at the time of review, the Engineer was not aware of any reasons to object to the plan. The acceptance of the plan, by the Engineer, does not relieve the Contractor of any responsibilities under the contract.
Construction Requirements. The Contractor shall employ a Certified Industrial Hygienist (CIH) or Certified Safety Professional (CSP) to develop and oversee implementation of the Contractor’s HASP. The CIH/CSP shall prepare the HASP to protect the Contractor’s employees, the subcontractor’s employees, NJDOT employees and consultants, and the public from contamination present in the areas requiring excavation as designated on the construction plans. The HASP shall be prepared in accordance with all applicable local, state, and federal rules and regulations, including the health and safety requirements of OSHA 29 CFR parts 1910 and 1926.
The CIH/CSP shall review the site specific data and address the proposed activities to the level of detail as needed to ensure that site specific data, appropriate regulations, and a description of the site conditions are incorporated into the HASP. The Contractor shall comply with all the requirements of the accepted HASP during the excavation, handling, stockpiling, disposal, or recycling of Contaminated Soils.
The HASP as needed shall describe workplace and emergency procedures to be followed so that this project may be constructed in a safe manner. The HASP shall govern all facets of the project constructed and encompass the activities of all persons who enter and/or work on the site. The HASP shall incorporate procedures that conform to all federal, state, and local regulations pertaining to employee working conditions where appropriate, National Institute for Occupational Safety and Health (NIOSH), Occupational Safety and Health Administration (OSHA), US Coast Guard, US Environmental Protection Agency (USEPA), and New Jersey Department of Environmental Protection (NJDEP).
The HASP shall require that a health and safety designate monitor the working conditions during all excavation procedures and during the handling of Contaminated Soils to ensure conformance with the accepted HASP. The CIH/CSP shall evaluate the need for air monitoring during excavation and loading operations in Contaminated Soil. The air monitoring program shall, if deemed necessary by the CIH/CSP, be implemented by the CIH/CSP or an assigned designate suitably trained and approved by the CIH/CSP for the work required. The CIH/CSP shall include in the HASP applicable training and qualifications documentation for him/her self and each health and safety designate.
The Contractor shall provide initial and annual training and medical monitoring for all Contractor employees scheduled to work in/with contaminated soil/water and per the Engineers request up to ten (10) state employees and/or their authorized representatives as per OSHA 29 CFR 1910. The initial training for state employees and/or their authorized representatives shall be provided one (1) month prior to any excavation.
The Contractor shall deliver four (4) copies of the HASP and a listing of the health and safety personnel prior to clearing site to the Engineer for review and acceptance at least one month prior to beginning excavation. No work on the site shall be permitted until the HASP has been submitted, reviewed, and accepted by the Engineer. The Contractor shall be responsible for implementing the HASP submitted to and accepted by the Engineer. The Contractor shall deliver original logs and reports related to the HASP to the Engineer on a weekly basis.
3. Material Handling Plan
This work shall consist of developing and implementing a Materials Handling Plan (MHP) for Regulated Waste/Contaminated Soil encountered, moved, and disposed and/or recycled during construction. The MHP shall explain the Contractor’s planned techniques to be used in managing Contaminated Soil so as to protect workers, the Resident Engineer and his representatives, visitors, the public and adjoining property owners against uncontrolled exposure to Contaminated Soil, plus to prevent uncontrolled release of Contaminated Soil to the environment.
The Contractor shall prepare and submit for Engineer’s approval a MHP prior to any excavation. The MHP shall detail standard operating procedures for excavation, stockpiling, transporting, sampling and analysis, measurement, transportation, and disposal of hazardous waste and Contaminated Soil. The Contractor shall make all necessary modifications to the MHP that result from comments given by the Engineer and the Department. The Contractor shall perform planning, administrative and control functions required in implementing the MHP. The MHP shall be in full compliance with the Specification. The Contractor shall implement the MHP in accordance with the contract documents.
The Contractor shall not commence work activities governed by the MHP until the Engineer has given written acceptance of the MHP. The Contractor shall submit the MHP to the Engineer for review and acceptance at least one month prior to commencing excavation.
The Contractor MHP shall include at a minimum: details of current certification, permits, insurance types and levels of coverage; qualifications of the transportation and receiving facilities; the types of equipment to be used in transporting Contaminated Soil; proposed route(s) to disposal facilities and weighing facilities; waste characterization forms, sampling logs and analyses reports; transport manifests; and waste disposal documentation forms from the receiving facility.
The Contractor shall provide periodic reports documenting the excavation, stockpiling, sampling, off-site management and on-site placement of Contaminated Soil. The periodic reports shall be mailed to the Engineer by the tenth calendar day of each month. The periodic reports shall provide the location and date(s) of excavation, stockpiling, sampling, off-site management, and placement of Contaminated Soil. The periodic reports shall explain any changes to or differences with construction plans. The periodic reports shall also include dates of planned excavation, sampling, and disposal of Contaminated Soil for the coming months.
The Contractor shall provide a final report documenting the Management of Contaminated Soil, including the location and date(s) of excavation, stockpiling, sampling, disposal/off-site management, and on-site placement of Contaminated Soil. The final report also shall include any plans depicting placement of Contaminated Soil. The Contractor shall deliver four paper copies and one digital copy of the final report to the Engineer within one-month of completing all Roadway Excavation, Regulated Waste and Disposal of Contaminated Soil.
202.09 Milling of HMA.
DETERMINE THE APPROPRIATE TIME INTERVAL FOR RESURFACING THE MILLED PAVEMENT BASED ON the project STAGING, TYPE OF PROJECT, LENGTH OF PAVING AND project cONSTRUCTABILITY. mAXIMUM TIME INTERVAL MAY VARY BUT SHALL NOT EXCEED 72 HOURS.
2.
THE FOLLOWING IS ADDED AFTER THE NINTH PARAGRAPH:
MILLED AREAS SHALL NOT BE LEFT UNPAVED FOR LONGER THAN 72 HOURS, UNLESS APPROVED BY THE ENGINEER.
202.14 Method of Measurement.
THE FOLLOWING IS ADDED
Environmental Sampling Personnel, Management and Reporting (HASP and Remedial Action Workplan), will include the development and implementation of the Material Handling Plan (MHP). Payment for preparation, implementation, monitoring, and administration of the MHP, including supervision, documentation, and monitoring performing during execution of excavation, handling, stockpiling and transport of Contaminated Soil, shall be included in applicable excavation and disposal pay items.
202.15 Basis of Payment.
BDC03s-02 dated march 17, 2003
PAYMENT WILL BE MADE UNDER:
Pay Item Pay Unit
environmental sampling personnel, management and reporting hours
THE FOLLOWING IS ADDED AFTER THE FOURTH PARAGRAPH.
SEPARATE PAYMENT WILL NOT BE MADE FOR SAWCUTTING WHEN USED WITH THE PAY ITEMS “JOINT REMOVAL” OR “REMOVAL OF CONCRETE BASE COURSE AND CONCRETE SURFACE COURSES”.
SECTION 203 – EMBANKMENT
203.08 CONTROL FILL METHOD.
BDC03s-19 dated n0vember 26, 2003
4. Procedure.
THE last SENTENCE OF THE fourth PARAGRAPH IS CHANGED TO:
DENSITY OF THE CONTROL STRIP WILL BE DETERMINED ACCORDING TO AASHTO T 191 OR AASHTO T 310 (DIRECT TRANSMISSION METHOD) EXCEPT THAT ONLY ONE METHOD WILL BE USED THROUGHOUT THE PROJECT.
B. Embankment Compaction.
THE third PARAGRAPH IS CHANGED TO:
THE DENSITY OF SUCH INACCESSIBLE AREAS WILL BE DETERMINED FROM THE AVERAGE OF FIVE RANDOMLY LOCATED MEASUREMENTS ACCORDING TO AASHTO T 191 OR AASHTO T 310 (DIRECT TRANSMISSION METHOD) EXCEPT THAT ONLY ONE METHOD WILL BE USED THROUGHOUT THE PROJECT.
203.10 Density Control Method.
BDC03s-19 dated n0vember 26, 2003
THE COMPACTED DENSITY OF EMBANKMENTS WILL BE DETERMINED BY TAKING THE AVERAGE OF A MINIMUM OF FIVE RANDOMLY LOCATED MEASUREMENTS FOR EACH 1,000 CUBIC YARDS PLACED ACCORDING TO AASHTO T 191 OR AASHTO T 310 (DIRECT TRANSMISSION METHOD) EXCEPT THAT ONLY ONE METHOD WILL BE USED THROUGHOUT THE PROJECT.
203.13 Vertical Drain Method.
include the following for zone 3 embankment when a specific rate of placement is required.
provide rate.
INCLUDE VERTICAL WICK DRAIN REQUIREMENTS WHEN APPLICABLE WITH APPROVAL FROM THE SME.
SECTION 204 – borrow excavation
204.03 CONSTRUCTION REQUIREMENTS.
BDC03s-19 dated n0vember 26, 2003
A MINIMUM OF TWO FIELD DENSITY TESTS WILL BE TAKEN ACCORDING TO AASHTO T 191 OR AASHTO T 310 (DIRECT TRANSMISSION METHOD) ON EACH COMPACTED LAYER AT EACH SUBSTRUCTURE UNIT, EXCEPT THAT ONLY ONE OF THE REFERENCED METHODS WILL BE USED ON THE PROJECT.
SECTION 207 – subsurface structure excavation
207.03 BEDDING MATERIALS.
BDC01s-15 dated august 30, 2002
207.03 BEDDING AND BACKFILL MATERIALS.
BDC01s-15 dated august 30, 2002
CONTROLLED LOW STRENGTH MATERIAL (CLSM) SHALL CONFORM TO SUBSECTION 919.22
207.04 Construction Requirements.
BDC03s-13 dated march 22, 2004
BEFORE EXCAVATING, EXISTING SUBSURFACE STRUCTURES WHICH MAY BE AFFECTED BY OR INTERFERE WITH THE PROPOSED CONSTRUCTION SHALL BE LOCATED. IF DIRECTED, TEST PITS SHALL BE EXCAVATED TO OBTAIN THE REQUIRED INFORMATION. TEST PITS OR PORTIONS OF A TEST PIT SHALL BE DUG BY HAND WHEN IN CLOSE PROXIMITY TO UTILITIES OR WHEN DIRECTED. EXCAVATION BEYOND THAT WHICH IS NECESSARY TO OBTAIN THE REQUIRED INFORMATION WILL NOT BE MEASURED FOR PAYMENT. TEST PITS SHALL BE BACKFILLED ACCORDING TO SUBSECTION 203.06.
1. Pipes and Culverts.
the FIRST paragraph is changed to:
THE WIDTH OF TRENCH SHALL BE AT LEAST 1 FOOT – 6 INCHES GREATER THAN THE OUTSIDE DIAMETER OF THE PIPE OR CULVERT. WHEN THE MATERIAL AT THE BOTTOM OF THE EXCAVATION IS ROCK OR OTHER HARD MATERIAL, IT SHALL BE REMOVED WITHIN 6 INCHES FOR REINFORCED CONCRETE CULVERT PIPE AND HIGH DENSITY POLYETHYLENE (HDPE) PIPE, AND 1 FOOT FOR CORRUGATED METAL, STEEL, OR ALUMINUM ALLOY CULVERT PIPE OUTSIDE THE BOTTOM OF THE PIPE OR CULVERT AND THE SPACE BACKFILLED WITH SUITABLE MATERIAL.
207.05 Bedding for Pipes and Culverts.
BDC03s-13 dated march 22, 2004
BEDDING FOR CORRUGATED ALUMINUM ALLOY CULVERT PIPE AND HDPE PIPE SHALL BE PLACED AS SPECIFIED FOR CLASS B BEDDING.
207.06 Backfilling.
BDC03s-13 dated march 22, 2004
THE entire subpart a. is changed to:
BACKFILL TO A HEIGHT OF 2 FEET ABOVE THE TOP OF PIPES AND CULVERTS, EXCEPT UNDERDRAINS, CORRUGATED ALUMINUM ALLOY CULVERT PIPE AND HDPE PIPE, SHALL BE MADE WITH EXCAVATED MATERIAL FREE FROM STONES OR ROCK FRAGMENTS LARGER THAN 2 INCHES IN ANY DIMENSION. BELOW THIS LEVEL, THE BACKFILL SHALL BE PLACED IN LAYERS NOT MORE THAN 6 INCHES THICK, AND EACH LAYER SHALL BE COMPACTED WITH FLAT-FACE MECHANICAL TAMPERS. BACKFILL SHALL BE WORKED INTO THE HAUNCH AREA AND COMPACTED FOR ALL PIPE.
For HDPE pipe, backfill to a height of 2 feet above the top of the pipe shall be made with excavated material free from class iv or class v materials according to ASTM D2321, with stones or rock fragments no larger than 1½ inch in any direction. Below this level, the backfill shall be placed symmetrically on each side of the pipe in layers not more than 6 inches thick with each layer compacted with flat-faced mechanical tampers for all pipe.
Backfill to a height of 2 feet above the top of corrugated aluminum alloy culvert pipe shall be made with a granular soil with the gradation as specified in Subsection 207.03. Below this level, the backfill shall be placed symmetrically on each side of the pipe in layers not more than 6 inches thick, and each layer shall be compacted with flat-faced mechanical tampers.
All backfill more than 2 feet above the top of pipes and culverts, except underdrains, shall be made with excavated material and compacted in 6 inches layers as follows:
1. By vibratory soil compactors, if the backfill material is predominately sand or sand and gravel.
2. By flat-faced mechanical tampers, if the backfill material is not predominantly sand or sand and gravel.
3. Flat-faced mechanical tampers may be substituted for the vibratory soil compactors where the shoring and bracing of trenches or other special conditions make the use of vibratory compactors impractical.
4. Care shall be taken to avoid contact between the pipe and compaction equipment at all times. All damaged pipes shall be removed and replaced at no additional cost to the State.
The Engineer may direct compaction to be according to Subsection 203.10 except that the frequency of measurements may increase. If a hydrohammer or hoe-pak is used for compacting the backfill over the pipe, a minimum of 4 feet of cover over the pipe shall be provided.
CLSM may be used as alternate backfill material when backfilling trenches for drainage pipe and utility conduit. Combining other backfill materials in the same trench as CLSM shall not be permitted. Mixing and placement of CLSM shall begin only when the ambient temperature is at least 30 (F. During placement, the CLSM mixture shall have a temperature of at least 41 (F and shall not be placed on frozen ground. The CLSM mixture shall be discharged directly from the truck into the trench to be filled with care taken to prevent the pipe from becoming displaced. After placement, the CLSM mixture shall be cured and protected to prevent damage from cold weather according to Subsection 405.14. CLSM shall not be used to replace pavement, base courses or drainage layers that form the structure of the roadway.
The special backfill in trenches for the underdrains shall be compacted by vibratory compactors. Earth backfill above the special backfill material shall be compacted as specified in Subsection 203.07.
Shoring, bracing, and sheathing shall be withdrawn as the backfilling proceeds. Compaction requirements shall not be compromised due to the removal of sheathing, shoring, trench boxes or other type of excavation support systems.
In rock cuts, the backfill shall be either broken stone or washed gravel.
THE FOLLOWING SECTION IS ADDED:
SECTION 212 – SOIL EROSION AND SEDIMENT CONTROL
212.06 Soil Erosion and Sediment Control Measures.
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K. CONCRETE WASHOUT FACILITY. DESIGN CONCRETE WASHOUT FACILITY TO FULLY CONTAIN ALL CONCRETE WASHOUT NEEDS OF THE WORK. CONCRETE WASHOUT FACILITY MAY BE PORTABLE OR A BERMED BASIN THAT IS LINED WITH A SINGLE SHEET OF A MINIMUM OF 10-MIL POLYETHYLENE SHEETING THAT EXTENDS OVER THE ENTIRE BASIN AND BERM TO PREVENT ESCAPE OF DISCHARGE. PLACE A SECURE, NON-COLLAPSING, NON-WATER COLLECTING COVER OVER THE CONCRETE WASHOUT FACILITY PRIOR TO INCLEMENT WEATHER TO PREVENT ACCUMULATION AND OVERFLOW OF PRECIPITATION. SUBMIT A PLAN FOR CONCRETE WASHOUT FACILITY FOR APPROVAL TO THE RESIDENT ENGINEER 10 DAYS BEFORE FIRST CONCRETE POUR. PROVIDE CONCRETE WASHOUT FACILITY TO PREVENT DISCHARGE FROM CONCRETE TRUCKS OR EQUIPMENT CLEANING TO INLETS, SURFACE OR GROUNDWATER. DESIGNATE AN AREA FOR THE CONCRETE WASHOUT FACILITY THAT IS NO CLOSER THAN 50 FEET FROM ENVIRONMENTALLY SENSITIVE AREAS SUCH AS WATERBODIES, WETLANDS, OR OTHER AREAS INDICATED ON THE PLANS. USE SIGNS TO DESIGNATE CONCRETE WASHOUT FACILITIES. ENSURE THAT THE CONCRETE WASHOUT FACILITY COMPLIES WITH ALL FEDERAL, STATE, AND LOCAL LAWS, RULES, AND REGULATIONS. ENSURE THAT THE CONCRETE WASHOUT FACILITY IS IN PLACE BEFORE DELIVERY OF CONCRETE TO THE SITE.
Ensure that concrete washout is limited to the designated areas. Contents of the concrete washout facility shall not exceed 50 % capacity of the facility. At or before the 50 % capacity is reached, discontinue pouring concrete until the facility is cleaned out. Remove hardened concrete and properly dispose or reuse it as specified in Subsection 202.12. Allow slurry to evaporate or remove from site and dispose of it as specified in Subsection 201.10.
If a lined basin is used, immediately replace the liner if it gets damaged. Remove concrete washout facility when it is no longer needed. Restore the disturbed area to its original condition.
L. Oil-Only Emergency Spill Kit. Before start of construction operations of the Work, place on site at least 2 oil-only emergency spill kits with each kit capable of cleaning up at least 50 gallons of spill. Ensure that each kit contains the items as provided in the Special Provisions:
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2. 10 oil-only absorbent booms (3-inch by 10-foot)
3. 60 absorbent mat-type pads (20-inch by 16-inch)
4. 20 temporary disposal bags and ties
5. 1 emergency response guide book
6. 1 instruction manual
7. 1 wheeled container for the above
8. One 40 lb bag loose absorbent pellets
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CONCRETE WASHOUT FACILITY WILL NOT BE MEASURED, AND PAYMENT WILL BE MADE ON A LUMP SUM BASIS.
Oil only emergency spill kit will be measured by the unit.
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PAY ITEM PAY UNIT
Concrete washout Facility Lump sum
OIL ONLY EMERGENCY SPILL KIT UNIT
.
division 300 – base courses
SECTION 301 – SOIL AGGREGATE BASE COURSE AND DENSE-GRADED AGGREGATE BASE COURSE
301.05 COMPACTION.
BDC03s-19 dated n0vember 26, 2003
THE IN-PLACE DRY DENSITY OF EACH COMPACTED LAYER WILL BE DETERMINED ACCORDING TO AASHTO T 191 OR T 310 (DIRECT TRANSMISSION METHOD) EXCEPT THAT ONLY ONE METHOD WILL BE USED THROUGHOUT THE PROJECT.
2. Compaction Acceptance Testing.
THE Third SENTENCE OF THE last PARAGRAPH IS CHANGED TO:
ONE DENSITY DETERMINATION WILL BE MADE AT EACH OF THE SELECTED LOCATIONS USING AASHTO T 191 OR T 310 (DIRECT TRANSMISSION METHOD) EXCEPT THAT ONLY ONE METHOD WILL BE USED THROUGHOUT THE PROJECT.
INCLUDE THE FOLLOWING WHEN APPLICABLE WITH APPROVAL FROM THE SME.
3.
the following is added after the first paragraph:
301.08 Maintenance Under Traffic.
INCLUDE THE FOLLOWING for projects with soil aggregate base course or dense graded aggregate base course when traffic is permitted to ride on completed base course.
WHEN IT IS PROVIDED ON THE PLANS THAT TRAFFIC IS PERMITTED TO RIDE ON THE COMPLETED BASE COURSE, THE BASE COURSE SHALL BE MAINTAINED SMOOTH AND UNIFORM UNTIL COVERED BY THE FOLLOWING STAGE OF CONSTRUCTION.
SECTION 302 – road-mixed stabilization
302.09 COMPACTION, SHAPING, AND FINISHING.
BDC03s-19 dated n0vember 26, 2003
THE last SENTENCE OF THE second PARAGRAPH IS CHANGED TO:
THE IN-PLACE DRY DENSITY OF EACH COMPACTED COURSE WILL BE DETERMINED ACCORDING TO AASHTO T 191 OR T 310 (DIRECT TRANSMISSION METHOD) EXCEPT THAT ONLY ONE METHOD WILL BE USED THROUGHOUT THE PROJECT.
SECTION 305 – CONCRETE BASE COURSE
305.05 OPENING TO TRAFFIC.
BDC02s-08 dated february 07, 2003
THE OPENING TO TRAFFIC SHALL BE AS SPECIFIED IN SUBSECTION 405.20.
DIVISION 400 – SURFACE COURSES
SECTION 402 – BITUMINOUS SURFACE TREATMENT
BDC04S-09 DATED JULY 09, 2004
403.01 DESCRIPTION.
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THIS WORK INCLUDES THE CONSTRUCTION OF OPEN GRADED FRICTION COURSE (OGFC), AND MODIFIED OPEN GRADED FRICTION COURSE (MOGFC). THE MOGFC SHALL CONTAIN POLYMER MODIFIED ASPHALT BINDER AND STABILIZING FIBERS.
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THE MATERIALS AND THEIR USE SHALL CONFORM TO SUBSECTION 404.02 EXCEPT AS FOLLOWS:
1. Aggregate for OGFC and MOGFC shall conform to Subsection 901.10; except that coarse aggregate shall be broken stone of gneiss, granite, quartzite, or trap rock. RAP will not be allowed.
2. Asphalt binder for OGFC shall be PG64-22 as specified in 904.01 and asphalt binder for MOGFC shall be PG76-22 as specified in 904.01.
3. For MOGFC, a stabilizing additive consisting of mineral fiber or cellulose fiber shall be added to the mix. The stabilizing additive shall conform to the requirements for stabilizing additives in AASHTO MP 8. Only one type shall be used per mix design. If using mineral fibers, the dosage rate shall be 0.4 percent by weight of total mix. If using cellulose fibers, the dosage rate shall be 0.3 percent by weight of total mix. The dosage rate may be increased, as necessary, to prevent draindown as measured by the Visual Draindown Asphalt Content in Section 990, NJDOT B-11. Control shall be provided for accurately proportioning the fibers into the mixture within +/- 10 percent of the required weight, and the equipment shall ensure uniform dispersion of the fibers. Fibers shall be stored in a dry location with a storage temperature not to exceed 120° F. The supplier of the cellulose or mineral fibers shall certify according to Subsection 106.04 that the material supplied complies with AASHTO MP 8. A technical representative from the additive supplier shall be on the site for the first full day of construction for technical assistance.
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A JOB MIX FORMULA (JMF) FOR EACH MIXTURE SHALL BE SUBMITTED ON FORMS SUPPLIED BY THE DEPARTMENT, WHICH SHALL INCLUDE A STATEMENT NAMING THE SOURCE OF EACH COMPONENT AND A REPORT SHOWING THE RESULTS MEET THE CRITERIA SPECIFIED IN TABLE 403-1.
The JMF for each mixture shall establish the percentage of dry weight of aggregate passing each required sieve size and an optimum percentage of asphalt binder based upon the weight of the total mix. The optimum asphalt content for OGFC will be determined according to Section 990, NJDOT B-12. The optimum asphalt content for MOGFC will be determined according to Section 990, NJDOT B-11. The JMF shall be within the design range specified in Table 403-1.
The Contractor shall prepare compacted test specimens for submittal to the Department Laboratory at least four weeks prior to the initial production date. These specimens shall be prepared from material mixed according to the final JMF, using 50 gyrations of the Superpave gyratory compactor according to AASHTO T 312. Two specimens will be tested to verify that the final JMF produces a mixture that has a minimum air void content as specified in Table 403-1. Percent air voids will be determined using AASHTO T 209 and either Section 990, NJDOT B-6 or AASHTO TP 69.
If required by the Regional Materials Engineer (RME), six specimens will be tested according to AASHTO T 283. For MOGFC, the freeze-thaw option will be utilized. The minimum tensile strength ratio (TSR) will be 80 percent. Should the ratio fall below this minimum, adjust the mixture so as to satisfy the minimum requirement. Adjustments may include the use of anti-stripping agents.
For MOGFC only, two test specimens will be tested for abrasion and impact resistance using a modified L.A. Abrasion Test as per Section 990, NJDOT B-11, Section C.6. The maximum loss as calculated by this method shall not be more than 30 percent.
The JMF for each mixture shall be in effect until modification is approved.
During production, one random acceptance sample will be taken from each lot of 300 tons to verify composition. Air voids and draindown tests shall be conducted as directed by the Engineer.
If the composition testing results are out of the production control tolerances specified in Table 403-2 for an acceptance sample, the Contractor shall determine if a plant adjustment is needed and immediately run a quality control sample. If the quality control sample is also out of the control tolerances in Table 403-2, corrective action shall be taken immediately. Additional quality control samples shall be taken after the corrective action to ensure that the mix is under control. If two consecutive acceptance samples are outside the tolerances specified in Table 403-2, production shall stop immediately. A plant correction shall be made prior to resuming production. Upon restarting production, no mixture shall be transported to the project before the results of a quality control sample from the mixture indicate that the mixture meets JMF tolerances. Any mixture produced at initial restarting that does not meet tolerances will be rejected.
Sampling will be performed according to Section 990, NJDOT B-2 or ASTM D 3665. Testing for composition will be performed according to AASHTO T 164, AASHTO T 308, or Section 990, NJDOT B-5. Testing for draindown will be performed according to Section 990, NJDOT B-11 or B-12
Table 403-1
Open Graded Friction Course
Job Mix Formula Design Ranges and Mixture Requirements
|Mixture Designations |
| |OGFC |MOGFC-1 |MOGFC-2 |MOGFC-3 |
|Sieve Sizes |% Passing |
|¾” | |100 |100 | |
|½” |100 |85-100 |90-100 |100 |
|3/8” |85-100 |35-60 |65-85 |85-100 |
|#4 |20-40 |10-25 |15-25 |20-40 |
|#8 |5-10 |5-10 |5-10 |5-10 |
|#200 |2-4 |2-5 |2-4 |2-4 |
| |
|Minimum asphalt binder |5.5% |5.7% |5.7% |6.0% |
|Min % Air Voids, design |15% |20% |18% |18% |
|Min lift Thickness, design |¾” |1 ¼” |1” |¾” |
Note 1: Aggregate % passing to be determined based on dry aggregate weight. Asphalt Binder content to be determined based on total weight of mix.
Table 403-2
Production Control Tolerances for OGFC and MOGFC Mixtures
|Production Control Tolerances |Sieve Sizes |
|( 6.0 |1/2” |
|( 5.5 |3/8” |
|( 5.5 |#4 |
|( 4.5 |#8 |
|( 2.0 |#200 |
| | |
|( 0.25 |Asphalt binder, % (AASHTO T 308 or T 164) |
|( 0.15 |Asphalt binder, % (Section 990, NJDOT B-5) |
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THE EQUIPMENT SHALL BE AS PROVIDED IN SECTION 404 EXCEPT THAT OGFC AND MOGFC MIXES SHALL BE TRANSPORTED IN CLEAN VEHICLES WITH SMOOTH DUMP BEDS THAT HAVE BEEN SPRAYED WITH A NON-PETROLEUM RELEASE AGENT. TRUCKLOADS OF MIXTURE WITHOUT THE SPECIFIED COVER, OR THAT CONTAIN LUMPS, CRUSTING OR SEGREGATION SHALL BE REJECTED. THE TIME BETWEEN THE LOADING OF THE TRUCK AND LAY DOWN SHALL NOT EXCEED 90 MINUTES.
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THE CONSTRUCTION REQUIREMENTS SHALL BE AS SPECIFIED IN SECTION 404 EXCEPT AS FOLLOWS FOR OGFC AND MOGFC:
1. Hand placing shall be avoided except where necessary.
2. Laying temperature for OGFC mix shall not be less than 225(F; laying temperature for MOGFC shall be as per binder manufacturer’s recommendations.
3. Ambient temperature shall be 60°F minimum.
4. Thickness for OGFC mix shall be ¾ ( ¼ inch; thickness for MOGFC shall conform to Table 403-1.
5. Temperature at discharge from the plant shall be maintained from 240(F to 270(F for OGFC; temperature at discharge from the plant for MOGFC shall be within the binder manufacturer’s recommended mixing range.
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PAY ITEM PAY UNIT
MODIFIED OPEN-GRADED FRICTION COURSE, mixture mogfc__ TON
THE FOLLOWING PAY ITEM IS DELETED:
PAY ITEM PAY UNIT
DENSE-GRADED FRICTION COURSE, MIX__ TON
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404.02 MATERIALS.
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Polymerized Joint Adhesive…………………………………………………………………………..908.08
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include the following for all projects.
23. MICROCOMPUTER AND WORKSTATION REQUIREMENTS SHALL BE ACCORDING TO SUBSECTION 106.06.
404.06 Vehicles for Transporting HMA Mixtures.
BDC02s-17 dated October 28, 2002
THE MIXTURE SHALL BE TRANSPORTED FROM THE MIXING PLANT TO THE PROJECT IN TRUCKS EQUIPPED WITH TIGHT, CLEAN BODIES, WHICH MAY BE LIGHTLY COATED WITH A SOAP OR LIME SOLUTION, OR OTHER SUCH NON-PETROLEUM-BASED RELEASE AGENT. UNDER NO CIRCUMSTANCE SHALL A PETROLEUM-BASED PRODUCT BE USED AS A RELEASE AGENT.
The trucks shall be permanently equipped with an airfoil that is capable at any speed or under any weather conditions to deflect air over the tarp and to prevent air from going under the tarp. The airfoil will be affixed no more than 2 feet in front of the tarp roll and be at least as high as the top of the tarp roll.
Each truckload shall be covered immediately after loading at the plant with a waterproof tarpaulin of such size to protect the mixture from the weather. The tarpaulin shall be able to withstand normal handling and placement temperatures of up to 400 ºF without endangering the structural integrity and serviceability of the fabric. The tarpaulin shall also comply with one of the following:
1. A heavyweight tarpaulin to completely drape the load. The heavyweight tarpaulin shall have a minimum weight of 18 oz./yd2 and shall be a minimum of 2 feet wider and 4 feet longer than the truck body. The heavyweight tarpaulin shall securely meet or overlap the top of the tailgate and be securely held in place so as to prevent air from lifting the tarp during transport.
2. A tarpaulin equipped with side and back flaps sufficient to lap down outside along the sides and rear of the truck bed a minimum of 12 inches. The tarpaulin shall be secured by tie downs at a maximum of 5 feet spacing along the sides and rear of the truck.
The truck bodies shall be insulated or heated as necessary, to ensure delivery of the mixture at the specified temperature. Any truck that: causes excessive segregation of the mixture by its suspension or other contributing factors; leaks; causes delays; does not have an airfoil; or does not have an approved tarpaulin shall be removed from the work until such conditions are corrected and the truck is presented for inspection to the Engineer. The Engineer may require that all vehicles for transporting HMA mixture to be used by the Contractor be made available for inspection at the plant laboratory prior to any shipments of materials.
404.07 Materials Transfer Vehicle (MTV)
BDC03s-18 dated december 04, 2003
THE MTV SHALL INDEPENDENTLY DELIVER MIXTURES FROM THE HAULING EQUIPMENT TO THE PAVING EQUIPMENT. A PAVER HOPPER INSERT WITH A MINIMUM CAPACITY OF 14 TONS SHALL BE INSTALLED IN THE HOPPER OF CONVENTIONAL PAVING EQUIPMENT WHEN AN MTV IS USED.
As a minimum, the MTV shall have a high capacity truck unloading system which will receive mixtures from the hauling equipment; a storage system in the MTV with a minimum capacity of 15 tons of mixture; and a discharge conveyor, with the ability to swivel, to deliver the mixture to the paving spreader while allowing the MTV to operate from an adjacent lane. In addition, the paving operation must contain a remixing system to continuously blend the mixture prior to placement. The remixing may be done by the MTV or in the paver hopper.
The use of an MTV is not required on this project and may not be utilized without the consent approval from the Resident Engineer and NJDOT Structural Evaluation Unit. Such request, including the worst case axle configuration and weights for fully loaded and empty MTV, and the project limits, shall be made in writing and faxed to (609) 530-4444.
SURFACE AND INTERMEDIATE COURSES
•
•
•
•
•
•
•
LIST STRUCTURE(S)
404.08 HMA Paver.
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WHEN WEDGE JOINT CONSTRUCTION IS REQUIRED, HMA PAVERS SHALL BE EQUIPPED WITH A SLOPED PLATE TO PRODUCE A WEDGE EDGE AT LONGITUDINAL JOINTS. THE SLOPED PLATE SHALL MEET THE REQUIREMENTS OF SUBSECTION 404.17.1.B AND SHALL BE ATTACHED TO THE PAVER SCREED EXTENSION.
THE seventh paragraph is deleted.
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1. LONGITUDINAL JOINTS. ALL LONGITUDINAL JOINTS SHALL BE CLEANED FREE FROM DUST AND COATED BEFORE PLACING THE HMA WITH A UNIFORM APPLICATION OF A POLYMERIZED JOINT ADHESIVE SELECTED FROM THE DEPARTMENT’S APPROVED PRODUCTS LIST. THE POLYMERIZED JOINT ADHESIVE MATERIAL SHALL BE APPLIED AT A SLOW RATE TO ENSURE AN EVEN COATING THICKNESS OF AN ⅛ OF AN INCH OVER THE ENTIRE JOINT FACE. FOR ECHELON PAVING THE LONGITUDINAL JOINTS NEED NOT BE TREATED WITH THE POLYMERIZED JOINT ADHESIVE.
The paving shall be done with the spring loaded end plates of the paver in the “down” position. When constructing the first lane, care shall be exercised in rolling so as not to displace the line and grade of the edges of the HMA. The longitudinal joint in one layer shall offset that in the layer immediately below by approximately 6 inches. The joint in the surface course shall be offset from the lane lines by 6 inches except for the centerline of a roadway in which the joint shall fall between the double yellow traffic stripe.
Paving, compaction and the supply of material shall proceed at a uniform rate with minimal or no stopping.
If a single paver does not spread the HMA material the entire width of the roadway, two pavers shall be used provided that the rate of production of HMA material can be maintained. The second unit shall follow within 300 feet of the first unit in echelon, so as not to permit cooling of the longitudinal joint between the two lanes. If echelon paving is to be utilized, the distance that the screed and end gate of the trailing paver shall extend over the uncompacted HMA layer behind the first paver shall be 1 inch or less. The inside end gate of the second paver must be set at the same level as the bottom of the screed plate of the first paver. Raking of the joint is not needed.
A wedge joint shall be constructed when traffic is to be maintained and lift thickness is greater than 21/4 inches. A vertical edge joint will be permitted for lift thickness 21/4 inches or less when traffic has to be maintained. For lift thickness greater than 21/4 inches and traffic is not required to be maintained, a vertical edge shall be utilized.
Longitudinal joints shall be constructed utilizing one of the following methods:
A. Vertical Edge Joint. The paver shall be positioned so that in spreading, the HMA material uniformly overlaps the edge of the lane previously placed by 1 to 2 inches and shall be left sufficiently high to allow for compaction. In general, the height of the uncompacted HMA above the compacted HMA shall be 1/4 inch for each 1 inch of compacted mix. The overlapped HMA material being placed in the abutting lane shall be tightly crowded (bumped) over the joint. Any material in excess of the 1 to 2 inch overlap shall be pulled away from the joint and removed instead of broadcasting onto the new mat. When compacted, the new mat at the joint shall be even or slightly higher (Maximum 1/8 of an inch) than the previously placed adjoining mat. If the newly compacted mat results in a depression at the joint of 1/8 of an inch or more lower than the previously placed adjacent HMA layer, all paving operations shall cease until corrective action is taken by the Contractor to prevent reoccurrence. For all longitudinal joints that do not meet this requirement, the Contractor shall saw joints according to dimension guidelines of Subsection 404.19 and seal with an approved sealer.
B. Wedge Joint. The sloped plate of the paver shall produce a wedge edge having a face slope of 3H:1V. The plate shall be so constructed as to accommodate compacted layer thickness of 2 to 4 inches. The bottom of the sloped plate shall be mounted 1 inch above the existing surface. The plate shall be interchangeable on either side of the screed. The Contractor shall maintain the wedge configuration under traffic conditions.
All loose material shall be removed from the traveled way before opening to traffic. The rolling operation of the adjoining lane shall proceed as indicated in subpart A above, except that care shall be taken to keep coarse aggregate away from the point where the wedge meets the surface of the previously placed lane.
To assure a true line, the paver shall closely follow lines or markings placed along the joint for alignment purposes. All longitudinal joints shall be constructed parallel to the centerlines within a tolerance of plus or minus 3 inches for every 100 linear feet. If this tolerance is not met, the mat shall be cut back to conform. The width and depth of overlapped material shall be kept uniform at all times. Overlapped material shall be luted back, pushing the material off of the cold HMA and onto the hot HMA mat directly over the joint. In no case shall excess material be broadcast across the new layer. All excess material shall be removed.
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WHEN COMPACTING THE LONGITUDINAL EDGE OF THE FIRST LANES PLACED USING THE WEDGE JOINT, THE BREAKDOWN ROLLER SHALL NOT EXTEND MORE THAN 2 INCHES OVER THE TOP OF THE SLOPED FACE OF THE WEDGE JOINT. THE CONTRACTOR SHALL SUBMIT A PLAN, TO ENSURE MATERIAL AT THE WEDGE EDGE IS PROPERLY SEATED AND LOOSE MATERIAL IS REMOVED, FOR THE RESIDENT ENGINEER’S APPROVAL PRIOR TO THE COMMENCEMENT OF PAVING OPERATIONS.
THE following is added after the fourth paragraph:
CARE SHALL BE TAKEN TO PREVENT LATERAL DISPLACEMENT OF THE UNCONFINED EDGE DURING THE COMPACTION OPERATION. THE EDGE OF THE DRUMS OF VIBRATORY OR STATIC WHEEL ROLLERS SHALL EXTEND OVER THE FREE EDGE OF THE MAT BY AT LEAST 6 INCHES. WHEN COMPACTING THE JOINT, WHILE PAVING THE ADJACENT LANE, THE ROLLER SHALL BE PLACED ON THE NEWLY PLACED HMA AND OVERLAP THE JOINT BY A DISTANCE OF APPROXIMATELY 6 INCHES.
THE fifth paragraph is changed to:
ALTERNATE TRIPS OF THE ROLLER SHALL BE TERMINATED IN STOPS APPROXIMATELY 2 FEET FROM THE PRECEDING STOP. WHEN PAVING IN ECHELON, ROLLERS COMPACTING THE MAT BEHIND THE LEAD PAVER SHALL MAINTAIN APPROXIMATELY 6 INCHES OF UNCOMPACTED MATERIAL ADJACENT TO THE SECOND PAVER. AFTER MIX FROM THE SECOND PAVER IS PLACED AGAINST THE UNCOMPACTED EDGE OF THE MAT FROM THE FIRST PAVER, THE ROLLERS SHALL COMPACT THE HMA ON BOTH SIDES OF THE JOINT.
THE following is added after the eleventh paragraph:
AFTER COMPACTION HAS BEEN COMPLETED, THE PAVEMENT SHALL BE FREE OF ALL VISIBLE DEFECTS SUCH AS SEGREGATION, BLEEDING, RUTS, RIDGES, ROLLER MARKS, CRACKING, TEARING, RAVELING, OPEN OR SEGREGATED TRANSVERSE OR LONGITUDINAL JOINTS, DEPRESSED OR RAISED AREAS AROUND MANHOLES OR RAISED AREAS AROUND INLETS IN THE TRAVELED WAY OR ANY OTHER DEFECTS, AS DETERMINED BY THE RESIDENT ENGINEER. ALL VISIBLE DEFECTS SHALL BE REPAIRED TO THE SATISFACTION OF THE RESIDENT ENGINEER AT NO ADDITIONAL COST TO THE STATE.
At the discretion of the Resident Engineer where it is deemed to be impractical to repair such visible defects, a payment reduction due to nonconformance will be applied according to Subsection 404.26.
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2.
THE DESIGNER SHALL DETERMINE THE PAYMENT REDUCTION REQUIREMENTS. PAYMENT REDUCTION PROVISIONS SHALL APPLY TO THE SURFACE COURSE WHEN THERE IS CONSTRUCTION OF SUFFICIENT LENGTH OF UNIFORM THICKNESS OF THRU TRAVEL LANES. PAYMENT REDUCTION PROVISIONS may APPLY TO AN ENTIRE PROJECT, PORTIONS OF A PROJECT, OR NOT AT ALL.
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404.25 Method of Measurement.
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POLYMERIZED JOINT ADHESIVE WILL BE MEASURED BY THE LINEAR FOOT.
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SEALING OF CRACKS IN HMA SURFACE COURSE WILL BE MEASURED BY THE LINEAR FOOT.
Sawing and sealing joints in HMA overlays will be measured by the linear foot. Sawing joints in base or intermediate course will be measured by the linear foot.
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THE MONTHLY ASPHALT PRICE INDEX WILL BE THE AVERAGE OF QUOTATIONS FROM SUPPLIERS SERVING THE AREA IN WHICH THE PROJECT IS LOCATED. THE ASPHALT PRICE INDEX FOR NORTH AND SOUTH OF ROUTE I-195 WILL BE POSTED EVERY MONTH ON THE DEPARTMENT’S WEB SITE: WWW.STATE.NJ.US/TRANSPORTATION/ENG/CCEPM/PRICEINDEX.SHTM.
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THE BASIC ASPHALT PRICE INDEX WILL BE THE PREVIOUS MONTH’S ASPHALT PRICE INDEX BEFORE RECEIPT OF BIDS.
The last PARAGRAPH IS deleted:
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BDC02s-07 dated june 13, 2002 and BDC02s-18 dated october 24, 2002
SAWING JOINTS IN INTERMEDIATE OR BASE COURSE LINEAR FOOT
CORE SAMPLES, HOT MIX ASPHALT UNIT
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PAY ITEM PAY UNIT
POLYMERIZED JOINT ADHESIVE LINEAR FOOT
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SEALING OF CRACKS AND JOINTS IN HOT MIX ASPHALT SURFACE COURSE LINEAR FOOT
BDC03S-18 DATED DECEMBER 04, 2003
SEPARATE PAYMENT WILL NOT BE MADE FOR MTV, TEST STRIPS, AND QUALITY CONTROL FOR COMPACTION, INCLUDING COMPARISON CORES, AND NUCLEAR DENSITY TESTING. ALL COSTS THEREOF SHALL BE INCLUDED IN THE PRICES BID FOR HOT MIX ASPHALT SURFACE COURSE ___, HOT MIX ASPHALT INTERMEDIATE COURSE ___, AND HOT MIX ASPHALT BASE COURSE ___.
SECTION 405 – CONCRETE SURFACE COURSE
405.08 MIXING CONCRETE.
BDC02s-08 dated february 07, 2003
a.
THIS FIRST SENTENCE IN THE fifteenTH PARAGRAPH IS CHANGED TO:
EACH BATCH SHALL BE MIXED NOT LESS THAN 50 REVOLUTIONS AT THE RATE OF ROTATION DESIGNATED AS MIXING SPEED.
b. Transit Mixing.
THE ninTH PARAGRAPH IS CHANGED TO:
MIXING SHALL BEGIN IMMEDIATELY FOLLOWING THE COMPLETE CHARGING OF THE DRUM AND CONTINUE FOR NOT LESS THAN 50 REVOLUTIONS OF THE DRUM AT THE MIXING SPEED RECOMMENDED BY THE MANUFACTURER OF THE TRUCK MIXER. UPON COMPLETION OF AT LEAST THE MINIMUM NUMBER OF MIXING REVOLUTIONS AT THE PLANT, THE SPEED OF THE DRUM SHALL BE REDUCED TO THE AGITATION SPEED RECOMMENDED BY THE MANUFACTURER.
THE LAST PARAGRAPH IS CHANGED TO:
TRANSIT MIX CONCRETE WILL BE REJECTED FOR ANY OF THE FOLLOWING REASONS:
a. If the concrete is not discharged within the specified time limit after loading all ingredients into the drum;
b. If the indicator on the counter shows that the instrument has been turned off or tampered with;
c. If the non-resettable total revolution counter shows more than 300 revolutions;
d. If water has been added while the truck mixer is en route to the Project. Two-way telephone or radio communication between the site of the placement of concrete and the batching plant shall be provided.
SECTION 406 – superpave HOT MIX ASPHALT courses
406.12 AIR VOIDS ACCEPTANCE PLAN.
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EACH MIXTURE IN A GIVEN LOT SHALL BE COMPACTED SO THAT THE COMBINED PERCENTAGE OF MATERIAL BELOW 2.0 PERCENT AIR VOIDS OR ABOVE 8.0 PERCENT AIR VOIDS SHALL BE NO MORE THAN TEN PERCENT.
the subpart (2) in the fifth paragraph is changed to:
c. COMPUTE QUALITY INDEX.
QL = ([pic]- 2.0)/S and QU = (8.0 - [pic])/S, where “Q” is the quality index.
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THE DESIGNER SHALL DETERMINE THE PAYMENT REDUCTION REQUIREMENTS.
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406.14 Thickness Requirements.
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CONFORMANCE TO THICKNESS REQUIREMENTS WILL BE JUDGED FROM THE FULL DEPTH CORES TAKEN FOR SURFACE COURSE AIR VOIDS DETERMINATIONS EVALUATED ACCORDING TO SECTION 990, NJDOT B-4.
THE third PARAGRAPH IS CHANGED TO:
ACCEPTANCE WILL BE BASED ON TOTAL THICKNESS AND THICKNESS OF THE SURFACE COURSE.
THE FOLLOWING IS ADDED to the end of this subsection:
EVALUATION OF THE SURFACE COURSE WILL BE PERFORMED SOLELY TO DETERMINE WHETHER A REMOVE-AND-REPLACE OR AN OVERLAY CONDITION EXISTS, NOT FOR PAY ADJUSTMENT. TO BE JUDGED ACCEPTABLE, NO MORE THAN 10.0 PERCENT OF THE SURFACE COURSE SHALL BE OF DEFICIENT THICKNESS AS CALCULATED BY THE PROCEDURE BELOW.
Acceptance for surface course thickness will be based on the percentage of the lot estimated to fall below the specified thickness as follows:
f. Compute the sample mean ([pic]) and the standard deviation (S) of the N Test Results (X1, X2,..., XN):
[pic] = X1 + X2 + ... + XN
N
S = [(X1 - [pic])2 + (X2 - [pic])2 + ... + (XN - [pic])2 / (N-1)]½
If for any reason the number of available test results is different from N = 5 for initial testing or N = 10 for retesting, tables for the appropriate sample size are to be used for Step (3).
g. Compute Quality Index.
QL = ([pic] – Tall)/S, where “Q” is the quality index and Tall is the minimum allowable thickness from the following table:
HMA Designation
Nominal Maximum Aggregate Size of Mix Minimum Allowable Compacted Lift Thickness (Tall)
9.5 MM 1.0 Inch
12.5 MM 1.25 Inches
19 MM 2.0 Inches
(3) Compute Percent Defective.
Using Table 914-5 for the appropriate sample size, determine the percentage of defective material (PD) falling below the allowable thickness associated with QL (lower limit).
(4) Retest.
If the initial series of N = 5 tests produces a percent defective value of PD ( 10, the Contractor may elect to take an additional set of N = 5 drilled cores at new random locations, as designated by the Engineer. The additional cores must be taken within 10 Working Days of the receipt of the initial core results. If the additional cores are not taken within the 10 Working Days, the initial core results (N = 5) will be used to determine acceptance. When additional cores are taken, Steps 1, 2, and 3 will be repeated using the combined data set of N = 10 test values to obtain the total PD estimate using Table 914-5.
h. Removal and Replacement.
If the surface course fails to meet the acceptance requirement the Department will require removal and replacement of the lot, or milling and overlaying, at the Contractor’s expense. When either replacement or milling and overlaying are done, the new courses are subject to the same requirements as the initial construction.
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PAY ADJUSTMENTS FOR AIR VOIDS, RIDEABLITY, AND THICKNESS WILL BE MADE ACCORDING TO SUBSECTIONS 406.12, 406.13, AND 406.14, RESPECTIVELY.
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SEPARATE PAYMENT WILL NOT BE MADE FOR MTV, TEST STRIPS, AND QUALITY CONTROL FOR COMPACTION, INCLUDING COMPARISON CORES, SEPARATE PAYMENT WILL NOT BE MADE FOR MTV, TEST STRIPS, AND QUALITY CONTROL FOR COMPACTION, INCLUDING COMPARISON CORES, AND NUCLEAR DENSITY TESTING. ALL COSTS THEREOF SHALL BE INCLUDED IN THE PRICES BID FOR SUPERPAVE HOT MIX ASPHALT __ __ __ SURFACE COURSE, SUPERPAVE HOT MIX ASPHALT __ __ __ INTERMEDIATE COURSE, AND SUPERPAVE HOT MIX ASPHALT __ __ __ BASE COURSE.
dIVISION 500 – BRIDGES AND STRUCTURES
SECTION 501 – CONCRETE STRUCTURES
501.01 DESCRIPTION.
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THIS WORK SHALL ALSO CONSIST OF THE CONSTRUCTION OF PORTLAND CEMENT CONCRETE DECK SLABS, PARAPETS AND SIDEWALKS WITH THE USE OF HIGH PERFORMANCE CONCRETE (HPC).
The second through six Paragraphs are deleted.
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HIGH PERFORMANCE CONCRETE 914.02
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THE EPOXY RESIN SYSTEM THAT IS TO BE USED FOR THE FILLING OF CONCRETE CRACKS BY PRESSURE INJECTION SHALL BE A TWO COMPONENT 100 PERCENT SOLID MOISTURE INSENSITIVE HIGH-MODULUS HIGH-STRENGTH EPOXY RESIN ADHESIVE. THE FOLLOWING PRODUCTS, OR APPROVED EQUAL, MAY BE USED:
1. Sikadur Hi-Mod LV, manufactured by Sika Corporation.
2. Duralcrete, as manufactured by Dural International Corporation.
3. Metaband HMLV, as manufactured by American Metaseal Company.
4. Thermal-Chem Injection Resin Product No. 2, as manufactured by Thermal-Chem, Inc.
5. Concressive 1380, as manufactured by Adhesive Engineering Co. of San Carlos, California.
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IN THE PRODUCTION OF HPC, IN ORDER TO ACHIEVE THE DESIRED RESISTANCE TO CHLORIDE PENETRATION, AN APPROPRIATE POZZALONIC OR OTHER CEMENTITIOUS MATERIAL; SUCH AS, SILICA FUME, FLY ASH OR GROUND GRANULATED BLAST FURNACE SLAG SHALL BE PROVIDED IN THE MIX DESIGN.
Silica fume shall not be used as a sole material to achieve the desired resistance to chlorides. When used, silica fume’s content shall be limited to a maximum of 5 percent of the total cement content and a proportion of fly ash or ground granulated blast furnace slag shall be included to obtain the resistance specified in 914.02 to chloride penetration. The fly ash and ground granulated blast furnace slag limitations specified in 914.02 may be increased in the fabrication of HPC.
The maximum water cement ratio shall be maintained at 0.40. In the fabrication of HPC, the cement content should not be increased for the purpose of achieving high early strength.
The fourth through six Paragraphs are deleted.
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include the following for all projects
7.
the first sentence of the second paragraph is changed to:
THE USE OF PERMANENT STEEL BRIDGE DECK FORMS SHALL CONFORM TO THE FOLLOWING:
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a.
THE seventh PARAGRAPH IS CHANGED TO:
THE SPACING (PITCH) OF THE RIBS (FLUTES) SHALL MATCH THE SPACING OF THE BOTTOM MAIN REINFORCEMENT STEEL, EXCEPT ON CURVED GIRDER STRUCTURES AND IN THE AREAS OF BRIDGE DECKS WITH A FLARED REBAR PATTERN. IN THESE LOCATIONS, THE PITCH OF THE FLUTES MAY BE INDEPENDENT OF THE BOTTOM MAIN REINFORCEMENT SPACING, AND THE FORMS MAY BE DROPPED AS NECESSARY TO ACHIEVE THE MINIMUM 1 INCH CONCRETE COVER BETWEEN THE MAIN REINFORCEMENT STEEL AND THE FORM. WHEN THE FORMS ARE DROPPED, ADDITIONAL DEAD LOAD SHALL BE ACCOUNTED FOR IN THE DESIGN. APPROVAL FROM THE ENGINEER TO DROP THE FORMS SHALL BE OBTAINED BEFORE CONSTRUCTION OF THE DECK BEGINS.
b. Construction.
The following is added at the end of the second paragraph:
JOINTS BETWEEN THE FORMS SHOULD BE LAPPED IN THE DIRECTION OF CONCRETE PLACEMENT.
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IN NO CASE, DURING MIXING AND PLACEMENT, SHALL THE TEMPERATURE OF THE CONCRETE BE LESS THAN 60 OR MORE THAN 90 DEGREES F.
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THE FOLLOWING IS ADDED after THE FIRST PARAGRAPH:
a. GENERAL PROVISIONS. THE FOLLOWING PROVISIONS SHALL BE ADHERED TO IN ALL CONCRETE DECK SLAB CONSTRUCTION.
THE 21 st PARAGRAPH IS CHANGED TO:
WHEN THE CONCRETE PLACING WITHIN ANY COMPLETE UNIT (I.E., FOR TRUSSES, ARCHES, CONTINUOUS OR CANTILEVERED UNIT) IS TO BE DIVIDED, THE PLACING SHALL BE MADE AND FINISHED IN THE NUMBERED SEQUENCE SHOWN, BEGINNING WITH THE LOWEST NUMBER. ALL SECTIONS HAVING THE SAME NUMBER SHALL BE PLACED BEFORE SECTIONS OF HIGHER NUMBER. THE SEQUENCE OF PLACING FOR SECTIONS HAVING THE SAME NUMBER SHALL BE OPTIONAL. NO DECK SECTION SHALL BE PLACED UNTIL ALL PREVIOUSLY PLACED CONCRETE WITHIN THE COMPLETE UNIT HAS CURED FOR 72 HOURS. THIS REQUIREMENT MAY BE WAIVED IF THE SUCCEEDING SECTION(S) CAN BE COMPLETED WITHIN FOUR HOURS AFTER THE START OF THE INITIAL PLACEMENT OF SECTION(S) OF ANY GIVEN UNIT FOR THAT DAY. A WRITTEN REQUEST TO WAIVE THIS REQUIREMENT SHALL BE SUBMITTED TO THE ENGINEER FOR APPROVAL. THIS REQUIREMENT MAY NOT BE WAIVED FOR DECK SLABS ON PRESTRESSED CONCRETE BEAMS THAT ARE CONTINUOUS FOR LIVE LOAD. THE NUMBERED SEQUENCE SHOWN ON THE PLANS SHALL BE ADHERED TO
The following is added:
B. HIGH PERFORMANCE CONCRETE (HPC) FOR DECK SLABS, SIDEWALKS, AND CONCRETE BASE FOR RAILINGS. HPC IS DEFINED AS CONCRETE THAT MEETS SPECIAL PERFORMANCE AND UNIFORMITY REQUIREMENTS THAT CANNOT ALWAYS BE OBTAINED BY USING CONVENTIONAL INGREDIENTS, NORMAL MIXING PROCEDURES AND TYPICAL CURING PRACTICES. THE FURNISHING OF HPC SHALL CONFORM TO THE REQUIREMENTS OF 914.02.
(1) The Contractor is advised that curing of the HPC deck slab shall be performed in accordance with the provisions of Subsection 501.17. Upon completion of the 14 day wet curing period, the HPC deck slab shall be further cured according to the provisions of Subsection 405.14, Subpart 1.
(2) The finishing machine equipment shall be set up so that the HPC is placed only 6 to 8 feet ahead of the machine.
15. Pumped Concrete.
The following is added:
AS PER THE PROVISIONS OF 914.04, FRESH MIXED CONCRETE SHALL BE SAMPLED ACCORDING TO THE REQUIREMENTS OF AASHTO T 141. SAMPLES SHALL BE TAKEN AT THE DISCHARGE OF THE CONCRETE PUMP. IF THE ENGINEER BELIEVES THAT THIS IS NOT A FEASIBLE, THE PUMP SHALL BE CALIBRATED TO CALCULATE SLUMP AND AIR ENTRAINMENT LOSSES. THESE LOSSES SHALL BE DEDUCTED FROM THE VALUES AS SAMPLED FROM THE CONCRETE TRUCK.
17. Slip-form Method of Parapet Construction.
18. Corrosion Inhibitor Admixture.
19. Pressure Injection.
20. Pressure Injection.
THE FOLLOWING IS ADDED:
21. Repair of Concrete. Repairs of concrete are classified according to the following types:
a. Type D Repairs. Type D repairs shall consist of removing all loose and disintegrated concrete and existing repair materials to expose sound concrete and extending the removal into the sound concrete for a depth of not less than 1/4 inch and not more than 1 inch and placing of Class B concrete to the level of the adjacent existing concrete surface.
b. Type E Repairs. Type E repairs shall consist of removing all deteriorated concrete and existing repair materials to a minimum depth of 1 inch below the existing reinforcing bars to sound concrete and extending the removal into the sound concrete for a depth of not less than 1/4 inch and not more than 1 inch and placing of Class B concrete to the level of the existing concrete surface.
22. Repairs of concrete shall conform to the following:
a. Preparation. The limits of all repairs shall be as determined by the engineer in a survey prior to construction. The plan quantities may be changed, increased, or decreased due to this final survey or as directed by the engineer during the construction.
b. Construction Procedures.
Repair areas shall be saw cut to a 3/4 inch depth in a rectangular shape prior to the removal of deteriorated concrete in the designated areas.
Temporary shielding shall be provided during removal and repair work (including but not limited to Type D and Type E substructure repairs) to be performed above the waterway to contain debris falling from the Contractor’s operations.
All loose and disintegrated concrete and existing repair materials shall be removed from the areas to be repaired in such a manner and to such an extent as to expose sound concrete. Sound concrete (beneath the disintegrated concrete) shall be removed for a depth of not less than 1/4 inch and not more than 1 inch, and the remainder of the area and all exposed reinforcement shall be cleaned and roughened by sandblasting. The work shall be done in such a manner as not to damage the concrete that is to remain.
Only pneumatic or hand tools shall be used in the removal of the disintegrated concrete and in preparing and shaping the areas to be repaired. The size of the hammers shall not exceed 30 pounds.
Hand chipping methods shall be used to remove concrete adjacent to exposed reinforcing steel. Care shall be taken so as not to damage or debond the reinforcement steel, or shatter the concrete beyond the area to be repaired.
For Type D repair, where the bond between existing concrete and reinforcement steel has been destroyed, or where more than half the diameter of the steel is exposed, the concrete adjacent to the bar shall be removed to a depth in accordance with a Type E repair. A minimum of 1 inch clearance around the bar will be required, except where adjacent bar mats make this impractical.
For Type E repair all corroded reinforcing bars shall be cleaned by sandblasting, water blasting, or wire brushing. Where the existing reinforcing bars are replaced due to section loss (25 percent or more loss to the original cross-sectional area) or damage, or where they are connected with new reinforcing bars, the splicing methods described in Subsection 501.08 shall be used.
Wherever necessary, forms shall be used to enable placement of concrete or quick-setting patch materials, and to match the repaired surface with the existing concrete surface.
If underwater patch materials are used for repairs, all operations shall conform to the manufacturer’s recommendations.
Two copies of the manufacturer’s technical data sheets shall be submitted at least 10 working days prior to the work.
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THE SURFACE OF THE DECK SLAB SHALL BE FINISHED ACCORDING TO SUBSECTION 405.13 EXCEPT THAT SUBPART G SHALL NOT APPLY. THE TIME BETWEEN STRIKE-OFF AND APPLICATION OF DECK SLAB SURFACE TEXTURE FINISH IN ANY LOCATION SHALL NOT EXCEED ONE HOUR. ALL CONCRETE BRIDGE DECK SLABS SHALL BE TEXTURED WITH A STIFF, COARSE BROOM AND SHALL BE SAW CUT GROOVE FINISHED AS FOLLOWS:
1. Broom Finish. Immediately after finishing has been completed, the surface shall be given a texture with an approved stiff, coarse broom.
The broom shall be operated in a longitudinal or transverse direction. Once begun, the direction of texturing shall not be changed. Transverse texturing shall be done from a work bridge.
The broom finish shall be applied so as to prevent ridges or gouges from forming in the concrete surface. The broom shall be weighted and the contact area changed as required to produce a uniform texture. The broom shall be cleaned periodically to remove all hardened concrete particles. Texture resulting from the broom shall stop within 1 foot of curbs.
3. Saw Cut Grooved Surface.
The second paragraph is deleted.
THE THIRD PARAGRAPH OF SUBPART 3 IS CHANGED TO THE FOLLOWING:
Grooves shall be cut perpendicular or radial to the centerline of the traveled way. Radial grooving shall be conducted in partial-width passes. Each pass shall be limited to one lane width. Adjustment along the longitudinal axis of the bridge deck shall be made at no less than 12-foot intervals, yielding a uniformly grooved surface finish. Grooves shall be rectangular in shape and shall conform to the following dimensions:
Approach Spans – Width 0.10 to 0.15 inch
Approach Spans – Depth ¼ to 3/8 inch
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B.
This Subpart is changed
DECK SLAB SURFACES SHALL BE CHECKED DURING PLACEMENT TO CORRECT SURFACE IRREGULARITIES WHILE THE CONCRETE IS IN WORKABLE CONDITION.
Such control testing shall be performed as follows:
1. After strike-off, the deck surface shall be checked with an aluminum straightedge having a minimum length of 10 feet, as provided by the Contractor. The Resident Engineer shall determine the specific conduct of the control testing, including the number and location of Straightedge checks. Surface variations shall be corrected before the concrete sets. Major deviations shall be corrected by the finishing machine or other strike-off, while minor deviations may be corrected by a straightedge or float. The addition of water to the surface of the concrete to assist in finishing operations will not be permitted.
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C. ACCEPTANCE TESTING. CONFORMANCE TO THE SURFACE TOLERANCE FOR CONCRETE DECK SLABS WILL BE DETERMINED IN LOTS, EACH BEING EQUAL TO THE LENGTH OF DECK IN ONE SPAN OR CONTINUOUS SPAN. THE LONGITUDINAL LIMITS OF THE LOT WILL BE BOUNDED BY THE EXPANSION JOINTS OR FIXED STRUCTURAL DECK JOINTS. THE FULL LENGTH OF THE LOT WILL BE TESTED THROUGH ANY CONSTRUCTION JOINTS WITHIN THE DECK, WHETHER THESE JOINTS ARE REQUIRED FOR THE PLACEMENT SEQUENCE OR CAUSED BY THE CONTRACTOR’S OPERATIONS. SUCH LOT QUANTITY WILL BE CALCULATED USING THE SPECIFIED NOMINAL DECK THICKNESS AND EXCLUDES THE QUANTITY OF CONCRETE PLACED IN HAUNCHES, END DAMS, AND DIAPHRAGMS. FOR THE SECOND COURSE OF THE TWO-COURSE DECK SLAB CONSTRUCTION, SUCH LOT QUANTITY WILL BE CALCULATED USING THE SPECIFIED NOMINAL THICKNESS OF THE CONCRETE OVERLAY PROTECTIVE SYSTEM.
501.17 Curing and Protecting Concrete.
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c.
this subpart is CHANGED TO:
CONCRETE DECKS, CURBS, AND TOPS OF SIDEWALKS FOR ONE-COURSE DECK SLAB CONSTRUCTION SHALL BE CURED ACCORDING TO SUBHEADING 4 OF SUBSECTION 405.14 WITH THE EXCEPTION THAT THE MINIMUM WET CURE PERIOD SHALL NOT BE LESS THAN FOURTEEN CALENDAR DAYS. THE BURLAP SHALL BE KEPT CONTINUOUSLY WET THROUGHOUT THIS CURING PERIOD. ACCORDING TO THE PROVISIONS OF SUBHEADING 3 OF SUBSECTION 405.14, THE WET BURLAP SHALL BE COVERED WITH WHITE POLYETHYLENE SHEETING FOR THE FOURTEEN-DAY DURATION. THE POLYETHYLENE SHEETING SHALL BE LAPPED AT THE JOINTS AND SECURED TO THE DECK AS TIGHTLY AS POSSIBLE
The time between final finishing and application of the wet burlap shall not exceed 20 minutes in any location within the placement area.
Other concrete structures and concrete surfaces to receive an epoxy coating, rubbed finish or to be covered with another material shall be cured according to Subheadings 2, 3, 4, and 5 of the sixth paragraph of Subsection 405.14.
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THE FOLLOWING IS ADDED:
Concrete repairs of the various types will be measured by the square foot along the face of the finished surface. For Type D and E repairs where the same spall is located on two adjacent intersecting faces, the area of repair will be measured for payment only on the face that has the largest area, and no payment will be made for the other face.
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d.
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PAY ITEM PAY UNIT
SAWCUT GROOVED DECK SURFACE SQUARE FOOT
THE FOLLOWING PAY ITEMS ARE ADDED:
CONCRETE IN SUPERSTRUCTURE, DECK SLABS, HPC CUBIC YARD
CONCRETE IN SUPERSTRUCTURE, SIDEWALKS, HPC CUBIC YARD
CONCRETE IN SUPERSTRUCTURE, PARAPETS, HPC LINEAR FOOT
CONCRETE REPAIRS, TYPE D SQUARE FOOT
CONCRETE REPAIRS, TYPE E SQUARE FOOT
THE 20TH PAY ITEM “REINFORCED CONCRETE BOX CULVERT, PRECAST” IS DELETED.
THE FOLLOWING IS ADDED:
IN THE CONSTRUCTION OF DECK JOINT SYSTEMS, NO SEPARATE PAYMENT WILL BE MADE FOR SUPPLYING AND INSTALLATION OF STEEL ARMORING THAT IS TO BE PLACED ON THE ROADWAY SIDE OF THE HEADER. SUCH COST SHALL BE INCLUDED IN THE BID PRICE FOR THE PAY ITEM “CONCRETE IN SUBSTRUCTURES, ABUTMENT WALLS”.
The Pay Item “Concrete in Superstructure, Sidewalks, HPC” will include payment for use of HPC for sidewalks and concrete bridge railing supports.
The quantities for Concrete Repairs, Type D and Type E are estimated and based on a limited visual field inspection, and may differ in the field than estimated herein. Additional quantities to these items or a reduction to these items may occur, if and where directed by the engineer. The price bid for these items shall include all materials and labor necessary to complete the work.
At concrete repair areas outlined as either Type D or Type E on the construction plans or at locations designated, final payment for each outlined area will be made for only one of the repair types determined by the final depth as measured in the field and in accordance with the construction details regardless of original designation or preparatory work for another repair type.
No separate payment will be made for the reinforcement steel, reinforcement steel couplers, coring and grouting, temporary shielding and forms. The cost thereof will be included under the appropriate concrete repair pay item.
No separate payment will be made for saw cutting, removal of concrete to sound concrete as necessary for repair, any necessary reinforcement steel to supplement or replace existing deteriorated reinforcement steel, drilling and epoxy grouting holes for new reinforcement, concrete or quick-setting patch materials for repair, or methods to protect the existing waterway from falling debris, materials, or equipment, the cost thereof shall be included in appropriate concrete repair pay item.
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503.01 DESCRIPTION.
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This work shall consist of the furnishing, fabrication, erection, painting, and metalizing of bridges, structures, furnishing of Structural Bearings and associated elements that include use of structural steel and miscellaneous metals.
THE FOLLOWING IS ADDED:
The rehabilitation of Structure #1506-152, Route 35 over the Manasquan River Bridge will include the following structural steel work as indicated on the plans:
Furnishing, fabrication, erection, and painting of repair plates, structural shapes, repair angles in the approach span end floorbeams, replacing lateral bracing gusset plates, strengthening struts, strengthening transverse box member, shimming live load bearings, replacing pinion bearing stiffeners, repairing anchor span girder stiffeners, replacement of all stringers in the bascule span (Span 6 from the North) and addition of new stringers in all the approach and flanking spans (Spans 1 to 5 and 7 to 9) including the spans over the counterweight, installation of shear studs on all existing stringers and floorbeams and new stringers or channel sections for shear transfer (on interior floorbeams), installation of steel rails and steel supports at deck joints and resetting the rocker bearings at Piers 1S and 2S, modification of existing structural steel supports to the existing water and sewer lines on the east side in Spans 7, 8, and 9 for reuse of existing metallic hood, steel supports for lighting standard at the southeast wingwall, and new platform framing for barrier gates and warning gates, as identified on the plans.
Removal of existing deteriorated rivets and installation of high strength bolts, in the bascule and approach spans.
Temporary supports under the new platforms for barrier gates and warning gates.
Girder Jacking (temporary jacking structures for rocker bearing resetting, at locations as identified on the plans).
Installation of bascule span and approach span railing.
Installation of steel median in the bascule span.
Installation of steel grid deck in bascule span.
This work shall be performed within specific construction stages as shown on the Contract Plans. This work shall include, drilling of holes, bolting, welding, forms, structural shapes, plates or material necessary to complete the work as shown on the Contract Plans and specified herein. This work shall also include, but not limited to, shear connectors, lightweight concrete fill in stringer lines as specified in Section 523, survey of the existing bascule span and miscellaneous attachments to the stringers.
The bascule span shall be maintained in an operable condition during construction. The span balance shall be maintained during the grid deck replacement and shall be coordinated with Section 527.
The work shall be performed in accordance with the current AASHTO’s LRFD Bridge Design Specifications and subsequent Interim Specifications; and as modified by the Contract documents.
This work shall be performed within specific stages in accordance to the Contract documents. The Contractor shall prepare a detailed Working Schedule for the removal and installation of the grid decks. The Schedule shall include all anticipated tasks and the duration required for the specific tasks for this work. The Schedule shall be detailed with the labor crew sizes, equipment requirements, and materials necessary to complete the work within scheduled time period. The Schedule shall be coordinated with the working drawings. The Contractor shall monitor the proposed schedule during the actual work and adjust the future work activities to complete the work within the time constraints.
This work shall also consist of installing of new steel grid flooring, and structural steel rolled beams, plates and shapes as detailed on the plans, including temporary supports designed and detailed for loads as shown in the plans, and temporary railing systems around the platforms, for supports for the new barrier gates and warning gates at locations as indicated on the plans. This work shall be performed in Pre- Stage I of the construction stages, as shown on the Contract Plans. This work shall include, drilling of holes, bolting, welding, forms, concrete fill within the grating under the barrier gates and warning gates housing for pedestals, at locations within the platform, plates or material necessary to complete the work as shown on the Contract Plans and specified herein.
Working drawings shall be prepared by the Contractor for the Engineer’s review and approval. The working drawings shall provide complete details and procedures to complete the assembly and the installation of the grid deck and stringers on the bascule span. Details and procedures shall include, but not be limited to, anticipated work crew and equipment, temporary devices, equipment placement and safety platforms. The working drawings shall be coordinated with the detailed working schedule.
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A. Materials
THE FOLLOWING IS ADDED:
Vertical sheet metal form pans installed in the grid prior to galvanizing shall conform to the latest specification for ASTM A1008 or A1011.
Use galvanized steel, sheet metal conforming to ASTM A653 for the forms.
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F. Steel Grid Flooring for Bascule Span Deck
Steel grid flooring shall conform to AASHTO Standard Specifications for Highway Bridges, Division II, Section 12 except as modified by these Supplemental Specifications. The grid flooring shall conform to the requirements of ASTM A709 Grade 50. The steel grid flooring shall consist of main rolled bars, secondary cross bars and supplemental bars. The main bar shall be 5-3/16 inch deep and spaced at 4 inch centers between main bars. The secondary cross bars shall intersect and be perpendicular to the main bars, spaced at 4 inch centers between secondary cross bars. A single supplemental bar shall be parallel and evenly spaced between the main bars. Serrations shall be provided on the tops of the bars approximately 3/16 inch deep x 3/8 inch wide, spaced randomly. The open grid deck shall have edge bars as detailed on the Contract Plans. A 20 gauge pan shall be provided as the form for the concrete fill at the stringer lines. The steel weight of this grid deck shall be approximately 24 pounds per square foot.
The individual supplemental bars, cross bars and main bars of grid deck panels shall be welded at all intersections. The size and type of welds shall be as shown on the Contract Plans. Welding shall conform to the requirements of ANSI/AASHTO/AWS Bridge Welding Code D1.5 and subsequent AASHTO Interim Specifications. A welding procedure specification shall be submitted for all welds.
Steel grid deck shall be painted in accordance with Section 503.15 of the Standard Specifications except as modified herein. A complete coating system of an inorganic zinc-rich primer, a high-build epoxy intermediate coat, and a urethane finish coat shall be selected from one of the approved coating systems under Section 912 of the Standard Specifications. Surfaces of steel that will be in contact with concrete shall be given a prime coat of zinc-rich primer only.
Automatic end-welded studs shall be used as shear connectors as shown on the Contract Plans. They shall conform to Section 7 of the ANSI/AASHTO/AWS D1.5 Bridge Welding Code.
Automatic end-welded studs shall be used as shear connectors as shown on the Contract Plans. They shall conform to Section 7 of the ANSI/AASHTO/AWS D1.5 Bridge Welding Code.
Unless otherwise modified by the Supplemental Specifications, Portland cement concrete, mortar, and grout for bascule span steel grating shall conform to Section 914 of the Standard Specifications. Other materials shall conform to the following Subsections of the Standard Specifications:
Air-Entraining Admixtures 905.01
Corrosion Inhibitor Admixtures 905.02
Chemical Admixtures 905.02
Curing Materials 905.03
Reinforcement Steel for Structures 915.01
Bolts and Bolting Materials 917.01
Permanent Steel Bridge Deck Forms 917.04
Structural Steel 917.10
Cement for the high early strength lightweight concrete shall be rapid set cement manufactured by CTS Manufacturing Company, Cypress, CA or approved equal. Materials shall be of recent manufacture (within one year) and uniform in composition and consistency.
Lightweight coarse aggregate shall comply with the requirements of the Standard Specifications Subsection 901.12, Subpart (E) except as modified herein. Aggregate shall be in the 3/8” to 3/32” size designation in Table 1 of ASTM C330. A durability report shall be available showing that concrete made from the aggregate has a minimum durability factor of 90% when tested in accordance with the latest edition of ASTM C33. Natural or manufactured sand shall conform to ASTM C33.
In the event that the scheduled concrete placement date may produce ambient conditions where it is desirable to control the concrete reactionary properties, or control of the concrete reactionary properties is otherwise warranted, the Contractor may add chemical admixtures, subject to the approval of the Engineer, as an integral part of the design mix. The use of the chemical admixtures shall conform to the requirements of Subsection 905.02 of the Standard Specifications. Additionally, chemical admixtures shall be used according to the manufacturer’s product specifications. According to the requirements of the Standard Specifications Subpart B of Subsection 914.02, to facilitate verification of the concrete mix, mix designs that incorporate the chemical admixture shall be submitted for approval. The admixture quantity used shall be a dosage rate according to the manufacturer’s product specificationsMaterials and construction operations not specifically covered in the Plans and in these Specifications shall be in accordance with Division II in the current AASHTO Standard Specifications for Highway Bridges.
G. Steel Grid Flooring for Barrier and Warning Gate Supports.
Steel grid flooring shall conform to AASHTO Standard Specifications for Highway Bridges, Division II, Section 12 except as modified by these Supplemental Specifications. The grid flooring shall conform to the requirements of ASTM A709 Grade 36. The steel grid flooring shall consist of main bearing bars, and secondary cross rods. The main bearing bars shall be 2-¼ inch deep by ¼ inch thick and spaced at 2-3/8 inch centers between the main bars. The secondary cross rods shall intersect and be perpendicular to the main bars, spaced at 2 inch centers between the secondary cross rods. Serrations shall be provided on top of the bars approximately 3/16 inch deep x 3/8 inch wide, spaced per Manufacturer’s specifications. The open grid deck shall have edge bars as detailed on the Contract Plans. A 20 gauge pan shall be provided as the form for the concrete fill within limits as indicated on the contract plans. The steel weight of this grid deck shall be approximately 12 pounds per square foot. The section modulus per linear of width for grid deck shall be a minimum of 1.07 in3.
The individual cross rods and main bearing bars of grid deck panels shall be welded at all intersections. The size and type of welds shall be as shown on the Working Drawings. Welding shall conform to the requirements of ANSI/AASHTO/AWS Bridge Welding Code D1.5 and subsequent AASHTO Interim Specifications.
Steel grid deck shall be painted in accordance with Section 503.15 of the Standard Specifications except as modified herein. A complete coating system of an inorganic zinc-rich primer, a high-build epoxy intermediate coat, and a urethane finish coat shall be selected from one of the approved coating systems under Section 912 of the Standard Specifications. Surfaces of steel that will be in contact with concrete shall be given a prime coat of zinc-rich primer only.
Materials and construction operations not specifically covered in the Plans and in these Specifications shall be in accordance with Division II in the current AASHTO Standard Specifications for Highway Bridges.
Inspection and testing shall conform to Section 6 of the ANSI/AASHTO/AWS D1.5 Bridge Welding Code as modified by Subsection 503.03 of the Standard Specifications.
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1. STEEL BRIDGE BEARINGS ARE CONSIDERED TO BE MAIN LOAD CARRYING MEMBERS.
The subpart 2 a is changed to:
2. A. SIMPLE STEEL BRIDGE STRUCTURES (SBR): INCLUDES HIGHWAY SIGN SUPPORT STRUCTURES, PARTS FOR BRIDGES (SUCH AS CROSS FRAMES), UNSPLICED ROLLED STEEL BRIDGES, STEEL BRIDGE BEARINGS AND HLMR BEARING ASSEMBLIES.
The subpart 4 c is changed to:
4. c. Fracture Control Plan. Steel bridge members or member components designated as Fracture Critical Members (FCM’s) shall conform to the provisions of the most current edition of the AASHTO/AWS D1.5 Bridge Welding Code, Section 12 “AASHTO/AWS Fracture Control Plan (FCP) for Non-Redundant Members”.
503.04 Working Drawings.
THE FOLLOWING SUBSECTIONS ARE ADDED:
D. Girder Jacking for resetting rocker bearings.
Girder Jacking – The work associated with this pay item consists of providing temporary supports for jacking the bridge spans, as designated on the plans, to remove the existing bearings and reset them to the correct position, consistent with the ambient temperatures. Loads and design criteria for temporary supports are shown on the plans. Temporary jacking support structures and design calculations/details and procedures shall be submitted for review and approval of the Engineer, prior to the start of construction for this item.
E. Temporary Supports, Barrier Gate, and Warning Gate Platforms. Temporary support details and design calculations/details and procedures shall be submitted for review and approval prior to start of construction for this item. Contractor’s calculations shall clearly identify the Dead Loading and Live Loading that the temporary system is being designed for, including any small construction loads that may be temporarily imposed on the existing sidewalk, with prior approval of the Engineer. Due regard to temporary and permanent loads as shown on the plans shall be considered and appropriate measures to ensure the same are incorporated into temporary support design.
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The following is added to the first listed Item 2.:
THE WRITTEN PLAN SHALL BE SIGNED BY A PROFESSIONAL ENGINEER LICENSED IN THE STATE OF NEW JERSEY. THE CONTRACTOR’S PROFESSIONAL ENGINEER AND THE STATE’S DESIGN ENGINEER SHALL ATTEND THE MEETING.
The following is added to the first list:
4. THE CONTRACTOR’S PROFESSIONAL ENGINEER SHALL INSPECT EACH PHASE OF GIRDER INSTALLATION PRIOR TO PERMITTING VEHICULAR OR PEDESTRIAN TRAFFIC ON OR BELOW THE BRIDGE.
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C. Setting Bearings:
THE ENTIRE SECTION IS DELETED AND REPLACED WITH THE FOLLOWING:
Where indicated on the plans at Piers 1S and 2S, all the existing rocker bearings shall be reset to be theoretically vertical at 70 degrees Fahrenheit, by removing the pins, rocker and masonry plates (the sole plate or top casting is riveted to the girder bottom flange), relocating the masonry plate to it’s new, corrected position, as well as the existing rocker to it’s new correct position to obtain a vertical alignment at 70 degrees.
Within one month of award of the contract, the Contractor shall field measure the existing bearings at Piers 1S and 2S, for their existing potion, at the ambient temperature. The extent of leaning of the rockers, as measured from the vertical, the direction of leaning (whether contracted or expanded) and the temperature adjacent to each rocker, weather conditions, time and date of measurements shall be recorded and submitted to the Engineer. For any installation temperature other than 70 degrees, the position of the rockers shall be corrected to predict the vertical position at 70 degrees, considering superstructure expansion/contraction rates for ambient temperatures. A sketch shall be shown on the erection drawings prepared by the Contractor indicating proper inclination for setting the bearings at various temperatures, at 10 degree intervals, from –30 degrees Fahrenheit to 110 degrees Fahrenheit.
The Contract Plans require verification of the actual position for the bearings to be reset. The Contractor shall compare predicted offset at 70 degrees from his measurement with the contract plan data for correlation of offsets to be used for bearing alignment correction.
All calculations and data shall be submitted to the Engineer for approval. The Contractor shall clearly mark on his working drawings, the distance from the edge of the pier to the centerline of the relocated masonry plate and positions of new anchor bolt sleeves.
During construction, the existing masonry plates, rockers, pins, and sole plates (if directed by the Engineer) shall be removed without damaging the girder flanges or any of the bearing components, end floorbeams, connection plates, bracing members, or their connections. Existing bearings may be removed by following the suggested procedure on the plans. If the Contractor suggests an alternative method, subject to all the limitations and conditions stipulated on the plans, detailed calculations, removal procedures and drawings, all sealed and signed by a NJ Licensed Professional Engineer , shall be submitted for the engineers approval before nay changes may be accepted.
The Contractor shall be responsible for ALL costs involved in bearing removal and resetting, whether he follows the suggested resetting procedures or his approved alternate, irrespective of any and all work steps required to complete the resetting, to the Engineer’s approval.
Suggested procedure, which is based on jacking when the deck is off within the Staged construction:
1) Jack the girder (outside ones only for Construction Stage II or III) and both interior girders (for Construction Stage I). Jack the two interior girders simultaneously. Secure the structure as indicated on the plans. Install structural grade timber shoring, in addition to the jacks. Details of timber shoring to be included in the working drawings for approval of the Engineer.
2) Remove the pier concrete to the limits shown on the Jacking Plans.
3) Cut the existing anchor bolts within the exposed portion of the concrete.
4) Temporarily secure the rocker assembly to the girder or otherwise support off of the pier top (in either case, working drawings shall provide method of temporary support), remove the masonry plate, remove the rocker assembly and remove the pin.
5) At all bearing resetting locations, the concrete that is removed to facilitate rocker removal shall be reconstructed with HPC concrete. If any existing rebars are damaged, supplemental rebars shall be installed to match existing rebars, as directed by the Engineer.
Following the removal of the existing bearing assembly, the inside surface of the sole plate, upon which the pin bears shall be closely examined by the Engineer. If directed by the Engineer, the sole plate shall be removed by removing the rivets connecting it to the bottom flange and the inside surface shall be finished to meet ANSI surface roughness requirements as defined in ANSI B46.1, Surface Roughness, Waviness and Lay, Part 1 (For Pins, ANSI 125). To account for this potential event, the Contractor shall submit his procedure and equipment proposed to meet the required surface finish to the Engineer for approval prior to the start of the work.
Following, anchor bolt replacement and pier top reconstruction, and the masonry plate and rocker relocation/resetting, the sole plate shall be connected to the girder bottom flange using HS bolts. The bearing components should have been cleaned, lubricated, and primed prior to reinstallation and should receive a full paint system as per Section 514.
The Contractor has the option of proposing a different method of removal and resetting the bearings, provided ALL of the criteria and restrictions stated on the plans are strictly adhered with. In case of any proposed changes, the Contractor shall submit his proposed procedure (Design, calculations, sketches and drawings), sealed and signed by a NJ professional Engineer for the Engineer’s approval, prior to beginning any of this work.
Structural Bearings
The first sentence is changed to:
THIS WORK SHALL CONSIST OF FURNISHING AND INSTALLING STRUCTURAL BEARING ASSEMBLIES THAT ARE ONE OR MORE OF THE FOLLOWING TYPES: HIGH LOAD MULTI-ROTATIONAL (HLMR) BEARINGS AS DEFINED IN 503.02 OR SEISMIC ISOLATION BEARINGS. AS PER THE REQUIREMENTS OF 105.04, WORKING DRAWINGS, FOR THE COMPLETE DESIGN OF SUCH STRUCTURAL BEARING ASSEMBLIES, SHALL BE SUBMITTED. THE DESIGNS SHALL CONFORM TO THE PROVISIONS OF THE AASHTO LRFD BRIDGE DESIGN SPECIFICATIONS AND/OR THE AASHTO LRFD BRIDGE CONSTRUCTION SPECIFICATIONS AND THESE SPECIFICATIONS.
503.09 High-Strength Bolts.
THE FOLLOWING IS ADDED AFTER THE FIRST PARAGRAPH:
Where bolts are to be installed in existing rivet holes, the existing rivets shall be removed using suitable pneumatic rivet chippers so as not to damage or enlarge the holes or cause harm to the adjacent steel. If necessary, rivets shall be drilled out. Flame cutting shall not be used to remove rivet heads or rivets.
New bolt holes are to be drilled. Burning of bolt holes is strictly prohibited. Upon drilling of a bolt hole or removal of a rivet or bolt, the base metal around the hole shall be examined for surface irregularities and deterioration. All oxidized material, nicks, burrs, steel peaks, and cusps that would interfere with the setting of bolt heads, nuts, and washers shall be removed. Where irregularities to the surface of the hole prevent normal alignment or insertion of the bolt without damage to the threads, the hole shall be reamed as required to facilitate proper installation. Washers or larger diameter High Strength bolts shall then be used to provide, as a minimum, the strength of an ASTM A325 bolt of the diameter used in the repair.
Any damage to the structure during rivet or bolt removal operations shall be immediately repaired to the satisfaction of the Engineer prior to the installation of any bolts at no cost to the State.
If reaming produces an oblong hole in any material, the largest diameter of which is more than 3/16 inch larger than the diameter of the removed rivet, increase the diameter of the new bolt by one size and ream the hole to fit the larger bolt.
Remove only one rivet at a time from any one member and replace it with a high strength bolt, unless otherwise specified on the plans or authorized by the Engineer. The replacement bolts shall be properly tensioned prior to the removal of a subsequent rivet.
For rivet replacement, rivets shall be removed and replaced one at a time. In areas where groups of rivets require replacement, the replacement shall be performed in a uniform pattern, so that the center of gravity of the rivet group will be maintained. Rivets shall be replaced using a method that ensures the stability of the superstructure and provides adequate strength for the self weight and imposed loads.
A. Rivet Replacement Criteria. The Contractor shall visually inspect with the Engineer all rivets from within arm’s reach. Hammer testing for loose rivets shall be performed on those rivets that do not appear to bear flush with the steel surface and on a minimum of 10% of all rivets. Prior to the visual inspection of the bridge, the structural steel shall be clean of all dirt, debris and any rust from the rivets in the area to be inspected. The Contractor shall replace all rivets identified by the Engineer based on the following criteria:
1. All missing rivets.
2. All sheared or broken rivets.
3. All loose rivets. A rivet is loose if it can be felt to move when struck with a hammer on the side of the head in a direction approximately perpendicular to its longitudinal axis. Rivets shall be replaced if any vibration is felt from the hammer test.
4. All headless rivets or those with rosette heads.
5. All rivets when either head exhibits loss of metal equal to or exceeding 50% of the original head by volume.
6. All rivets if either head has corroded to the point of loosing 50% or more of its lip or projection beyond the shank.
In addition to the shipping requirements noted in Subsection 917.01 and the manufacturer’s recommendations, the following shall be adhered to:
Bolts shall be protected from dirt and moisture at the job site. Only as many bolts as anticipated to be installed and tightened during a work shift shall be taken from protected storage. Bolts not used shall be returned to protected storage at the end of the shift. Bolts shall not be cleaned of lubricant that is present in as-delivered condition. This lubricant condition on the bolts cannot to be modified, that is: never clean, strip or add additional lubrication to the product.
Methods and procedures of inspection and testing shall conform to Subsection 917.01. Deviations from the Standard Specifications to conform to manufacturer’s specifications, where different, will not be permitted without approval of the Engineer.
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THIS SUBSECTION IS CHANGED TO:
503.15 Cleaning, Painting, and Metalizing of Structural Steel.
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REPLACE THE SECOND PARAGRAPH WITH THE FOLLOWING:
A complete coating system of an organic zinc primer, a high-build epoxy intermediate coat, an intermediate stripe coat, and a urethane finish coat shall be selected from one of the approved coating systems under Subsection 912.15. All new and/or replacement structural steel members or shapes that will be installed during the project shall, at a minimum, be cleaned and primed in the shop.
New and replacement steel to be shop metalized includes, but is not limited to, replacement roadway stringers, replacement gusset plates, lateral bracing members, and repair plates/steel shapes in the bascule span. Metalizing in the shop shall be performed as defined in Section 514.
All shop metalizing shall be performed in an enclosure which provides the required atmospheric conditions and shall prevent any exposure to inclement weather prior to the coating being completely cured.
New and replacement steel to be shop painted includes, but is not limited to, replacement roadway stringers and repair plates/steel shapes, new diaphragms, platform framing for barrier and warning gates, and steel median barrier.
The new 4 bar steel bridge railings and base plates, and steel median barrier on the bascule span and connection plates, shall be treated with hot dip galvanizing and an organic paint system as specified in Subpart D of this section.
4.. Paint Application.
THE FOLLOWING IS ADDED AFTER THE FIRST SENTENCE OF PARAGRAPH F :
SURFACES OF STEEL THAT WILL BE EMBEDDED IN CONCRETE SHALL BE GIVEN A PRIME COAT OF PAINT ONLY.
5. Number of Coats and Film Thickness.
THE FIRST TWO PARAGRAPHS ARE CHANGED TO:
A minimum of three coats plus one brush-applied stripe coat shall be applied by either of the following methods:
a. prime, intermediate stripe coat, intermediate, and finish in shop; or
b. prime in shop, intermediate stripe coat, intermediate, and finish in field.
The dry film thickness of the paint at any point shall be within the following ranges:
For the prime coat 2.5 to 4 mils
For the intermediate stripe coat visual coverage
For the intermediate coat 3.5 to 5 mils
For the finish coat 2 to 3 mils
For the three-coat system 8 to 12 mils
ADD THE FOLLOWING AFTER THE LAST PARAGRAPH:
The Intermediate Stripe Coat shall be applied by brush to all edges, corners, welds, crevices, rivets, bolt threads, bolt heads, and other surface irregularities prior to application of the full intermediate coating. Visual coverage of the coated surface is required.
5. Color.
THE LAST PARAGRAPH IS CHANGED TO:
The color for the intermediate stripe coat shall contrast the primer and the intermediate coat. The color for the intermediate coat shall be white or an approved color that contrasts with the prime and finish coats.
6. Painting Galvanized Surfaces.
THE FOLLOWING IS ADDED TO THIS SUBPART:
The following steel components shall be galvanized and painted with a shop applied intermediate coat and a shop applied finish coat; all painting to be done at galvanizer’s facility. Adhere to paint manufacturers recommended dry film thicknesses for each coat:
Component Finish Color
4 Bar Steel Bridge Railing FED-STD-595B color chip No. 35190 (Lusterless Blue)
Steel Bridge Railing Base Plates FED-STD-595B color chip No. 35190 (Lusterless Blue)
Steel Median Barrier – Bascule Span FED-STD-595B color chip No. 35190 (Lusterless Blue)
Steel Median Barrier Connection Plates FED-STD-595B color chip No. 35190 (Lusterless Blue)
The process shall conform to Subsection 917.12 for galvanizing and follow the coating manufacturers written instructions for coating application requirements.
The galvanizing application shall use the dry kettle process to eliminate flux inclusions on the surface of the galvanized material.
Prior to galvanizing, the steel shall be immersed in a pre flux solution (zinc ammonium chloride). The pre flux tank must have a specific gravity of 1.09 to 1.1 and contain less than 0.4% iron.
The galvanizing plant shall provide the following to the Engineer for review prior to scheduling a pre-construction meeting or any production work:
• Coating Materials: Submit product data sheets, material safety data sheets, and application instructions for the materials to be applied to the galvanizing. The finish coat shall have similar gloss and match the color of the finish material selected by the Contractor according to Section 514.
• Verification samples: Submit two 3-inch by 6-inch samples of the factory applied coating systems. The samples shall be 100% galvanized, 75% painted with the primer, and 50% painted with the finish coating so that all coating layers are visible on the samples.
• Quality control records: Submit results of monitoring the temperature of the galvanizing bath. Include relevant specification criteria with the submittal.
• Quality control records: Submit test results documenting the hydrochloric acid percent of the pickling tanks is maintained between 10% and 14%. Demonstrate that the iron content is less than 8% and the zinc content is less than 3%. Provide documentation of weekly titration testing
• Quality control records: Submit weekly test results for all chemicals and zinc used in the galvanizing process. Include applicable ASTM A123 criteria.
• Apply prime coat within 12 hours after galvanizing in a controlled environment meeting applicable environmental regulations and as recommended by the coating manufacturer.
• Apply finish coat in the same controlled environment as the intermediate adhering to paint manufacturers intermediate recoat interval.
• References: The galvanizer shall submit documentation of at least five years experience in the successful completion of hot dip galvanizing followed by application of organic coatings at the galvanizing shop. Submit a minimum of three end user client references with contact names, telephone numbers, addresses, and a brief description of the work performed.
The Contractor shall schedule a meeting to be attended by the Contractor, designer, Engineer, fabricator, and galvanizer. Agenda shall include: project schedule, scope of services, coordination between fabricator and galvanizer, finish of surfaces, application of coatings, submittals, and approvals.
Prior to fabrication and final submittal of shop drawings to the Engineer, the fabricator shall submit drawings to the galvanizer for review of suitability of the components for galvanizing. Contractor will coordinate any required modifications.
Acceptable products include the COLORGALV and PRIMERGALV systems by Duncan Galvanizing:
Duncan Galvanizing
69 Norman Street
Everett, MA 02149
telephone 617-389-8440
fax 617-389-2831
Equivalent systems will be evaluated and approved by the Engineer. Other suppliers include:
American Galvanizing Co Inc
PO Box 408
Folsom NJ 08037
609-567-2090
Voigt & Schweitzer
2520 East Hagert St
Philadelphia PA
215-739-8911
503.16 Steel Grid Flooring.
the following is added AFTER THE FIRST PARAGRAPH:
Steel grid panels shall be as manufactured by the following or approved equal:
1. Interlocking Deck Systems International
115 41st Street
Pittsburgh, Pennsylvania 15201
Contact: Chris Davis (412) 682.3041
2. Foster Fabricated Products
1016 Greentree Road
Pittsburgh, Pennsylvania 15220
Contact: Mike Riley (412) 928.3452
The Contractor is alerted that the work is to be performed in specific construction stages as shown on the Contract Plans unless otherwise approved by the Engineer.
The removal of the existing deck shall be performed so as not to interfere with the installation of the new system. The Contractor’s method for demolishing and removing the bridge items may be his/her choice, subject to the approval of the Engineer. All material removed, except for items to be reinstalled, shall become the property of the Contractor.
Waterway users shall be protected at all stages of the construction process. The Contractor’s operations shall not interfere with free navigation, as per the requirements of Section 107 of the Standard and Supplemental Specifications. Care shall be taken to avoid damaging existing structures or members to remain. Temporary shielding shall be coordinated with the balancing of the lift span detailed in Section 527 of the Supplemental Specifications. The Contractor shall be aware that the amount of weight that can be added to the bascule span is limited. Therefore, the Contractor is expected to pay careful attention to the type and weight of the temporary shielding used on the lift span.
In the furnishing of deck panels, the Contractor shall submit to the Engineer a detailed plan of operations for the removal of the existing open grid deck and installation of the proposed steel grating. The plan shall include the following:
1. Working Drawings in accordance with Subsection 105.04 of the Standard Specifications.
2. Method of transporting, storing, and handling the proposed steel deck panels in accordance with these Supplemental Specifications.
3. Detailed construction plan for the removal of the existing open grid deck panels and installation of the proposed deck panels. The construction plan shall include all anticipated tasks and their durations. The plan shall be detailed with the labor crew sizes, equipment requirements, equipment placements, temporary devices, and safety platforms necessary to complete the work within the scheduled time period. The construction plan shall be coordinated with the working drawings. The Contractor shall monitor the construction plan during the actual work and adjust future work activities where necessary to complete the work within the time constraints.
4. List of materials suppliers.
5. Knowledge level of Contractor’s or Subcontractor’s work force.
6. Maintenance and protection of traffic.
Fabrication and Welding shall be performed in accordance with Subsection 503.05 of the Standard Specifications except as modified herein.
The Contractor shall survey and measure the existing bascule span for dimension verification; unrecorded modifications to the structure; and to determine the relative elevations of the stringers and floorbeams to determine any adjustments necessary for the fabrication of the grid deck. The survey and measurement of the bascule span for elevation shall be performed with no live load traffic on the bascule span. The survey and measurement shall include, but not be limited to, the elevation of the floorbeams at all the stringer intersections, the finish grade elevation of the existing grid deck at each floorbeam and lane line, the depth from top of existing grid deck to the top of each floorbeam at each of these locations, and the shim thickness between the floorbeams and stringers. Adjustments, if any, shall be noted and incorporated into the shop drawings. The steel survey shall be submitted with shop drawings. A datum shall be provided with the survey.
Welding. A welding procedure and a welding sequence shall be submitted for review. Welding procedures shall be submitted for all welds. The welding sequence shall include the sequence and methods to prevent and minimize distortions and residual welding stresses in the completed grid flooring.
Fabrication. The grid flooring shall be fabricated on a level solid surface. The flatness of grid deck panel shall be monitored during the fabrication process. Welding of the grid deck shall be sequenced and controlled to prevent distortions during and after the fabrication process of the grid deck. A welding procedure shall be submitted for all welds.
Tolerances. The grid deck panels shall be fabricated within the following tolerances:
Overall Panel Length and Width: plus zero (+0) to minus one eighth (-1/8) inch maximum from the approved shop drawings.
Panel Squareness: Diagonal lengths between extreme corners of a panel shall measure within one-quarter (1/4) inch from each other.
Panel Flatness: The transverse camber (width) of panel shall be no more than 0.001 times the width of the panel. The longitudinal camber (length) shall be no more than 0.003 times the length of the panel.
Sweep: The side bow (sweep) shall be no more than plus or minus one-quarter ((¼) inch per 10 linear feet in either direction.
Main Bar Verticality: The main bar shall be no more than one sixteenth (1/16) inch out of vertical on the full bar height.
Cross Bar Verticality: The cross bar shall be no more than one sixteenth (1/16) inch out of vertical on the full height.
Main Bar Spacing: Center to center spacing of the main bar shall be no more than plus or minus one-sixteenth ((1/16) inch from the detailed bar spacing.
Cross Bar Spacing: Center to center spacing of the cross bar shall be no more than plus or minus one-sixteenth inch ((1/16) inch from the detailed bar spacing.
The grid deck panels shall be installed within the following tolerances:
Panel Alignment:
Cross bar alignment between adjacent grid deck panels shall be no more than plus or minus one-sixteenth ((1/16) inch.
The overall cross bar alignment of grid deck panels from end to end of the bascule span leaf shall be no more than plus or minus one-quarter ((1/4) inch.
Transport and Storage. Shipping, Handling and Erection shall be in accordance with Subsection 503.07 of the Standard Specifications except as modified herein. In the transportation of the steel deck panels the deck panels shall be supported in a manner to prevent distortion during transport and storage. Adequate support or dunnage beneath the grid deck panel shall be provided at the ends of the panel and at intermediate points. The intermediate spacing of the supports or dunnage during transport and storage shall be no more than half the maximum stringer spacing. The grid deck shall be fully secured during transport. The flatness of deck panels shall be within the allowable tolerances as noted in these Supplemental Specifications after transport and/or storage.
Handling. The grid deck panels shall be supported in a manner to prevent distortion during handling. Care shall be taken during lifting and placing to avoid overstressing, damaging or distorting the grid deck panels. The panels shall not be placed or dragged over any obstruction that will damage the components of the grid deck.
Repairs. The Contractor shall submit repair procedures for non-conforming grid deck panels or assemblies. The repair procedure shall not be construed as acceptance of the deck panel or assemblies. All repairs shall be documented and submitted to the Engineer.
Shop and Field Assembly. The grid deck panels and stringers for each bascule span leaf shall be completely assembled and match marked in the shop. During the assembly of the components, the stringers shall be set at correct grades and spacing by use of blocking and bolted temporary steel diaphragms. The grades shall be based on the survey of the bascule span performed prior to shop drawing submission. The temporary diaphragm rows shall be located at the ends of the stringers and at intervals of approximately every 25 feet. The alignment of the cross bars between grid deck panels shall be checked prior to drilling holes for hold down connections. The assembled grid deck panels and the stringers shall be inspected for discrepancies and overall fit up. A template shall be used to locate the bolt holes to minimize conflicts with the components of the grid deck. The interface between the main bars and the stringers shall be inspected for bearing before and after the installation of the temporary hold down fasteners. The edge bars shall be fully bearing on the stringers unless otherwise shown on contract drawings. The assembled deck panels and stringers shall be surveyed and the recorded information shall be submitted to the Engineer prior to shipping the grid deck.
Temporary diaphragms and connections shall be removed after the permanent assembly has been completed on the bascule span. Open holes from temporary connections shall be filled with high strength bolts.
The placement of construction equipment on the bascule span shall be limited. Prior to placement of any equipment on the bridge structure, the Contractor shall submit calculations to determine the capacity of the deck and span with location of the equipment clearly defined on the work plans. The calculations shall be performed and sealed by a Professional Engineer licensed in the State of New Jersey.
The grid deck panels should be placed and installed in such a manner so that no initial stress is induced into the bridge structure or grid deck panel. No external force shall be applied to the new grid deck panel, new stringer or existing structure to fit the component except to close a gap less than 1/16 inch between the new deck panel and new stringer. There shall be no imposed undue stresses or distortions of the grid deck during installation. If a gap greater than 1/16 inch exists between the deck panel and stringer, shims shall be provided to fill the gap.
Any deck panel installed with an undue stress or distortion shall be removed and replaced with a new panel section at no additional cost to the Department. Any non-conforming deck panels installed shall be removed and replaced with a new panel at no additional cost to the Department.
In the furnishing of grid deck panels for the barrier and warning gate supports, the Contractor shall submit to the Engineer a detailed plan of installation of the proposed steel grid flooring. The plan shall include the following:
1. Working Drawings in accordance with Subsection 105.04 of the Standard Specifications.
2. Method of transporting, storing and handling the proposed steel deck panels in accordance with these Supplemental Specifications
3. List of materials suppliers
Fabrication and Welding shall be performed in accordance with Subsection 503.05 of the Standard Specifications except as modified herein.
The grid deck panels shall be installed within the following tolerances:
Panel Alignment:
Cross bar alignment between adjacent grid deck panels shall be placed with a tolerance of one-sixteenth ((1/16) inch.
For the bascule span high early strength lightweight concrete closure pours, the provisions of the Standard Specification Subsections 501.05 through 501.17 as applicable shall apply with the following modifications. The Contractor shall furnish the mix design for the strength, unit weight and properties specified.
a. Materials shall be proportioned to produce lightweight concrete with a 4-hour compressive strength of 3000 psi.
b. Materials shall be proportioned to produce lightweight concrete with an average 28-day compressive strength of 4,000 psi, or greater, with no individual cylinder compressive strength less than 3,600 psi.
c. Materials shall be proportioned to produce lightweight concrete with a maximum dry unit mass of 115 lb/cf at 28 days when tested in accordance with ASTM C567.
d. The air content shall be 6% +/- 1.5% when measured by the volumetric method in accordance with ASTMC173
e. The concrete slump shall be 6 inches +/- 2 inches when measured in accordance with ASTM C143 Concrete.
f. Cement for the high early strength lightweight concrete shall be Rapid Set Cement manufactured by CTS Manufacturing Company, Cypress, CA or approved equal. Materials shall be of recent manufacture (within one year) and uniform in composition and consistency.
g. A minimum eight-bag cement mix with a 0.42 water to cement ratio using a super plasticizer is required unless otherwise approved by the Engineer.
h. The 28-day drying shrinkage shall not be more than 400 microstrains
No later than 30 calendar days after the notice to proceed is given, the Contractor shall begin preparing trial batches of concrete. Sand-lightweight concrete mixes shall be designed by a testing laboratory, approved by the Department, retained by and at the Contractor’s expense. Trial batches and mix designs shall be developed and tested for the specific fine and coarse aggregate from the exact manufacturing plant that is to be used by the Contractor for the Project. In order to represent the strength development of the Project in place concrete, the trail batches shall be maintained at a similar temperature as the anticipated project temperature. The Contractor shall be responsible for preparing the trial batches and demonstrating the mix’s ability to achieve the specified properties in accordance with Section 914 of the Standard Specifications except as modified herein. Changes other than minor fluctuations in admixture dosage rates will require a new mix design. The Engineer may halt pouring and order additional trial batches whenever the specified properties are not achieved. Alternate mix designs will be considered provided the Contractor demonstrates the ability to meet the requirements of this specification to the Engineer’s satisfaction.
The mixes shall be proportioned by weight. They shall be designed and proportioned in accordance with the applicable requirements of ACI Standard 211.1, “Recommended Practice for Selecting Proportions of Structural Lightweight Concrete”, ACI Standard 211.2 “Standard Practice for Selecting Proportions for Structural Lightweight Concrete”, 213R, “Guide for Structural Lightweight Aggregate Concrete” and Section 8 of Division 2 of the 1996 AASHTO Standard Specifications for Highway Bridges including all addendums.
The design mixes, along with the entire test results as specified in the Standard Specifications, Section 914 (as modified herein) shall be submitted to the Engineer for approval. The copy of the design mix shall provide, at a minimum, the following information:
1. Fine and coarse aggregate (saturated surface dry condition) content in lb/cf
2. Cement content in lb/cf
3. Water content in lb/cf
4. Air content in %, measured by volumetric method in accordance with ASTM C173
5. Water cement ratio
6. Slump in inches
7. Dry unit mass in accordance with ASTM C567
8. 28 day compressive strengths
9. Batch Masses.
Approved batch weights shall be used to manufacture all lightweight concrete for this project. The Contractor shall periodically correct batch masses to account for the changes in fine aggregate fineness modulas and aggregate moisture content.
The specific gravity and absorption of the lightweight aggregate shall be checked for each shipment. Lightweight aggregate shall be in a saturated surface dry condition when delivered by the manufacturer. Absorption shall be limited to a maximum of 6%-9%. Lightweight aggregate stockpile(s) shall be constructed so as to maintain uniform moisture throughout the pile. The stockpiles shall be continuously and uniformly sprinkled with water for a minimum of 24 hours using a sprinkler system approved by the Engineer. At the end of the wetting period, the stockpiles shall be allowed to drain for 12 to 15 hours immediately prior to use, unless otherwise directed by the Engineer.
At least 30 days before the placement of concrete, a plan of action shall be submitted for approval for the placement of concrete during hot and cold weather conditions as defined in the Standard Specifications, Subsection 501.11 - Limitations of Placing. Cold and hot weather concreting shall be according to the provisions of the Standard Specifications Subsection 501.11 – Limitations of Placing. Measures shall be provided by the Contractor to maintain the concrete mix temperature between 60 ºF and 70 ºF. Proposed methods of maintaining concrete mix temperature shall be included in the plan of action and shall be in accordance with the recommendations of the materials suppliers.
The Contractor shall submit to the Engineer a detailed plan of operations for the removal and installation of the steel grating panels in accordance with the requirements the Supplemental Specification for Steel Grid Deck Replacement. In addition to the requirements specified therein, the written plan shall include the following:
1. Method of concrete mixing, handling and placement for the closure pours in the field.
2. A plan for discontinuing placement and protecting the closure pour concrete during unfavorable weather conditions.
3. Contingency plan for interruptions of pours, work schedules, limits of pours.
4. Equipment descriptions.
5. List of concrete materials suppliers.
All lightweight concrete shall be placed, finished, cured and protected as specified in Section 501 of the Standard Specifications, unless otherwise recommended by the manufacturer’s product specifications and/or approved by the Engineer. Lightweight concrete shall have a good workability and other properties such that proper placement, consolidation, and finishing are obtained. Lightweight aggregates and sand shall be batched by weight. Lightweight concrete shall be consolidated with vibrators taking care to provide uniform consolidation without over-vibration. The closure pour concrete shall be covered promptly after final finishing with a single, clean layer of wet burlap. The burlap shall remain until six hours minimum of wet curing has occurred. The burlap shall be kept continuously wet for the 6-hour duration.
The exposed surfaces of all metals such as deck joint plates and shapes that are not galvanized or metallized shall be painted. Painting and metalzing shall conform to the Special Provisions.
The supplier of the lightweight aggregate shall provide a technical representative at the site for the first day of closure pour placement. The representative shall be responsible to assist the Contractor and Engineer in the control of lightweight aggregate moisture content, unit weight, batching and placement requirements.
The supplier of the high early strength cement shall provide a technical representative at the site for the first day of closure pour placement. The representative shall be responsible to assist the Contractor and Engineer in the control of high early strength cement mixing and placement operations.
Field-testing shall be performed in accordance with the Standard Specifications, Section 914 as modified by this section. Concrete cylinders shall be cured under the same conditions as the in-place concrete.
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THE FOLLOWING IS ADDED:
Lightweight Class A concrete fill over the stringers and the side form pans over the bascule span stringers will not be measured separately for payment. Cost is to be included under the Pay Item “Steel Grid Flooring.”
Replace Rivets with High Strength Bolts will be measured on a unit basis for the number of rivets replaced.
Girder Jacking shall not be measured for payment. This item will be paid on a lump sum amount shown on the Proposal.
Finger Joints will be measured by pounds.
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Pay Item Pay Unit
replace rivets with high strength bolts unit
GIRDER JACKING LUMP SUM
PLATFORMS FOR BARRIER GATES AND TRAFFIC GATES LUMP SUM
REPAIR OF STRUCTURAL STEEL LUMP SUM
CLEANING, IF AND WHERE DIRECTED LUMP SUM
THE LUMP SUM PRICE FOR CONSTRUCTING THE NEW BARRIER GATE AND TRAFFIC GATE PLATFORMS SHALL INCLUDE ALL LABOR, MATERIALS, TOOLS, AND EQUIPMENT, INCLUDING ALL INCIDENTALS, FURNISHING AND INSTALLING PLATFORMS AND SUPPORTS AS DETAILED ON THESE PLANS. NO SEPARATE PAYMENT WILL BE MADE FOR THE GRID DECK PANELS, CONCRETE PEDESTALS UNDER THE BARRIER GATE AND TRAFFIC GATE HOUSINGS, STRUCTURAL STEEL SUPPORTS, TEMPORARY BRACING AND SUPPORTS, SHAPES, CONNECTIONS, SHEAR STUDS INSTALLED FOR BARRIER GATE AND TRAFFIC GATE SUPPORTS, GALVANIZING AND PAINTING OF ALL COMPONENTS OF THE SUPPORTS; THE COSTS THEREOF SHALL BE INCLUDED IN THE PAY ITEM FOR “PLATFORMS FOR BARRIER GATES AND TRAFFIC GATES”.
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STRUCTURAL BEARING ASSEMBLIES SHALL INCLUDE PAYMENT FOR FURNISHING ALL LABOR, MATERIALS, TOOLS, EQUIPMENT AND INCIDENTALS, AND ALL WORK INVOLVING FURNISHING, TESTING, AND INSTALLING SAID BEARING ASSEMBLIES, COMPLETE AND IN PLACE, AS SHOWN ON THE WORKING DRAWINGS.
THE FOLLOWING IS ADDED AFTER THE SECOND PARAGRAPH:
THE LUMP SUM PRICE FOR THE BASCULE SPAN GRID DECK REPLACEMENT SHALL INCLUDE THE COST OF FURNISHING ALL THE LABOR, MATERIAL, AND EQUIPMENT TO SATISFACTORILY COMPLETE THE WORK IN ACCORDANCE WITH CONTRACT DOCUMENTS. THE COST FOR LIGHTWEIGHT CONCRETE CLASS A FILL OVER THE STRINGERS, SHEAR STUDS, PAINTING, INCIDENTALS, ADJUSTMENTS, AND INSPECTION OF THIS WORK SHALL BE INCLUDED IN THE SQUARE FOOT PRICE.
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504.03 CONSTRUCTION REQUIREMENTS.
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505.03 EQUIPMENT.
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subpart 3. is changed to:
3. FOR STEAM OR AIR HAMMERS, THE WEIGHT OF THE RAM SHALL BE NO LESS THAN 1/3 THE WEIGHT OF THE PILE. FOR DIESEL HAMMERS, THE WEIGHT OF THE RAM SHALL BE NO LESS THAN ¼ THE WEIGHT OF THE PILE.
E. Leads and Followers.
The following is added after the second sentence:
LEADS MAY BE EITHER OF THE FIXED OR SWINGING TYPE. FIXED LEADS, WHEN USED, SHALL BE HELD IN POSITION BY GUYS OR BRACES TO ENSURE SUPPORT TO THE PILE DURING DRIVING. SWINGING LEADS, WHEN USED, SHALL BE FITTED WITH A PILE GATE AT THE BOTTOM OF THE LEADS AND, IN THE CASE OF BATTERED PILES, A HORIZONTAL BRACE MAY BE REQUIRED. SWINGING LEADS SHALL BE ADEQUATELY EMBEDDED IN THE GROUND OR THE PILE CONSTRAINED IN A STRUCTURAL FRAME SUCH AS A TEMPLATE TO MAINTAIN ALIGNMENT.
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F.
the following is added:
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1. Hammer Cushion.
The second and third sentences are change to:
HAMMER CUSHIONS (CAP BLOCK) SHALL BE MADE OF MANUFACTURED MATERIALS ACCORDING TO THE HAMMER MANUFACTURERS GUIDELINES. WOOD, ROPE, WIRE ROPE, HOSE, TIRES AND ASBESTOS CUSHIONS ARE SPECIFICALLY DISALLOWED AND SHALL NOT BE USED.
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The first sentence is changed to:
FOUNDATION AND FENDER PILES SHALL BE DRIVEN WITH A VARIATION OF NOT MORE THAN ¼ INCH PER FOOT FROM THE VERTICAL OR FROM THE BATTER. FOUNDATION PILES SHALL NOT BE OUT OF THE REQUIRED POSITION BY MORE THAN 6 INCHES AFTER DRIVING, OR ¼ OF THEIR DIAMETER, WHICHEVER IS GREATER.
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1.
the following is added:
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2. EMPIRICAL PILE FORMULA. IF NO OTHER METHODS OF DETERMINING PILE CAPACITY ARE STATED IN THE SPECIAL PROVISIONS OR PLANS, THEN THE ENR FORMULA SHALL BE USED.
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The third sentence of the fifth paragraph is changed to:
THE RESTRIKE SHOULD BE TERMINATED WHEN THE ULTIMATE CAPACITY OF THE PILE IS REACHED OR THE PENETRATION REACHES 6 INCHES OR THE TOTAL NUMBER OF HAMMER BLOWS REACHES 50, WHICHEVER OCCURS FIRST.
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The third paragraph is changed to:
AS SHOWN ON THE PLANS, ALL PILES SHALL BE ANCHORED TO THE STRUCTURE.
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SPLICES FOR ALL TYPE PILES WILL BE MEASURED PER EACH INDIVIDUAL SPLICE. HOWEVER, SPLICES WITHIN THE PILE LENGTH ORDERED BY THE ENGINEER WILL NOT BE MEASURED UNLESS THE ORDERED LENGTH IS IN EXCESS OF 80 FEET.
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506.01 DESCRIPTION.
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THIS WORK SHALL ALSO CONSIST OF DESIGNING, FURNISHING AND INSTALLATION OF FIBERGLASS-CONCRETE COMPOSITE PILES (FCCP) AND FIBERGLASS REINFORCED PLASTIC PILES (FRPP) THAT MAY BE USED FOR THE CONSTRUCTION OF FENDER SYSTEMS AND DOLPHINS. ALL EQUIPMENT, MATERIALS AND LABOR THAT ARE REQUIRED TO INSTALL THESE TYPE PILES, AS SHOWN ON THE PLANS, SHALL BE INCLUDED.
This work shall also consist of designing, furnishing and installing Fiberglass Reinforced Plastic Lumber (FRPL) wales for fender systems and smaller dimensional FRPL for fender system platforms as shown on the plans and specified herein.
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FIBER REINFORCED PLASTIC LUMBER………………………………………………..………….…..921
Fiberglass Reinforced Plastic Piles……………………………………………………………..922
Fiberglass-Concrete Composite Piles…………………………………………………………..923
The following is added:
THE MATERIAL CONFORMANCE CRITERIA OF SECTION 921 SHALL BE FOLLOWED FOR SUPPLYING FRPL, OF SECTION 922 FOR SUPPLYING FRPP AND OF SECTION 923 FOR SUPPLYING FCCP.
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506.06 FIBERGLASS-CONCRETE COMPOSITE PILES / FIBERGLASS REINFORCED PLASTIC PILES / FIBERGLASS REINFORCED PLASTIC LUMBER.
A. Fiberglass-Concrete Composite Piles (FCCP). The following criteria shall be followed in furnishing (FCCP).
1. Working Drawings. According to the requirements of 105.04, Working Drawings for FCCP shall be submitted. The submission shall include test results and calculations to establish the flexural strength requirements stated herein and shall also include the following criteria:
a. The outside diameter of the FCCP and wall thickness of the composite reinforcement tube.
b. The location of any embedded or attached lifting devices and use of pick up or support points.
c. The location of the roughened surface where skin friction is needed between the pile and the soil.
d. The location of detailing of any splices, shoes and top of pile connections that may be required.
2. Additional Submittals. The following documentation and details shall be submitted to the Engineer for approval at least thirty (30) days prior to the scheduled FCCP installation.
a. Documentation that indicates the fiberglass tubing physical properties and the diameter and wall thickness of the tubes.
b. The method of placing concrete in the fiberglass tubes.
c. Catalog cuts, illustrations, schedules, diagrams, performance charts, instructions, brochures or lab reports that illustrate the size, physical appearance and other characteristics of FCCP that indicate conformity to the requirements of the Plans and the requirements specified in Section 923.
d. Lab reports from an independent testing facility shall include calculations that confirm that the FCCP meets the ultimate strength requirements specified in Section 923. A minimum of three (3) flexural tests shall be required. The average of the three tests shall exceed the specified ultimate flexural strength.
e. Placement method of the concrete for the fiberglass tubes. The concrete shall be placed in one continuous bottom to top operation in a manner that prevents voids from forming.
3. Storage and Handling. FCCP shall not be installed until 30 days after concrete has been placed in the tubes. FCCP shall be stored and handled to avoid damage to all components including fiberglass tubes, protective coatings and concrete. During storage, the piles shall be placed on minimum 6 inch wide timber cribbing arranged to give even support and to maintain straightness within the tolerance specified herein.
4. Lifting Piles. Only fabric slings may be used to lift the piles. Chain or cable in direct contact with the piles may not be used.
5. Splices. Full length piles where practicable shall be used. Where splices are unavoidable their number and locations will be subject to written approval by the Engineer. Splicing details shall be submitted to the Engineer for approval.
6. Shoes. Steel shoes for FCCP, when required, shall be provided. Install shoes in conformance with details submitted to and approved by the Engineer.
7. Equipment for Driving FCCP.
a. Equipment for driving FCCP shall conform to the requirements of 505.03.
b. As per the requirements of 505.03 G., an approved hammer cushion block to transfer pile hammer energy to the FCCP shall be used. Each hammer shall be equipped with a helmet/drive head to fit the diameter of the FCCP to be driven.
c. As per the requirements of 505.03 G., an approved pile cushion block to prevent damage to the FCCP shall be used. At a minimum frequency, the pile cushion block shall be inspected after each FCCP is driven and replaced as needed.
8. Allowable. Variation in Pile Alignment. FCCP shall be installed truly vertical or accurately battered as indicated on the Plans. The top of any FCCP driven its full length into the ground shall not vary from the plan location by more than 2 inches.
9. Defective Composite Piles. The provisions of 505.08, in addition to the following, shall apply for determining FCCP defective characteristics. The following will be causes for rejection of a FCCP:
a. Incorrect pile location or batter.
b. Pile damage from any cause prior to driving.
c. Insufficient concrete strength, based on testing of cylinders.
d. FCCP broken by reason of internal defects (even if placed in the leads), or improper driving.
10. Cutting Off Piles. Tops of FCCP shall be cut off at the elevation indicated on the Plans, or as established by the Engineer. The FCCP shall be cut to a true plane, in accordance with the detail shown on the Plans. All cut off lengths will become the property of the Contractor.
B. Fiberglass Reinforced Plastic Lumber (FRPL). The following criteria shall be adhered to in furnishing FRPL for the project:
1. Submission Requirements. The Contractor shall submit the following information to the Resident for approval at least thirty (30) days before installation of FRPL.
a. Copies of the FRPL manufacturer’s standards and most recent brochure for the product covered by these Specifications.
b. According to the requirements of Subsection 106.04, the Contractor shall submit a written certification from the FRPL manufacturer that their product satisfies the requirements of Section 921 and has been in service for a minimum of three (3) years on other bridge protection applications in the United States. This written certification shall include project owner information, project names, locations, contacts and phone numbers.
c. Copies of independent lab test reports and performance test data that confirm that the FRPL meets the Plastic material properties and the structural property requirements specified in Section 921.
2. Shipping, Storage, Handling. During storage FRPL materials shall be protected at all times against exposure to extreme heat or impact. FRPL shall be shipped in a manner that will minimize scratching or damage to the outer surfaces. FRPL shall be stacked on dunnage above ground so that it may be easily inspected and stored in a manner that will avoid damage. FRPL shall be handled with nylon slings. Sharp instruments shall not be used in handling the product. FRPL damaged in shipping or handling will be rejected.
3. Installation. FRPL shall be cut, beveled, drilled, countersunk, and otherwise fabricated in accordance with the manufacturer’s recommendations. Set all material accurately to required levels and lines, with members plumb and true and accurately cut and fitted. Securely attach all FRPL to substrate by anchoring and fastening as shown on plans.
C. Fiberglass Reinforced Plastic Piles (FRPP). The following criteria shall be adhered to in furnishing FRPP piles:
1. Working Drawings. According to the requirements of Subsection 105.04, FRPP submissions shall consist of working drawings. The submission shall include calculations to establish the FRPP structural properties found in Tables 3-A and 3-B.
2. Additional Submittals. Submit the following documentation and details to the Engineer for approval at least thirty (30) days prior to driving the piles.
a. Copies of FRPP manufacturer’s standards and most recent product brochure for the product covered by these specifications.
b. Written certification from the FRPP manufacturer that their product meets the requirements of Section 922 and that the product has been in service for a minimum of three (3) years on at least 5 bridge protection applications in the United States. The certification shall include project owner information, project names, locations, contacts and phone numbers.
c. Independent test lab report confirming that FRPP meets the Plastic Material Properties and structural properties specified in Section 922.
d. Manufacturer’s field guide with recommendations on handling, storage, cutting, drilling and driving. Driving recommendations shall include recommended driving energies.
3. Splices. Splices shall not be permitted except where overhead restrictions in the driving area require splices to be used. Splicing details shall be submitted to the Engineer for approval.
4. Pile Points. Steel pile points shall be provided by the manufacturer and attached prior to shipment.
5. Allowable Variation in Pile Alignment. Install FRPP truly vertical or accurately battered as indicated on the Contract Plans. The top of any pile driven its full length into the ground shall not vary from the plan location by more than 2 inches.
6. Defective FRPP. The provisions of Subsection 505.08, in addition to the following, shall apply for determining FRPP defective characteristics:
a. Incorrect pile location or batter.
b. Pile damage from any cause prior to driving.
c. Pile broken by reason of internal defects (even if placed in the leads0, or improper driving.
7. Cutting Off Piles. Cut off the tops of FRPP at the elevation indicated on the Contract Plans, or as established by the Engineer. Cut the piles to a true plane, in accordance with the detail shown on the Contract Plans. All cut off lengths become the property of the Contractor.
8. Wrapping. Wrapping for the FRPP that are to be placed in clusters shall be ½” diameter cable (5/8” OD covering) polypropylene impregnated wire rope.
To verify suppliers of Composite Piles/Fiber Reinforced Plastic Piles/Composite Lumber that may be used, the Contractor is advised to study the “Bureau of Material’s Approved List” on the following NJDOT website:
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506.07 METHOD OF MEASUREMENT.
The following is added:
FRPP AND FCCP WILL BE MEASURED IN LINEAR FEET OF PILE THAT IS PLACED IN ACCORDANCE WITH THE PLANS.
FRPL will be measured in cubic feet computed on the basis of actual volumes and the shortest commercially available lengths which may be used and that is placed in accordance with the Plans.
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506.08 BASIS OF PAYMENT.
The following is added:
PAY ITEM PAY UNIT
FIBERGLASS REINFORCED PLASTIC PILE (FRPP), 12-INCH DIAMETER LINEAR FOOT
FIBERGLASS REINFORCED PLASTIC LUMBER (FRPL) CUBIC FOOT
FENDER PILE SPLICE UNIT
WRAPPING IS TO BE PAID FOR UNDER THE ITEM FIBERGLASS REINFORCED PLASTIC PILE (FRPP), 12-INCH DIAMETER.
No additional payment will be made for re-driving of FCCP or FRPP that are forced up by any cause. Included in the Payment will be all costs for all material, labor, equipment, and other necessary items required for completing the work including storage costs, disposal of unused piles, repair to damaged piles, and transportation costs. Parts of pile cut off will not be included for payment.
Payment for FRPL shall include all material, labor, equipment, fasteners, and other necessary items required for completing the work including storage costs, disposal of unused materials, and transportation costs.
Also, no separate payment will be made for grout, plates, bolts, screws or other hardware that is needed for attaching the wales to the dolphins or for assembly and or installation of a platform. All costs hereof is to be included in the item FIBERGLASS REINFORCED PLASTIC LUMBER.
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SECTION 508 – METAL BRIDGE RAILING AND FENCE
508.04 CONSTRUCTION REQUIREMENTS.
The following is added at the end of the section.
Shop Plans shall indicate the locations of break in the railings to accommodate new warning gates and barrier gates, consistent with the size of the gates, so as to allow full operation of the gates. The clearance from the most restrictive gate dimension to the railing termination shall be one (1) inch. The ends of rails shall be covered at these break locations with shop welded end cap plates, details of which shall be included in the shop plans.
508.08 Method of Measurement.
The following is added at the end of the section.
Steel posts, plates, shims, bolts, nuts, washers, welding if required – will not be measured separately for payment. All these aforementioned items in the railing system to be included in the bid item “4-Bar Open Steel Bridge Railing”.
SPECIAL PROVISIONS ARE TO BE PROVIDED BY THE DESIGNER ON A PROJECT-TO-PROJECT BASIS.
513.05 METHOD OF MEASUREMENT.
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TEMPORARY SHEETING WILL BE MEASURED BY THE SQUARE FOOT BASIS. THE AREA MEASURED WILL BE THE PRODUCT OF THE AVERAGE HEIGHT AND THE LENGTH OF SHEETING THAT IS DRIVEN. THE AVERAGE HEIGHT WILL BE DETERMINED BY EXTENDING A LINE FROM THE BOTTOM OF EXCAVATION TO A VERTICAL PLANE OF THE TOP OF SHEETING.
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514.01 DESCRIPTION.
THIS SECTION IS REPLACED WITH THE FOLLOWING:
The intent of this work is to clean, paint, and/or metalize all exposed previously painted surfaces of the steel components of the bridge, including, but not limited to: all structural steel in the approach and flanking spans, including bearings, steel work within the interior and exterior of the machinery house, and metalizing all bascule span steel and counterweight casings. The only area not included in the scope of work is the interior of the control houses. The work shall consist of the cleaning and painting of structural steel and metal surfaces on the bridge during the rehabilitation of the bridge and metalizing all steel components of the bascule span. A finish coat of paint shall also be applied to the outside face of the bascule girder and all steel outside that girder that supports the roadway and sidewalk. The color of the finish coat shall match the finish coat on the approach spans. All steel within the limits of the project shall be completely painted and/or repair painted to the requirements of this Section, whether partially or fully painted in the shop or painted at the project location.
All cleaning performed in the field for this project will be paid under the Item “NEAR-WHITE BLAST CLEANING”; with the exception of localized areas in the vicinity of sensitive mechanical/electrical components, which will be paid under “HAND/POWER TOOL CLEANING”. All field painting performed for this project will be paid under the Item “PAINTING BRIDGES – EXISTING STEEL”. All field metalizing performed for this project will be paid under the Item “METALIZING BRIDGES – EXISTING STEEL”.
The cleaning and coating work is to be sequenced such that the following conditions are achieved:
1) All cleaning and painting or metalizing of structural steel below the roadway shall be performed during Stage III except the bascule span, which will be done in Stage IV. These parts of the bridge are not subject to significant structural steel repairs.
2) All new and/or replacement structural steel members or shapes that will be installed during the project shall be treated according to Section 503.15.
3) Field cleaning and painting or metalizing of structural steel at elevations below the roadway shall be performed after deck replacement.
4) The new center median barrier in the Bascule Span shall be cleaned, galvanized, and painted in the shop. (Per Section 503.15)
The work shall consist of the cleaning and painting of all existing and re-constructed metal surfaces on the bridge with an Organic Zinc Coating System. A prime coat only of the organic zinc shall be used when repainting surfaces that will be in contact with freshly placed concrete. The specified surface preparation method shall not be changed.
All Mechanical equipment shall be painted and/or re-painted according to Subsection 525.04 “Painting” with machinery enamel as approved by the Engineer.
Whenever the term “coat” or “coating” is used hereinafter, it shall constitute as many applications as are necessary to achieve the specified dry film thickness.
Whenever there is a discrepancy between these Specifications and the manufacturer’s recommendations, with the approval of the Engineer, the manufacturer’s recommendations shall govern.
514.02 Materials.
THE THIRD, FOURTH, AND FIFTH PARAGRAPHS ARE CHANGED TO THE FOLLOWING:
For the organic zinc coating system, a complete coating system of an organic zinc-rich primer, a stripe coat of the epoxy intermediate coat, a high-build epoxy intermediate coat, and a urethane finish coat shall be selected from one of the approved coating systems described in Subsection 912.15. The color of the finish coat shall be Lusterless Blue and shall match the following color chip of FED-STD-595B:
Lusterless Blue Chip No. 35190
The primer shall be tinted to contrast the base metal.
The color for the intermediate stripe coat shall contrast the primer and the intermediate coat.
The color for the intermediate coat shall be white or an approved color that contrasts with the prime and finish coats.
For the metalizing operations, certified alloy wire is required. The Contractor will obtain written certification from the manufacturer of the alloy and will provide the certifications at the end of the project. The wire certification shall indicate percent composition.
514.04 Limits of Cleaning and Painting.
A. General.
THE FOLLOWING IS ADDED AFTER THE FIRST PARAGRAPH:
Surfaces to be cleaned and painted shall also include all appurtenances including, cat walks, metal junction boxes, electrical junction boxes, electrical conduit and related pipe hangers and rollers, ladders, light arms and fixtures inside the machinery rooms, metal grate flooring, navigational aids & lights, bell standards, wiring brackets, navigational sign supports, etc. Components to be metalized include all structural steel members of the bascule span.
C. Organic Zinc Coating System.
THIS SUBPART IS CHANGED TO THE FOLLOWING:
All structural members and appurtenances to be painted shall be near-white blast cleaned.
514.05 Cleaning Methods.
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2. Blast Cleaning.
THE FOURTH PARAGRAPH IS DELETED.
INSERT THE FOLLOWING AFTER THE FIFTH PARAGRAPH:
Chlor*Test soluble salt detection tests will be used by the Engineer to determine levels of chloride contamination on blast cleaned surfaces. The Engineer will only test areas of previously corroded/pitted steel and/or areas where visual indications of salt contamination are present. All testing will be performed prior to application of any coating. The maximum allowable reading must be less than 10 micrograms per square centimeter of Chloride. Areas shall be re-cleaned and re-tested until less than 10 micrograms per square centimeter of Chloride are detected. The Contractor may use other field test methods for quality control purposes; however, the Chlor*Test method will determine acceptability.
subpart b. is changed to:
B. EPOXY MASTIC COATING SYSTEM. ALL EXISTING SURFACES SHALL BE HAND/POWER TOOL CLEANED ACCORDING TO SUBPART A.1 ABOVE, EXCEPT WHERE COMMERCIAL BLAST CLEANING IS INDICATED ON THE PLANS. ALL COMMERCIAL BLAST CLEANED SURFACES SHALL LEAVE AN ANCHOR PROFILE FROM 1.5 TO 3.0 MILS DEEP.
C. Organic Zinc Coating System.
THE FOLLOWING IS ADDED AFTER THE LAST SENTENCE OF THE FIRST PARAGRAPH:
In the event that the anchor profile exceeds 2.5 mils, the coating thickness for the organic zinc shall exceed the anchor profile by a minimum of one (01) mil. In the event that the anchor profile exceeds 3.5 mils, the entire area shall be rejected and re-blasted to achieve the specified anchor profile.
THE FOLLOWING IS ADDED:
D. Surface Preparation for Metalization.
Clean to a near-white metal cleaning standard. Steel surface will be free of all oil, grease, dirt, mill scale, rust, corrosion products, oxides, paint, and other foreign matter. Surface finish and cleanliness shall be confirmed according to SSPC-VIS1 or visual inspection.
A profile of 3 to 5 mils is required. Angular blast media-Mineral and slag abrasives shall be selected and evaluated per SSPC-AB1, (aluminum oxide) recycled ferrous metallic abrasives per SSPC-AB2, steel grit per SSPC-AB3.
Hardened flame cut edges shall be ground with a disk wheel grinder to a smooth contour prior to abrasive blasting.
Measurements shall be taken using profile tape and a micrometer, as outlined in ASTM D4417. Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel/NACE Standard RP0287, Field Measurement of Surface Profile of Abrasive Blast Cleaned Steel Surfaces Using a Replica Tape.
THE FOLLOWING IS ADDED AT END OF THIS SUBSECTION:
E. Removal of Bird Excrement.
Bird excrement is present in the pockets of both counterweights. It is expected that this material will be removed prior to any span balancing activites. All removal activities shall be conducted in accordance with the recommendations of the Department of Health and Human Services, National NIOSH Publication Number 97-146.
All work performed to remove and dispose of the material shall be conducted by a specialty contractor with expertise in the removal and disposal of bird excrement, and the following:
1. Cleaning, If and Where Directed, Removal of Bird Excrement.
a. Permits and Approvals. The Contractor shall prepare and submit all documents to obtain all permits and approvals necessary for this work. The charges to prepare the documents and the fees required for all permits, approvals, and registrations shall be paid by the Contractor according to Subsection 107.05
The Contractor shall notify the Engineer and the Bureau of Project Support and Engineering six weeks before removal of the material to allow for the Department to coordinate the work.
The Contractor shall ensure that the waste disposal or recycling facility planned for receipt of the material is properly permitted to accept the material. A copy of the permit shall be submitted to the Engineer one week before disposal or recycling.
The waste transporters shall provide proof of all requisite licenses, permits, training and insurance to transport the waste.
b. Removal Operations. The work shall be conducted in accordance with the Health and Safety Program (Section 107.10) and the standard operating procedure detailed in the relevant NIOSH publication.
One month prior to start of work submit a Spill Prevention and Control Plan to prevent any uncontrolled exposure or discharge of the material to the environment. This plan shall detail methods and equipment that will be provided during the removal to ensure that the work is conducted in a safe and workmanlike manner accordance with the applicable regulations.
The contractor shall also submit a Waste Disposal Plan prior to starting the site work, detailing methods for safe transportation and off-site disposal in accordance with Federal and State laws, and the waste management plan of the district of origin.
c. Manifesting and Transporting. The Contractor shall be responsible for all labeling and placarding of the waste material.
A transporter that has a valid New Jersey hazardous waste transporter’s permit shall transport the waste material.
One copy of each manifest shall be returned to the Engineer within two business days after notification of receipt at the disposal facility. If the Contractor does not receive notification of receipt of any waste shipment within two weeks of departure from the site, the Contractor shall immediately notify the Engineer and contact the disposal facility to determine the status of the shipment and resolve the discrepancy. Any manifest discrepancies shall be reported to the Engineer and be resolved by the Contractor.
514.07 Conditions for Painting.
A. General
THE FOLLOWING IS ADDED:
Drying times between subsequent coats and recoating of existing coats shall be as per the manufacturer's recommendations. However, no painting of subsequent coats shall be permitted within twenty-four (24) hours of the application of a previous coat.
514.08 Number of Coats and Film Thickness.
C. Organic Zinc Coating System.
THIS SUBPART IS CHANGED TO THE FOLLOWING:
A minimum of three coats plus one brush applied stripe coat shall be applied in the field: prime, intermediate stripe coat, intermediate, and finish coats.
The dry film thickness of the paint at any point shall not be less than the following minimums:
Prime Coat 3 mils
Intermediate Stripe Coat N/A - Visual Coverage
Intermediate Coat 3.5 mils
Finish Coat 2 mils
The Intermediate Stripe Coat shall be applied by brush to all edges, corners, welds, crevices, rivets, bolt threads, bolt heads, and other surface irregularities prior to application of the full intermediate coating. Visual coverage of the coated surfaces is required.
514.11 Paint Application.
THIS SUBSECTION IS CHANGED TO:
514.11 Paint Application and Metalizing.
A. General.
REPLACE SUBPART 6 WITH THE FOLLOWING:
6. All small cracks, joints, and cavities which were not sealed in a watertight manner by the first coat of paint shall be filled with a caulking compound. Fill all voids caused by impacted rust between steel plates with a caulking compound. Apply the caulk after the intermediate coat and prior to the finish coat. The coating system manufacturer shall recommend the caulking material in writing for Engineer approval. All manufacturer instructions shall be followed during the installation of caulking. Any cracks or defects found in the steel by the Contractor should be immediately reported to the Engineer according to Subsection 108.09.
ADD THE FOLLOWING AFTER ARTICLE C:
D. Provisions for Metalizing of Steel Members.
1. Metal Thickness.
The applied zinc metalizing thickness should be an average of 10 to 12 mils (dependent on environment) and recorded for each coated component using certified coating thickness calibration standards in accordance with SSPC PA2 standards.
If rust bloom, blistering, or a degraded coating appears at any time during the application of the Thermal Spray Coating, the following process shall be followed:
a. Stop spraying
b. Mark off the unsatisfactorily sprayed area
c. Call the Thermal Spray Inspector/Foreman to observe and evaluate the error
d. Report the deficiency to the purchaser and record the deficiency
e. Repair the area by removing the Thermal Spray Coating, re-blast to a minimum near-white metal finish (SSPC-10 standard) and as specified anchor tooth profile depth
f. Recoat the area
g. Record the actions taken to resume the job
2. Adhesion.
Random adhesion testing shall be performed for each coated component, utilizing specified pull/off adhesion testing equipment, in accordance with ASTM D4541 standards.
Zinc adhesion = 600 psi
3. Metalizing Equipment.
The metalizing equipment shall be set up, calibrated, and operated.
• The wire feed method shall be push type system only.
• The system shall be capable of operation at 1000 amps continuous duty cycle.
• The system shall be able to operate remotely from the power supply unit for a distance up to 1,200 feet.
• The wire feed unit and thermal spray gun shall be portable and capable of operating from a reach-all scaffolding, harness, sling, boat, or small barge location.
• Power source must be separate from wire drive to meet containment safety requirements.
Metalizing should occur while substrate still meets specified standards. Care must be taken to avoid contamination with oils and dirt.
4. Compressed Air.
Compressed air shall meet ASTM D4285, method for Indicating Oil or Water in Compressed Air. Utilize a compressed air system capable of delivery at the nozzle of 125 cfm at 120 psi. To minimize any contamination, use an oil/water separator on the airline. 120 psi of compressed air maintains the proper atomization of the molten wire, producing the optimum spray pattern.
5. Painting Metalized Bridge Members.
A urethane finish coat shall be applied directly after the metalizing application. The finish coat shall only be applied to the outside face of the fascia girder, and the bottom flange and the other steel members outside of the fascia girder that support the roadway and sidewalk as shown on the plans. The finish coat color shall match the finish coat of the approach spans and shall be paid for under PAINTING BRIDGES – EXISTING STEEL. Metalizing leaves a surface profile that readily accepts paint coatings with no surface preparation. Directions as to the mixing of the coating material shall be in accordance with the manufacturer’s latest instructions.
6. Qualifications.
The contractor or subcontractor executing the metalizing work shall have a minimum of five (5) years of previous experience in providing surface preparation for metalizing and metalizing application services in the shop and field, and a minimum history of three (3) completed similar projects.
The thermal spray technician must have a minimum of one year of experience in the operation of thermal spray equipment and hold a certificate of satisfactory completion of training.
Documentation of prior experience for a “Thermal Spray Coating Inspector/Foreman” shall be available for review. Documentation will consist of a minimum of four (4) separate project “Quality Assurance” sheets signed by the company “Thermal Spray Coating Inspector/Foreman” and customer representative.
7. Quality Assurance Plan.
The Contractor will provide a written quality assurance plan that will be submitted to the Engineer or contracting officer for approval. Such a plan shall include a method of adhesion testing, thickness measuring, bend test protocol, and MSDS sheets for material utilized on the projects. A micrograph study, performed by an independent laboratory, must be supplied with the QA Plan, depicting less than 10% porosity in the thermal spray coating.
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Projects that involve lead paint abatement shall require that the Contractor’s personnel, who supervise and/or perform the lead paint abatement work, be trained in the applicable programs that concern health and safety compliance and environmental regulations regarding lead abatement. The training shall be certified by the Department of Health, in accordance with N.J.S.A.26:2q.1 et seq. and N.J.A.C. 8:62-1.1 et seq. Each supervisor and worker shall possess an individual lead permit as issued by the Department of Health. Also, the Contractor’s firm shall be certified by the Department of Community Affairs, Division of Codes and Standards, in accordance with N.J.S.A. 52:27d-427 et seq. And N.J.A.C.5:17-1.1 et seq. The Contractor shall submit a copy of the Department of Community Affairs certification to the Bureau of Construction Services, Division of Procurement (609.530.2103), prior to the award of this Contract. The Contractor shall maintain the appropriate lead abatement certification throughout the duration of this Contract. The applicable regulating State agencies will monitor projects for compliance with the training and certification requirements through random inspections.
1. Blast Cleaning Requirements.
a. Pollution Control System.
1) Containment Plan.
(a) Description.
THE FOLLOWING IS ADDED AFTER THE SECOND PARAGRAPH:
A “Level-1 Class-A Containment System”, as specified in accordance with SSPC Guide 6i (con), shall be utilized on this project for all surface preparation for all structural steel, bearings and appurtenances. Visible emissions for this project shall not meet or exceed section 5.5.1.1, level 1 Emissions. Compliance with all Federal, State and Local Regulations shall be verified in accordance with section 5.5.4 Method D, Ambient Air Monitoring for Toxic Metals.
The Contractor shall consider the following time frames when submitting all plans required under the pollution control system for this project. The Department will require up to two (2) weeks in order to complete the review process for all containment plans, waste disposal plans and lead health and safety plans. An additional two (2) weeks may be required each time plans are resubmitted, if revisions are necessary.
(c) Construction.
THE FOLLOWING IS ADDED:
Reference information can be obtained from the following sources:
SSPC Guide 6i(con), latest version.
A “suspended work platform” shall only be permitted provided that all of the below listed criteria can be met:
1. The platform shall have a minimum live load design of twenty-five (25) pounds per square foot, excluding all OSHA safety factors.
2. The minimum clearance shall be greater than sixteen (16) feet after installation and during operations under Span 1.
3. The Contractor shall specify and employ continuous vacuuming of all spent blast material, during all blast cleaning operations. This shall be noted in the Containment Plans.
4. The Contractor shall have an independent qualified individual certify in writing that each “suspended work platform” has been constructed in accordance with the Containment Plans accepted by the Department. The qualified individual shall not be an employee of the Contractor or have any affiliation with the individual or firm that prepared the Contractor’s Containment Plans. The credentials of the qualified individual who certifies the construction of the suspended work platform shall be subject to the approval of the Resident Engineer. No blast cleaning operations shall be permitted until this written certification has been received by the Resident Engineer.
The Resident Engineer shall be responsible for approving the type and design of containment structures prior to implementation for use at each specific location.
For all work over water, suspended work platforms may be utilized, provided all of the above listed criteria can be met for suspended work platforms for use over roadways with the following exceptions:
1. The minimum clearance over each span shall be determined on a case-by-case basis, depending on the use of the waterway.
2. The minimum clearance over Span 3 shall be 19 feet above MHW during cleaning and painting operations.
No specific payment shall be made for providing the above noted independent written certifications. All costs shall be deemed included in the various unit prices bid in the Proposal.
The Engineer may request the Contractor to conduct or request others to conduct air quality, water quality or such other testing that will determine the quality of any materials escaping from the containment system(s) employed on the Project. If it is determined that pollution of the environment adjacent to the site has occurred, the Contractor shall be responsible for all corrective action and cleanup.
2. Blast Cleaning Requirements.
b. Pollution Control System.
2) Waste Disposal Plan.
The following is added after the third paragraph:
THE HAZARDOUS WASTE GENERATOR IDENTIFICATION NUMBER(S) FOR USE ON THE MANIFEST IS (ARE) AS FOLLOWS:
|Structure No. | |
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| | |
Department of Transportation
Bureau of Project Support
951 Parkway Ave.
P. O. Box 600
Trenton, NJ 08625
THE FIRST SENTENCE OF THE TWENTY THIRD PARAGRAPH IS CHANGED TO:
Prior to any reclaiming/disposal activities the Contractor shall also specify the proposed transportation/storage/disposal (TSD) facility, including a commitment letter from the TSD facility indicating that it has the capacity to accept the estimated volume of waste material and stating that it will be open for business during the Contract duration to accept the estimated volume of waste materials specified herein.
THE FOLLOWING IS ADDED TO THIS SUBSECTION:
The Contractor is advised that it is the Department’s intent to dispose of the waste generated on this project at an approved USEPA lead reclaiming facility. The Department is aware of the following two possible lead reclaiming facilities which believes are currently approved by USEPA:
1. Exide Corporation
645 Penn Street
Reading, Pa. 19612
1-800-437-8495
Contact: Robert F. Jordan
2. Encycle Texas
5500 Upriver Road
Corpus Christi, Texas 78407
512-289-0300
Contact: Rick Gilbert
The Contractor is specifically warned to verify that the lead reclaiming facility it intends to use is currently approved by USEPA for lead reclaiming.
Lead reclaiming facilities that are not listed above may be used, but only if such facilities are approved by the United States Environmental Protection Agency (USEPA) for lead reclaiming. The Contractor is advised to contact USEPA to determine whether a particular lead reclaiming facility is approved by USEPA. Proof of approval by USEPA of the reclaiming facility shall be submitted to the Engineer prior to any cleaning or blasting.
In the event that the Contractor is unable to legally dispose of the waste at a lead reclaiming facility, an alternate transportation/storage/disposal (TSD) facility may be selected. The alternate TSD shall meet all the requirements of this subsection, with the exception of the lead reclaiming requirements. However, in order to use the alternate TSD, the Contractor shall provide sufficient documentation to the Resident Engineer indicating that the waste was unable to be disposed of at a lead reclaiming facility.
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1.
b. Lead Health and Safety.
(1) Lead Health and Safety Requirements
(h) Medical Surveillance Program.
THE FOLLOWING IS ADDED AFTER THE END OF SUB PARAGRAPH 7):
The Resident Engineer shall verify that all blood monitoring is conducted at a New Jersey clinical laboratory approved by OSHA, and has demonstrated proficiency in blood lead analysis. A list of all currently approved laboratories for the State of New Jersey can be obtained from the following web site:
(k) Reference Documents
THE FOLLOWING IS ADDED TO EACH SUB PARAGRAPH
1) Additional information is also available from the home page of the following website under laws and regulations – standards:
2) Additional information is also available from the home page of the following website under laws and regulations – standards:
3) This publication is available from the following website address:
4) Additional information is also available from the home page of the following website:
5) This publication is available from the following website address:
the first paragraph of subpart (2) is changed to:
2) LEAD HEALTH AND SAFETY PLAN (LHASP). WHEN OVER 500 TONS OF STRUCTURAL STEEL ARE TO BE BLAST CLEANED, THE FOLLOWING ADDITIONAL REQUIREMENTS AND PROVISIONS SHALL BE COMPLIED WITH BY THE CONTRACTOR.
THE DESIGNER SHALL INCLUDE THE STRUCTURE NUMBER AND EPA ID NUMBER BELOW AS REQUIRED ON A PROJECT TO PROJECT BASIS.
2.
a. Pollution Control System.
2) Hazardous Waste Collection and Disposal.
The following is added after the third paragraph:
THE HAZARDOUS WASTE GENERATOR IDENTIFICATION NUMBER(S) FOR USE ON THE MANIFEST IS (ARE) AS FOLLOWS:
|Structure No. 1506-152 |EPA ID No . NJR0000??????? (State to Provide) |
LIST identification NUMBER(S)
| | |
514.14 Provisions for Inspection.
THE EQUIPMENT LIST AT THE END OF THE FOURTH PARAGRAPH IS CHANGED TO READ AS FOLLOWS:
Equipment Quantity
1. SSPC Publications Volume 1 and 2 1 set
2. “Positector 6000” 2 each
3. NIST calibration standards 2 sets
4. Plastic shims 2 sets
5. “Dew Check” conditions meter (fully electronic) 2 each
6. Testex “Press-O-Film” test kits (appropriate size) 2 each
7. Digital thermometer, 1% accuracy 2 each
8. Disposal latex gloves (sizes as needed) 200 pairs
9. “Tyvek” suits (sizes as needed) 100 each
10. Portable flashlight 14,000 candle power 2 each
11. Coating inspection mirrors 6 each
12. SSPC Visual Standard Vis 1 2 each
13. SSPC Visual Standard Vis 2 2 each
14. Chlor*Test surface chloride test kits As Required
15. Respirators (self contained breathing apparatus) As Required
shall be properly fitted for each person designated by the Engineer complete with appropriate chemical cartridges as specified by the manufacturer.
THE FOLLOWING IS ADDED:
The Contractor shall have available for use by the Project Manager one (01) dry film thickness – Tooke Gauge. This will only need to be provided if requested by the Project Manager.
514.15 Method of Measurement.
THE FOLLOWING IS ADDED AFTER THE FIRST SENTENCE:
Metalizing existing steel bridges will not be measured, and payment will be made for the quantity in the Proposal adjusted for Change Orders except as provided for in Subsection 109.01.
the following is added:
Cleaning, If and Where Directed by the Engineer, will be measured on a lump sum basis.
514.16 Basis 0f Payment.
THE FOLLOWING IS ADDED:
Pay Item Pay Unit
METALIZING BRIDGES – EXISTING STEEL TON
CLEANING, IF AND WHERE DIRECTED LUMPS SUM
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SECTION 518 – BRIDGE DECK REHABILITATION
PROVIDE PROVISIONS FOR ADDITIONAL WORK ITEMS. SEE BRIDGE DESIGN MANUAL SUBSECTION 1.9B.2 FOR PARTIAL LISTING OF ADDITIONAL ITEMS.
02.
A.
THE SECTION IS DELETED AND REPLACED WITH THE FOLLOWING:
A. Repair of Concrete Deck and Sidewalks: This work shall consist of the removal and disposal of loose concrete, the preparation of the surface, cleaning and replacement of the existing reinforcement steel, application of epoxy bonding coat, and placing of concrete patch materials as shown on the plans for the bridge deck and sidewalks of ONLY the spans over the north and south bin abutments.
518.02 Materials.
BDC03s-06 dated april 24, 2003
The second “Other Materials” reference is changed to:
EPOXY BONDING COAT ……………………………………………………………………………912.06
THE FIRST SENTENCE OF THE SECOND PARAGRAPH IS CHANGED TO:
TO VERIFY THE APPROVED PRODUCT LISTING OF QUICK-SETTING PATCHING MATERIALS THAT MAY BE USED, THE CONTRACTOR IS ADVISED TO STUDY THE “BUREAU OF MATERIAL’S APPROVED LIST” ON THE FOLLOWING NJDOT WEBSITE:
B. Membrane Waterproofing.
THE FIRST SENTENCE OF THE first PARAGRAPH IS CHANGED TO:
TO VERIFY APPROVED MEMBRANE WATERPROOFING PRODUCTS, THE CONTRACTOR IS ADVISED TO STUDY THE “BUREAU OF MATERIAL’S APPROVED LIST” ON THE FOLLOWING NJDOT WEBSITE:
C. Concrete Deck Overlay Protective System.
THE second SENTENCE OF subpart 6 IS CHANGED TO:
TO VERIFY APPROVED LISTING OF CONCRETE DECK OVERLAY PROTECTIVE SYSTEMS THAT MAY BE USED, THE CONTRACTOR IS ADVISED TO STUDY THE “BUREAU OF MATERIAL’S APPROVED LIST” ON THE FOLLOWING NJDOT WEBSITE:
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THE TITLE IS CHANGED TO:
518.04 Repair of Concrete Deck and Sidewalks.
The words “and sidewalks” are added to this entire subsection after the word “deck” and “decks”, wherever referred to in this subsection.
518.06 Concrete Deck Overlay Protective System.
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13. Saw Cut Grooving.
The first sentence is changed to:
AFTER THE COMPLETION OF THE CURING TIME SPECIFIED IN C.12. THE OVERLAY SHALL BE SAWCUT GROOVED ACCORDING TO SUBSECTION 501.15, ITEM 3., PROVIDED THAT THE CONCRETE HAS ATTAINED A STRENGTH OF AT LEAST 4000 PSI AS DETERMINED FROM CYLINDERS THAT ARE CAST DURING THE PLACEMENT.
518.09 Basis of Payment.
THE FIRST PAY ITEM IS DELETED AND REPLACED WITH;
Pay Item Pay Unit
REPAIR OF CONCRETE DECK, TYPE B SQUARE FOOT
REPAIR OF CONCRETE DECK, TYPE C SQUARE FOOT
ADD THE FOLLOWING AT THE END OF THE SECTION:
Repair Areas of Sidewalks, as designated on the Plans will be included for payment under REPAIR OF CONCRETE DECK, TYPE B, or REPAIR OF CONCRETE DECK, TYPE C, as determined by the Engineer.
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SECTION 523– exodermic bridge deck system
523.01 DESCRIPTION.
This work shall consist of the furnishing and installing steel grid panels, metal forms and cast-in-place high-performance concrete (HPC) in all the approach spans, flanking spans and spans over the counterweight, as shown in the contract plans. Produce steel grid panels according to Manufacturer’s recommendations. Purchase the steel grid panels for the patented Exodermic deck from:
L.B. Foster Company American Bridge Manufacturing
1016 Greentree Road 2000 American Bridge Way
Pittsburgh, PA 15220 or Coraopolis, PA 15108
TEL: (412) 928-7820 TEL: (412) 631-3040
FAX: (412) 928-3514 FAX: (412) 631-4001
or other licensed Exodermic deck steel grid panel Manufacturers such as:
The D.S. Brown Company
300 E. Cherry Street
North Baltimore, OH
TEL: (419) 257-3561
FAX: (419) 257-2200
Website:
(All royalty payments are paid by licensed Manufacturers.) Licensing status and other information can be obtained from:
D.S. Brown Company
Exodermic deck technology.
Notify the Engineer of the name, address, telephone number, and contact person of the steel grid panel Manufacturer.
523.02 Materials.
Steel Grid Panels:
Structural Steel – 917.10
(ASTM A992 Structural Tees with a minimum 0.20% copper content, unless plans show otherwise.)
Galvanized Coatings and Repair Methods 917.12
Leveling Bolts ASTM A307, Grade A
Nuts ASTM A563
Stud Shear Connectors 503.10
Use ASTM A36 for the distribution bars and miscellaneous plates. Vertical sheet metal form pans installed in the grid prior to galvanizing shall conform to the latest specification for ASTM A1008 or A1011.
Use galvanized steel, sheet metal conforming to ASTM A653 for the forms.
Cast-In-Place High-Performance Concrete (HPC):
Admixtures:
Air-Entraining 905.01
Chemical 905.02
Reinforcement Steel for Structures 915.01
Mineral:
Fly Ash 919.07
Microsilica 924
Portland Cement 919.11
Water 919.15
523.03 Mix Design and Fabrication.
Cast-In-Place High-Performance Concrete (HPC).
523.04 Construction Requirements.
A. Steel Grid Panel Manufacturing Details.
Prior to steel grid panel manufacture, check the proposed panel layout, and verify all shop drawing dimensions and cross-slopes in the field for accuracy.
Manufacture the steel grid panels with the properties and to the dimensions shown on the plans, shop drawings, and in accordance with Section 503. Weld sizes shall be in conformance with established grid industry practice unless otherwise indicated on the contract plans. It shall be the Contractor’s responsibility to field verify all dimensions in order to make necessary changes prior to fabrication. Due consideration shall be given to the placement of leveling devices to provide adequate clearance for their field adjustment from above using a socket wrench and for adequate clearance for field placement of headed shear studs. The use of tertiary or supplemental bars to develop composite action between the concrete deck and the steel grid shall not be allowed.
Gas Metal Arc Welding (MIG) may be used for steel grid panel manufacture.
Use the Bridge Grid Flooring Manufacturers Association current standards for dimension tolerances.
After the attachment of all edge bars, leveling devices (with clearance for on-top field adjustment), and other components, galvanize the grid according to Subsection 917.12. Repair defects in galvanizing as specified in Subsection 503.14. Leveling bolts need not be galvanized if minimum to cover over the bolts of 2.5 inches is provided.
Identify each steel grid panel for correct placement on the structure. Support the steel grid panels with wood or similar blocks to avoid distortion or other damage during transportation and storage.
Lifting locations and procedures shall be included on the shop drawing submission. Care shall be taken to avoid twisting of the panels or bending of the panels in the distribution bar direction. [Use of multiple pick points is recommended].
Any Contractor proposed changes, additions, substitutions to the details/dimensions shall be accompanied by calculations sealed and signed by a Licensed Professional Engineer licensed to practice in the State of New Jersey.
B. Steel Grid Panel Installation:
1. Panel layout shown in contract plans is suggested. The fabricator shall develop the layout and detail it in the shop drawings. The layout is subject to approval by the Engineer. When rehabilitating a structure, and prior to steel grid panel installation, blast clean the top surface of beam flanges, and the surfaces of concrete or reinforcing that will be in contact with new concrete, according to the following:
a. Blast clean all surfaces to be in contact with new concrete. Remove all grease and dirt. Remove all rust and mortar which is not firmly bonded to the surface being cleaned. Rust and concrete deposits which are firmly bonded and cannot be removed by blast cleaning may remain. A light coating of orange rust that forms on steel surfaces after blast cleaning is not considered detrimental to bond and may remain. Remove all debris created by blast cleaning.
b. After structural slab wetting and immediately before placing concrete, use stiff, nylon-bristle brooms to brush a thin (approximately 3 mm) coating of grout into the prepared surfaces, including any slabs, curbs, longitudinal and transverse joints and reinforcing steel. Do not allow the grout to puddle.
c. Apply the grout with straight handled stiff, nylon-bristle brooms around reinforcing steel, and at joints.
d. Limit the application of grout, according to atmospheric conditions, to that area which will be covered with new concrete before the grout begins to dry. Dry bonding grout appears light grey in color and has a chalky texture. Do not place concrete on dry bonding grout. Concrete placement operations must be interrupted if dry bonding grout is encountered. Install construction dams, wait at least 48 hours, remove dry grout by blast cleaning, and place new grout and concrete, all in accordance with this specification.
e. Place positive-tie-downs at a maximum spacing of 4 feet.
f. Repeat blast cleaning if more than 48 hours pass before bonding grout placement begins.
2. Check the steel grid panels for defects and identification. Repair or replace steel grid panels or metal forms damaged during shipment and site storage to the satisfaction of the Engineer.
3. Position steel grid panels on the steel beams and align with adjacent panels. Measure from fixed points to avoid cumulative error. Adjust elevations with the attached leveling devices and square-up as necessary.
4. After sheet metal form and miscellaneous form installation, attach the shear studs through openings in the steel grid panels as per Subsection 501.10. With precise layout, and the Engineer’s permission, shear studs may be welded in place prior to placing the steel grid panels. Sheet metal forms shall be installed in such a manner as to minimize leakage.
5. Break the ceramic ferrules around the welded studs, and remove all debris.
C. High-Performance Concrete Placement:
Apply the provisions of Section 501 and the following modifications:
1. Install epoxy coated reinforcing steel in accordance with Subsection 501.08. Position the top rebars, which run in the same direction as the tertiary bars with the vertical studs, a minimum of 1 inch away from the tertiary bars.
2. Add the following to Section 501.10:
a. Introduce coarse aggregate, along with approximately 2/3 of the total mixing water, into the mixer and mix for a minimum of 10 minutes. Add the fine aggregate, admixtures, cement, fly ash, microsilica, and remaining mixing water and mix completely.
b. Have the aggregate manufacturer supply a service representative at the site for the first two days of concrete placement operations to assist in the control of concrete mixing and placement operations.
3. Handle and place concrete according to Subsections 501.10 to 501.12. No waivers will be granted. Insert concrete vibrators deeper at the haunch and full depth areas between panels.
a. During concrete placement, wash off any mortar that leaks through the steel grid panels and drips onto any structural steel.
b. Test the concrete according to Section 914.
4. Cure concrete according to Subsection 501.17, except that only a continuous 14-day wet cure is allowed.
5. Make any repairs as per the provisions of Section 518. In addition, the Engineer will reject any concrete represented by a cylinder set with an average compressive strength less than 4400 psi, or an individual cylinder with a compressive strength less than 4000 psi. Proposed repairs shall be submitted to the Engineer for approval.
6. The loading limitations of Subsection 501.24 apply, except that concrete cylinder sets designated for early loading must attain an average compression strength of 4400 psi, or greater, with no individual cylinder less than 4000 psi.
523.05 Method of Measurement.
Exodermic deck will not be measured and payment will be made for the quantity in the Proposal.
523.06 Basis of Payment.
Payment will be made at the unit price bid per square foot of Exodermic deck stated in the Proposal. Include the cost of all labor, materials, and equipment necessary to complete the work in the square foot bid price, which includes High Performance Concrete. Reinforcement steel required as detailed in the plans is paid for under “Reinforcement Steel, Epoxy-coated”.
Make progress payments on a per span basis as follows:
1. 40 percent of the estimate area after all steel grid panels and reinforcing is properly placed.
2. 40 percent of the estimate area after concrete placement, and curing initiated.
3. Pay the remainder after curing is complete and the deck construction accepted by the Engineer.
Payment will be made under:
Pay Item Pay Unit
EXODERMIC DECK SYSTEM SQUARE FOOT
THE FOLLOWING NEW SECTION IS ADDED:
SECTION 524 – VINYL SHEET PILING
524.01 Description.
This work shall consist of furnishing and installation of vinyl sheet piles as part of a new bulkhead to be constructed in front of the existing north timber bulkhead.
The work shall also consist of furnishing, installation and testing of earth anchors to support the vinyl sheet piles and furnishing and placement of in-fill soil between the existing and proposed bulkheads.
524.02 Materials.
A. Vinyl Sheet Piles
Sheet pile profile shall be manufactured with an interlocking feature that ensures adjacent panels maintain alignment. The sheeting shall be UV resistant, homogeneous, uniform in color, free from visible cracks, and free from other injurious defects. Manufacturer’s extrusion facility shall have at least 5 years experience with the manufacturing of vinyl sheet piling and 10 years experience with the manufacturing of other PVC parts. The sheeting shall be Shoreguard 950 as manufactured by Crane Materials International of Atlanta, Georgia or approved equal. The color shall be brown.
Acceptable manufacturers of vinyl sheet piling are:
a. Northstar Vinyl Products, LLC of Kennsaw, GA
800-558-6702
b. Crane Materials International of Atlanta, GA
866-867-3762
Pile Capping shall be as recommended by the manufacturer and approved by the Engineer to match the proposed sheet piles.
B. Earth Anchors
Earth anchors shall be Manta Ray anchors as manufactured by Foresight Products, LLC of Commerce City, Co. or Williams Form Engineering Corp. of Grand Rapids, MI, or approved equal.
C. Anchor Rods and other Hardware
All steel for anchor rods, anchor rod couplers, washers, turnbuckles, nuts, bolts, washers, and all other hardware shall be of steel with dual coating system consisting of zinc coating (galvanizing) and coal tar epoxy-polyamide paint. Coal tar epoxy-plyamide paint shall be applied immediately after the installation of all connections except that anchor rods excluding threaded ends, shall be painted at least 72 hours before the installation. All galvanized surfaces to receive coal tar epoxy-polyamide paint shall be cleaned according to the procedure given under Painting Galvanized Steel in Steel Structures Painting Manual. Galvanizing shall not be damaged during the cleaning process.
D. Drainage-Filtration Elements
Drainage-filtration elements shall be 3 inch long flanged Blue Marlin Filter as manufactured by Blue Marlin Filter, Inc. of Marco Island, Florida or approved equal.
E. In-Fill Soil
In-fill material placed between the existing and proposed bulkheads shall be I-9 material with the added restriction that the maximum particle size shall not exceed ¾ inch.
F. Geotextiles
Geotextile placed in front of the existing bulkhead, at the east and west end terminations of the new bulkhead, shall follow material specifications of NJDOT Standard Specifications, latest edition, Section 919.06, Geotextiles Section 2. – Roadway Stabilization, Riprap Filter, Retaining Structure Filter.
524.03 Submittals.
A. Vinyl Sheet Piles and Capping
The following documentation shall be submitted to the Engineer for approval at least thirty (30) days prior to the scheduled bulkhead installation:
• Records documenting a minimum of five years experience in driving sheet piles and a minimum of five previous vinyl sheeting jobs of similar or greater scope. Names of individuals (with address, affiliation, title, and telephone number) who can attest to the adequacy of the work done on these projects shall be submitted.
• Shop drawings showing elevation, plan, and cross-sections of the proposed vinyl bulkhead together with the existing timber bulkhead. Shop drawings shall also be provided showing the ends where the proposed bulkhead ties in with the existing bulkhead.
• Catalog cuts of proposed sheet pile capping.
• Method of installing the sheeting, including hammer information.
• Test reports documenting the testing and data pertaining to the vinyl sheeting material properties.
B. Earth Anchors
The following documentation shall be submitted to the Engineer for approval at least thirty (30) days prior to the scheduled bulkhead installation:
• Records documenting a minimum of three years experience in Manta Ray or approved equal earth anchor installation and a minimum of five previous anchoring jobs of similar or greater scope. Names of individuals (with address, affiliation, title, and telephone number) who can attest to the adequacy of the work done on these projects shall be submitted.
• Shop drawings, test reports, construction sequence, and documentation of properties of all materials to be used shall be submitted to the Engineer prior to installation. Shop drawings shall include, but not be limited to the following:
a) Proposed temporary platform and any other related access work required to install the anchors.
b) Anchor schedule giving:
▪ Load for each anchor
▪ Type and size of anchor
▪ Total anchor length
c) A drawing of the Manta Ray earth anchor system and corrosion protection
d) Detailed description of the proposed procedures, including specific makes and models of equipment to be used for driving Manta Ray anchors.
e) Detailed description of proposed procedures and applicable manufacturer’s literature for the equipment to be used for pulling Manta Ray anchors to their locked position, including but not limited to the following:
▪ Diagrams showing the arrangement of the pulling equipment relative to the anchor and the calibration of the loading measuring device.
▪ The Contractor’s proposed equipment set-ups for monitoring movement of the existing bulkhead during installation and pulling the Manta Ray anchors.
▪ The Contractor shall also submit a report to the Engineer within 5 working days after completion of the Manta Ray anchor work containing as-built drawings showing the locations of the anchors and total anchor lengths.
C. Anchor Rods and other Hardware
Applicable manufacturer certification and/or literature for anchor rods, anchorage fittings, and accessories shall be submitted to the Engineer for approval at least thirty (30) days prior to the scheduled bulkhead installation.
D. Drainage-Filtration Elements
Dimensions and method of installation of drainage-filtration elements shall be submitted to the Engineer for approval at least thirty (30) days prior to the scheduled bulkhead installation.
E. In-Fill Soil
The following documentation shall be submitted to the Engineer for approval at least thirty (30) days prior to the scheduled bulkhead installation:
• Gradation of the in-fill soil.
F. Backflow Check Valve at the Outlet End of 18” RCP Outfall Extension
Dimensions and method of attachment to outfall end of pipe, type of valve, manufacturer catalogs, and accessories shall be submitted 30 days prior to the scheduled bulkhead construction.
524.04 Delivery and Storage.
Upon delivery of materials to the site, Contractor shall visually inspect all materials for defects or damage. If serious defect or damage is detected, Contractor shall notify Engineer immediately. Any defective vinyl sheet pile components shall be replaced at no cost to the State. Bundled vinyl sheet piles shall be stored on relatively level surface with a slight pitch to allow water to drain. Contractor shall not break bundled sheets until ready for immediate installation.
524.05 Installation.
The Contractor shall follow the installation sequence shown on the Contract Drawings. Additionally, the following requirements shall be followed:
A. Before installation the Contractor shall inspect bulkhead components including anchors and vinyl sheeting for breaching of coating. If breaches exist, they shall be repaired according to manufacturer’s recommendations. If any part is deemed defective beyond repair by the Engineer, it shall be replaced at no additional cost to the State.
B. Vinyl sheet piles shall be driven using a guiding system with adequate precautions to ensure that they are driven plumb. The completed piling shall be vertical, in line, driven to the prescribed depth, cut off to a straight line at the prescribed elevation, and practically watertight at the joints. Sheet piling shall not be driven more than ½-inch per foot out of plumb in the plane of the wall, nor more than 1/16-inch per foot “out” of plumb perpendicular to the plane of the wall, nor more than 1-inch per foot “in” of plumb perpendicular to the plane of the wall.
C. Sheet piles shall be driven preferably in pairs to the depth specified on the plans. The method of construction shall conform to Section 505 except that lighter driving equipment or vibratory pile drivers may be used. Jetting shall not be used without the written approval from the Engineer. Under no circumstances shall the Contractor cut-off or install shorter sheets without written authorization from the Engineer. Sheet piles driven out of interlock with adjacent sheets or otherwise damaged shall be removed and replaced by new sheet piles at the Contractor’s expense.
D. Wales, anchor rods and anchors shall be installed as noted on the plans.
E. The Contractor shall extend existing drainage pipe through the vinyl sheet piles as noted on the drawings.
F. In-fill soil between existing and proposed bulkheads shall be placed as noted on the Plans.
G. The Contractor shall install sheet piles between November 1 and November 30, and in coordination with Bogan’s Basin as not to interfere with their business operations. This work will not be done at the same time as the contaminated soil removal at the north abutment.
H. Water levels in the river vary rapidly during the day. It is the Contractor’s responsibility to check predicted tidal variations of the Manasquan River at the project location to plan and optimize his work. The Contractor shall bid the job taking into account the large tidal variations in water levels. It is also the Contractor’s responsibility to visit the site of the bulkhead prior to bidding in order to envision the construction aspects of the project including the possible need for the installation of a temporary platform above the river bed and to consider the clearance under the bridge in installing the sheeting, the piles and the earth anchors. No claim shall be made by the Contractor for any additional cost resulting from his lack of knowledge of the site conditions.
I. It is the Contractor’s responsibility to determine with the utility company the location of the gas pipe on the eastern side of the bulkhead and any other existing pipes. The Contractor shall be responsible for any damage to the pipe or any other existing utilities as a result of his bulkhead installation procedure.
524.06 Method of Measurement.
Vinyl sheet piles will be measured by the square foot of projected area inclusive of the embedded and exposed areas and exclusive of indentation of pile section.
Earth anchors will be measured by the number of earth anchors installed. No separate measurement shall be made for the components of the earth anchors including Manta Ray anchor or approved equal, anchor rod, couplers, washers, nuts or any other components of the earth anchor.
Geotextile will be measured by the Square Yard.
Drainage-filtration elements will be measured by the number of elements installed.
Bolts, screws, threaded bars, washers, nuts, or other hardware that is needed for tying the proposed bulkhead to the timber bulkhead and for attaching the capping to the vinyl sheeting will not be measured, the cost thereof will be included in the vinyl sheet piling unit cost.
524.07 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
VINYL SHEET PILING SQUARE FOOT
EARTH ANCHORS UNIT
DRAINAGE-FILTRATION ELEMENTS UNIT
IN-FILL SOIL CUBIC YARD
GEOTEXTILE SQUARE YARD
No separate payment will be made for furnishing all labor, equipment, temporary access work, materials, setup, mobilization and demobilization, storage, disposal of unused piles, repair or replacement of damaged piles and incidentals necessary to satisfactorily complete the installation of the vinyl sheeting as shown on the contract drawings and specified herein. All costs thereof shall be included in the item VINYL SHEET PILING. Parts of sheeting cut off will not be included for payment.
No separate payment will be made for furnishing all labor, equipment, temporary access work, materials, equipment, setup, mobilization and demobilization, storage, disposal of unused anchors, repair or replacement of damaged anchors and incidentals necessary to satisfactorily complete the installation of the earth anchors as shown on the contract drawings and specified herein. All costs thereof shall be included in the item EARTH ANCHORS.
No separate payment will be made for furnishing all labor, equipment, temporary access work, equipment, setup, transportation, and incidentals necessary to satisfactorily complete the placement of the in-fill soil as shown on the contract drawings and specified herein. All costs thereof shall be included in the item IN-FILL SOIL.
No separate payment will be made for capping, bolts, screws, threaded bars, washers, nuts or other hardware that is needed for tying the proposed bulkhead to the timber bulkheads and for attaching the capping to the vinyl sheeting. All costs thereof will be included in the item VINYL SHEET PILING.
No separate payment will be made for the installation of the drainage-filtration elements. All costs thereof shall be included in the item DRAINAGE-FILTRATION ELEMENTS.
No separate payment shall be made for extending the existing reinforced concrete drainage pipe or the backflow check valve required at its outfall end, through the vinyl sheeting. All costs thereof will be included in the item VINYL SHEET PILING.
THE FOLLOWING NEW SECTION IS ADDED:
SECTION 525 - BASCULE SPAN FIBER REINFORCED POLYMER (FRP) SIDEWALK
525.01 Description.
This work shall consist of the installation of fiber reinforced polymer (FRP) sidewalk panels on the bascule span.
This work shall also consist of applying a non-skid surface for the FRP sidewalk.
MATERIALS
525.02 Materials.
FRP panels shall be as manufactured by the following or approved equal:
1. Bedford Reinforced Plastics, Inc.
264 Reynoldsdale Road
Bedford, PA 15522-7401
Product Name: Prodeck 4 Composite Decking
Contact: Mr. Tom Wright (814) 623-8125
2. Martin Marietta Composites
2501 Blue Ridge Road
Raleigh, NC 27607
Product Name: DuraSpan 500
Contact: Matt Sams (919) 882-2310
3. Strongwell
400 Commonwealth Avenue, PO Box 580
Bristol, VA 24203-0580
Product Name: EXTREN Series 4”x 4” x ¼” square tubes with EXTREN Series 500 3/8” Plates.
Contact: Dan Witcher (276) 645-8151
Materials shall conform to the following:
A. Fiber type. Any commercial grade E-glass fiber is permitted to produce a FRP (fiber reinforced polymer) composite bridge deck module. The fiber can be in the form of unidirectional rovings of any size, weight and in the form of continuous strand mats, bidirectional or multidirectional fabrics of any weight. The fabrics can be stitched/non-stitched, woven/non-woven, knitted or braided.
B. Resin type. Only thermoset resins, specifically commercial grade vinyl ester resin are permitted in FRP composite bridge deck module production. Vinyl ester has good stability against harsh environments compared to other thermoset resins and more ductile than epoxy.
C. Fiber architecture. The performance of FRP composite bridge deck modules depends on the relative volume of fiber and resin present in the composites. Since fibers are main load resisting constituents in composites, the fiber content should be high compared to resin content. The fiber content in composite deck modules is normally expressed in terms of fiber volume fraction.
The overall fiber volume fraction in a given FRP composite bridge deck module made of fibers/fabrics should be no more than 60% and no less than 25%. The overall upper bound fiber volume fraction of 60% is the practical limit from the manufacturing point of view due to wet-out problems in the part beyond 60% and the overall lower bound fiber volume fraction of 25% is to be maintained in the part to prevent any catastrophic shear failure, or excessive deck flexibility.
The ratio of fiber reinforcement in the minor bending direction of the FRP composite bridge deck module should be no less than one-fourth of total fiber reinforcement in the major bending direction.
D. Laminate type. The laminates in a FRP composite bridge deck module are built by orienting the fibers/fabric in various directions. Fiber orientation is expressed in terms of angle with respect to the main bending direction of the part. For laminates resisting bending stress, the fibers should be distributed along the major bending direction of the part i.e., should be oriented at 00 (i.e., along the major bending axis) and for laminates resisting shear stress, the fiber should be distributed in other directions i.e., should be oriented at 900, ± 450.
E. Other materials. The other materials such as additives, fillers, pigments, fire retardants etc appropriate with the E-glass fiber and vinyl ester resin are permitted.
F. Mechanical properties of constituent materials. The fiber and resin materials acquired from a supplier shall be certified in accordance with ASTM standards. The fiber and resin materials must be accompanied with a certification document clearly stating the type of material and its mechanical properties. The mechanical properties of reinforcing fibers, resin and FRP laminates shall be determined as per the following ASTM standard tests:
|Materials |Properties |ASTM Standards |
|Fibers |Tensile strength and modulus of elasticity |D 3379 |
| |Fiber volume content |D 3171 |
|Resin |Tensile strength and modulus of elasticity |D 638 |
|Laminates |Tensile strength and modulus of elasticity |D 3039 |
| |Flexural strength and modulus of elasticity |D 790 |
| |Shear strength |D 3846 |
G. Wearing surface. The thickness of the polymer concrete wearing surface shall be in conformance to the Manufacturing Section of this document and the field application of the wearing surface shall be in conformance to Construction Section.
Polymer concrete overlay shall be as manufactured by the following or approved equal:
1. Tamms Industries
3835 State Route 72
Kirkland, IL 60146
Product Name: Flexolith
Contact: (800) 862-2667
2. Transpo Industries, Inc.
20 Jones Street
New Rochelle, NY 10801
Product Name: T-48 Thin Overlay System
Contact: (914) 636-1000
H. Adhesive. Epoxy adhesive for bonding fiberglass panel to fiberglass panel shall be as manufactured by the following or approved equal:
1. Magnolia Plastics, Inc.
5547 Peachtree Industrial Boulevard
Chamblee, GA 30341-2296
Product Name: Magnobond 56 A/B
Contact: (770) 451-2777
2. Ashland Specialty Chemical Company
Specialty Polymers and Adhesives Division
Corporate Office: P.O. Box 2219
Columbus, OH 43216
Product Name: Pliogrip Adhesive systems 8000/6660
Contact: (800) 322-6580
CONSTRUCTION
525.03 Manufacturing.
The FRP deck manufacturer shall be certified to be qualified under the provisions of ISO 9000, 9001 standards for manufacturing performance. If the FRP deck manufacturer’s facility is not qualified as an ISO 9000, 9001 facilities, then the FRP deck manufacturer must supply a Quality Assurance Plan which clearly states how the manufacturer will ensure that the deck products produced will be of consistent and required quality.
The FRP deck manufacturer shall supply the Contractor with manufacturer’s process specification that details the manufacture of FRP composite deck modules. The process specification shall have the following details:
A. Materials. The specification shall include details on fiber and resin such as fiber architecture, laminate type, mechanical properties etc. to be used in the FRP deck manufacturing process. The specification on materials shall be in conformance with the Materials Section.
B. Processing. The selection of the composite processing technique will be the choice of the FRP composite deck manufacturer. Processing of constituent materials (fibers and resin) into composite bridge deck module shall be accomplished by varying techniques that include pultrusion, resin transfer molding, wet lay-up, SCRIMP and others.
C. Curing. The process specification shall specify curing temperature (room temperature), pressure (vacuum), RH and time to cure. The FRP deck modules shall be prevented from any deformation during curing.
D. Assembly. The modules shall be connected in the manufacturing plant to produce FRP panel. A module shall be fabricated to maximum length and width and assembled to FRP panel with maximum dimensions for ease of transportation by trailers.
The specification shall address the details on connecting modules into composite bridge deck panels. The modules shall be connected either by bonding, bolting, or combination of bonding and bolting. The modules should be connected so as to have proper horizontal and vertical shear transfer from one module to another.
E. Wearing Surface. Wearing surface shall be field applied. The wearing surface materials shall be in accordance to Materials Section. The polymer concrete wearing surface shall be of ¼” thick and shall be applied after surface preparation of deck as per Construction Section.
The manufacturer shall apply the wearing surface in accordance with material supplier instructions, and also follow instructions as per Construction Section.
The process specification shall specify the details on reinforcement of field joints that shall be applied in accordance with Construction Section.
The Manufacturer’s process specification shall define specific quality assurance testing to be conducted to assure that the finished composite deck module/panel has been manufactured to the quality and workmanship levels necessary to meet the functional and structural performance requirements for the intended application. As a minimum static and fatigue tests have to be conducted on the FRP module/panel to verify the structural properties of the module/panel.
Transportation. The sections shall be manufactured to maximum dimensions for ease of transportation on trailers. They shall also be provided with proper lifting devices or methods to prevent damage during shipping and unloading.
Marking. The manufacturer shall provide tags or markings on each section shipped with details such as name of the manufacturer, date manufactured, etc.
Joints. The sections shall be manufactured so as to have adequate shear transfer between panels bonded in the shop and spliced in the field. All field joints shall be reinforced with two layers of glass fabrics of weight 24-26 oz/SY to prevent reflective cracking of wearing surface and resist thermal induced stresses.
Documentation. The manufacturer shall assemble and maintain a project documentation file for the FRP bridge project. Project documentation shall include:
1. Design data and calculations
2. Approved fabrication drawings
3. Manufacturing quality control records
4. Installation instructions
5. Terms of warranty
This documentation shall be made available for review and copying during the project and shall be archived at the manufacturer’s facility for a period of at least five years after the product is shipped. Documentation shall be copied and submitted as record to the owner.
525.04 Design.
A. Deflection criteria. The maximum global deflection (deflection of stringer) in FRP bridge deck stiffened with stringer or concrete girder system shall be limited to L/800, where L is the effective span of support stringers or girders.
The maximum deck deflection (deflection of deck relative to two contiguous stringers or diaphragms as per the traffic flow) shall be limited to S/500, where S is the center-to-center distance between the stringers or diaphragms.
The maximum local deflection (deflection of top flange of deck) shall be limited to s/100, where s is the distance between two contiguous webs in the FRP deck module.
B. Strength criteria. The deck shall be designed to resist the following two loading conditions: 1) 85 psf pedestrian load and 2) HS 25 wheel load on sidewalk with an impact of 25%. An increase in allowable stress of 150% shall be permitted for HS25 wheel loading. The failure load of the original deck under static loading shall be no less than 125 kips, which includes knockdown factors.
The FRP bridge deck system (deck supported on stringers) should be capable of sustaining 2 million cycles at a load range 1 – 26 kips under fatigue loading.
C. Flexure Criteria. The maximum allowable bending strain in FRP bridge deck shall be limited to 20% of strain to failure under service loads including environmental/aging effects.
The maximum allowable dead load strain shall be limited to 10% of strain to failure of FRP composite material. This includes 3 to 6 psf of wearing surface.
D. Shear Criteria. The maximum allowable shear strain in FRP bridge deck shall be limited to 16% of the ultimate strain under service loads including environmental/aging effects.
E. Coefficient of thermal expansion. The maximum coefficient of thermal expansion in major and minor bending direction shall not exceed 5.5 x 10-6 and 9.5 x 10-6 per deg F respectively.
The maximum Transverse Load Distribution Factor (TLDF) in FRP bridge deck system shall be taken no more S/5.5, where S is the center-to-center distance of stringers.
The FRP bridge deck system shall be designed for 0% structural compositeness, between the FRP deck and stiffening stringers.
525.05 Construction.
A. Transportation. The panels shall be manufactured to maximum dimensions or ease of transportation on trailers. The panels should be provided with proper lifting provisions to prevent any damage under shipping and handling loads.
B. Deck marking. The manufacturer shall provide tags on each batch of deck panels, with details such as name of the manufacturer, date manufactured etc.
C. Installation. The panels shall be installed as per the manufacturer’s installation guide. The panels shall be assembled so as to have adequate shear transfer from one panel to another.
D. Connections. The FRP bridge deck shall be connected to stringer by mechanical fasteners.
E. Joints.
1. Expansion joints. The type of expansion joint should be specified in the manufacturer’s specification. The specification should also have the details of materials for the closure pour or filler material, between the deck and the back wall of the bridge seat.
2. Field joints. All field joints shall be reinforced with two layers of glass fabrics of weight 24-26 oz/yd2, to prevent reflective cracking of wearing surface and resist thermal induced stresses.
For best bonding results, the fabrics should be reinforced in the late afternoon of a hot day (i.e., 5 to 6 p.m.) after the water from the joint is evaporated to its maximum and the evaporation may not be one hundred percent.
The joints should be effective in transferring moments between the panels and eliminate water seepage.
F. Surface preparation. The surface area of the deck where the glass fabric is to be attached should be mechanically abraded to remove any gloss from the surface of the deck.
The surface should be cleaned with proper chemical solvent to clean dust and chemical residue after 30 minutes of cleaning with solvent. The fabric should be rolled over the joint, which is followed with the resin. The excess resin shall be removed and allowed to cure for about 24 hours prior to apply the wearing surface.
During surface preparation, the minimum temperature shall be 50(F and the weather condition should be dry.
Application of peel ply at factory and removal at field to apply wearing surface is also permitted.
G. Cold weather. The required FRP sidewalk installation must be scheduled to meet contract schedule. Contractor shall provide cold weather protection as required. Protection methods shall be submitted to the Engineer for approval.
525.06 Acceptance.
A. Finished Geometric Tolerances. The finished dimensions of the FRP bridge structures shall conform to the following dimensional tolerances unless otherwise specified on the fabrication drawings:
1. Overall depth: +/-¼ inch
2. Out-of-straightness (bow): +/-1 inch per 25 feet of length
3. Panel length and width: +/-¼ inch
B. Submittals. Fabrication drawings shall be submitted to the Engineer for review and approval. The following information shall be included as a minimum:
Cross sectional and overall dimensions
Material references
Recommended lifting method and locations
Instructions and recommendations for panel delivery, storage, and installation
Design calculations shall be submitted to the Engineer for review and approval. Calculations shall be prepared by a Professional Engineer licensed in the State of New Jersey.
C. Inspection. The quality of materials, the process of manufacture and the finished sections shall be subject to inspection by the Engineer. The Engineer reserves the right to hire a consulting engineer for the inspection of the materials delivered and installation of the materials at the site.
D. Rejection. The Engineer may reject any section if, in the Engineer’s opinion, the structural integrity or service life of the section has been reduced due to materials, manufacture, handling, or installation.
COMPENSATION
525.07 Method of Measurement.
Bascule Span Fiber Reinforced Polymer (FRP) Sidewalk will be measured by the square foot.
FRP sidewalk panel overlay will not be measured.
525.08 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
BASCULE SPAN FIBER REINFORCED PoLymer (FRP) SIDEWALK square FOOT
NO SEPARATE PAYMENT WILL BE MADE FOR THE OVERLAY MATERIAL THAT IS APPLIED ON THE FRP SIDEWALK PANEL. THE CONTRACTOR SHALL INCLUDE THE COST OF FURNISHING AND APPLYING THE OVERLAY FOR THE PAY ITEM “BASCULE SPAN FIBER REINFORCED POLYMER (FRP) SIDEWALK”.
SECTION 526 – BASCULE SPAN MEDIAN BARRIER
526.01 Description.
This work shall consist of furnishing and installation of Bascule Span Median Barrier as shown on the contract drawings and specified herein. Additional replacement sections shall be furnished as specified on the contract drawings. Replacement sections shall be delivered to a location designated by the Engineer. All equipment, materials, and labor that are required to fabricate, deliver, and install the barrier as shown on the plans and specified herein shall be included.
526.02 Materials.
Structural steel for median barrier shall be AASHTO M270, Grade 50 (ASTM A709, Grade 50). The material conformance criteria of Section 503 shall be followed.
526.03 Inspection and Testing.
The inspection and testing criteria of Section 503 shall be followed.
526.04 Working Drawings.
Working Drawings shall be furnished according to Subsection 105.04.
526.05 Fabrication and Welding.
The fabrication criteria of Section 503 shall be followed.
526.06 Shipping, Handling, and Erection.
The criteria of Section 503 shall be followed.
526.07 Cleaning and Painting.
Median barrier shall be galvanized and shop painted the same as the bridge railing in accordance with Section 503. Color to match proposed bridge railing.
526.08 Method of Measurement.
Bascule Span median barrier shall be measured by the linear foot.
526.08 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
BASCULE SPAN MEDIAN BARRIER LINEAR FOOT
SECTION 527 – BASCULE SPAN BALANCING
527.01 DESCRIPTION.
This work shall include balancing and balance testing the movable span to ensure compliance with the design criteria listed on the Plans and elsewhere herein for the bascule span leaves. Balance testing shall be performed using the dynamic strain gage procedure as described herein. This item includes the calculation and documentation of the span balance procedure and methods. All work required to complete the span balance, including furnishing, placing, removing and adjusting the location of the balance blocks within the counterweight and counterweight pockets, is included in this item. The span must be kept operable in accordance with the provisions of Section 107.13, Construction Over or Adjacent to Navigable Waters
Balance calculations shall be prepared prior to performing any work potentially affecting the span balance. Calculations shall be based on approved shop drawings and material tests, and shall be submitted to the Engineer for review and approval.
The Contractor shall measure the imbalance moment and determine the location of the leaf center of gravity a minimum of six (6) times.
1. Existing Condition: Prior to construction to determine the existing balance condition and adjust the balance to 700 lbs. toe heavy per girder.
2. Stage I completion
3. Stage II completion
4. Stage III completion
5. Stage IV completion - After leaf construction is completed to determine the balance condition and to determine the required final adjustments.
6. Final - After Stage IV balance block adjustments, to determine if the revised imbalance is within the limits specified on the Plans and as described herein. Leaf operation for final balance testing shall be performed with the span drive machinery. If the second balance testing indicates that the revised imbalance is not within acceptable limits, further balance block adjustments and imbalance measurements are to be performed until the criteria specified on the Plans and herein are met.
In all cases above, prior to performing balance testing, the Contractor shall submit balance calculations and summary tables to the Engineer for review. The Contractor shall perform span balance calculations of the draw span for the removal of existing bascule span components and installation of the new components to determine the interim and final balance of the span. The Contractor shall update span balance calculations continually throughout construction and at a minimum shall be prepared for each weekly opening as defined in Section 107.13 “Construction over or adjacent to Navigable Waters”. The calculations shall be formatted such that each removal and installation is in sequential order according to the Contractor's planned schedule. The maximum calculated span imbalance as shown on the Contract Plans shall not be exceeded at any leaf position.
Included in this Section are the following Items:
1. Inventory the existing balance blocks and plates in the horizontal and vertical pockets of the draw span counterweight boxes. The inventory shall include documenting and recording the weight and location of the existing balance blocks and plates. The existing blocks and plates shall be weight measured for the inventory.
2. In addition, as the existing bascule span components are removed and new components are installed, the balance of the bascule span shall be adjusted. This work shall consist of balancing the leaves by adding, removing, or shifting existing concrete or new cast iron balance blocks in the counterweights to obtain interim balance of the bascule spans during the various stages of construction. The installation of additional cast iron blocks and the removal and replacement of existing concrete blocks with cast iron blocks shall be performed as necessary so that the bascule span is balanced at all times. At the completion of the work on the bascule span, the bascule span shall be toe heavy 700 pounds per girder at the lock bar assembly. This work shall be scheduled to be performed after the installation of the strain gages to assist in maintaining the bascule span balancing.
MATERIALS
527.02 Materials.
New balance blocks shall be constructed of cast iron and conform to ASTM A48 of any class. Block dimensions and quantity furnished shall be as shown on the Contract Plans. Cast iron balance blocks shall be cleaned to meet the requirements of SSPC-SP2, Hand Tool Cleaning (as depicted in SSPC Vis. 1) prior to painting. Case iron balance blocks shall be shop painted with one coat of epoxy mastic primer, one intermediate coat of approved epoxy paint compatible with the prime coat system, and one final coat of approved polyurethane paint resistant to weathering and abrasion and compatible with intermediate coat.
CONSTRUCTION
527.03 Construction.
A. Calculation of Leaf Balance During Construction. The Contractor shall submit balance calculations as specified herein to the Engineer for review and approval. A Professional Engineer licensed in the State of New Jersey shall perform the balance calculations. The calculations shall be formatted such that each removal and installation is in sequential order according to the Contractor's planned schedule. The quantity and location of balance material required within the counterweight pockets, based on the specified balance requirements and the weight and center of gravity of each bascule leaf shall be computed. These calculations shall be based on weights of approved shop details and material tests for the actual material on each leaf, including the counterweight box. The calculated weight shall be extremely accurate and account for all material, weld fillets, bolt heads, washers, nuts, paint, normal overruns on plate thickness, etc. The balance calculations shall incorporate the distributions of leaf weight in the vertical, horizontal, and transverse directions. The balance calculations and summary tables shall be updated by the Contractor throughout construction and be submitted to the Engineer prior to each weekly opening, as defined in Section 107.13 “Construction over or adjacent to Navigable Waters”. The balance calculations shall be approved by the Engineer before removal operations can begin. The balance calculations summary shall be prepared using an Excel spreadsheet. The calculations and results shall be submitted with a Microsoft Windows compatible CD.
Weights for new work shall be developed on the shop drawings for each component. Summary balance tables shall be developed and shown on the shop drawings. Summary tables shall be developed for all phases of the balance and the proposed imbalances. The format of these tables shall be in accordance with the balance tables shown in the Plans. Temporary balance material, if used, shall be accounted for in the summary tables. All summary tables and back-up materials shall be submitted for review. A narrative shall be included with the outline of the proposed phasing, the duration of the imbalance condition, and all other aspects of the work in accordance with the approved construction schedule. This information shall be coordinated with the Contractor’s scheduling requirements and shall be submitted to the Engineer for review.
It shall be the Contractor’s responsibility to provide temporary bracing and supports and/or temporary balance material as required to stabilize the movable span during construction. It shall be the Contractor’s responsibility to coordinate work such that the bascule leaves are never in an unbalanced condition that may be detrimental in any way to the structure, electrical/mechanical components or the safety of construction personnel or the public.
Review of the balance calculations, counterweight details, and quantity and location of balance material does not relieve the Contractor from making such changes in the counterweights and balance material as deemed necessary to balance each leaf. All changes shall be submitted for approval.
B. Measurement of Span Balance. The balance of each leaf of the movable span shall be measured using the dynamic strain gauging technique. The Contractor shall furnish and install all equipment, materials, instruments, and labor necessary to determine the imbalance by dynamic strain gauging.
Immediately prior to strain gauge testing, the Contractor shall lubricate all trunnions to the satisfaction of the Engineer. The Contractor shall employ the services of an established testing company experienced in dynamic strain gage measurement of movable bridge imbalance, subject to approval of the Engineer. Such experience shall be demonstrated by identifying a minimum of six movable bridges including at least three trunnion bascule bridges for which the company has provided complete and satisfactory dynamic strain gage measurements and reporting. The measurements shall be made under the immediate direction of a Professional Engineer registered in the State of New Jersey who has had hands-on-experience measuring movable span imbalance by the dynamic strain gage procedure.
The testing company shall furnish and install the required strain gages, all cabling and transmission equipment, data acquisition equipment and strip chart recorders and produce fully documented reports detailing the results of the measurements. Acceptable testing companies include:
SMI Incorporated, Pittstown, NJ
Teledyne Engineering Services, Waburn, MA
Stafford Bandlow Engineering, Washington Crossing, PA.
The approved testing company shall submit the following items to the Engineer for approval:
(1) Description of experimental procedure including type and method of installation of strain gage rosettes, method of transmission of low level signals, data acquisition equipment and/or strip chart recorders.
(2) Layout of span drive machinery showing proposed location of strain gages, amplifiers, cable or radio links, data acquisition equipment and all associated cabling.
(3) Details of method of transmission of signals from shafting to data acquisition units.
(4) Elementary wiring diagrams of interconnection of strain gages, amplifiers, data acquisition equipment, and strip chart recorders.
(5) Sample computations of: shaft torque from measured strains, span imbalance, curve fitting, and basis for friction correction.
Two foil resistance strain gage rosettes shall be affixed as close as practicable to each of the main pinion shafts, in accordance with the strain gage manufacturer’s installation instructions. They shall be 2-arm 90 degree rosettes mounted such that the grids are oriented at 45 degrees with the shaft axis and the two rosettes shall be affixed “back-to-back”, spaced 180 degrees apart circumferentially. The gages shall be connected such that any bending strains in the shafts will be canceled and torsional shearing strains will be measured on each pinion shaft. The areas of the shafts where the gages are to be mounted shall be sufficiently cleaned to remove all contaminants. On each shaft, two rosettes shall be mounted at 180 degrees from each other. The two gages shall be connected such that any direct shear forces in the shafts are neglected and true torsional shear is measured.
The strain gage leads on each shaft shall be connected to a four arm amplifier. Transmission of signals from the gauges to the data acquisition equipment shall be either through cable links or amplified and then through wireless transmitters.
Output leads from each channel of the amplifiers shall be connected to either a computer-based data logger provided with a two-channel strain gage module streaming the amplified data to disk at a minimum1-kHz sample rate, or a five channel minimum strip chart recorder with at least ten inch wide chart paper. An inclinometer shall be provided to provide continuous leaf angle to either the datalogging equipment or the strip chart recorder. The chart speed shall be step-wise adjustable and shall include a setting of at least 250 mm per minute. The recorder shall be capable of recording data from at least 4 channels if it is equipped with a dedicated event marker or 5 channels if a channel is used to record events.
The strains in both shafts shall be recorded simultaneously versus span opening angle during opening and closing to a suitable scale. The readings for all shafts shall be recorded at the same strain scale and the chart speed, if a strip chart recorder is used. At least 3 opening/closing runs shall be made, when the wind speed is less than 5 mph and the bridge deck is visibly dry. Wind-up torque in the operating machinery shall be released prior to each run as verified by space between the faces of the engaged teeth of main pinion and gears.
The strains induced in the shafts shall be numerically converted to torque by applying fundamental stress-strain relationship calculations for each strain plot for both opening and closing. This data shall be processed to give leaf imbalance (kip-ft) versus opening angle, corrected for friction, at each trunnion. From them, plots of total span imbalance shall be prepared.
Upon completion of each of the six (6) required span balancing stages, the Contractor shall submit five copies of a report documenting the results of the strain gage measurements. Separate reports are required for each leaf. The reports shall contain the following:
(1) Description of experimental procedure and equipment used.
(2) Span drive diagram showing location at which strain gages were attached and all applicable gear ratios.
(3) Photocopies of a sample original strip chart for one complete run of each of the three sets in the case of strip chart recordings or data and chart files in Excel format if recorded by a data logger. They shall be annotated with strain scales, angle of opening, significant ordinates, etc.
(4) Description of relationships and sample calculations for obtaining shaft torque from strains, span imbalance from shaft torque, curve fitting, and basis for friction correction.
(5) Plots of the following parameters versus degree of opening during each opening/closing run and fitted balance curves corrected for friction:
a. Total imbalance (kip-feet) for span.
b. Frictional moment (kip-feet) for span.
(6) Tabulation of imbalance moment at seated position for each leaf/run including the average value for each leaf.
(7) The location of the leaf center of gravity.
The reports will be bound between heavy plastic covers. The report shall include an introductory section giving the name of the bridge, the date of the measurements, weather conditions during measurements and any other information requested by the Engineer.
The final imbalance measured by the procedures described herein shall be considered acceptable if:
(1) The allowable range of imbalance with the leaf in the seated position and the maximum allowable imbalance throughout the operational travel of each leaf meets the requirements stipulated on the Contract Plans.
(2) The location of the final center of gravity for each leaf in the seated position is as shown on the Contract Plans.
Drift tests shall also be used to corroborate the final balance of the bascule leaf by testing for a tendency of the leaf to move more in one direction than the other. They shall be performed as follows, preferably by using the regular electric motors for the operation of the leaf and the position indicator for measurement of drift:
(1) Each bascule leaf shall be raised and lowered alternately, and at three selected points in its travel, as determined on the leaf position indicator, the operating power shall be cut off and, with the leaf brakes released, the leaf allowed to come to a stop through the friction of the trunnion and span drive system alone. Balance blocks shall be placed in the pockets of the counterweights or blocks/plates shall be removed, until the angular movement of the leaf (drift) in the closing direction is 1½ times greater than the drift in the opening direction.
(2) The mid-travel and quarter-travel positions of the leaf shall be used in conducting these drift tests. The minimum number of drift tests shall not be less than 2 full cycles of the span opening and closing. Additional drift tests shall be performed as directed by the Engineer to determine the span balance.
(3) Operation of the leaves by temporary drive power, and measurement of drift by means other than the position indicators will be permitted subject to approval by the Engineer.
Records of the drift tests shall be submitted to the Engineer.
COMPENSATION
527.04 Method of Measurement.
A. Span Balancing
No measurement shall be made for this work.
B. Balance Block
The quantity of balance blocks furnished shall be as shown on the Contract Drawings. Additional balance blocks shall be furnished if required to meet the balance criteria specified in the Contract Documents. If, with the Engineer’s approval, the Contractor modifies the mass of the bascule leaves solely for the purpose of facilitating his/her operations, there will be no measurement made for additional blocks necessitated to balance such modifications.
527.05 Basis of Payment.
A. Span Balancing
The lump sum price bid for "Bascule Span Balance" shall include the cost of all labor, materials, and equipment necessary to complete the work in accordance with the Contract Plans and Specifications. The cost of all analyses, testing, and Professional Engineer services shall be included in the unit price. The price bid shall include the cost of installing, removing, and/or adjusting the location of balance blocks to achieve final balance. One sixth of the Lump Sum shall be paid after completion of each of the six different span balancings.
B. Balance Blocks
The unit price for “Balance Blocks” shall include the cost of all labor, materials, and equipment necessary for fabricating and transporting the blocks to the site.
Payment will be made under:
Pay Item Pay Unit
SPAN BALANCING LUMP SUM
BALANCE BLOCKS POUNDS
SECTION 528 – BASCULE SPAN FINGER AND HEEL JOINTS
528.01 DESCRIPTION.
This work shall consist of furnishing and installation of Bascule Span finger and heel joints as shown on the contract drawings and specified herein. All equipment, materials, and labor that are required to fabricate, deliver, and install the joints as shown on the plans and specified herein shall be included.
528.02 Materials.
Structural steel for finger and heel joints shall be AASHTO M270, Grade 50 (ASTM A709, Grade 50). The material conformance criteria of Section 503 shall be followed.
528.03 Inspection and Testing.
The inspection and testing criteria of Section 503 shall be followed.
528.04 Working Drawings.
Working Drawings shall be furnished according to Subsection 105.04.
528.05 Fabrication and Welding.
The fabrication criteria of Section 503 shall be followed.
528.06 Shipping, Handling, and Erection.
The criteria of Section 503 shall be followed.
528.07 Cleaning and Painting.
Finger and heel joints shall be shop painted in accordance with Section 503. Color to match proposed bridge railing.
528.08 Method of Measurement.
Bascule Span finger and heel joints shall be measured by the pound.
528.09 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
BASCULE SPAN FINGER AND HEEL JOINTS POUND
SECTION 529 – CONTROL HOUSE WORK
529.01 DESCRIPTION.
This work shall consist of the following:
1. Removal of existing steel doors and thresholds, modifying door jambs, and furnishing and installing new steel doors, thresholds, and weather strips at locations indicated on drawings.
2. Modification of the stairs to eliminate tripping hazard due to impacted rust as shown on the drawings.
3. Modification of the existing louver opening for new diesel engine generator louver as shown on the drawings.
4. Replacement of the timber bumper block as shown on the drawings.
MATERIALS
529.02 Materials.
A. Steel Doors, Jambs, and Accessories. All steel used to manufacture doors, jambs, and accessories shall meet at least one or more of the following requirements:
1. Cold rolled steel shall conform to ASTM A1008, “Standard Specification for Steel Sheet, Cold-Rolled, Carbon, Structural, High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability” and A568, “Standard Specification for Steel Sheet, Carbon, and High-Strength, Low-Alloy, Hot-Rolled and Cold-Rolled, General Requirements for.”
2. Hot rolled, pickled and oiled steel shall comply with ASTM A1011, “Standard Specification for Steel Sheet and Strip, Hot-Rolled, Carbon, Structural, High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability” and A568, “Standard Specification for Steel Sheet, Carbon, and High-Strength, Low-Alloy, Hot-Rolled and Cold-Rolled, General Requirements for.”
3. Aluminum doors at roadway level shall be extruded aluminum having the properties of aluminum alloy 6063-T5.
B. Prime Finish. Doors and frames shall be thoroughly cleaned and chemically treated to insure maximum paint adhesion. All surfaces of the door and frame exposed to view shall receive a factory applied coat of rust inhibiting primer, either air-dried or baked-on. The finish shall meet the requirements for acceptance stated in ANSI/SDI A250.10, “Test Procedure and Acceptance Criteria for Prime Painted Steel Surfaces for Steel Doors and Frames.”
C. Factory Applied Finish Paint. Doors and frames shall be finish painted on all surfaces of the door and frame exposed to view. The factory applied finish paint shall meet the performance requirements and acceptance criteria as stated in ANSI/SDI A250.3, “Test Procedure and Acceptance Criteria for Factory Applied Finish Painted Steel Surfaces for Steel Doors and Frames.” Consult individual manufacturers for product availability and color selection.
D. Field Applied Finish Paint. Unless doors and frames are factory finish painted, a compatible coat of finish paint shall be applied in the field. The finish paint shall be of a type recommended for use on primed steel. Consult the door and frame manufacturer’s literature for description of primer used.
E. Test Procedures. The products furnished shall have demonstrated successful performance to the following established standard test methods:
1. ANSI/SDI A250.3 – Test Procedure and Acceptance Criteria for Factory Applied Finished Painted Steel Surfaces for Steel Doors and Frames.
2. ANSI/SDI A250.4 – Test Procedure and Acceptance Criteria for Physical Endurance for Steel Doors, Frames, Frame Anchors, and Hardware Reinforcings.
3. ANSI/SDI A250.10 – Test Procedure and Acceptance Criteria for Prime Painted Steel Surfaces for Steel Doors and Frames.
F. Design Clearances.
1. The clearance between the door and frame shall be a maximum of 1/8”.
2. The clearance measured from the bottom of the door to the bottom of the frame (Undercut) shall be a maximum of ¾” unless otherwise specified.
3. All clearances shall be, unless otherwise specified in this document, subject to a tolerance of +/-1/32”.
G. Door Faces and Edge.
1. Full Flush. Each door face shall be formed from a single sheet of steel. There shall be no visible seams on the surface of the faces. A full height vertical seam is permitted on door edges.
2. Seamless. In addition to the requirements for full flush doors, no visible seams are permitted along the vertical edges.
3. Door edges shall be fabricated with a square edge – edge of door which is 90 degrees to the face
H. Door Hardware.
1. General.
a. Hardware shall be of best grade, entirely free of imperfections in manufacture and finish, and shall satisfactorily perform various functions needed.
b. Do not use manufacturer's products which have manufacturer's name or trade name displayed in a visible location (omit removable nameplates), except in conjunction with UL labels. Manufacturer's identification shall be permitted on rim of lock cylinders only.
c. Furnish necessary screws, bolts, or other fastenings of suitable size and type to anchor hardware in position and match hardware as to material and finish. Provide Phillips flat-head screws except as otherwise indicated.
d. Do not use through-bolts for installations where bolt head or nut opposite face is exposed in other work, use of hex bolts shall not be allowed.
e. Drawings show direction of slide, swing, or hand of each door leaf. Furnish each item of hardware for proper installation and operation of door movement as indicated. Items of hardware not definitely specified, but needed for satisfactory installation of hardware shall be provided. Such items shall be of type and quality suitable for service needed and comparable to adjacent hardware.
2. Hinges. Provide full mortise, template, 5-knuckle, heavy duty, button tip hinges with non-rising loose pins and ball type bearings.
a. Out-swinging exterior doors shall be furnished with solid bronze, extra heavy weight hinges with non-removable pins or security studs.
b. Interior doors with locksets shall be furnished with non-removable pin hinges.
c. Hinges shall be furnished in following quantities, per door leaf:
Doors Up to 90 in. in height; 3 hinges
Doors over 90 in. in height: Add one hinge for every additional 30”
d. Furnish hinge sizes as follows for 1-3/4 in. thick doors:
Doors up to 3 ft-0 in. wide - 4 ½ x 4 ½ in.
Doors 3 ft. –0 in. to 3 ft.-4 in. wide: 5 x 4 ½ in.
Doors over 3 ft. –4 in. wide: Extra heavy 5 x 4½
e. Furnish hinges of sufficient throw where needed to clear trim or permit doors to swing 180 degrees.
3. Locksets and Latchsets. Series 1000, Operational Grade 1
a. Provide heavy duty mortise locksets and latchsets.
(1) Provide one piece ¾ in., stainless steel, anti-friction latch bolts, and V stainless steel deadbolt with hardened steel roller inserts.
(2) Hand of lock is to be easily field reversible without opening lock body case.
(3) Lever trim is to be thru-bolted through door and lock case.
(4) Cylinder collars for mortise locks to be cast.
(5) Locksets shall be equipped with Best Lock cylinders with interchangeable cores. Cores shall be provided by Contracting Officer.
b. Locks and cylinders shall be provided with manufacturer’s standard 7-pin tumblers which comply with A156.5, unless otherwise indicated. Lock cylinder parts shall be made from brass/bronze, stainless steel, or nickel silver.
c. Provide manufacturer's standard wrought box strike for each latchset and lockset with curved lip extended to protect frame. Finish shall match hardware set.
d. Where rabbeted door stiles are indicated, provide special rabbeted front on locksets, latchsets, and bolts.
e. Seals and Gaskets. Seals and gaskets shall be continuous and without unnecessary interruptions at door comers and hardware. Provide components which shall not become ineffective as seals due to misalignment at corners, minor out-of -adjustment of doors and frames, temperature variations, and normal wear and aging. Provide resilient or flexible weather-seals that are easily replaceable and readily available during projected life of installation.
f. Thresholds. Extruded aluminum, 6063-T5 alloy. Thresholds shall extend full width of opening. Miter both ends of threshold as necessary to suit Project conditions.
g. Keys:
(1) Verify keying requirements with Owner.
(2) A new master key and grand master key shall be established for this Project in compliance with specific requirements determined in consultation with Owner and to work with building's established keying system.
(3) Locksets shall be construction master keyed for use during construction.
h. Furnish keys as follows:
(1) Grand Master Keys: 6 total
(2) Master Keys: 6 per set
(3) Change Keys
(4) Locks Keyed Alike: 4 per set
(5) Locks Keyed Different: 3 per lock
(6) Construction Master Keys: 12 total
i. Provide a key control system complete with accessories. Key cabinet shall be set up with keys and hooks tagged, keys installed, and index cards completed. Install key cabinet in location as indicated on Drawings or as directed by Engineer.
H. Timber Block.
Timber for bumper blocks shall be white oak or similar hardwood as approved by the Engineer. Timber shall be treated with a water based preservative by pressure process as specified by the latest edition of the American Wood Preserver’s Association Standards, Section C2 (above ground requirements).
CONSTRUCTION
529.03 Steel Doors.
A. Installation. Install steel doors and accessories according to Shop Drawings, manufacturer's data, and as specified.
B. Door Installation. Comply with ANSI A250.8. Fit hollow-metal doors accurately in frames, within clearances specified in ANSI A250.8. Shim as necessary to comply with SDI 122 and ANSI/DHI A115.1G.
C. Adjusting and Cleaning. Immediately after installation, Contractor shall sand smooth any rusted or damaged areas of prime coat and apply touch up of compatible air-drying primer. Immediately before final inspection, Contractor shall remove protective wrappings from doors.
529.04 Door Hardware.
A. Examination. Examine doors, frame, and related items for conditions that would prevent proper application of hardware. Correct conditions detrimental to timely and proper execution of Work. Do not proceed until unsatisfactory conditions have been corrected. Commencement of installation constitutes acceptance of conditions and responsibility for satisfactory performance.
B. Securely install finish hardware items in compliance with accepted schedule and templates furnished with hardware.
C. Provide metal fasteners of type and size which will not work loose as a result of normal door use, and which are compatible with metal materials of hardware item and doors and frames. Provide only smooth exposed fastener heads, which do not constitute a snagging hazard to clothing. Finish of exposed fastener shall match finish of hardware item.
D. Install mortised items flush with adjacent surfaces.
E. Install locksets, surface mounted closers, and trim after finishing of doors and frames is complete. Wherever cutting and fitting is needed to install hardware onto or into surfaces which are later to be finished, install each item completely and then remove and store in a secure place during finish application. After completion of finishes, reinstall each item.
F. Locate items on hollow metal doors in compliance with Door and Hardware Institute publication Recommended Locations for Architectural Hardware for Standard Steel Doors and Frames. Mounting heights shall be measured from finish floor, except top butt.
1. Butts:
a. Top: 11-3/4 in. center of butt to top of door
b. Intermediate: Equal distance between top and bottom butts
c. Bottom: 13 in. to center of butt
2. Locksets and Latchset: 40-5/16 in. to center of strike
3. Deadlocks: 48 in. to center of strike.
4. Exit Devices: 40-5/16 in to center of strike.
G. Field Quality Control. Provide manufacturer's field representation consisting of the following services.
1. Supplier of door hardware shall make periodic visits to Site during and at completion of hardware installation for purpose of monitoring compliance with manufacturer's installation requirements.
2. Prepare and submit, to Contracting Officer a written report of each periodic and final site visits. Report shall be submitted within 3 days following site visits.
H. Adjusting.
1. Final Adjustment. Before final completion, adjust hardware so doors operate in perfect order. Test and adjust hardware for quiet, smooth operation, free of sticking, binding, or rattling. Adjust closers for proper, smooth operation.
2. Exposed hardware shall be carefully cleaned by methods not injurious to finish, immediately preceding occupancy. Replace defective, damaged, or missing hardware.
3. At final completion, properly tag and identify keys and deliver to Owner.
COMPENSATION
529.05 Method of Measurement.
Control house work will not be measured, and payment will be made on a lump sum basis.
529.06 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
control house work lump sum
SECTION 530 – control house repairs due to water leakage
530.01 DESCRIPTION.
This work shall consist of removing existing caulk and, furnishing and installing silicon based sealants on all metal seams and concrete/metal interface around the perimeter of all the control houses.
MATERIALS
530.02 Materials.
Silicone Weatherseal Joint Sealants. Medium and Low Modulus Silicone Joint Sealant, one-part, non acidic, neutral curing, Type S, Grade NS, Class 25, Use NT, capable of withstanding movements from +50 to -50 for medium modulus and +100 to -50 percent for low modulus.
CONSTRUCTION
530.03 Construction.
A. Examination. Prior to the installation of sealant, and at the Engineer’s direction, meet at the project site to review the material selections, joint preparations, installation procedures, and weather conditions. Examine sample installations, which have been prepared, and determine and record whether everyone present is in agreement that the proposed installations are likely to perform as required. Accepted control sections shall be standard to which all other sealant work must conform.
B. Examine the substrates and the conditions under which the work is to be installed. Do not proceed with the work until satisfactory conditions have been corrected. Proceeding with work indicates acceptance of conditions.
C. Preparation. Clean all joints thoroughly, removing all foreign matter, dust, oil, grease, water, surface dirt, frost, old caulking material and loose or latent materials.
D. Clean porous materials where necessary by grinding, sand or water-blast cleaning, mechanical abrading, acid washing or combination of these methods as required to provide a clean, sound base surface for sealant adhesion. Clean nonporous surfaces, either mechanically or chemically.
E. Remove laitance by acid washing, grinding or mechanical abrading. Remove form oils by sand or water
blast cleaning. Remove all loose particles present or resulting from grinding, abrading, or blast cleaning by blowing out joints with oil free compressed air or by vacuuming joint prior to application of sealant.
F. Remove protective coatings on metallic surfaces by a solvent that leaves no residue. Use clean white cloths or lintless paper towels for cleaning with solvent and drying. Clean joint areas protected with masking tape or strippable film with solvent after removal of tape or film. Do not allow solvent to air dry without wiping.
G. Joint Widths. Joints must be uniform in width.
Clean out and rake to full width and depth, joints to receive sealant. Make joints of sufficient width and depth to accommodate specified joint sealant.
H. Application. Follow sealant manufacturer's instruction regarding surface preparation, priming, application life, and application procedure. Consult sealant manufacturer for recommendation for application procedure. Consult sealant manufacturer for recommendation for application of sealant when air temperature is below 40° F, or surface temperatures of sealant contact surfaces are above 120° F.
1. Apply masking tape, where required, in continuous strips in alignment with joint edge. Remove tape immediately after joints have been sealed and tooled as directed.
2. Prime surfaces, where required, with primer as recommended by sealant manufacturer. Prime metals where moisture or joint movement occurs. Prime all concrete and masonry surfaces, as required by sealant manufacturer.
3. Install back-up material or joint filler at proper depth in joint to provide specified sealant dimensions. Compress back-up material 25% to 50% into the joints as required. Do not apply sealant without back-up materials. Install bond breaker strip between sealant and non-release type backup material. Three- side adhesion is acceptable only for the sealing at joinery of members that are to be rigidly attached to each other by means of screws or welding restricting all movement.
4. Install back-up rod stock into the joint to avoid length-wise stretching. Rod stock shall not be twisted or braided. Use bond breaker strip in all joints where sufficient room for backup does not exist.
5. Apply sealant under pressure with power actuated gun having nozzle of proper size, or other appropriate means. Provide sufficient pressure to completely fill joints as detailed.
6. Neatly point or tool sealant to provide proper contour. Dry tool joints. Do not use water-wet tool or tooling solution. Sealant on face of adjacent materials will not be acceptable.
7. Surfaces of joints to be sealed must be dry. Do not attempt sealant work on wet surfaces or where frost is present.
I. Cleaning. Clean adjacent surfaces free of sealant or soil resulting from this work as the work progresses. Use solvent or cleaning agent as recommended be sealant manufacturer. Leave all finished work in a neat, clean condition.
J. Curing and Protection. Cure sealants in compliance with manufacturer’s instructions and recommendations, to obtain high early bond strength, internal cohesive strength and surface durability. Cure and protect sealants in a manner which will minimize increases in modulus of elasticity and other accelerated aging effects. Replace or restore sealants which are damaged or deteriorated during the construction period.
COMPENSATION
530.04 Method of Measurement.
Control house repairs due to water leakage will not be measured, and payment will be made on a lump sum basis.
530.05 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
control house repairs due to water leakage lump sum
SECTION 531 – PAINTING CONCRETE
531.01 DESCRIPTION.
This work shall consist of preparing and painting of the exterior concrete walls of the Control Houses. It shall include furnishing all labor, materials, tools, equipment, and incidentals, and for doing all the work involved in preparing the concrete and applying the paint to concrete surfaces, as shown on the plans, and as directed by the Engineer.
MATERIALS
531.02 Materials.
Paints to be applied to concrete surfaces shall be Acrylic Emulsion, Exterior White and Light and Medium Tints designed for use on exterior masonry. Paint shall be tinted to provide color specified by Engineer. This paint shall comply in all respects to Federal Specification TT-P-19 (latest revision), Paint, Acrylic Emulsion, Exterior.
This paint may be tinted by using “universal” or “all purpose” concentrates.
CONSTRUCTION
531.03 General.
A. Surface Preparation. Prior to painting concrete surfaces, laitance and curing compounds shall be removed from the surface by abrasive blast cleaning in conformance with the requirements in ASTM Designation: D 4259. Protection of Environment, Structure, Persons, and Property shall be according to Subsection 514.13. The cleaned surface shall have a roughened, textured appearance.
Concrete surfaces shall be thoroughly dry and free of dust at the time the paint is to be applied.
Any artificial drying procedures and methods shall be subject to approval by the Engineer.
B. Weather Conditions. Paint shall be applied only on thoroughly dry surfaces and during periods of favorable weather. Blast cleaning or application of solvent-borne paint will not be permitted when the atmospheric or surface temperature is at or below 35( F or above 100(F, or when the relative humidity exceeds 85 percent at the site of the work. Application of water-borne paint will not be permitted when the atmospheric or surface temperature is at or below 50(F, or above 100(F, or when the relative humidity exceeds 75 percent at the site of the work. Application of paint will not be permitted when freshly painted surfaces may become damaged by rain, fog, or condensation, or when it can be anticipated that the atmospheric temperature or relative humidity will not remain within the specified application conditions during the drying period, except as provided in the following paragraph for enclosures. If fresh paint is damaged by the elements, it shall be replaced or repaired by the Contractor at the Contractor’s expense.
Subject to approval by the Engineer in writing, the Contractor may provide suitable enclosures to permit painting during inclement weather. Provisions shall be made to control atmospheric conditions artificially inside the enclosures within limits suitable for painting throughout the painting operation and drying period. Full compensation for providing and maintaining the enclosures shall be considered as included in the prices paid for the various contract items of work requiring paint and no additional compensation will be allowed therefore.
C. Application. The Contractor shall notify the Engineer, in writing, at least one week in advance of the date cleaning and painting operations are to begin.
Painting shall be done in a neat and workmanlike manner. Unless otherwise specified, paint shall be applied by brush, or spray, or roller, or any combination of these methods. Airless spray methods shall not be used.
Each application of paint shall be thoroughly cured and any skips, holidays, thin areas or other deficiencies corrected before the succeeding application. The surface of the paint being covered shall be free from moisture, dust, grease or any other deleterious material which would prevent the bond of the succeeding applications. In spot painting, old paint which lifts after the first application shall be removed by scraping and the area repainted before the next application.
Unless otherwise specified, should 7 days elapse between paint applications, the painted surface shall be water rinsed prior to the next paint application. Water rinsing is defined as a pressurized water rinse with a minimum nozzle pressure of 1,160 pounds per square inch. During rinsing, the tip of the pressure nozzle shall be placed between 12 inches and 18 inches from the surface to be rinsed. The nozzle shall have a maximum fan tip angle of 30(.
Brushes, when used, shall have sufficient body and length of bristle to spread the paint in a uniform film. Paint shall be evenly spread and thoroughly brushed out.
On all surfaces which are inaccessible for painting by regular means, the paint shall be applied by sheepskin daubers, bottle brushes or by any other means approved by the Engineer.
Rollers, when used, shall be of a type which does not leave a stippled texture in the paint film.
Runs, sags, thin and excessively thick areas in the paint film, skips, and holidays, or areas of non-uniform appearance shall be considered as evidence that the work is unsatisfactory, and the Contractor may be required to blast clean the areas and reapply the paint.
A water trap acceptable to the Engineer shall be furnished and installed at each spray spot.
Mechanical mixers shall be used to mix paint. Prior to applying, the paint shall be mixed a sufficient length of time to thoroughly mix the pigment and vehicle together.
Precautions in the handling and the application of the paints shall be in conformance with all applicable occupational safety and health standards, rules, regulations and orders established by the State of New Jersey.
Application of Acrylic Emulsion Paint. Acrylic emulsion paint shall be applied in not less than 2 applications to produce a uniform appearance.
C. Thinning paint. Paints specified are formulated ready for application, and no thinning will be allowed unless permitted by the Engineer.
D. Protection against damage. The Contractor shall provide protective devices, such as tarps, screens, or covers, as necessary to prevent damage to the work and to other property or persons from all cleaning and painting operations.
Paint or paint stains which result in an unsightly appearance on surfaces not designated to be painted shall be removed or obliterated by the Contractor at the Contractor’s expense and to the satisfaction of the Engineer.
All painted surfaces that are marred or damaged as a result of operations of the Contractor shall be repaired by the Contractor, at the Contractor’s expense, with materials and to a condition equal to that of the coating specified herein.
Upon completion of all painting operations and of any other work that would cause dust, grease or other foreign materials to be deposited upon the painted surfaces, the painted surfaces shall be thoroughly cleaned.
COMPENSATION
531.04 Method of Measurement.
Cleaning and painting of concrete surfaces will not be measured, and payment will be made on a lump sum basis.
531.05 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
painting concrete lump sum
SEPARATE PAYMENT WILL NOT BE MADE FOR CLEANING OF CONCRETE SURFACES. ALL COSTS ASSOCIATED WITH CLEANING THE CONCRETE SURFACES SHALL BE INCLUDED IN THE PAY ITEM “PAINTING CONCRETE”.
Separate payment will not be made for the preparation of the required pollution control system submission, which includes the containment plan and waste disposal plan or the implementation of each plan, as it pertains to the Project Site including but not limited to permits; capture, containment, collection, storage and disposal costs; and revisions, alterations and resubmissions; and all record keeping that may be required during the execution of the Work. All costs thereof shall be included in the lump sum price bid for “Painting Concrete”
SECTION 532 – MACHINERY HOUSE WALL PANELS
532.01 DESCRIPTION.
This work shall consist of installing wall panels in the machinery rooms as shown on the contract plans and described herein. This work includes factory-formed panels in vertical installation and all necessary metal flashings and trim.
MATERIALS
532.02 Materials.
A. Wall Panels:
1. Profile: Longitudinal ribs 7/8 inch (22 mm) deep, spaced 2.7 inches (68 mm) on center, 35-1/2 inch (902 mm) sheet width
2. Size: 32 inches (813 mm) cover width, lengths indicated on drawings.
3. Material: Galvanized steel sheet conforming to ASTM A 653/A 653M, G90 coating; 26 gage sheet thickness.
4. Finish: Siliconized polyester color coat applied to sight-exposed face of sheet after pretreatment and priming in accordance with coating manufacturer's recommendations.
5. Color: Match existing machinery house.
B. Trim
1. Manufacturer's standard sheet metal matching panel material and finish, break-formed to profiles indicated on drawings, including, but not limited to copings, terminations and transition strips.
2. Color: Match panel finish
C. Clips and Fasteners: Supply items required for installation of panels in accordance with manufacturer's installation instructions and other indicated items; supply galvanized clips and fasteners.
D. Panel Performance Requirements
1. Air infiltration: Maximum 0.06 cubic feet per minute per lineal foot (0.33 cu m per hour per linear meter) of seam at static pressure of 6.24 pounds per square foot when tested per ASTM E 1680.
2. Water penetration: No uncontrolled water penetration through panel joints when tested in accordance with AAMA 501.2.
E. Finish Performance Requirements
1. Color change and fade resistance: No cracking, peeling, blistering, or loss of adhesion when tested in accordance with ASTM G 90; color change, after removal of surface deposits such as dirt or chalk, maximum 5 NBS units.
2. Humidity resistance: No blistering, peeling, or loss of adhesion, after 1,000 hours testing in accordance with ASTM D 2247.
F. Submittals
1. Product Data: Manufacturer's product literature for panel, finishes, and trim.
2. Shop Drawings. Indicate layout of panels and panel sizes, including custom-fabricated panels if indicated; indicate each item of trim and accessories. Indicate in detailed drawings profile and gauge of interior and exterior sheets, locations and types of fasteners; indicate locations, gages, shapes, and methods of attachment of panels, trim and accessory items. Indicate products/materials required for construction activities of this section not supplied by manufacturer of products of this section.
3. Quality Assurance Submittals. Contractor's certification that Manufacturer of products of this section meets specified qualifications and installer of products of this section meets specified qualifications. Manufacturer's certification that materials comply with specified performance characteristics and physical requirements. Manufacturer's instructions.
4. Closeout Submittals. Warranty documents issued and executed by manufacturer of products of this section, countersigned by Contractor.
G. Quality Assurance
1. Installer Qualifications: Installer experienced in performing work of this section who has specialized in the installation of work similar to that required for this project.
2. Quality Standard: Comply with Sheet Metal and Air Conditioning Contractors National Association (SMACNA) Architectural Sheet Metal Manual.
H. Delivery, Storage and Handling
1. Delivery: Deliver materials in manufacturer's original, unopened, undamaged containers with identification labels intact; identify fabricated components with UL 90 label where appropriate.
2. Packing, Shipping, Handling and Unloading. Bundle panels in waterproof wrapping paper. Package trim and accessories in waterproof wrapping paper.
3. Storage and Protection. Stack prefinished material to prevent twisting, bending, abrasion, scratching, and denting; elevate one end of skid to allow for moisture run off. Store products of this section in manufacturer's unopened packaging until installation of products. Maintain dry, heated storage area for products of this section until installation of products.
I. Project/site conditions. Obtain field measurements before cutting panels to size.
J. Warranty. Panel manufacturer's standard warranty against defects in product workmanship and materials, including deterioration of panel finish.
CONSTRUCTION
532.03 Wall Panels.
A. Installation. Install panels plumb, true, and in correct alignment with structural framing, in accordance with shop drawings and manufacturer's printed installation instructions.
B. Installation Tolerances
1. Variation from Plumb: Maximum 1/8 inch
2. Variation from Level: Maximum 1/8 inch
3. Variation from True Plane: Maximum 1/8 inch
4. Variation from True Position: Maximum 1/4 inch
5. Variation of Member from Plane: Maximum 1/8 inch
C. Cleaning. Remove strippable coating and perform dry wipe-down cleaning of panels as erected.
D. Protection of installed products. Protect installed products from damage by subsequent construction activities. Replace products having damage other than minor finish damage. Repair products having minor damage to finish in accordance with panel manufacturer's recommendations. Engineer shall be sole judge of acceptability of repair to damaged finishes; replace products having rejected repairs.
COMPENSATION
532.04 Method of Measurement.
Machinery House wall panels will not be measured, and payment will be made on a lump sum basis.
532.05 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
MACHINERY HOUSE WALL PANELS lump sum
SECTION 533 – MACHINERY IN GENERAL
533.01 DESCRIPTION.
A. Scope of Work. Section 533 applies to the installation of auxiliary drive machinery, lock machinery, electric motors, brakes, limit switches, position transmitters, resolvers, selsyns, encoders, and tach-overspeed switches to be mounted with the machinery but supplied under the Electrical Work.
Work on the bridge machinery includes installation of new and rehabilitation of existing machinery components in accordance with the Contract Drawings.
All special machining, tools and installation shall be included as part of the work. This work shall include coordination of special machinery manufacturer requirements, special shimming, and alignment.
The Contractor, except as noted otherwise on the Plans or as specified otherwise in these Specifications, shall furnish, install, lubricate, test, paint, and place in satisfactory operating condition new machinery components.
B. Basis of Machinery Design. The design of new machinery conforms to the applicable requirements of the AASHTO Standard Specification for Movable Highway Bridges, except as otherwise noted on the Contract Drawings or otherwise specified herein.
C. Shop Drawings. The Contractor shall prepare shop drawings in accordance with Section E, and additionally, meet the following requirements:
1. Manufacturer's data and/or shop drawings shall be submitted for all manufactured and purchased items of machinery to the Engineer for approval.
2. The Contractor shall coordinate the work of the machinery component manufacturers where components interface. The Contractor shall review and approve all shop and working drawings prepared by those Manufacturers for coordination prior to submittal of shop drawings to the Engineer for approval.
3. Shop drawings shall show all parts completely detailed and dimensioned. Reproduction of the Plans shall not be used as base sheets for assembly or erection drawings.
4. Materials and material specifications shall be stated for each part. Where ASTM or any other standard specifications are used, the applicable numbers of such specifications shall be given.
5. Required finish machining shall be shown including grade of finish in accordance with ANSI B46.1, Surface Texture, and dimensional tolerances and allowances for specific fits in accordance with ANSI B4.1, Preferred Limits and Fits for Cylindrical Parts.
6. Shop drawings shall conform to the provisions of the general requirements of the Standard Specifications as supplemented and amended herein and to the special requirements specified hereinafter. All drawings shall be in conformance with NJDOT Microfilming Standards, latest revision.
7. Submittals for each manufactured item shall be manufacturer's descriptive literature, drawings, diagrams, performance and characteristic curves, and catalog cuts, and shall include the manufacturer's name, trade name, catalog model or number, nameplate data, size, certified layout dimensions, capacity, specification reference, including ASTM, ANSI, Federal Military Specification and any other applicable references, and all other information necessary to establish Contract compliance.
8. The fits and finishes used shall conform to the requirements for fits and finishes given in the Plans and to any other requirements given hereinafter in this General Specification.
9. Shop drawings shall show all external dimensions and clearances necessary for installation and operation of all new machinery components.
10. For all assemblies and parts, the Contractor shall furnish complete assembly drawings or diagrams showing each part contained therein and the manufacturer's part number assigned to each part. The drawings or diagrams shall be sufficient to enable complete disassembly and reassembly of the assemblies covered. In the event that any part is modified in any manner from the way it is described or delivered by its original manufacturer, the Contractor shall furnish a drawing which details each modification and the part shall be assigned a unique part number to assure the furnishing of replacement parts modified in similar fashion.
11. Certified prints of each manufactured assembly shall be furnished. Certified prints are manufacturer's drawings of proprietary products on which the manufacturer or supplier states mounting dimensions, ratios, speeds, ratings, and any other correctness for use on this specific project. In addition to identifying and describing each part, they shall show:
a. Dimensions of all principal parts comprising the assembly.
b. Certified external dimensions affecting clearances and required for installation.
c. Capacity and normal operating ratings.
d. Recommended lubrication, including location, lubrication fittings, and provisions for adding, draining and checking the level of lubricants.
e. Inspection openings, seals, and vents.
f. Details or description of all fasteners required to mount the assembly.
g. Gross weight.
h. Certified prints shall be signed by an officer of the manufacturing company.
12. All proprietary items shall be shown in outline on shop drawings, which shall also indicate the method and sequence to be employed in assembly of bridge machinery and installation of necessary utilities support and service facilities. The assembly drawings of each item shall, in addition to identifying and describing each internal part, contain dimensions of all principal elements within the item; certified external dimensions affecting interfaces or installations; gross weight capacity and normal operating ratings; method and recommended type of lubrication, including location and type of fittings and provisions for adding, draining, and checking the level of each lubricant employed; inspection openings, seals, and vents; and details of all fasteners used to mount the equipment to its foundation.
13. Complete shop bills of materials shall be made for all machinery parts. If the bills are not shown on the shop drawings, prints of the bills shall be furnished for approval in the same manner as specified for the shop drawings.
14. The weight of each piece of machinery shall be stated on the shop drawing upon which it is detailed or billed.
15. Complete assembly and erection drawings shall be furnished. These drawings shall give part numbers, match marks, and essential dimensions for locating each part or assembled unit with respect to the bridge structure or foundation.
16. Marks or indentations of any type shall be clearly shown and detailed on the drawings. In general die-stamping or scoring shall be avoided unless otherwise called for on the plans. All components and assemblies shall be detailed separately to assure correct fabrication, assembly, and erection. Use of mirror image or opposite hand erection drawings will not be allowed.
17. Each shop drawing shall be given a suitable title to describe the parts detailed thereon and shall state by whom shop inspection will be made.
18. Where equipment or materials are specified to conform to requirements of the standards of an organization, such as American Society for Mechanical Engineers (ASME), Underwriters Laboratories (UL), American Gas Association (AGA), and American Refrigeration Institute (ARI), that use a label or listing as method of indicating compliance, proof of such conformance shall be submitted and approved. The label or listing of the specified organization will be acceptable evidence. In lieu of the label or listing, the Contractor shall submit a certificate from an independent testing organization adequately equipped and competent to perform such services and approved by the Contracting Officer, stating that the item has been tested in accordance with the specified organization's test methods and that the item conforms to the specified organization's standard or code.
19. As used herein, certified test reports refer to reports of tests conducted on previously manufactured materials or equipment identical to that proposed for use.
20. As used herein, factory tests refer to tests required to be performed on the actual materials or equipment proposed for use. Results of the tests shall be submitted in accordance with the provisions of this Contract for laboratory test results.
21. The Contractor shall prepare a list of all machinery items that require lubrication and their recommended cycle for lubrication. The list shall contain the types of lubricant used and the date it was lubricated by the Contractor and shall be given to the Engineer prior to start up and testing of the machinery.
22. Lubrication charts shall be prepared and submitted as working drawings.
23. If any departures from the Contract Documents are deemed necessary by the Contractor, details of such departures and the reasons therefore shall be submitted to the Engineer in writing as soon as practicable for his approval. No departures from Contract Drawings shall be made without the Engineer's approval. If any departures from the Contract documents are made without this approval the Contractor may at his own expense be required to remove the equipment, correct any modifications, and replace with approved equipment, components, etc.
24. If the Contractor has any objection to any feature of the machinery as designed or required by the Contract Plans, he shall state his objection in writing to the Engineer at the time of submitting shop drawings or prior thereto; otherwise his objection will not be considered if offered later as an excuse for malfunctioning, defective or broken machinery.
25. It is the Contractor's responsibility to manufacture and install suitable functioning machinery. Review and approval of shop drawings by the Engineer does not relieve the Contractor of this responsibility.
D. Submittals. The Contractor shall submit the required shop drawings for machinery items to the Engineer for review within 120 days after the date of award of contract.
The Contractor shall submit to the Engineer for his approval seven (7) prints of all shop drawings. In case of correction or rejection, the Contractor shall resubmit seven (7) prints of shop drawings until drawings are approved. The Contractor shall bear all costs for damages, which may result from the ordering of any materials prior to the approval of the shop drawings; and no work shall be done until the shop drawings therefore have been approved. After approval of the shop drawings, the Contractor shall supply the Engineer with up to seven (7) prints of the approved shop drawings as may be ordered.
E. Delivery and Storage.
1. Protection for Shipment.
a. Machinery parts shall be cleaned of dirt, chips, grit, and all other injurious materials prior to shipping and shall be given a coat of corrosion-inhibiting preservative.
b. Finished metal surfaces and unpainted metal surfaces that would be damaged by corrosion shall be coated as soon as practicable after finishing with a rust-inhibiting preservative. Excepting unfinished metal surfaces inside of gear reducers, this coating shall be removed from operation and from all surfaces prior to painting after erection.
c. Any interface between stainless steel or aluminum and Structural Steel shall receive an Engineer approval coat of zinc-chromate primer prior to assembly.
d. Shims shall be coated prior to shipment with a rust-inhibiting preservative, and before erection, this coating shall be removed from the shims that are used.
e. Machinery parts shall be completely protected from weather, dirt, and all other injurious conditions during manufacture, shipment, and storage.
f. Shaft journals that are shipped disassembled from their bearings shall be protected during shipment and before erection by a packing of oil-soaked waste secured in place by burlap and covered with heavy metal thimbles or heavy timber lagging securely attached. Every precaution shall be taken to ensure that the bearing surfaces are not damaged and that all parts arrive at their destination in satisfactory condition.
g. Assembled units shall be mounted on skids or otherwise crated for protection during handling and shipment.
2. Packaging and Delivery of Spare Parts. Spare parts shall be protected for shipment and prolonged storage by coating, wrapping, and boxing.
a. All spare parts shall be durably tagged or marked with a clear identification showing the designation used on the approved shop drawing.
b. Boxes for spare parts shall be clearly marked on the outside to show their contents. Spare parts shall be delivered to a location designated by the NJDOT.
3. Guarantee and Warranties. Manufacturer's warranties or guarantees on equipment, materials or products purchased for use on the Contract which are consistent with those provided as customary trade practice, shall be obtained by the Contractor and, upon acceptance of the Contract, the Contractor shall assign to the New Jersey Department of Transportation, all manufacturer's warranties or guarantees on all such equipment, material or products furnished for or installed as part of the Work.
The Contractor shall warrant the satisfactory in-service operation of the mechanical equipment, material, products, and related components. This warranty shall extend for a period of one year following the date of final acceptance of the Project.
QUALITY ASSURANCE
533.02 Quality Assurance.
A. Qualifications, Personnel, and Facilities. Products used in the work under the Machinery Pay Items shall be produced by manufacturers regularly engaged in the manufacture of the specified products.
For the fabrication, installation, cleaning, aligning, testing, and all other work required by the Machinery Pay Items, the Contractor shall use adequate numbers of skilled, trained, and experienced mechanics and millwrights who are thoroughly familiar with the requirements and methods specified for the proper execution of the specified work. The Contractor shall provide personnel and supervisory personnel with a minimum of two movable bridge jobs as previous experience in the installation of bridge machinery.
The Contractor shall provide adequate plant and all necessary tools and instruments required for the proper performance of the personnel engaged in the execution of the specified work.
B. Codes and Standards. Work under machinery pay items shall comply with, but not be limited to, all applicable requirements of the following codes and standards and their abbreviations used in this Specification shall be as shown:
1. American Association of State Highway and Transportation Officials AASHTO
2. American Gear Manufacturers Association AGMA
3. American Iron and Steel Institute AISI
4. American National Standards Institute ANSI
5. American Society for Testing and Materials ASTM
6. American Welding Society AWS
7. Anti-Friction Bearing Manufacturers Association AFBMA
8. National Lubricating Grease Institute NLGI
9. Society of Automotive Engineers SAE
10. Steel Structures Painting Council SSPC
11. New Jersey Standard Specifications NJSS
The work shall meet the requirements of all other codes and standards as specified elsewhere in these Specifications. Where codes and standards are mentioned for any pay item, it is intended to call particular attention to them; it is not intended that any other codes and standards shall be assumed to be omitted if not mentioned.
C. Rules, Regulations, and Ordinances. Work shall comply with all applicable Federal, State and local rules, regulations, and ordinances.
In the event of a conflict between these Specifications and the above-mentioned codes, standards, rules, regulations, and ordinances, the most stringent requirement shall apply.
D. Measurements and Verification. Dimensions indicated on the Contract Drawings are nominal and are intended for guidance only. All variations from the nominal dimensions on the Contract Drawings shall be noted on the shop drawings.
E. Substitutions. The terms "approved equal", "of equal quality" and "or equal" which appear on the Contract Drawings and in these Specifications are intended to allow the Contractor to substitute other manufacturers and model numbers of products of equal quality and rating for those specified.
Prior to the Contractor's ordering of any substitute product, the Engineer's approval of the equivalence of the substitute product shall be obtained in writing. The acceptance of the substitute products is at the sole discretion of the Engineer who will establish the basis for equivalence and will review the quality of the materials and products described in detail on the submitted shop drawings and product data.
The Engineer will review and stamp substitute material either "No Exceptions" or "Revise and Resubmit". Upon return of a shop drawing showing rejection, the Contractor shall resubmit the shop drawing showing the specified product. Rejection shall not in any way result in any extra cost.
Approval by the Engineer of any substitute products submitted by the Contractor shall not relieve the Contractor of responsibility for the proper operation, performance, or functioning of that product.
Where a particular product is specified by a manufacturer's name and catalog or part number in this Specification or on the Contract Drawings, it is so specified to establish quality, configuration, and arrangement of parts. An equivalent product made by another manufacturer may be substituted for the specified product subject to the approval of the Engineer; however, all necessary changes required by the substitution in related machinery, structural, architectural, and electrical parts, shall be made by the Contractor at no additional cost.
If any departures from the Contract Drawings or these Specifications are deemed necessary by the Contractor, details of such departures and the reasons therefore shall be submitted as soon as practicable for approval. No such departures shall be made without approval by the Engineer. If any departure from the Contract documents is made without this approval the Contractor may at his own expense be required to remove the equipment, correct any modifications, and replace with approved equipment, components, etc.
F. Shop Assembly. Shop assembly of machinery is covered under Section 535 – “Miscellaneous Mechanical Work” and Section 534 – “Auxiliary Span Drive Machinery”.
G. Specialized Machinery Components Field Installation, Adjustment, and Inspection. For the installation, adjustment, and alignment of all specialized machinery components the Contractor shall provide for the presence at the job site of manufacturers’ service personnel skilled in these specialties. Such service personnel shall be properly equipped with all necessary instruments to assure that related components have been provided within acceptable tolerances and to make all necessary adjustments for attaining the specified ratings.
H. Inspection and Testing. The Contractor shall give no less than ten (10) working days notice to the Engineer of the beginning of work at foundries, forge, and machine shops so that inspection may be provided. No materials shall be cast, forged, or machined before the Engineer has been notified where the orders have been placed.
The Contractor shall furnish all facilities for the inspection of material and workmanship in the foundries, forge, and machine shops and the Inspector designated by the Engineer shall be allowed free access to necessary parts of the premises. Work done while the Inspector has been refused access or presented in a manner that prevents adequate inspection will automatically be rejected.
The Engineer’s Inspector shall have the authority to reject materials or workmanship that does not fulfill the requirements of these Specifications.
Inspection at the foundries, forge, and machine shops is intended as a means of facilitating the work and responsibility in regard to imperfect material or workmanship and to avoid the necessity of replacing defective materials or workmanship delivered to the job site.
The Contractor shall furnish the Engineer with a copy of all orders covering work performed by subcontractors or suppliers.
Unless otherwise provided, the Contractor shall furnish without additional charge test specimens as required, and all labor, testing machines, tools, and equipment necessary to prepare the specimens and to make the physical tests and chemical analyses required by material specifications. A copy of all test reports and chemical analyses shall be furnished to the Engineer.
The acceptance of any material or finished parts by the Engineer shall not be a bar to their subsequent rejection if found defective. Rejected material and workmanship shall be replaced or made acceptable by the Contractor at no additional cost to the State – NJDOT.
I. Defective Materials and Workmanship. All machinery rejected during inspection and testing shall be removed from the work site and replaced without additional cost.
Delays resulting from the rejection of material, equipment or work shall not be the basis of any claim by the Contractor.
All defects found during the guarantee period resulting from faulty material, components, workmanship, or installation shall be corrected by the Contractor without cost. The NJDOT reserves the right to make necessary correction with its own forces and charge the resulting costs to the Contractor.
J. Training. The Contractor shall provide three (3) days of instruction to NJDOT Maintenance personnel. The instruction shall include but not be limited to the following with respect to all machinery components.
1. Brake adjustment and operation
2. Checking, adding, and purging lubricants to newly installed components
3. Auxiliary drive operation
4. Instrument drive and limit switch adjustments
MATERIALS
533.03 Materials.
A. Standard Products. Materials and equipment shall be essentially the standard catalogued products of manufacturers regularly engaged in production of such materials or equipment and shall be manufacturer's latest standard design that complies with the specification requirements. Materials and equipment shall essentially duplicate items that have been in satisfactory commercial or industrial use at least two years prior to bid opening. Where two units of the same class of equipment are required, these units shall be products of a single manufacturer; however, the component parts of the system need not be the products of the same manufacturer. Each major component of equipment shall have the manufacturer's name and address and the model and serial number on a nameplate, securely affixed in a conspicuous place. The nameplate of the distributing agent will not be acceptable.
B. Manufacturer’s Recommendations
Where installation procedures or any part thereof are required to be in accordance with the recommendations of the manufacturer of the material being installed, printed copies of these recommendations shall be furnished to the Engineer prior to installation. Installation of the item will not be allowed to proceed until the recommendations are received. Failure to furnish these recommendations can be cause for rejection of the material. The Contractor shall provide all special machining and installation required by the manufacturer without additional cost.
C. Castings and Forgings. All necessary precautions shall be taken to fabricate the castings free of cracks, cold shuts, shrink holes, blowholes, and porosity.
All castings shall be cleaned free of loose scale and sand; all fins, seams, gates, risers, and other irregularities shall be removed. All unfinished edges of castings shall be neatly cast with rounded corners, and all inside angles shall have ample fillets.
All castings shall be ultrasonically tested in accordance with ASTM A609, Method A, Quality Level 3. Castings that do not pass this test may be rejected. Test results, whether positive or negative, shall be submitted to the Engineer. Test records meeting Quality Level 4 may be considered for weld repaired, provided the fabricator submits a procedure to the Engineer for review and approval. All repair procedures shall include a means to qualify the repair. Test records meeting Quality Level 5 or higher shall be cause for rejection, and not be allowed for weld repair. Rejection shall result in the Contractor providing a new casting meeting the acceptance criteria, at no additional cost to NJDOT.
All castings shall be visually inspected in accordance with ASTM A 802, Level II. Castings that do not pass this test may be rejected. Test results, whether positive or negative, shall be submitted to the Engineer. Test records meeting Level III may be considered for weld repair, provided the fabricator submits a procedure to the Engineer for review and approval. All repair procedures shall include a means to qualify the repair.
All castings shall be magnetic particle examined in accordance with ASTM E125. The following level of discontinuities will be acceptable.
Type I Cracks/Hot Tears ¼” max
Type II Shrink Degree 3
Type III Inclusions Degree 3
Type IV Chaplets Degree 2
Type V Porosity Degree 1
Test results, whether positive or negative, shall be submitted to the Engineer. All surface discontinuities may be considered for weld repaired, provided the fabricator submits a procedure to the Engineer for review and approval. All repair procedures shall include a means to qualify the repair.
All proposed weld repairs shall be performed prior to all heat treatment so that no weld repairs will be necessary after machining. In addition, all surface defects removed by machining shall be performed prior to heat treatment.
Carbon Steel and Alloy Steel Forgings shall meet the requirements of ASTM A668 unless otherwise approved by NJDOT.
D. Shafting and Pins. All shafts and pins shall be accurately finished, round, smooth, and straight and, when turned to different diameters, shall have rounded fillets at the shoulders. Each shaft or pin having a uniform diameter of 8” or more and each shaft or pin having several diameters, of which the smallest is 8” or more, shall be bored lengthwise through the center to a diameter approximately one-fifth the smallest body diameter.
All shafts shall conform to tolerances in ASTM A29 unless otherwise indicated. Turned, ground and polished shafting straightness tolerances shall be 0.005” per foot for shafts up to and including 1½” in diameter and 0.010“ per foot for shafts over 1 ½” in diameter.
Each end of all shafts, when finished to the required lengths shall have a 60-degree lathe center, with clearance hole, at the exact center of the shaft. Shafts that are bored with an inspection hole shall have the ends prepared for the attachment of a centering device equivalent to the lathe center. All such devices shall be furnished as part of the work.
Where shown on the drawings, stepped shafts shall have fillets blended in smoothly to adjacent surfaces without tool marks or scratches. Unless otherwise required herein or on the drawings to have a finer finish, the surfaces shall have an ANSI maximum roughness of 0.8 microinches.
All cold-finished shafting shall be steel of the type and grade shown on the drawings and shall be tested for its mechanical properties, and a test certificate shall be furnished to the Engineer. Each cold-finished shaft shall be free from camber and shall run without vibration, noise, or chatter at all speeds up to and including the maximum rated speed.
All hubs mounted on the ends of cold-finished shafts shall have the fit specified herein or on the drawings. To obtain the required fit between hub and shaft, the Contractor shall furnish the cold-finished shaft 1/16” larger than the nominal diameter specified and shall turn the ends to the required dimension for the hub. The Contractor may, at his option, furnish any cold-finished shaft of one diameter end to end; but such shaft shall have tolerances selected from the normal manufacturing range to provide the specified fit. The selected tolerances shall be shown on the shop drawings.
Turned, ground, and polished commercial shafting of the grade specified shall be used where shown on the drawings.
E. Fasteners. All bolts for connecting machinery parts to each other or to supporting members shall be as shown on the plans or specified otherwise and conform to one of the following types:
1. Machinery Fit, high-strength bolts.
2. Structural Fit, high strength bolts.
3. Turned bolts, turned cap screws, and turned studs.
All high strength bolts shown on the mechanical drawings shall be machinery fit unless otherwise noted. All high strength bolts shall meet the requirements of ASTM A325.
Holes for Machinery Fit high strength bolts shall be individually reamed for a clearance of not more than 0.01” with the actual bolt for that hole. The clearance shall be checked with a 0.011” wire. The hole shall be considered too large if the wire can be inserted in the hole together with the bolt. Structural Fit high strength bolts shall have a maximum clearance of 1/16” between the bolt shank and hole.
Both Machinery Fit and Structural Fit high strength bolts shall be connected using nuts meeting the requirements of ASTM A563.
Turned bolts, turned cap screws, and turned studs shall have turned shanks and cut threads. Turned bolts shall have semi-finished, washer-faced, hexagonal heads and nuts. Turned cap screws shall have finished, washer-faced, hexagonal heads. All finished shanks of turned fasteners shall be 1/16” larger in diameter than the diameter of the thread, which shall determine the head and nut dimensions. The shanks of all turned fasteners shall have Class LC1 fit in the finished holes in accordance with ANSI Standard B4.1. The material used for machining turned shank fasteners shall meet the requirements of ASTM A193, Grade B7. Turned bolts shall be connected using nuts meeting the requirements of ASTM A194. Turned fasteners shall be fully detailed on shop drawings.
The dimensions of all bolt heads, up to and including size 1 ½” shall be in accordance with ANSI Standard B18.2.3.7 – Heavy Hex Structural Bolts and for bolt sizes 1 5/8” – 4” shall be in accordance with ANSI B18.2.3.5 – Hex Bolts. All Heavy Hex nuts shall be in accordance with ANSI Standard B18.2.4.6 – Heavy Hex Nuts and all Hex Nuts shall be in accordance with ANSI Standard B18.2.4.2 – Hex Nuts.
The dimensions of socket-head cap screws, socket flathead cap screws, and socket-set screws shall conform to ANSI Standard B18.3. The screws shall be made of heat-treated alloy steel, cadmium-plated, and furnished with a self-locking nylon pellet embedded in the threaded section. Unless otherwise called for on the drawings or specified herein, set screws shall be of the headless safety type, shall have threads of coarse thread series, and shall have cup points. Set screws shall neither be used to transmit torsion nor as the fastening or stop for any equipment that contributes to the stability or operation of the bridge.
Threads for bolts, nuts, and cap screws shall conform to the coarse thread series and shall have a tolerance Class 2A bolts and nuts in accordance with the ASME Standard for Unified Inch Screw Threads.
Bolt holes through unfinished surfaces shall be spotfaced for the head and nut, square with the axis of the hole.
Unless otherwise called for, all bolt holes in machinery parts or connecting these parts to the supporting steel work shall be subdrilled at least 1/16” smaller in diameter than the bolt diameter and shall be reamed assembled for the proper fit at assembly or at erection with the steel work after the parts are correctly assembled and aligned.
All elements connected by bolts shall be drilled or reamed assembled to assure accurate alignment of the hole and accurate clearance over the entire length of the bolt within the specified limit.
Holes in shims and fills for machinery parts shall be reamed or drilled to the same tolerances as the connected parts at final assembly.
Wherever possible, high strength bolts connecting machinery parts to structural parts or other machinery parts shall be inserted through the thinner element into the thicker element.
High-strength bolts shall be installed with a hardened plain washer meeting ASTM F436 at each end.
Positive locks of an approved type shall be furnished for all nuts, except those on ASTM A325 bolts. If double nuts are used, they shall be used for all connections requiring occasional opening or adjustment. If lock washers are used for securing, they shall be made of tempered steel and shall conform to the SAE regular dimensions. The material shall meet the SAE tests for temper and toughness.
All cotters shall conform to the SAE standard dimensions and shall be made of half-round stainless steel wire, ASTM A276, Type 316.
All fasteners shall be of United States manufacture and shall be clearly marked with the manufacturer's designation.
F. Keys and Keyways. Keys and keyways shall conform to the dimensions and tolerances for square and flat keys of ANSI Standard B17.1, Keys and Keyseats, unless otherwise specified. All keys shall be effectively held in place, preferably by setting them into closed-end keyways milled into the shaft. The ends of all such keys shall be rounded to a half circle equal to the width of the key. Keyways shall have a radius in the inside corners. Keyways shall not extend into any bearing. If two keys are used in a hub, they shall be located 120 degrees apart and in line with wheel arms where practicable. The fit between key and keyways shall be as shown on the drawings.
Unless otherwise specified herein or in the drawings, keys shall be machined from carbon steel forgings, ASTM A668, Class K.
G. Enclosed Gear Reducer. Speed reducers shall be standard models from one manufacturer, with ratios, dimensions, construction details, and AGMA ratings as shown on the Plans. Ratings shall be based on a service factor of 1.0 or higher.
Reducers shall be manufactured in accordance with the requirements of the AGMA and shall have nameplates giving the rated horsepower, ratio, speed, service factor, and AGMA symbols.
Reducers shall be tested at no-load by rotating at operating speed for two hours in each direction.
Gear reducers shall have provisions for oil expansion due to churning and temperature change.
The manufacturer shall submit for approval a certified print of each speed reducer showing as a minimum the following:
1. All external mounting dimensions including shaft sizes, bores, and keyways where required.
2. Internal drawings showing each gear box component with part numbers.
3. The ratings that will appear on the nameplate.
4. Location of all lubricant connections.
5. Lubrication recommendations.
The reducer shall meet the additional requirements set forth on the Contract Plans and in these Specifications.
Reducers that drive electrical controls shall be as shown on plans or approved equal.
H. Hubs and Bores. The hubs of all couplings shall be finished on both faces and polished where the hub face performs the function of a collar to prevent shaft movement. The hubs shall be bored concentric with the outside of couplings. All hubs shall have an ANSI Class FN2 shrink fit on the shafts, unless otherwise specified. Assembly shall be accomplished by heating the hub, cooling the shaft and moving the parts to correct position with out force. The use of liquid nitrogen for cooling is prohibited.
I. Shims. Where shown on the drawings, all machinery shims required for leveling and alignment of equipment shall be steel, neatly trimmed to the dimensions of the assembled parts and drilled for all bolts that pass through the shims. In general, sufficient thickness shall be furnished to secure 1/64” variations of the shim allowance plus one shim equal to the full allowance. Shims shall be Stainless Steel ASTM A272 Type 302. Shims shall be provided without boltholes and shall be reamed in the field to the same fit as the other connected components. Shims greater than ½” shall include one solid plate of thickness equal to ½” less than total shim thickness.
Shims shall be shown and fully dimensioned as details on the working drawings. Shims with open side or U-shaped holes for bolts will not be permitted. No shims shall have less than two holes for bolts.
The use of peelable laminated shims with solder or resin bonding will be permitted as previously specified. Plastic or other non-metallic shims will not be permitted.
J. Welding. Welding required for machinery shall be done in accordance with the requirements for welding structural steel. Stress relieving will be required only when specified. All welds used to fabricate machinery shall be completely tested by ultrasonic inspection (ASTM E164-74) per AWS D1.5, Section 6, Part C, and are subject to the acceptance criteria of Section 9.25.3. All machining shall be performed after welding and stress relieving.
Welding joint sizes and details shall be shown on working drawings. Where multi-pass welds are required, welding procedures shall be submitted on or with shop drawings.
Distortion during fabrication shall be kept to a minimum by the use of welding fixtures and proper welding procedures.
K. Machinery Guards. Machinery guards shall be provided for all brakes and shall be constructed to comply with the applicable requirements of ANSI B15.1, Safety Standard for Mechanical Power Transmission Apparatus.
Unless otherwise indicated or specified, all machinery guards shall be constructed of stainless steel having minimum thickness of No. 12 Gauge (0.105 inch) and shall have provision for removal without requiring disassembly of any machinery component.
Machinery guards shall be provided with removable hinged or bolted covers for access to lubrication fittings enclosed by the guard. Phenolic nameplates shall be provided on these covers with lubrication instructions.
The inside of machinery guards shall be painted Safety Orange.
L. Flexible Couplings. Gear-type, self-aligning, full-flexible couplings or semi-flexible couplings with floating shafts shall be used to connect all machinery components, except where other types of couplings are called for on the drawings. All couplings shall have shrouded bolts.
The gear-type couplings shall be made of machined forged or cast steel, have curved face teeth and shall provide for at least a ( ¾ degree misalignment per gear mesh.
Grid-type, self-aligning, fully flexible, torsionally flexible couplings shall be used to connect electric motors to machinery components.
The grid-type couplings shall have steel hubs, alloy steel grids, and steel or aluminum covers. Bolts in the covers shall be shrouded.
Couplings shall be the standard products of an established manufacturer.
Special couplings shall be as shown on the drawings.
Coupling hubs shall be bored by the coupling manufacturer to the required size and tolerances, including keyways, and each hub shipped to the proper location for installation on its shaft by the manufacturer of the connected component.
All coupling hubs with interference fits shall be provided with tapped holes for a means of removal from the shafts.
Grid type flexible couplings shall be as manufactured by one of the following companies, or approved equal:
1. Falk Corporation, Milwaukee, WI
2. Lovejoy Corporation
3. Mondel Engineering (brakewheel)
Gear couplings shall have two bolt-connected halves, consisting of either two flexible halves or one flexible half and one rigid half and each flexible half shall consist of two parts with meshing teeth; a hub and a flanged sleeve or outer casing. Gear couplings shall be as manufactured by one of the following companies, or approved equal;
1. Falk Corporation, Milwaukee, WI
2. Kop-Flex, Incorporated, Baltimore, MD
3. Sier-Bath Gear Company, Inc., North Bergen, NJ
M. Lubrication. Standard grease fittings for a pressure system of lubrication shall be provided where applicable as shown on the Plans. Not more than two sizes of fittings shall be used. The large size shall be used wherever possible, and the smaller size shall be used for motor bearings and other small devices. Pressure fittings shall be rated at a minimum of 10,000 psi. Fittings shall contain a steel check valve that will receive grease and close against backpressure.
The large fittings shall be connected directly into the bushings by ¼” minimum size, extra strong, threaded steel pipe and forged threaded fittings. The smaller fittings shall be connected with ¼” pipe where pipe extensions are required or by the size pipe thread furnished with the device to be lubricated.
Pipe extensions shall be provided to facilitate access for lubrication but shall be kept as short as practical and shall be rigidly supported at the fittings and at intermediate points.
Immediately after the completion of fabrication, all grease fittings shall be plugged until components are installed and regular lubrication is started. The plugs will then be replaced with the proper grease fittings.
The Contractor shall furnish component manufacturer's lubrication literature for every machinery component, which requires lubrication.
The bridge shall be furnished with an amount of lubricants as specified for each lubricant. The amount shall be in addition to the lubricant required for initial lubrication. The lubricant shall be stored in new steel containers in a location specified by NJDOT Maintenance Forces.
The lubricant for each type of machinery component shall be kept separately in clearly marked new steel containers in a l. All measures shall be taken to prevent lubricant contamination.
During installation and where applicable, the Contractor shall lubricate rotating and sliding parts of the machinery and fill gear reducers and flexible couplings with lubricants indicated on the manufacturer's lubrication literature.
Lubrication fittings shall be as manufactured by one of the following companies, or approved equal:
1. Stewart Warner Alemite Corp., Charlotte, NC
2. Lincoln, Inc., St. Louis, MO
3. M. Brown Fitting Specialists, Inc., New York, NY
4. Auto Vehicle Parts Co., Covington, KY
N. Lubricants.
1. General. The Contractor shall submit proposed lubricant selections to the Engineer for approval.
2. Enclosed Gear Reducer. Enclosed gear reducer lubricant shall meet the requirements of the American Gear Manufacturers Association (AGMA) Standard 9005-D94 "Industrial Gear Lubrication".
The lubricant shall be manufactured by a reputable and knowledgeable supplier of lubrication and all lubricant shall be recommended for use in each application by the lubricant manufacturer.
The lubricant shall be recommended for use by the reducer manufacturer.
The lubricant should contain oxidation inhibitors, rust inhibitors, anti-foaming agents and anti wear additives.
Enclosed Gear Reducer Lubricant specification to be used in conjunction with AGMA Standard 9005-D94.
The maintenance of the lubricant, method of application and re-lubrication intervals, shall be recommended by both the reducer manufacturer and the lubricant manufacturer, and meet the requirements of the AGMA Standard 9005-D94, unless otherwise stated herein.
3. Open Gearing. The open gear lubricant utilized must bond strongly to gear teeth to maintain a continuous film on bearing surfaces despite high loading and high load repetition, contain an EP additive, repel water, resist throw off and dripping, maintain consistency over wide temperature variations, and allow for east in application and removal.
The lubricant shall have an operating range of (-18 to 94)(C and shall be considered a heavy bodied, adhesive type open gear lubricant by a reputable lubricant manufacturer.
Some adhesive lubricants are available in a diluted form for ease of application. This type of lubricant is diluted with solvent that quickly evaporates after application leaving behind an adhesive tacky film. If such a lubricant is desired, the solvent must be non-flammable and the mixture must not pose any hazard to health. The detailed specifications for open gear lubrications that will satisfy the above requirements do vary. The lubricant chosen shall be comparable to the following lubricants:
Mobil Mobiltac LL
Exxon Dynagear
4. Roller Bearings. The roller bearing lubricant, the maintenance of the lubricant, method of application and re-lubrication intervals shall be recommended or approved by the manufacturer unless otherwise stated herein.
5. Sleeve Bearings. The lubricant shall be comparable to the following:
Mobil Mobilux EP-2
Exxon Lidok EP-2
6. Couplings. Coupling lubricant shall be comparable to Falk LTG as specified by the coupling manufacturer.
7. Lock Bars. Lock bar front guide, rear guide, and receiving socket grease shall be comparable to the grease used in sleeve bearings as specified herein. Lock bar rack and pinion grease shall be comparable to the grease used for open gearing as specified herein.
O. Tools and Equipment. The following tools and lubrication equipment shall be provided:
One each of any other special size wrench and special tools or special lubrication equipment necessary to service machinery components actually installed on the bridge, which are not otherwise specified.
P. Spare Parts. In addition to the spare parts described under other items the following spare parts shall be provided:
1. One grid for each grid-type coupling.
2. One complete set of gaskets for every new flexible coupling.
3. Complete list of every new shaft and coupling seal used at the job, including current part number and manufacturing of each seal furnished plus sufficient generic description and dimensions to order seals in the future when current models/manufacturers may no longer be identifiable.
Q. Paints. All new machinery components and existing machinery components as shown on the Plans shall be coated with one coat of epoxy mastic primer manufactured by one of the following companies or an approved equal.
1. Sherwin-Williams Co., Epoxy Mastic Aluminum II
2. Carboline Carbomastic 15-Epoxy Mastic
Paint for the pre-final field painting of machinery shall consist of one intermediate coat of approved epoxy paint compatible with the prime coat system.
The final field applied paint shall consist of one coat of approved polyurethane paint resistant to weathering and abrasion and compatible with the intermediate coat.
Paint for painting the interior of gear housings, pillow blocks and flexible couplings shall be special oil-resistant crankcase paint as approved by the paint manufacturer.
No paints used shall contain lead. All layer thicknesses shall meet paint manufacturer’s specification.
R. Coatings. Where indicated on the Contract Drawings fabricated steel parts and weldments shall be hot-dip galvanized in accordance with NJDOT Standard Specifications.
In general, fabricated steel parts having thickness’ less than ¼” shall be hot-dip galvanized unless made of corrosion resisting material.
The threads of all mounting bolts shall be coated with anti-seize compound before assembly of the nuts to prevent corrosion or galling and to facilitate future removal if necessary.
Anti-seize compounds shall be as manufactured by the following companies, or approval equal:
1. Huron Industries, Port Huron, MI Neolube #1
2. Fel-Pro, Inc., Skokie, IL #C-670
3. SPC Technologies Unbrako, Jenkintown, PA
Rust-inhibiting coatings for temporary protection of machined surfaces shall be as manufactured by one of the following companies, or approved equal:
1. E.F. Houghton & Co., Rust Veto 344
Valley Forge, PA Cosomoline 1058
2. Sanchem, Inc., Chicago, IL No-Ox-Id "A" Special "X”
3. A.W. Chesterton, Co., Heavy-Duty Rust Guard
Stoneham, MA
4. Texaco, Houston, TX Metal Protective Oil L.
CONSTRUCTION
533.04 Construction Requirements.
A. Shop Assembly and Operation. Machinery components shall be shop assembled to verify their correct fit prior to shipment. Any components requiring selective assembly shall be match marked for future assembly.
B. Erection. The Contractor shall submit calculations, plans, and procedures detailing his intended scheme for installing all machinery.
Construction and installation shall be done in a coordinated manner to ensure that the machinery components fit the adjacent material furnished under other items.
All parts of the machinery shall be match marked for proper assembly and correct orientation. Before final drilling or reaming, all parts shall be adjusted to exact alignment by means of shims. Tapered shims shall be provided at no additional cost only if required. Electric motors, and devices such as limit switches and encoders, shall be included with the machinery for such erection. After final alignment and bolting, all parts shall operate smoothly.
The span shall not be operated by the auxiliary drive machinery until all other machinery is in final alignment and bolted as approved by the Engineer.
All edges and corners of machinery parts, sheet metal work, bedplates, and fabricated supports that are exposed in the finished work shall be rounded or chamfered. All burrs or other surface defects that could be injurious to workers erecting or maintaining the bridge machinery shall be removed.
Bolt holes in structural steel for connecting machinery shall, in general, be drilled from the solid after final alignment of the machinery. Sufficient erection holes, subdrilled ¼” undersize, for temporary bolts may be used for erection and alignment of the machinery. When the machinery is aligned in its final position, full-size holes for the remaining bolts shall be subdrilled and reamed, the full-size bolts installed, and the temporary bolts removed and the bolt holes for temporary bolts reamed full size and bolts installed.
ASTM A325 bolts shall be torqued to produce a tension equal to 70% of their minimum specified tensile strength. The tension shall be checked using a calibrated wrench.
Torques for other grades of bolts shall be proportioned to their strength and shall be indicated on the erection drawings.
The machinery shall be erected and adjusted by millwrights competent in the type of work involved. They shall be provided with all necessary measuring and leveling instruments as may be required.
The Contractor shall be responsible for verifying and documenting all measurements required to assure that the machinery has been properly installed. The Contractor shall schedule all final measurements with the Resident Engineer. All measurements will be subject to the Engineers approval.
C. Contractor’s Inspection. After erection is completed, the Contractor shall make a thorough inspection to insure that all parts are properly aligned and adjusted as closely as practicable without actual operation, and that all bolts are properly tightened.
Inspection of tightened fasteners shall be in accordance with the NJDOT Standard Specifications. The Contractor's inspection shall also verify that field painting has been performed as specified herein. Touch-up painting shall be performed to correct all painting defects found during this inspection.
The Contractor's inspection shall also verify that all machinery components have been lubricated as specified herein.
The Contractors shall be accompanied by the Engineer, during his final inspection before machinery testing. On the basis of the results of this inspection, the Engineer shall determine whether the bridge is ready for testing.
D. Painting.
1. General. Cleaning and painting of all unfinished surfaces of machinery shall comply with all the applicable additional requirements of the NJDOT Standard Specifications. The Contractor shall submit for review with the working drawings an outline of painting materials and methods.
2. Shop Painting. All unfinished machinery external surfaces shall be cleaned with final surface preparation, prior to painting, done by blast cleaning to meet the requirements of SSPC-SP6 "Commercial Blast Cleaning" with the following exceptions:
a. Flexible couplings.
b. Roller bearing pillow blocks
c. Electric motors
d. Brakes
e. Limit switches
f. Other equipment with shaft seals
g. The equipment excepted by the Engineer
The excepted machinery or equipment shall be cleaned with solvent and hand tools to meet the requirements of SSPC-SP2, Hand Tool Cleaning as depicted in SSPC Vis. 1.
After proper surface preparation, all unfinished machinery surfaces, except for those inside of gear housings and flexible shall be given two shop coats of primer by hand brushing. The shop coat shall be coordinated with the final field coat for compatibility. Application of primer shall adhere to all relative NJDOT Standard Specifications and the paint manufacturer recommendations. Insides of gear housings shall be cleaned and protected from rusting by an oil resistant paint as previously specified herein.
Field Painting. After erection is complete, all machinery surfaces remaining exposed, except rubbing surfaces, shall be thoroughly cleaned with an approved high-flash solvent (noted below), all exposed metal surfaces such as mounting bolts, lifting points and all other paint defects or voids shall be given two coats of primer. After successfully completing the prime coats, all machinery shall be given two field coats of machinery enamel (minimum 2 mils dry each coat) applied by hand brushing. Application of paint shall adhere to all relative NJDOT Standard Specifications and the paint manufacturer recommendations. Acceptable machinery enamels are given under MATERIALS. Colors for the field coats will be selected from manufacturer's standard samples with the approval of the Engineer.
The Contractor shall take special care to avoid painting of machinery surfaces, which are in normal rubbing contact. All nameplates, legend plates, and escutcheons mounted on machinery shall be masked for protection from paint. Lubrication fittings shall be kept clog-free.
After completion of the operating tests and acceptance of the machinery, all accumulated oil, grease, dirt, and other contaminants shall be washed from exposed machinery surfaces, excepting rubbing surfaces, with an approved high-flash solvent. The cleaned exposed surfaces shall then be hand brush painted a third final field coat of machinery enamel as specified above, which shall color-code the machinery to distinguish between fixed and moving parts. Again, the application of paint shall adhere to all relative NJDOT Standard Specifications and the paint manufacturer recommendations. The following colors shall be used.
1. FEDERAL SAFETY ORANGE: Except for rubbing surfaces, for all moving parts of the machinery such as shafting, couplings, and the side of gears and brakewheels.
2. FEDERAL SAFETY GREEN: For all stationary parts of the machinery.
Paint for the final field coat, which shall be compatible with the previous field coats, shall be a high-gloss machinery enamel resistant to weathering and abrasion, conforming to OSHA color requirements of the Safety Color Code for Marking Physical Hazards, ANSI Z53.1. The brand and colors shall be submitted to the Engineer for approval. The Contractor shall place cautionary signs in the Operator's House and at the entrances to the machinery rooms that shall explain the color code. Details of the sign giving text, dimensions and materials shall be placed on a shop drawing.
E. Field Testing. Field testing is required for both the auxiliary drive machinery and the permanent electric motor drive machinery after it is installed.
When the mechanical machinery and electrical equipment is ready for testing, the Contractor shall meet with the Engineer to arrange a test schedule, and shall keep available a complete crew of mechanics for a minimum of four working days in order to provide operation of the span for all tests and to make all adjustments and corrections which shall be required to complete the tests.
The Contractor shall prepare a field testing procedure which shall be approved by the Engineer. The testing procedure shall be coordinated with tests required for the electrical equipment and shall include measurements of power and current drawn by the motors when operating under load as required hereinafter. The Contractor shall be responsible not to exceed the electrical design ratings of any component during all testing.
The testing procedure shall include but not be limited to the verification of the proper operation and/or final adjustment of the following:
1. Coupling alignment
2. Machinery mounting integrity
3. Span operating times
4. Brake settings
5. Span seating and balance
When the permanent machinery is ready for field testing, the operating machinery shall be driven by the main electrical system through at least ten complete cycles.
Additional testing requirements are detailed in the Electrical Specifications.
Strain gauge balance tests shall be performed. The strain gauges shall be mounted appropriately on each main pinion shaft. See additional requirements under Section 526, “Span Balancing”.
During the test runs, the entire operating machinery shall be inspected to determine whether everything is in proper working order and fully meets the requirements of the Contract Drawings and these Specifications. The temperature rise of all electrical components shall not exceed design ratings. If any tests show that any components are defective or inadequate, or function improperly, the Contractor shall make all corrections, adjustments, or replacement required before the final acceptance at no additional cost.
The Contractor shall coordinate the machinery with the structural supports and with the installation of electric motors, brakes, limit switches and other electrical components furnished under other items with the work in this item.
E. Lubrication. The following amounts of additional lubricant shall be stored at the site in coordination with NJDOT Maintenance Forces:
1. Reducer Oil – 55 gallons
2. Grid Coupling Lubricant - 25 pounds
3. Gear Coupling Lubricant - 50 pounds
COMPENSATION
533.05 Method of Measurement.
Machinery in General will not be measured for payment. It shall include all items and activities noted and required in this section.
533.06 Basis of Payment.
Separate payment will not be made for Machinery in General. All costs associated with this work shall be included in the applicable pay items for mechanical work.
SECTION 534 – EMERGENCY SPAN DRIVE MACHINERY
534.01 DESCRIPTION.
The work shall consist of furnishing and placing in proper operating condition, acceptable to NJDOT, the temporary span drive machinery, complete with all appurtenances required for proper operation. Work includes removal and replacement of existing vertical floating shafts, existing auxiliary drive reducers (miter boxes), and modifying existing horizontal output shafts to accept new reducers. Work also includes the modification of existing supports to accept the new reducers and gear motor assemblies.
It is the intent and purpose of these Specifications to cover and include all apparatus, appliances, material, plant and labor necessary to properly install, equip, test, adjust, paint, and put in approved working order the respective portions of the work herein specified.
The existing components of the existing auxiliary drive machinery to be replaced shall be removed in accordance with Section 201 “Clearing Site”.
MATERIALS
534.02 Materials and Equipment.
A. Conformance. All equipment and its installation shall conform to the requirements of the latest revision of the Standard Specifications for Movable Highway Bridges of the American Association of State Highway and Transportation Officials, except as may be otherwise provided herein.
Materials and construction shall conform to the requirements of the current National Electrical Code and to any applicable local rules and ordinances. The Contractor shall obtain any required permits and approvals of all Departments or Agencies having jurisdiction.
B. Equipment and Material Provisions. The temporary span drive machinery and all associated equipment and materials shall be new. All equipment, materials, and workmanship shall be first-class in every aspect of this project and shall be manufactured and erected to the satisfaction of the Engineer and NJDOT Movable Bridge Engineering Group. See Section 533, “Machinery in General” for related requirements. The Contractor shall warrantee the in-service working of the temporary span drive machinery for one year following the date of installation. If the Contractor has any objection to any feature of the equipment as designed and laid out, he must state his objection at once, in writing, to the Engineer and NJDOT Movable Bridge Engineering Group; otherwise, his objection will be not be valid as an excuse for operational malfunctioning of the equipment or for defective or broken apparatus.
If any changes from the Plans or these Specifications are deemed necessary by the Contractor, details of such departures and the reasons therefore shall be submitted for approval as soon as practicable before construction. No such changes shall be made without approval of the Engineer and NJDOT Movable Bridge Engineering Group.
Material requirements for apparatus, equipment, and materials will be found in the articles under "Construction" in this item.
CONSTRUCTION
A. Shop Assembly and Operation. The temporary span drive machinery includes the motors, reducers, electric clutches, and coupling halves. The gear motors shall be shop assembled and shipped to the field as assembled units. The auxiliary reducers (miter boxes) shall be shop assembled with all three coupling halves and shipped to the field.
Visual inspection of the shop-assembled machinery shall be made by, and shop tests shall be witnessed by, a designated representative of the Engineer. Testing shall be in accordance with “Mechanical Work” Section 533.03 Materials, Part G. ENCLOSED GEAR REDUCERS. If any malfunctions are observed, they shall be corrected and such units shall pass all shop tests before release from the machinery manufacturer's shop.
After each unit has passed all shop tests, the manufacturer shall prepare Certificates of Compliance with the specified tests and shall submit them to the Engineer.
B. Field Testing. Following the installation and alignment work, the Contractor shall test the temporary span drive machinery. The Engineer and NJDOT Movable Bridge Engineering Group and bridge operators shall be notified of the time and date of the site test. The tests shall include:
1. Time of operation
2. Movement during starting and stopping
3. Vibration during running
4. Overheating and leaking of oil
Should the tests show that the gear motor or any component piece of equipment or apparatus, in the judgment of the Engineer and NJDOT Movable Bridge Engineering Group, is defective or functions improperly, such adjustments and/or replacements shall be made by the Contractor as to make the installation satisfactory to the Engineer and NJDOT Movable Bridge Engineering Group at no extra cost.
C. Warranty and Maintenance. The temporary span drive machinery shall be guaranteed against defects and poor workmanship for the duration of the project.
COMPENSATION
534.03 Method of Measurement.
Measurement will be on a lump sum basis.
534.04 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
EMERGENCY SPAN DRIVE MACHINERY LUMP SUM
SECTION 535 – MISCELLANEOUS MECHANICAL WORK
535.01 DESCRIPTION.
The work shall consist of furnishing, rehabilitating, and placing in proper operating condition, acceptable to NJDOT, miscellaneous machinery components, including but not limited to the span instrumentation, motors, brakes, couplings, and span lock machinery, complete with all appurtenances required for proper operation. Work includes removal and replacement of existing span motors, motor brakes, machinery brakes, instrumentation and limit switches, lock motors, shaft couplings and coupling seals as shown on the Plans, and primary differential reducer seals. Work also includes any modifications to existing supports to accept new machinery.
The span lock bars are to be removed and milled and a temporary lock is to be manufactured and installed while existing bars are removed, one at a time. New proximity limit switches are to be installed for lock bar positioning. The front guides and receiving sockets are to be shimmed and provided with new socket shoes. The lock machinery reducers are to be cleaned and painted.
It is the intent and purpose of these Special Provisions to cover and include all apparatus, appliances, material, plant and labor necessary to properly install, equip, test, adjust, paint, and put in approved working order the respective portions of the work herein specified.
Existing components as called out on the Plans shall be removed in accordance with Section 201 “Clearing Site Bridge”.
MATERIALS
535.02 Materials and Equipment.
D. Conformance. All equipment and its installation shall conform to the requirements of the latest revision of the Standard Specifications for Movable Highway Bridges of the American Association of State Highway and Transportation Officials, except as may be otherwise provided herein.
Materials and construction shall conform to the requirements of the current National Electrical Code and to any applicable local rules and ordinances. The Contractor shall obtain any required permits and approvals of all Departments or Agencies having jurisdiction.
B. Equipment and Material Provisions. The machinery covered in this section and all associated equipment and materials shall be new. All equipment, materials, and workmanship shall be first-class in every aspect of this project and shall be manufactured and erected to the satisfaction of the Engineer and NJDOT Movable Bridge Engineering Group. See section 525, “Machinery in General” for related requirements. The Contractor shall warrantee the in-service working of the miscellaneous machinery for one year following the date of acceptance. If the Contractor has any objection to any feature of the equipment as designed and laid out, he must state his objection at once, in writing, to the Engineer and NJDOT Movable Bridge Engineering Group; otherwise, his objection will be not be valid as an excuse for operational malfunctioning of the equipment or for defective or broken apparatus.
If any changes from the Plans or these Specifications are deemed necessary by the Contractor, details of such departures and the reasons therefore shall be submitted for approval as soon as practicable before construction. No such changes shall be made without approval of the Engineer and NJDOT Movable Bridge Engineering Group.
Material requirements for apparatus, equipment, and materials will be found in the articles under "Construction" in this item.
CONSTRUCTION
535.03 Construction Requirements
A. Shop Assembly and Operation. All motors shall be shop-assembled with their respective coupling halves prior to shipment to the field. The main span and lock electric motors, brakes, brakewheel couplings, flexible couplings, and limit switches shall be shipped to the bridge for field assembly and inspection.
The instrumentation drive machinery, including gear reducer, rotary limit switch, and resolvers, has been designed as a shop-assembled package that shall include alignment of all shop assembled components. Components may require disassembly at installation. The shaft alignments shall be rechecked and adjusted as necessary at erection.
E. Field Testing. Following the installation and alignment work, the Contractor shall test all machinery furnished and rehabilitated under this section. The Engineer and NJDOT Movable Bridge Engineering Group and bridge operators shall be notified of the time and date of the site test. The tests shall include:
1. Span time of operation and trip positions (min. 5 cycles)
2. Lock bar time of operation and trip positions (min. 5 cycles)
3. Movement of span operating and lock machinery during starting and stopping
4. Vibration during running/operating
5. Overheating and leaking of oil
Should the tests show that any component piece of equipment or apparatus, in the judgment of the Engineer and NJDOT Movable Bridge Engineering Group, is defective or functions improperly, such adjustments and/or replacements shall be made by the Contractor as to make the installation satisfactory to the Engineer and NJDOT Movable Bridge Engineering Group at no extra cost.
F. Warranty and Maintenance. The machinery in this section shall be guaranteed against defects and poor workmanship for one year after acceptance of the bridge.
COMPENSATION
535.04 Method of Measurement.
Measurement will be on a lump sum basis.
535.05 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
MISCELLANEOUS MECHANICAL WORK lump sum
SECTION 536 – BRIDGE OPERATION AND MAINTENANCE DURING CONSTRUCTION
536.01 Description.
The Contractor shall be held responsible for operation of the bascule span during periods of restricted openings defined in Section 107.13 “Construction over or Adjacent to Navigable Waters.” The Contractor shall also be responsible for the maintenance of the existing bridge components from the construction start date until final acceptance. During this period the Contractor shall be responsible to operate and maintain the existing bridge uninterrupted for pedestrian, vehicle, and marine traffic. The Department will meet the Contractor over the first 6 months to review operations and maintenance history. The Contractor shall maintain a log of all operation and maintenance activities and submit them to the Department on a monthly basis. Completed forms shall be submitted to the Engineer and Mr. John Rainiero at the Bureau of Maintenance Engineering Bridge Section, 1035 Parkway Avenue, Trenton NJ, 08625 for record. The Sample Forms are included in Appendix B for contractor’s use; see Forms EL-45DCER, EL-45EER, and EL-45MER. In the event of an operational or bridge malfunction, the Contractor shall notify Engineer and contact Mr. Robert Cunningham, Manager, Bureau of Maintenance Engineering and Operations at (609) 530-2702 and Mr. John Rainiero, Project Engineer, Bureau of Maintenance Engineering-Bridge Section at (609) 530-3708.
A. Maintaining Existing Facilities. The Contractor shall maintain the existing electrical and mechanical components of the bridge operating system in operating condition at all times throughout the construction of the project. This includes, but is not limited to, navigation lights, traffic signals, warning and barrier gates, roadway lights, bridge lighting and heating and any other electrical facilities required for safe operations of the span. The Contractor shall furnish and install any temporary equipment necessary to conform with the above requirements. The arrangement of any temporary facilities and controls shall be approved by the Engineer. Lane closures shall be in accordance with the requirements listed of the maintenance of traffic plan sheets.
The maintenance shall include regular greasing, fluid change, electrical control maintenance, Fire Alarm System maintenance, up-keep for the Operator’s Houses including, but is not limited to, cleaning, garbage removal, , and maintaining stairs to provide for safe access to Operator’s Houses, and also repairs to any breakdowns during the construction period.. The following is a summary of typical required bridge maintenance for the movable bridge.
1. Monthly Greasing – Four (4) trunnions, six (6) span lock guides, all open gears and remaining bearings shall require monthly greasing. For location of moveable components requiring greasing, the contractor shall refer to as-built plans for the existing bridge located at NJDOT, Trenton office and as-built plans of Route 35, Sec.12P – Electrical and Mechanical Rehabilitation contract located at NJDOT Freehold office, Moveable Bridge Engineering Unit.
2. Annual Maintenance – All gear reducers require an oil flush and fill every 12 months.
The Contractor shall be responsible for disposal of lubrication oil, grease, and hydraulic fluids in accordance with the all applicable environmental regulations.
3. Electrical Maintenance – The work shall include, but is not limited to, the following tasks:
• Contact cleaning and tightening of connections of electrical panel components in the operator’s house.
• CCTV system maintenance and repositioning and relocation of cameras to get clear view of channel for bridges openings during construction.
• Relamping of street lights, Operator’s House lights, navigational lights, traffic signal lights and traffic/barrier gate lights as necessary.
The Contractor and Engineer will examine all the required facilities on the bridge and will note items requiring modification prior to the start of mandated maintenance.
Upon issuance of a report of non-operating items to the Engineer, the Engineer will make arrangements with Contractor or other parties to repair any mal/non-functioning items. Contractor shall assume the full responsibility for maintenance of the bridge once these non-operating items are addressed but no later than six (6) months after the award of the project.
Thirty (30) days prior to assuming responsibility for operation of the bridge, the Contractor shall submit to the Engineer for approval an Emergency Bridge Operation Response Plan (EBORP) explaining the Contractor’s planned response to open the bridge in event the bridge fails open. The EBORP shall detail the Contractor’s list of emergency response personnel and equipment. If the bridge fails to operate for any reason, the Contractor’s is required to respond to the project site with emergency personnel and equipment within two (2) hours from the bridge becomes un-operational to address emergencies. Should the Contractor fail to respond and costing the State to respond with its own forces to restore bridge operation, the Contractor agrees to pay the State the following damages:
• For each occurrence that the Contractor fails to provide scheduled bridge openings on Sundays, for the period between November 1 through March 1, each season throughout the construction duration, as described under Section 107.13, the Contractor shall pay liquidated damages consisting of Road User Costs and Consulting Engineering Costs to the State in the amount of $4,800 plus USCG civil penalties in the amount of $15,000 per day in 2006, $20,000 per day in 2007, and $25,000 per day in 2008 and beyond, plus $5,400 per every offense for mobilizing the State’s forces and equipment, plus
• The Contractor shall be held liable for any lawsuits and damaged assessed against the State by marine operators for their losses.
Approved EBORP shall be kept at the Operator’s House for record.
02. Materials and Workmanship.
All electrical equipment and its installation shall conform to the requirements of the 2000 AASHTO LRFD Movable Highway Bridge Specifications with current interims, except as may be otherwise provided herein.
All work shall conform to the requirements of the current national electrical code, and to any applicable local rules and ordinances. The Contractor shall obtain any required permits and approvals of all departments or agencies having jurisdiction.
All equipment and materials except those designated to the reused shall be new. All equipment, materials, and workmanship shall be manufactured end erected to the satisfaction of the Engineer.
The contractor shall coordinate all mandated lubrication of the bridge machinery with the Engineer. Refer to Section 533 – Machinery in General for lubricant requirements.
03. Bridge Operating Personnel.
During periods of restricted openings defined in Section 107.13 “Construction over or adjacent to Navigable Waters”, the Contractor shall provide three (3) operators (operators must have the ability to speak, write, and communicate in English).
The basic qualifications of a Bridge Operator is the ability to seat the bridge safely without causing damage to the bridge structure by using eye-hand coordination to operate semi-automatic and manual controls. The individual must have good communicative skills, as they will be required to operate marine band radios to transmit and receive messages from the mariners, as well as communicate with the general public and law enforcement agencies. The Bridge Operator must have ability to use sound judgment and good common sense when dealing with day-to-day situations that arise.
The Contractor shall provide names and resumes of these operators to the Engineer and US Coast Guard for approval prior to beginning training as specified under Section 101.01 herein for security reasons.
Bridge opening time for construction and test purposes, shall be limited to certain hours for training and testing as directed by the Engineer.
Throughout the construction period, during working hours, the Contractor shall have available on call at the bridge a person who is knowledgeable as to the bridge workings and be able to perform electrical trouble shooting. At all other times he shall be available to report at the bridge within one hour, after verbal notification by the department or other duly appointed representative.
The bridge is required to open on signal from 8 a.m to 11 pm with the following exceptions:
1. During periods of restricted openings defined in Section 107.13 “Construction over or adjacent to Navigable Waters”,
2. From May 15 through September 30 the draw need only open 15 minutes before the hour and 15 minutes after the hour on:
a. Saturdays, Sundays and Federal holidays, from 8 a.m. to 10 p.m.
b. Mondays to Thursdays from 4 p.m. to 7 p.m.
c. Fridays, except Federal holidays, from 12 p.m. to 7 p.m.
Year round from 11 p.m. to 8 a.m. the draw need only open if at least four (4) hours of notice is given.
During the initial week of employment, all new operators will be instructed with the normal operating procedure by the Department’s Chief Bridge Operator. Once they are ready to certified, the Department will observe their performance and certify their ability to correctly operate the structure. The Sample Form used for certification of the Operator is included in Appendix B; see Form “Bridge Operator’s Certification”. Once Operators are certified to operate the bridge by the Department; the completed certification form shall be submitted to the Engineer and one copy shall be kept at the Bridge Operator’s Room for record. Operators shall not be allowed to operate the bridge unless certified by the Department. It is the Contractors responsibility to provide adequate training and get operators certified. Normally, two (2) months of training is required prior to certifying Operator for safe operation of the bridge. The Department will pay for the two months of training for each Operator. If Operator leaves during employment or after receiving training, the Department will not pay for any additional training required to train additional Operators.
536.04 Method of Measurement.
Bridge Operation and Maintenance During Construction will not be measured for payment. It shall include all items and activities noted and required in this section
536.05 Basis of Payment.
Separate payment will not be made for Bridge Operation and Maintenance During Construction. All costs associated with monthly greasing and gear reducer annual oil flush shall be included under MISCELLANEOUS MECHANICAL WORK. All costs associated with Bridge Operators and Electrical Maintenance shall be included under ELECTRICAL WORK.
dIVISION 600 - INCIDENTAL CONSTRUCTION
SECTION 602 - PIPES
602.02 Materials.
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MATERIALS SHALL CONFORM TO THE FOLLOWING SUBSECTIONS:
Ductile Iron Culvert Pipe 913.02
Ductile Iron Water Pipe 913.03
Concrete Pipe 913.04
Corrugated Aluminum Alloy Culvert Pipe and Pipe Arches 913.05
Corrugated Steel Culvert Pipe and Pipe Arches 913.07
Corrugated Steel Sewer Pipe and Pipe Arches 913.08
High Density Polyethylene (HDPE) pipe 913.11
Mortar and Grout 914.03
Gaskets 919.08
Portland cement concrete for pipe plugs, encasements, or saddles shall conform to Section 914.
Where corrugated metal culvert pipe is designated, corrugated aluminum alloy culvert pipe or corrugated steel culvert pipe may be used.
Where corrugated metal culvert pipe arch is designated, corrugated aluminum alloy culvert pipe arch or corrugated steel culvert pipe arch may be used.
End sections shall be of the same material as the pipe or pipe arch to which the end sections are attached, except that end sections for HDPE pipe for outfall systems shall be concrete.
For jacked pipe, reinforced concrete culvert pipe shall conform to Subsection 913.04 except that the pipe shall be Class V, Wall B, tongue and groove type.
The tube material shall conform to the requirements of ASTM F 1216. The tube shall be fabricated to a size that, when installed, conforms to the internal circumference and length of the original pipe.
The wall color of the interior tube surface after installation shall not be of a dark or non-reflective nature that could inhibit proper closed-circuit television inspection.
All HDPE pipe shall be type S (smooth interior with annular corrugations), with gasketed silt-tight joints according to AASHTO M294
All HDPE pipes shall be in compliance with the requirements of the National Transportation Product Evaluation Program’s (NTPEP) evaluation of HDPE and thermoplastic pipe. NTPEP test results shall be furnished to the Resident Engineer and to the Bureau of Materials Engineering and Testing before construction operation.
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602.03 CONSTRUCTION AND INSPECTION REQUIREMENTS.
A. Construction. Excavation, bedding, backfilling, and disposal of excess material shall conform to Section 207 and the following:
1. Trench openings shall not remain open overnight, unless adequately protected, within or adjacent to roadways on which traffic is being maintained or within the normal limits of pedestrian access.
2. When installing storm drains across private property, the topsoil and sod disturbed by excavation operations shall be salvaged for use in restoring the area to its original condition.
3. Except where necessary to maintain flow, drains shall not be placed in embankment until it has been constructed to a height of at least 3 feet above the top of the pipe or to the top of the embankment, whichever is lower, and then a trench shall be excavated for placing of the pipe.
4. Before the installation of HDPE pipe, and at the discretion of the Resident Engineer, a technical representative from the pipe manufacturer shall be on site for the first day of pipe installation to validate proper installation procedures.
5. Existing drainage flow during construction shall be maintained until proposed drainage facilities are completed and put into service.
6. Pipe shall be handled and stored carefully in order to prevent damage such as cracking, denting and breaking. Pipe shall be lifted off of the delivery vehicle in order to avoid damage while unloading. Pipe shall not be dragged off the vehicle. Pipe shall be stored in an area where it will not be damaged during construction operations. When pipe is stacked, it shall be properly blocked or strapped, and the bell and spigots shall alternate to reduce the load on the bells. Pipe that is damaged, bowed or considered unacceptable for other reasons will be rejected by the Engineer and shall not be used on the Project.
7. If heavy construction equipment (100 kips axle load) will be used in or over the vicinity of HDPE pipe or corrugated aluminum alloy culvert pipe, a temporary compacted cover of a minimum of 4 feet shall be placed over the top of the pipe. The materials for the temporary cover shall be excavated material free from stones larger than 2 inch for concrete pipe, 1½ inch for HDPE and 1 inch for corrugated steel pipe.
8. Sections of pipe damaged during construction shall be removed and replaced.
B. Inspection.
1. Video Inspection of Pipe.
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2.
Approximately 25 percent of the length of HDPE pipe shall be tested for deflection no sooner than 30 days after installation. Perform the deflection testing using either electronic deflectometers, calibrated television or video cameras, properly sized “go, no-go” mandrel, direct measurement extension rulers and tape measures in pipes that permit safe entry, or another acceptable device.
Where deflection is greater than 5 percent of the base inside diameter, the Contractor shall develop and submit a remediation or replacement plan to the Resident Engineer for approval.
Remedial action may include but is not limited to removal and replacement or an accepted repair procedure.
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PIPE WILL BE INSPECTED BEFORE AND DURING BACKFILLING OPERATIONS. ANY PIPE FOUND TO BE OUT OF ALIGNMENT, EXCESSIVELY SETTLED, LIFTED, OR DAMAGED SHALL BE REMOVED AND RELAID OR REPLACED.
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JOINTS FOR RIGID PIPE SHALL BE MADE WITH MORTAR, GROUT, OR GASKETS. OTHER TYPES OF JOINTS RECOMMENDED BY THE PIPE MANUFACTURER MAY BE PERMITTED AS APPROVED BY THE RESIDENT ENGINEER. CORRUGATED METAL PIPE SHALL BE JOINED BY COUPLING BANDS.
THE FOLLOWING is added after the last paragraph:
THE USE OF SPLIT COUPLINGS FOR HDPE PIPE SHALL NOT BE PERMITTED UNLESS APPROVED BY THE RESIDENT ENGINEER FOR USE IN JOINING FIELD CUTS. ALL JOINTS SHALL BE OF THE BELL AND SPIGOT, OR BELL AND SPIGOT TYPE WITH A GASKET ACCORDING TO ASTM F 477 TO PROVIDE A SILT-TIGHT SEAL. PIPE CONNECTIONS SHALL BE CONSTRUCTED ACCORDING TO THE MANUFACTURER’S RECOMMENDATIONS FOR ASSEMBLY OF JOINT COMPONENTS, LUBRICATIONS AND MAKING OF JOINTS. THE PIPE FITTINGS SHALL BE FREE OF INCLUSIONS AND VISIBLE DEFECTS. THE ENDS OF THE PIPE SHALL BE CUT SQUARELY SO AS NOT TO ADVERSELY AFFECT JOINING.
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___” X ___” REINFORCED CONCRETE CULVERT PIPE ARCH, CLASS ___ LINEAR FOOT
___” X ___” REINFORCED CONCRETE SEWER PIPE ARCH, CLASS ___ LINEAR FOOT
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___ " HIGH DENSITY POLYETHYLENE PIPE LINEAR FOOT
DEFLECTION TESTING OF HIGH DENSITY POLYETHYLENE PIPE LINEAR FOOT
THE FOURTH PARAGRAPH IS CHANGED TO:
SEPARATE PAYMENT WILL NOT BE MADE FOR MATERIAL USED AS A TEMPORARY COVER OVER CORRUGATED ALUMINUM ALLOY CULVERT PIPE OR HDPE PIPE.
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WAS THIS STUFF ADDED BY PB? - KR
603.08 INLETS.
THE FOLLOWING IS ADDED:
TO PROVIDE FOR TEMPORARY DRAINAGE, AND TO PROVIDE A BETTER RIDING SURFACE AFTER THE BASE AND INTERMEDIATE PAVEMENT COURSES ARE CONSTRUCTED, INLETS AND MANHOLE CASTINGS SHALL BE INITIALLY SET 2 INCHES BELOW THE INDICATED GRATE ELEVATION. INLETS WITH CURB PIECES SHALL BE PROVIDED WITH A CURB PIECE 2 INCHES HIGHER THAN NORMALLY PROVIDED SO THAT THE CURB PIECE MATCHES THE ADJACENT CURB HEIGHT. TYPE D INLETS IN BARRIER CURB SHALL BE CONSTRUCTED IN THE NORMAL MANNER. AS THE FINAL 2 INCH SURFACE COURSE IS CONSTRUCTED, INLETS AND MANHOLES SHALL BE FITTED WITH A 2-INCH FRAME OR RING, AND THE GRATE REINSTALLED.
SECTION 605 - CURBS
605.07 CONCRETE CURBS.
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THE FOLLOWING IS ADDED:
CONCRETE BARRIER CURB TRANSITION WILL BE MEASURED BY THE LINEAR FOOT.
605.11 BASIS OF PAYMENT.
THE FOLLOWING IS ADDED:
PAY ITEM PAY UNIT
Concrete barrier curb transition linear foot
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607.02 MATERIALS.
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HMA SHALL CONFORM TO SECTION 903 EXCEPT THAT THE COMPOSITION OF THE MIXTURE FOR THE TOP LAYER MAY ALSO INCLUDE UP TO 20 PERCENT OF RAP. PORTLAND CEMENT CONCRETE SHALL CONFORM TO SECTION 914 EXCEPT THAT DRIVEWAYS SHALL ATTAIN A STRENGTH OF NOT LESS THAN 3,000 POUNDS PER SQUARE INCH IN THREE DAYS. OTHER MATERIALS SHALL CONFORM TO THE FOLLOWING SUBSECTIONS:
Soil Aggregate 901.09
Prime Coat:
Cut-back Asphalt, Grade MC-30 or MC-70 904.02
Tack Coat:
Cut-back Asphalt, Grade RC-70 or RC-T 904.02
Emulsified Asphalt, Grade RS-1, SS-1, or SS-1h 904.03
Cationic Emulsified Asphalt, Grade CSS-1 or CSS-1h 904.03
Curing Materials 905.03
Preformed Expansion Joint Filler 908.01
Reinforcement Steel 915.03
Detectable Warning Surfaces 905.06
Dense-graded aggregate for base course used with HMA sidewalk shall conform to Subsection 901.08.
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607.06 CONCRETE SIDEWALKS, DRIVEWAYS, AND DETECTABLE WARNING SURFACES.
SUBPART 5 heading and entire text are CHANGED TO:
5. DETECTABLE WARNING SURFACES. IMMEDIATELY BEFORE INSTALLING SAFETY RED COLOR AND DETECTABLE WARNING SURFACES, THE DESIGNATED AREA SHALL BE THOROUGHLY CLEANED AND DRIED ACCORDING TO THE MANUFACTURER’S RECOMMENDATION. THE INSTALLATION OF DETECTABLE WARNING SURFACES SHALL BE ACCORDING TO THE CORRESPONDING CONSTRUCTION DETAILS AND THE MANUFACTURER’S RECOMMENDATION. THE BACKGROUND SURFACE UPON WHICH THE DETECTABLE WARNING SURFACE IS INSTALLED, SILICON CARBIDE 60 GRIT SHALL BE EVENLY BROADCAST AT A RATE OF 0.07 POUNDS PER SQUARE YARDS FOR SKID RESISTANCE.
A list of approved manufacturers will be provided in the Special Provisions.
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SAFTI-TRAXTM COTE-L Industries, Inc 1542 Jefferson Street
Teaneck, NJ 07666
201-836-0733
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DETECTABLE WARNING SURFACES WILL BE MEASURED BY THE SQUARE YARD.
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PAY ITEM PAY UNIT
PUBLIC SIDEWALK CURB RAMP DELINEATION SQUARE yard
THE FOLLOWING PAY ITEM IS ADDED:
PAY ITEM PAY UNIT
Detectable Warning Surfaces SQUARE yard
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SECTION 616 – SLOPE AND CHANNEL PROTECTION
616.01 Description.
This work shall consist of installation of riprap stones around Piers 1N and 2N, as shown in the plans. This work shall also consist of installation of riprap stones over the excavated contaminated soil in front of each abutment, the limits as specified in the plans.
616.02 Materials.
The following is added at the end of this subsection:
Riprap Stone Channel Protection, Piers 1N and 2N, shall consist of clean rock, identified as riprap in accordance with Subsection 901.16, with the following modifications: stones shall not weigh more than 200 pounds each, with at least 90 percent of the stones weighing more than 50 pounds each, but not more than 40 percent weighing more than 100 pounds each.
616.07 Riprap Stone Slope or Channel Protection.
The following is added at the beginning of this subsection:
Riprap Stone Slope Protection shall be placed at both the existing north and south abutments as shown on the plans. Riprap stone channel protection shall be installed at existing Piers 1N and 2N of the existing bridge, as shown on the plans and as described below:
The plan and cross sections as depicted in the plans is generic, and meant to represent the typical expected type, area, and location of stone channel protection riprap to restore the original cross section of the scoured areas adjacent to these piers.
The below-water surface areas shall be inspected by a diver prior to placement to determine the location and quantity of riprap required. The estimated quantity has been approved for filling in the water by the NJDEP and USCOE and the total volume may not be increased without prior approval of these agencies.
The elevations to which the top of riprap shall be terminated may not deviate by more than three inches, so as to not change the riverbed, as large boats frequent these spans.
Sections of geotextile fabric and riprap protection shall be constructed to the lines and grades and in the areas shown on the contract drawings or modified by the Engineer.
The second paragraph is replaced with the following:
The geotextile is to extend over the entire surface over which the riprap is to be placed and extend a minimum of 1 foot out on each side. At the time of installation, fabric shall be rejected if it has defects, rips, holes, flaws, deterioration, or damage incurred during manufacture, transportation, or storage. The fabric shall be laid smooth and free of tension, stress, fold, wrinkles, or creases. The strips shall be placed to provide a minimum width of 3 feet of overlap for each joint. Securing pins with washers shall be inserted through both strips of overlapped fabric at no greater than 3-foot intervals along a line through the midpoint of the overlap. Additional pins, regardless of location, shall be installed as necessary to prevent any slippage of the filter fabric. When laid parallel to the shoreline, the fabric shall be placed so that the upper strip of fabric will overlap the next lower strip. Each securing pin shall be pushed through the fabric until the washer bears against the fabric and secures it firmly to the foundation. The fabric shall be protected from contamination form spillage or contact with unsuitable material at all times during construction and any contaminated fabric shall be removed and replaced with uncontaminated fabric. The filter fabric shall be protected from damage due to the placement of stone protection by limiting the height of drop of the material. Before any placement of stone, the Contractor shall demonstrate that the placement technique will prevent damage to the fabric.
616.08 Method of Measurement.
The following is added at the end of the subsection:
Riprap Stone Channel Protection, Piers 1N and 2N, will be measured by the cubic yard.
616.09 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
RIPRAP STONE SLOPE PROTECTION, 16” THICK (D50 = 8”) SQUARE YARD
RIPRAP STONE CHANNEL PROTECTION, PIERS 1N AND 2N CUBIC YARD
SEPARATE PAYMENT WILL NOT BE MADE FOR GEOTEXTILES AND COARSE AGGREGATE PLACED UNDER RIPRAP STONE SLOPE OR CHANNEL PROTECTION.
SECTION 612 – BEAM GUIDE RAIL
612.08 BEAM GUIDE RAIL ON BRIDGES.
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THE FOLLOWING IS ADDED
THE EXISTING GUIDE RAIL ANCHORS AND POSTS ON THE ASHLEY AVENUE BRIDGE ARE TO REMAIN. THE CONTRACTOR WILL TAKE CARE TO AVOID DAMAGING THE EXISTING GUIDE RAIL ELEMENTS TO REMAIN. NO EXTRA PAYMENT WILL BE MADE FOR REPLACEMENT OF ELEMENTS TO REMAIN THAT ARE DAMAGED BY THE CONTRACTOR OR FOR THE UNFORESEEN REPLACEMENT OF EXISTING ELEMENTS.
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617.02 MATERIALS.
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MATERIALS SHALL CONFORM TO THE FOLLOWING SUBSECTIONS:
Removable Wet Weather Pavement Marking Tape and Removable Black Line Masking Tape 912.12
Temporary Pavement Markers 912.16
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TRAFFIC CONTROL DEVICES SHALL BE NCHRP-350 CRASH TEST COMPLIANT BY THE NJDOT IMPLEMENTATION DATES STATED IN THE TABLE BELOW AND SHALL BE DULY CERTIFIED, IF NECESSARY.
| | | | | |
|Traffic Control | |AASHTO/FHWA |NJDOT implementation date|NJDOT deadline |
|Device Category |Commonly used |implementation date for|for newly purchased |By which devices |
| |NJDOT |newly purchased Devices|Devices |must be |
| |Traffic Control Devices | | |NCHRP-350 |
| | | | |compliant |
| | | | | |
| |Traffic cones, drums and | | | |
|1 |delineator guide posts |10/1/1998 |1/1/2003 |8/15/2003 |
| | | | | |
| |Vertical panel, portable sign | | | |
|2 |supports, and type III barricades |10/1/2000 |1/1/2003 |8/15/2003 |
| | | | | |
| |Truck mounted attenuators and | | | |
| |traffic barriers-impact |10/01/1998 attenuators | | |
| |attenuators (crash cushions), |10/01/2002 temporary | | |
|3 |barrier terminals, and |barriers |10/01/1998 |3/15/2005 |
| |longitudinal barriers | | | |
| | | | | |
| |Portable, usually trailer-mounted,| | | |
| |devices such as lighting supports,| | | |
| |flashing arrows panels, temporary | | | |
|4 |traffic signals, and changeable |to be announced |6/15/2005 |6/15/2007 |
| |message signs used in or adjacent | | | |
| |to the traveled way | | | |
Note: Resident Engineer’s approval shall be obtained to use traffic control devices that are certified NCHRP 350 compliant, but not listed in the table.
Newly purchased devices shall be NCHRP-350 compliant. A list of NCHRP 350 compliant and FHWA approved devices can be found at:
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3.
a. Work Area Protection – Arrowmaster Model WAAW–15-SB
b. Solar Technology Inc. – Silent Sentinel
c. Trafcon Industries Inc. – Model TC1-15S
d. Protect-O-Flash Inc. – Model No. M-90 (LED bulbs only)
e. TRACOM (Trailer Component Mfg., Inc.)
Temporary bridge barriers for the bascule span shall be connected to the open steel grid deck as shown on the contract plans.
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Emergency towing service shall be provided during those periods of time when construction operations require closure of a lane or lanes of traffic, and during AM and PM traffic peak periods Monday through Friday, on holidays and other periods (as defined in the General Notes of the Traffic Control Plans), plus on Fridays 4 PM to 12 midnight and Sundays 12 noon through 12 midnight from Memorial Day to Labor Day, or as directed by the Resident Engineer. Emergency towing service shall consist of having personnel and equipment at the designated locations on the project site capable of removing disabled vehicles, without damage to the vehicle, from the construction zone to the nearest location that will permit the disabled vehicle to be legally parked without interfering with traffic. Emergency towing service shall respond immediately upon notice of a disabled vehicle by the Resident Engineer or Contractor personnel.
D. Emergency Towing Service (On-Call). Thirty days before the start of Construction Operations, the Contractor shall provide an Emergency Towing Service Plan for approval by the Resident Engineer, which shall indicate the name and location of a reputable, licensed towing service(s) to be used.
Emergency towing services (on-call) shall provide for the call up of a designated tow operator during hours when on-site Emergency Towing (617.10C) is not provided to remove a disabled vehicle from the construction zone. The tow service shall be capable of removing disabled vehicles, without damage to the vehicle, from the construction zone to the nearest location that will permit the disabled vehicle to be legally parked without interfering with traffic. Emergency towing service shall respond immediately upon notice of a disabled vehicle by the Resident Engineer, Contractor personnel, Bridge Tender, or police.
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617.15 REMOVABLE WET WEATHER PAVEMENT MARKING TAPE.
Removable wet weather pavement marking tape shall be installed at designated locations and according to the Manufacturer’s recommendations. The tape shall be white or yellow and shall be installed in single or double lines, as designated.
The surface upon which the tape is to be installed shall be prepared according to Subsection 618.05. Removable wet weather pavement marking tape shall be installed on dry surfaces, when the surface temperature is between 50 (F and 150 ºF and when the ambient temperature is 50 ºF and rising, and when the weather is otherwise favorable as determined by the Engineer. The tape shall not be overlapped, and only butt splices shall be used.
To ensure maximum adhesion, the tape shall be tamped and a truck shall be driven slowly over the tape several times. The tape shall be removed when no longer required for traffic control.
Removable tape that has become damaged and is no longer serviceable shall be replaced immediately and will not be measured for payment. Tape that is damaged by construction operations shall also be replaced without additional compensation.
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REMOVABLE WET WEATHER PAVEMENT MARKING TAPE WILL BE MEASURED BY THE LINEAR FOOT OF 4-INCH WIDE STRIPS, DEDUCTING THE GAPS.
Emergency Towing Service On-call will be measured on a per response basis.
Temporary bridge barrier for bascule span will be measured by the linear foot.
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EMERGENCY TOWING SERVICE WILL BE MEASURED BY THE NUMBER OF HOURS AT THE PROJECT SITE.
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PAY ITEM PAY UNIT
REMOVABLE PAVEMENT MARKING TAPE LINEAR FOOT
ADD THE FOLLOWING PAY ITEMS:
PAY ITEM PAY UNIT
REMOVABLE WET WEATHER PAVEMENT MARKING TAPE LINEAR FOOT
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EMERGENCY TOWING SERVICE HOURS
TEMPORARY BRIDGE BARRIER – BASCULE SPAN LINEAR FOOT
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618.01 DESCRIPTION.
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REMOVAL OF PAVEMENT REFLECTORS AND CASTINGS CONSISTS OF THE REMOVAL AND DISPOSAL OF EXISTING RAISED PAVEMENT MARKERS, INCLUDING THE LENS WHEN STILL INTACT.
Removal and replacement of pavement reflector lenses consists of the removal of existing pavement reflector lenses and installing new mono(directional or bi(directional pavement reflector lenses.
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THE EPOXY RESIN STRIPING AND LIQUID SYSTEM STRIPING EQUIPMENT SHALL BE SO DESIGNED, EQUIPPED, MAINTAINED, AND OPERATED THAT THE MATERIAL IS PROPERLY APPLIED IN VARIABLE WIDTHS AT A CONSISTENT TEMPERATURE. THE STRIPING EQUIPMENT SHALL INCLUDE A TACHOMETER AND A PRESSURE GAUGE AND A CALIBRATED HOLDING VESSEL FOR EACH COMPONENT. THE HOLDING VESSELS FOR ALL PIGMENTS AND HARDENERS SHALL HAVE THERMOMETERS FOR MEASURING THE TEMPERATURE OF THE VESSEL CONTENTS. THE STRIPING EQUIPMENT SHALL BE EQUIPPED WITH A SEPARATE POWER UNIT FOR THE PUMPS USED IN THE MIXING AND DISTRIBUTION OF THE COMPONENTS. THE FOLLOWING SHALL BE FURNISHED WITH EACH STRIPING EQUIPMENT:
1. A calibration sheet that shows the number of the truck body, the capacity thereof, and an outage table in increments of not over ½ inch. This calibration sheet must be certified by the manufacturer or testing agency.
2. A metal rod for each holding vessel, with accurate divisions marked and consecutively numbered starting at the bottom. The rod shall be not less than 1 foot longer than the depth of the vessel.
3. Slip-proof steps with handrail to reach ground level.
4. Slip-proof catwalk with handrail, running along the top of the vessel.
5. Fire extinguisher in working order.
The equipment for applying thermoplastic material shall be capable of providing continuous mixing and agitation of the material. The parts of the equipment conveying the material between the main reservoir and the shaping die shall be so constructed to prevent accumulation and clogging. The mixing and conveying parts and the shaping dies or spray gun shall be capable of maintaining the material at optimum plastic temperature. The equipment shall be so constructed to ensure continuous uniformity in the dimensions of the entire stripe or marking. The kettle provided for the melting and heating of the thermoplastic material shall be equipped with an automatic thermostat control device and heated by a controlled heat-transfer liquid rather than by a direct flame. The heating kettle and applicator shall be equipped and arranged to meet the National Board of Fire Underwriters and State and Federal regulations. The parts of the equipment that come in contact with the material shall be easily accessible for cleaning and maintenance.
All equipment for applying traffic stripes or traffic markings shall be equipped with glass bead dispensers of a type that will mechanically and automatically dispense beads uniformly on wet stripes or markings at the rates specified.
Equipment for removing the various types of traffic stripes or traffic markings shall be designed with a vacuum system to remove all millings from the pavement surface and prevent airborne residue from escaping into the atmosphere.
All equipment including traffic marking tape applicator and retrometer shall be duly calibrated and shall conform manufacturer’s requirements.
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THE CONTRACTOR SHALL FURNISH FOR APPROVAL, 20 CALENDAR DAYS BEFORE PLACEMENT, A COMPLETE SCHEDULE OF OPERATIONS FOR APPLYING PAVEMENT MARKINGS, INCLUDING THE NUMBER AND TYPES OF EQUIPMENT, AND PROCEDURES FOR THE PROJECT.
When long-life traffic stripes are required on the Project, the Contractor shall furnish the manufacturer’s written instructions for proper use of the materials, including but not limited to, mixing ratios and application temperatures.
The Contractor shall arrange for and have each long-life material manufacturer’s representative on the site for the first full day of applying either long-life traffic stripes or traffic markings to provide technical assistance.
The Contractor shall furnish a LTL-2000 Retrometer for the Engineer’s use in determining the retroreflectance values of the various traffic stripes or traffic markings. This equipment is for the sole use of the Engineer and will become the property of the Contractor after Acceptance.
Before starting long-life traffic striping operations, the Contractor shall construct one or more test strips. Each test strip shall consist of approximately 500 linear feet of pavement with white and yellow striping (lane and edge lines) or markings similar to that required for the Project. The test strips shall demonstrate the capability of the proposed materials, equipment, and procedures to produce long-life traffic stripes that comply with the Specifications, including dimensions, appearance (stripes with uniform color and crisp, well defined edges), wet film thickness, drying time, adhesion, and glass beads application and retention. A test strip will be required for each applicator equipment used. Additional test strips may be required when major equipment repairs or adjustments are made or when the traffic stripes fail to comply with the Specifications. Permission to proceed with the striping operations will be given when the test strips are in compliance. Each test strip may remain in place and become part of the finished stripes subject to the requirements of Subsection 618.10.
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THE CONTRACTOR SHALL APPLY A PRIMER-SEALER CONFORMING TO NJDEP VOLATILE ORGANIC CONTENT (VOC) REQUIREMENTS TO THE AREAS OF HMA AND PORTLAND CEMENT CONCRETE SURFACES AS REQUIRED, IN ACCORDANCE WITH THE STRIPING MANUFACTURER’S RECOMMENDATIONS.
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618.07 LONG-LIFE TRAFFIC STRIPES.
The Contractor shall mix epoxy resin material with an automatic proportioning and mixing machine and hot-spray the compound at a temperature between 100 and 130 ºF onto thoroughly dry surfaces. The material shall only be placed during anticipated dry weather when the ambient temperature is a minimum of 45 ºF and the surface temperature is a minimum of 50 ºF. The temperature of the sprayed mixture shall be adjusted as required for prevailing conditions, including the air and pavement surface temperatures, to achieve a no-track drying time of 30 minutes or less. The epoxy resin mixture shall be applied in a wet film thickness of 20 ( 1 mil.
Immediately after, or in conjunction with the epoxy resin application, the Contractor shall apply large glass beads and small glass beads to the wet compound. Each type of bead shall be applied in a uniform pattern and each at a rate of 12 pounds per gallon of epoxy resin material.
The Contractor shall remove all epoxy resin material that has been tracked or spilled in areas outside of the intended placement areas.
Alternate liquid striping materials shall be selected from the approved product list maintained by the Bureau of Materials.
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618.08 LONG-LIFE THERMOPLASTIC AND PREFORMED TAPE TRAFFIC MARKINGS.
The Contractor shall apply preformed thermoplastic or hot extruded thermoplastic or preformed tape traffic markings, using equipment and procedures that produce markings that are straight and have sharp edges; that are the specified color, width, and thickness; that have uniform retroreflectivity; and that are properly bonded to the pavement. The thermoplastic material shall be applied as follows:
1. Preformed Thermoplastic. The Contractor shall place preformed thermoplastic traffic marking tape on thoroughly dry surfaces and during anticipated dry weather. The preformed thermoplastic tape shall be melted using the flame from a propane-type torch, according to the manufacturer’s recommendations, to bond the traffic markings permanently in position.
If required, the Contractor shall apply additional glass beads to the hot-wet material in a uniform pattern, to attain the minimum initial retroreflectance value specified in Subsection 618.10 for thermoplastic tape.
2. Hot Extruded Thermoplastic. The Contractor shall heat the thermoplastic material uniformly and apply the melted material at a temperature between 400 and 425 ºF, to thoroughly dry surfaces and during anticipated dry weather, when the ambient and surface temperatures are a minimum of 50 ºF. The thermoplastic traffic markings shall be extruded on the HMA or Portland cement concrete pavement in a thickness of 90 ( 5 mils.
Immediately after, or in conjunction with the thermoplastic application, the Contractor shall apply, by mechanical means, glass beads to the wet material in a uniform pattern and at a minimum rate of 10 pounds per 100 square feet of markings. Hand throwing of the beads will not be allowed.
3. Preformed tape. Preformed traffic tape shall be applied according to the tape manufacturer’s installation instructions. The use of primers or other adhesion promoting agents shall be used according to the recommendations of the tape and primer/agent manufacturers. Applied stripes and markings shall be free from snaking, air bubbles, loose edges or any other condition that may cause early failure as determined by the engineer.
Tape shall be applied at least 3 inches away from longitudinal joints. In areas where it is not possible to avoid a joint beneath the tape, such as transverse construction joints, short lengths of longitudinal joints or other pavement depressions and irregularities directly beneath the tape, the tape shall be cut or treated according to the tape or marking manufacturer’s recommendations. In no case shall more than two continuous feet of striping tape be placed over a longitudinal joint.
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THE CONTRACTOR SHALL REPLACE LONG-LIFE TRAFFIC STRIPES OR TRAFFIC MARKINGS DETERMINED TO BE IN NONCONFORMANCE WITH THE SPECIFICATIONS, OR NOT PLACED AT THE LOCATIONS OR IN THE DIMENSIONS SPECIFIED. THE DEFECTIVE STRIPES OR MARKINGS SHALL BE REMOVED ACCORDING TO SUBSECTION 618.12.
The Contractor shall replace defective long-life traffic stripes based on the following:
1. The entire 10 foot broken line if the line to be replaced is determined to have a deficiency.
2. The entire length of epoxy resin striping determined to have a wet film thickness of less than 19 mils shall be restriped with 20 mils of new epoxy resin, based upon the calculated and measured yields.
3. The entire length of striping shall be replaced where improper curing or discoloration has occurred. Discoloration is defined as localized areas or patches of brown or grayish colored epoxy resin material. When improper curing or discoloration occurs intermittently in intervals of 100 feet or less throughout the striping, the entire length of striping shall be replaced from where it first occurs until where it no longer exists plus 5 feet on each end.
4. The entire length of striping that has failed to bond or adhere to the pavement, or has chipped or cracked, shall be replaced from where it first occurs to where it no longer exists. When more than 25 spots (combined or individual) of chipping, cracking or poor bonding/adhesion has occurred within a 1,000 linear foot distance, the entire 1,000 linear feet shall be replaced.
5. The entire length of 1 mile of striping shall be replaced where the initial retroreflectance value of two of four readings for that 1 mile of 4-inch wide striping is not in compliance with the following:
As measured with a LTL-2000 Retrometer
| |White |Yellow |
|Type |(Millicandelas per square foot per footcandle) |(Millicandelas per square foot per footcandle) |
|Epoxy Resin |375 |250 |
|Permanent Tape |500 |300 |
6. The entire area of striping shall be replaced where the glass bead coverage or retention is deficient, based on yield determinations made during application and on visual comparisons of the production traffic stripes with those of the test strips.
The Contractor shall replace defective long-life thermoplastic traffic markings based on the following:
1. The entire area of marking determined to be less than the required thickness, to have an incorrect color or width, to have failed to bond to the pavement, or to have chipped or cracked shall be replaced. The minimum replacement area is an individual word or symbol, or entire length of longitudinal line from where the deficiency first occurs to where it no longer exists.
2 The entire area of marking shall be replaced where the initial retroreflectance value is less than 375 millicandelas per square foot per footcandle for white or 250 millicandelas per square foot per footcandle for yellow. Initial retroreflectance will be determined as follows:
Step 1: Visual night inspections will be made to identify traffic markings that appear to be below the specified minimum value.
Step 2: All retroreflectance measurements taken with an LTL-2000 retrometer will be made on a clean, dry surface.
Step 3: a. For word markings, three random retroreflectance measurements will be made on each letter.
b. For symbols, nine random retroreflectance measurements will be made over the symbol.
Step 4: All retroreflectance measurements within an area will be averaged to determine if the minimum retroreflectance requirements are met.
At no Additional Compensation to the State, the Contractor shall remove all traffic paint where the striping or markings will not be directly under long-life material, replace long-life traffic stripes or traffic markings damaged due to any sawing or sealing of joints in the HMA overlay, and replace all existing pavement reflectors that have been marred by striping or marking material as a result of improperly located traffic stripes or traffic markings.
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618.12 REMOVAL AND REPLACEMENT OF TRAFFIC DELINEATION DEVICES.
A. Removal of Traffic Stripes, Markings, or Reflectors and Castings. The Contractor shall remove all types of traffic stripes or traffic markings by methods that do not damage the integrity of the underlying pavement or adjacent pavement areas, and that do not cause gouging, or create ridges or grooves in the pavement that may result in compromising vehicular control. Obliterating stripes or markings by painting over them shall not be permitted.
Before starting removal operations, the Contractor shall demonstrate the proposed method to accomplish the complete removal of the reflectors and castings and the removal of approximately 95 percent of the stripe or marking without the removal of more than 1/16 inch of pavement thickness. Area of removal includes the area of the stripe or marking plus 1 inch on all sides. Removal operations shall not be permitted until the method of removal has been approved.
Debris from the removal of traffic stripes and markings shall be disposed of according to Subsection 201.10.
Disposal of pavement reflectors and castings shall be in conformance with Subsection 201.10.
B. Removal and Replacement of Pavement Reflector Lenses. The Contractor shall remove existing pavement reflector lenses and install new mono(directional or bi(directional pavement reflector lenses within the limits of construction or as directed by the Engineer. The reflector adhesive used in the bonding of the reflector lenses to the casting shall be in conformance with Subsection 912.17.
The Contractor shall remove and replace pavement reflector lenses by methods that do not damage the underlying castings.
Disposal of pavement reflectors lenses shall be in conformance with Subsection 201.10.
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REMOVAL OF PAVEMENT REFLECTORS AND CASTINGS WILL BE MEASURED BY THE NUMBER OF UNITS.
Removal and replacement of pavement reflector lenses will be measured by the number of units.
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PAY ITEM PAY UNIT
REMOVAL OF PAVEMENT REFLECTORS AND CASTINGS UNIT
REMOVAL AND REPLACEMENT OF PAVEMENT REFLECTOR LENSES UNIT
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TRAFFIC STRIPES, LONG LIFE, PREFORMED TAPE LINEAR FOOT
TRAFFIC MARKINGS, LINES, PREFORMED TAPE LINEAR FOOT
TRAFFIC MARKINGS, SYMBOLS, PREFORMED TAPE SQUARE FOOT
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619.03 REGULATORY AND WARNING SIGNS.
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REGULATORY AND WARNING SIGNS SHALL BE FABRICATED OF FLAT ALUMINUM SHEETS AND SHALL BE COVERED WITH ASTM D 4956 TYPE III RETROREFLECTIVE SHEETING. LEGENDS, BORDERS, AND ACCESSORIES SHALL BE TYPE B UNLESS OTHERWISE DESIGNATED. SIGNS SHALL BE FABRICATED ACCORDING TO SUBSECTION 916.08.
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619.07 Basis of Payment.
THE FOLLOWING IS ADDED:
Separate payment shall not be made for relocating signs but shall be included in the price bid for Clearing Site as indicated in Section 201.03.
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GUIDE SIGNS FABRICATED OF EXTRUDED ALUMINUM SHEETS SHALL BE COVERED WITH ASTM D 4956, TYPE III, TYPE VIII OR TYPE IX RETROREFLECTIVE SHEETING DEPENDING ON THE FOLLOWING:
1. Guide signs on steel “U” posts shall be fabricated of flat aluminum sheets and shall be covered with ASTM D 4956 Type III retroreflective sheeting. Legends, borders, and accessories shall be Type B unless otherwise designated.
2. Guide signs on overheads and breakaway or non-breakaway posts shall be fabricated of extruded aluminum panels covered with ASTM D 4956 Types VIII or IX retroreflective sheeting. Legends, borders, and accessories shall be Type A.
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620.03 Ground Mounted Flexible Delineators.
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A. Ground Mounted Flexible Delineators. Flexible delineator units shall be driven vertically into the ground to a minimum depth of 1 foot-6 inches. Units shall be installed so that the plane face of the center of the reflective area is at an angle of zero degrees with a perpendicular to the direction of traffic. Retroreflective sheeting, ASTM D 4956 Types VII or VIII shall be pre-applied to the front (surface facing traffic) of the unit by the manufacturer. The retroreflective sheeting shall cover a minimum area of 3 by 12 inches, beginning a maximum of 2 inches from the top of the post. The color shall be white when the delineator is located on the right side to the direction of traffic and shall be yellow when the delineator is located on the left side to the direction of traffic.
B. Surface Mounted Flexible Delineators. Flexible delineator shall be used as a temporary channelization device to separate pedestrian and vehicular traffic on a roadway surface. The delineator shall be capable of withstanding numerous vehicle impacts. The delineator shall be a two-piece design to allow the post to be unscrewed from the base. The delineator shall consist of a rod of round polymer alloy material with a minimum length of 36 inches and 3 inch diameter, and a 1 lbs, 7 inch diameter base made of a rubber composite. The base shall be affixed to the roadway surface using an epoxy adhesive as recommended by the delineator's manufacturer. The color of the polymer rod shall be red with 3 bands of orange retroreflective sheeting applied 2 inches from the top of the rod.
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RETROREFLECTIVE SHEETING, ASTM D 4956 TYPES VII OR VIII SHALL BE APPLIED TO THE UPPER PORTION OF THE FLEXIBLE DELINEATOR PANEL. THE RETROREFLECTIVE SHEETING SHALL COVER A MINIMUM AREA OF 4 ½ BY 4 ½ INCHES (4 ½ BY 9 INCHES FOR DECELERATION AND ACCELERATION LANES). THE COLOR SHALL BE WHITE WHEN THE DELINEATOR IS LOCATED ON THE RIGHT SIDE TO THE DIRECTION OF TRAFFIC AND SHALL BE YELLOW WHEN THE DELINEATOR IS LOCATED ON THE LEFT SIDE TO THE DIRECTION OF TRAFFIC.
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RETROREFLECTIVE SHEETING, ASTM D 4956 TYPES VII OR VIII SHALL BE APPLIED TO THE UPPER PORTION OF THE FLEXIBLE DELINEATOR PANEL FACING TRAFFIC AND PERPENDICULAR TO THE TOP OF THE CONCRETE BARRIER CURB. THE RETROREFLECTIVE SHEETING SHALL COVER AN AREA OF 3 ½ BY 3 ½ INCHES. THE COLOR SHALL BE WHITE WHEN THE DELINEATOR IS LOCATED ON THE RIGHT SIDE TO THE DIRECTION OF TRAFFIC AND SHALL BE YELLOW WHEN THE DELINEATOR IS LOCATED ON THE LEFT SIDE TO THE DIRECTION OF TRAFFIC.
620.07 Basis of Payment.
the following pay item IS added:
PAY ITEM PAY UNIT
FLEXIBLE DELINEATOR, SURFACE MOUNTED UNIT
All incidentals required to furnish, install, remove, and maintain shall be included in the bid price. No separate payment shall be made to replace damaged delineators during the entire construction duration.
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622.02 MATERIALS.
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SECTION 623 –SNOW REMOVAL AND DEICING
623.01 DESCRIPTION.
This work shall include the removal of accumulated snow on active walkways and curbs, bridge sidewalks and along construction barrier through the work zone including the Contractor’s work zone in the bridge approach spans, adjacent to the bascule spans. This work encompasses the bridge and approach roadways, pedestrian routes, and pedestrian detour routes (when in effect) as depicted on the Traffic Control Plans. The work is to include removal of snow resulting from the snow plowing operations of the Department’s and/or local municipal maintenance forces or their agents during all stages of construction as well as from normal snow accumulations. The snow removal shall include disposal of the snow by the Contractor at areas approved by the Engineer. The Contractor shall also spread deicing materials on all walkways after removal of snow and/or when icing conditions exist.
623.02 Method of Construction.
The Contractor shall utilize snow removal equipment that can remove the plowed snow deposits from the edges of the roadways and walkways and within the work zone on the bridge spans, adjacent to the bascule spans and the approach roadways, utilizing a moving lane closure in accordance with NJDOT TCD 22 –Multi-lane Moving Lane Closure. The snow deposits shall be displaced into hauling equipment or into the work areas of the roadways. Snow shall not be permitted to be placed anywhere on the bridge spans. The snow removal equipment shall only travel in the direction of traffic. Snow shall also be removed from walkways along active pedestrian routes and pedestrian detour routes utilizing appropriate equipment and methods. The Contractor may be directed to perform snow removal at any time while the Contract is in force. The Contractor shall initiate snow removal operations within four hours after notification by the Engineer. The failure to commence work within a four-hour notification time-frame will result in back charges for all costs incurred by the Department to remove snow adjacent to construction barriers, walkways and on the bridge spans and associated areas within work zone limits and along pedestrian routes and pedestrian detour routes when in effect. In addition the Contractor will be charged a $1,000.00 per hour penalty for each hour over the above four-hour notification timeframe up to $4,000.00 for each event.
All lane closings for snow removal work under Snow Removal and Deicing shall be performed by the Contractor’s forces.
The Contractor shall submit his plan for snow removal and deicing to the Engineer for review and approval 30 days after Contract is awarded. The plan shall detail the Contractor’s methods for removal of plowed or accumulated snow deposits and placing of deicing materials, including the work force and number and type of equipment to be used and the type of deicing material to be used.
The removal of snow deposited in the Contractor’s work areas by Department or municipal plowing operations or the Contractor’s snow removal operations shall not be eligible for payment.
623.03 Method of Measurement.
Snow Removal and Deicing will not be measured for payment but measurement will be made on a Lump Sum basis for the time and material used per each occurrence.
623.04 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
SNOW REMOVAL AND DEICING – WALKWAYS (NOT A BID ITEM) LUMP SUM
PAYMENT FOR SNOW REMOVAL AND DEICING INCLUDES ALL MANPOWER, EQUIPMENT AND MATERIALS FOR REMOVAL AND DISPOSAL AS DIRECTED BY THE ENGINEER, MOVING LANE CLOSURES AND PLACEMENT OF DEICING MATERIALS, AND WILL BE MADE ON A LUMP SUM BASIS FOR EACH OCCURRENCE IN ACCORDANCE WITH SUBSECTION 109.03 AGAINST A FORCE ACCOUNT TOTAL AMOUNT OF $50,000 OVER THE DURATION OF THE WORK.
SECTION 624 – BOAT SLIP ACCOMMODATIONS
624.01 Description.
This work shall consist of the rental of a boat slip at Brielle Marine Basin during the periods of time that the bascule span is closed to large vessels (not permitted to open for vessels taller than 30 feet). This time period shall be from December 1 through March 15 for the calendar years 2006, 2007, 2008, and 2009), Monday through Saturday, with designated opening times on Sundays only. Each rental period shall be limited to a period of 1 to 6 days (maximum) and shall end on the Sunday when the bascule span is opened to let the vessel pass. The Marina owners and vessel owners to the west of the bridge will be required to notify the Engineer when a large vessel is to arrive within the Manasquan River so that he may alert Brielle Marine Basin (Fred Ziemba @ 732-528-6200) to make the accommodations.
624.02 Method of Measurement.
Boat Slip Accommodations will not be measured for payment but will be made on a Lump Sum basis for the actual rental time required for the boat slip for each occurrence. Any portion of a day shall be paid as a full day.
624.03 Method of Payment.
Payment will be made under:
Pay Item Pay Unit
BOAT SLIP ACCOMMODATIONS (NOT A BID ITEM) LUMP SUM
PAYMENT FOR BOAT SLIP ACCOMMODATIONS WILL BE MADE ON A LUMP SUM BASIS FOR EACH OCCURRENCE IN ACCORDANCE WITH SUBSECTION 109.03 AGAINST A FORCE ACCOUNT TOTAL AMOUNT OF $50,000 OVER THE DURATION OF THE WORK. BRIELLE MARINE BASIN WILL PRESENT A VOUCHER TO THE ENGINEER FOR EACH RENTAL OCCURRENCE THAT WILL BE APPROVED BY THE ENGINEER FOR PAYMENT.
diVISION 700 - ELECTRICAL
SECTION 701 – COMMON PROVISIONS
701.01 DESCRIPTION
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THESE PROVISIONS ARE COMMON TO ALL WORK SPECIFIED IN DIVISION 700.
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BEFORE STARTING WORK ON EXISTING ELECTRICAL FACILITIES, THE CONTRACTOR SHALL PROVIDE NOTIFICATION AS SPECIFIED IN SUBSECTION 105.09 AND ARRANGE A MEETING WITH THE DEPARTMENT IF REQUESTED TO VERIFY THE PROPER OPERATION OF THE EXISTING FACILITIES. THE CONTRACTOR SHALL DOCUMENT THE RESOLUTIONS OF ANY MEETINGS AND FORWARD A WRITTEN SUMMARY TO THE RESIDENT ENGINEER AND ALL ATTENDEES.
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FURNISH, AS SPECIFIED IN SUBSECTION 105.04, CERTIFIED WORKING DRAWINGS FOR ALL NON PRE-APPROVED ELECTRICAL MATERIALS AND EQUIPMENT, AND APPROVED WORKING DRAWINGS AS SPECIFIED. THE DEPARTMENT WILL ALLOW THE USE OF PRE-APPROVED MATERIALS PROVIDED THE MATERIALS MEET ALL REQUIREMENTS OF THE CONTRACT. THE CURRENT PRE-APPROVED MATERIALS LIST IS AVAILABLE ON THE WEB SITE SPECIFIED IN SUBSECTION 701.02. THE CONTRACTOR SHALL SUBMIT A LIST OF ALL PRE-APPROVED MATERIALS TO BE USED FOR THE DURATION OF THE PROJECT WITH THE INITIAL MATERIALS QUESTIONNAIRE FORMS AS SPECIFIED IN SUBSECTION 106.01.
As specified in Subsection 701.10, approval of the working drawings for the precast foundations or junction boxes shall only apply to the locations designated.
Other certified or approval working drawings shall be submitted as specified.
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702.02 Materials and Equipment.
THE FOLLOWING IS ADDED:
13. Temporary Trailer-Mounted Traffic Signal. Temporary trailer-mounted traffic signals shall be model SQ3 or SQ5, as manufactured by Horizon Signal Technologies, 216 Line Road, Malvern, Pennsylvania 19355 (1.800.852.8796), or approved equal.
Temporary trailer-mounted traffic signals shall consist of a towable trailer equipped with two signal heads each with three 12 inch signal sections (Red, Yellow, and Green). One signal head is to be mounted on a mast arm capable of extending over the traveled lane with a minimum vertical clearance above the adjacent road surface of 20 feet while the second head is to be mounted on the pole at minimum height of eight feet above the pavement surface. The trailer is to be equipped with a battery case and charger. The system is to contain a cabinet mounted controller with a conflict monitor. Each unit is programmed with a movable module, called the microterminal.
The cabinet is to be water tight and equipped with a secure keyed lock.
A remote module switch shall be included with the temporary trailer-mounted traffic signals. The remote module switch shall be capable of freezing the signal heads on the units on a red interval.
The signal heads shall conform to ITE specification “Vehicle Traffic Control Signal Heads”.
The trailer unit shall be capable of operating from an AC voltage source of 117 volts ( 10 percent. If the unit is not to be wired to a continuous source of 117 volts ( 10 percent power, it shall be equipped with solar panels capable of maintaining sufficient battery charge to operate the system. The time required for battery charging shall not exceed 72 hours. The solar array shall contain a method for anti-theft and the run time of batteries only (autonomy) shall be a minimum of 21 days at 77 degrees Fahrenheit.
The trailer mounted traffic signals shall be hardwired to the existing bridge traffic signals by means of an aerial wire feed. All wiring and connections shall be in accordance with NJDOT Electrical Specifications for Traffic Signal installations. The system shall be equipped with a manual switch that has off, on, blink red, blink yellow, and manual functions. The trailer unit shall have the following standby modes that can be set by the Bridge Tender:
A) Off. All lights are off.
B) Blink Yellow. The yellow light blinks at 60 times/minute.
C) Blink Red. The red light blinks at 60 times/minute.
D) Red. The red light is on continuously.
The trailer unit shall be capable of operating in a stand-alone configuration except for manual operation.
The trailer unit shall operate at any temperature between minus 93 degrees Fahrenheit and 163 degrees Fahrenheit. The trailer unit shall operate in any humidity environment up to 100 percent as would be encountered in North America. The trailer unit shall survive wind gusts of up to 80 MPH without sand bagging or staking.
702.04 Temporary and Interim Signal Systems.
1. Temporary Traffic Signals
This subsection is revised as follows:
Two traffic signal heads with control features as described in Subsection 702.02 above shall be installed in accordance with the Maintenance and Protection of Traffic plans. One traffic signal head shall be installed above the traffic lane and one shall be installed to the right of the traffic lane.
The temporary traffic signal system shall consist of a trailer-mounted signals conforming to Subsection 702.02 above.
The trailer-mounted signals shall be installed behind temporary construction barrier following manufacturer’s recommendations. If required the Contractor shall construct and install a temporary platform to support the temporary traffic signals at the height and location as specified in section 702.2 and shown on the plans. The Contractor shall submit catalog cuts of the proposed temporary traffic signals to the Engineer for approval prior to their use.
The Contractor shall be responsible for furnishing, installing, relocating and maintaining the temporary traffic signal system for as long as required to construct the project and shall be responsible for its removal when no longer needed to the Contractor’s yard or returned to the leasing company.
If the temporary traffic signals malfunctions, the Contractor shall immediately, and at his own expense, provide trained flaggers and communications devices for use by them and the Bridge Tender to control the flow of traffic at the direction of the Bridge Tender until the signal system is repaired and operating.
702.07 Basis of Payment.
The following is added:
All incidentals required to furnish, install, operate, relocate, store, remove, and maintain the temporary traffic signals such as, but not limited to wiring, temporary platform construction, equipment repair, traffic protection, flaggers, and communications devices, shall be included in the Lump Sum price bid for the temporary traffic signals.
The following is added to the Pay Item table:
Pay Item Pay Unit
Temporary Traffic Signals Lump Sum
THE FOLLOWING IS ADDED:
SECTION 703 – HIGHWAY LIGHTING
703.02 Materials and Equipment
2. Lighting Standard Assemblies.
THE FOLLOWING IS ADDED TO THIS SUBSECTION:
Lighting standard assemblies shall be furnished with internal vibration dampers.
Fuse assemblies shall be furnished in the junction box adjacent to each lighting standard assembly mounted on the bridge,
703.03 Temporary Highway Lighting System.
THE FOLLOWING IS ADDED TO THIS SUBSECTION:
The work shall consist of furnishing and installing a temporary highway lighting system, and maintaining continuous highway lighting during all dark hours. It shall include, but not be limited to temporary wire, conduit, splices, ballasts, electric services, junction boxes, and other incidentals deemed required. Existing lighting poles and arms will be used as part of the system, as shown on the traffic control and staging plans.
In order to provide temporary power to the existing bridge mounted highway lights, it will be necessary to furnish and install the two new permanent load centers (“CN” and “CS”) and some conduit and junction boxes as called for on the highway lighting plans. The new load centers will be utilized to provide temporary power to the existing bridge mounted highway lights during the various stages of construction. In addition, the contractor shall provide temporary power to the existing bridge mounted highway lights. This will include furnishing and installing new temporary conduits, wiring, splices, junction boxes, and other incidental materials required. As called for in the staging plans, the temporary lighting power system will be run from the new load centers to the existing lights. Some of the existing bridge mounted highway lights will also be powered from the existing power source and load center.
703.04 Construction Requirements.
THE FOLLOWING IS ADDED:
The Contractor shall furnish and install all labor, materials, and equipment required to maintain the existing lighting on the bridge as shown on the traffic control and staging plans.
703.06 Method of Measurement.
THE FOLLOWING IS ADDED:
The temporary highway lighting system shall not be measured and payment will be made on a lump sum basis. Separate payment shall not be made for lighting equipment consisting of, but not limited to, conduits, wire, junction boxes, and all other incidental materials required. All costs shall be included in the price bid for “Temporary Highway Lighting System”.
703.07 Basis of Payment.
THE LAST PARAGRAPH IS DELETED AND THE FOLLOWING IS ADDED:
Pay Item Pay Unit
TEMPORARY HIGHWAY LIGHTING SYSTEM LUMP SUM
Exposed Rigid Metallic Conduit shall be paid for as Rigid Metallic Conduit, Type CUG.
SECTION 706 - intelligent transportation services facilities
706.03 CONSTRUCTION REQUIREMENTS.
the following is INSERTED IN this subsection:
Fiberglass Multi-duct (Communications) Conduit. Fiberglass multi-duct (communication) conduit is for fiber optic conduit installations and shall be installed and furnished where shown on the plans. Minimum bend radius shall be maintained. The Contractor shall eliminate/modify any conduit bends which may obstruct any future installation of optical fiber cables. The total sum of all the conduit bends, in degrees, between junction boxes, shall not exceed a total of 180 degrees. No bends shall be greater than 90 degrees.
The Contractor shall install a pre-lubricated woven pull tape in each spare duct that has been installed for this project. The tape shall be marked with sequential distance measurements. The tape shall have a pull strength of at least 877.5 lbf (3900 Newtons). Each duct installed or utilized by the Contractor shall be sealed with a properly sized duct plug, as is standard in the telecommunications industry. Duct plugs shall be manufactured by Calam, Carlon, or other approved equal manufacturer.
Type F, Fiberglass Multi-duct (Communications) Conduit shall conform to NJDOT Material Specification EB-MULTI-2. Type F Fiberglass Multi-duct (Communications) Conduit shall be mounted onto bridge structure as shown in the plans for future fiber optic cable installation. The following subsections of the Material Specification are to be revised as noted.
• Conduit General – II: Paragraphs 2-11 and 2-12 do not apply.
• Training –VI: Paragraphs 6-1 and 6-2 do not apply.
• Instructions and Guarantees – VI paragraph 7-2: Replace paragraph as follows: – “No changes or substitutions in these requirements will be acceptable unless authorized in writing by the Resident Engineer.”
• Paragraph 7-3: Change “... Manager, Office of ITS Engineering…” to “Resident Engineer”.
• Paragraph 7-4: Change “…within the warranty period.” to “…until State’s acceptance of the project”. In last sentence of paragraph delete “…for two years after…” and insert “until”.
In general, Type F conduit shall be installed under the bridge superstructure and mounted to the bridge abutments and moveable bridge span piers on both the south and north bridge spans. The exposed conduits shall be fastened to bridge steel/concrete using conduit mounting support hardware as shown on the bridge structural plan details. Conduit mounting support spacing shall not be more than 10 feet, 0 inches.
Expansion fittings shall be provided at all expansion joints. The expansion fittings shall provide a minimum of 4” straight line movement (2” in either direction from center), and also provide radial movement. The movement shall be sufficient to cover the full width of the expansion joint.
Type F, Fiberglass Multi-duct (Communications) Conduit shall include, but not be limited to, furnishing and installing fiberglass multi-duct conduit mounted to the bridge structure and its abutments and piers and furnishing, conduit mounting support hardware, expansion fittings, and end caps. The installation shall be as noted in the bridge plan and details and to the satisfaction of the Engineer.
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the following is INSERTED IN this subsection:
Fiberglass multiduct (communications) conduits for optical fiber cable installation shall be measured by the linear foot installed and furnished.
Measurement will not be made for expansion fittings, pull tape, hangars, mounting clamps, hardware and all labor, equipment, and materials necessary to perform the work. All such labor, material, and equipment will be considered incidental to the multiduct conduit item and costs shall be included in the multiduct conduit item.
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the following is added to this section:
Pay Item Pay Unit
TYPE F FIBERGLASS MULTIDUCT (COMMUNICATIONS) CONDUIT LINEAR FOOT
No separate payment will be made for expansion fittings, pull tape, hangars, clamps, hardware and all labor, equipment, and materials necessary to perform the work. All costs shall be included into bid price for Type F fiberglass multiduct (communications) conduit.
The contract item and unit price bids set forth in the bid schedule shall include all services, permits, labor, equipment, transportation, materials, testing, and supplies for the complete work, including, without limitation, mobilization and demobilization for completion of the work.
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707.01 DESCRIPTION.
The work shall consist of furnishing, installing, and satisfactorily completing an operating system with electrical equipment for operation of the bascule span and its auxiliaries, including electric heating and other electrical facilities, all as indicated on the Plans, called for in these specifications, or as may be required to complete the project to the approval of New Jersey Department of Transportation (NJDOT), Movable Bridge Engineering Group (MBEG). The Contractor's attention is also directed to the requirements for electrical work appearing in other items of these Specifications.
It is the intent and purpose of these Specifications to cover and include all apparatus and appliances to properly install, wire, connect, equip, test, adjust, and put into approved working condition the respective portions of the electrical work herein specified. The work shall also include disconnecting and removing the existing equipment and facilities to be replaced. Any incidental apparatus, appliance, material, or labor not herein specifically mentioned or included that may be found necessary to comply with the requirements of the related documents and referenced standards or codes shall be furnished and installed, if applicable, by the Contractor without any extra cost to NJDOT.
Installation, alignment and fastening of electrical equipment to be incorporated into the bridge machinery, such as bascule span motors, brakes, motor encoders, position resolvers, selsyns, proximity switches and overspeed switches, shall be done under "Mechanical Work". Installation of inclinometers shall be done under structural work.
Shop drawings and operation & maintenance manuals shall be provided as specified hereinafter.
MATERIALS
707.02 Materials and Equipment.
A. Conformance. All electrical equipment and its installation shall conform to the requirements of the latest revision of the Standard Specifications for Movable Highway Bridges of the American Association of State Highway and Transportation Officials, except as may be otherwise provided herein.
Materials and construction shall conform to the requirements of the current National Electrical Code and to any applicable local rules and ordinances. The Contractor is responsible for obtaining any required permits and approvals of Agencies/Departments having jurisdiction.
B. Equipment and Material Provisions. All equipment and materials shall be new. All equipment, materials, and workmanship shall be first-class in every aspect of this project and shall be manufactured and erected to the satisfaction of the Resident Engineer (the engineer) and NJDOT MBEG. The Contractor shall warrantee the in-service working of the electrical installations for one year or the manufacturer’s warranty period, whichever is greater, following project acceptance by New Jersey Department of Transportation. If the Contractor has any objection to any feature of the electrical equipment as designed and laid out, the Contractor must state the objection in writing to the Engineer and NJDOT MBEG prior to shop drawing submittal, fabrication and/or installation.. If an objection is not received in writing by the Engineer and NJDOT MBEG and the equipment or apparatus malfunctions, it will be deemed defective or broken. The Contractor shall be responsible for replacing the defective/broken equipment at no additional cost to NJDOT.
Each piece of electrical equipment and apparatus shall have a corrosion-resisting stainless steel metal nameplate on which is stamped the name of the manufacturer, the rating or capacity of the equipment or apparatus, etc.
All metal parts of the installation, except structural steel, shall be of corrosion-resisting material, such as bronze or stainless steel. Malleable iron, or steel with a hot-dip galvanized finish, shall be used where specified herein. Structural steel shall conform to the requirements given under "Structural Steel".
All mounting hardware and all wire and cable terminals shall be vibration proof and weather proof.
If any changes from the Plans or these Specifications are deemed necessary by the Contractor, details of such changes and the reasons therefore shall be submitted in writing for approval as soon as practicable, but before the first submittal. No such changes shall be made nor work started without approval of the Engineer and NJDOT MBEG.
Material requirements for specific apparatus, equipment, and materials are found in the articles under "Construction Requirements" in this item.
C. Bridge Control System Vendor. All apparatus and equipment comprising the bridge control system, including, but not limited to, drives, motors, brakes, limit switches, flux vector drives, control cabinets, special control panels, modifications to the control desk, programmable controllers, interfacing equipment, laptop hardware for local troubleshooting, and other apparatus required to provide a complete functioning system, shall be manufactured or furnished and assembled by a single qualified control system vendor. The vendor shall assemble the control panels, programmable logic controller racks/chassis and flux vector drives at an Underwriters Laboratory approved Facility in accordance with UL 508. The Bridge Control System Integrator will be Link Controls, Inc or NJDOT MBEG approved equal.
The control system vendor shall have experience in providing electrical control systems for movable bridges of various types, including bascule, vertical-lift, swing bridges, and control systems, including AC flux vector drives and programmable logic controllers. Such experience shall be demonstrated by identifying a minimum of five movable bridges for which the system vendor has provided complete systems, including flux vector drives, motors, controls and programmable logic controller hardware and software within the past ten years.
The control system vendor shall assume complete system responsibility for the integrated functioning of all components to provide a satisfactory assembled system operating in accordance with specified requirements. The control system vendor shall be responsible for the detailed schematics and fabrication of the total control and power distribution system to ensure compatibility of equipment and suitability for the intended system functioning. The vendor shall provide supervisory assistance in the installation of equipment to ensure maximum reliability and ease of maintenance.
The system vendor shall provide a field service staff having the capability of providing services for field coordination during construction and final adjustments to the control and drive systems. Upon final acceptance of the bridge by New Jersey Department of Transportation, the system vendor's staff shall provide on-call warranty service for a period of one year. System vendor/integrator field staff shall be capable of responding to an emergency within eight (8) hours.
The Contractor shall provide written certification of compliance with specified requirements for the control system vendor, Link Controls Inc. or NJDOT MBEG approved vendor. This certification shall be included in the bid documents and shall be subject to approval by the New Jersey Department of Transportation.
CONSTRUCTION
707.03 Working Drawings and Samples.
A. Working Drawings. The Contractor shall prepare and submit for review within thirty (30) working days after the award of the Contract the following working drawings executed in accordance with the provisions of the Contract:
1. Certified dimension prints of all motors, bascule span brakes, brake wheels, limit switches, and other electrical apparatus external to the control desk, control panels, panelboards and transfer switches.
2. A complete schematic wiring diagram, including all power, control, and lighting connections. Both electrical devices and each wire between devices shall be identified by an individual unique designation of letters, numbers, or a combination of both; and such designations shall be used wherever the devices or wires appear on other drawings. Certified dimension prints of all motors, bascule span brakes, brake wheels, limit switches, and other electrical apparatus external to the control desk, control panels, panelboards and transfer switches. A complete set of catalog cuts for materials furnished shall be included for review at time of schematic submittal.
3. Layout drawings and internal connection wiring diagrams of the modified control desk, power distribution and control panels, and flux vector drive panels.
4. A schedule of electrical apparatus for each cabinet or panel which shall list each electrical device by its designation as shown on the schematic wiring diagram and shall state for each device its rating, number of poles or contacts, function, catalog number, and location.
5. A complete interconnection diagram(s) for all electrical apparatus and equipment used in the operation of the bascule span and its auxiliaries. The diagram(s) shall be of the elementary type and shall show the external connections of all devices and equipment. Computer-generated interconnection lists will not be acceptable in lieu of a true interconnection diagram.
6. Outline drawings and complete construction details of the position indicator to be installed in the control desk. Details of the indicator dial shall also be submitted.
7. Layouts of the dynamic resistors for the bascule span flux vector drives, together with construction details of the resistor enclosures.
8. Outline drawing, details, and connection diagram for the temporary manual transfer switch, its components, and assembly.
9. A complete schematic conduit and cable diagram or diagrams showing the interconnection of all devices and equipment, including ducts and junction boxes, and showing all conduit. The size of each conduit, and the wire number and size of each conductor in conduit shall be shown on the diagrams. Each conduit shall be suitably numbered or lettered, and percent wire fill shall be shown.
10. A complete set of layout and installation drawings for the electrical work showing the location and installation, including support and mounting details, of all electrical apparatus and equipment. These drawings shall be made to scale and shall show the exact location of all conduits, cables, wiring ducts, boxes, motors, brakes, limit switches, disconnect switches, and other electrical equipment and the method of supporting them on the structure.
11. Detail drawings showing the construction of cabinets, brackets, and special supports required for the installation of the inclinometers.
12. Catalog cuts of electric air conditioning/heating equipment, if required to be installed.
13. Arrangement of conduits, wiring, and boxes (including their support) for the existing bridge electrical equipment to remain viz. lighting fixtures and switches, receptacles, intercom system, outside telephone, navigation and pier lights, air conditioning equipment, etc.
14. Arrangement of conduits, wiring, and equipment for the electric heating units in the control house and machinery room.
15. Detail drawings showing the construction and mounting details of all wiring troughs and raceways.
16. A complete list of all spare parts furnished as part of the contract.
17. Material listing and specifications for programmable controllers, including input/output units, programming terminal, and equipment for interfacing.
18. The programmable controllers programs (both temporary and permanent) listing in ladder rung format. Circuit functions shall be described; all contacts and outputs shall be identified by word description and by number designation. Ladder rungs shall be numbered sequentially for reference. The ladder diagram shall be fully documented, and internal ladder logic relay contacts usage in other rungs shall be identified and listed. Inputs and outputs shall be referenced to locations of signals on interconnection diagram.
19. Any other drawings, which, in the opinion of the Engineer and NJDOT MBEG, may be necessary to show the electrical work.
Certified dimension prints of the apparatus shall state in the certification the name of the job, the application of the apparatus, device designation, number required, right-hand or left-hand assembly, electrical rating, number of poles or contacts, material, finish, and any other pertinent data to show that the apparatus meets the specified requirements.
Upon completion of the work, the Contractor shall correct all working drawings, including all working drawings submitted by the electrical system vendor, to show the work as-built and shall provide two (2) sets of 22 inch x 36 inch, 4 mil thick, Mylar reproduced of all as-built working drawings. One (1) set to be submitted to the Resident Engineer and one (1) set to be delivered to Roy Bill, MBEG.
All as-built working drawings submitted by the electrical system vendor, including all electrical schematics, ladder diagrams, system documentation, dimension drawings of equipment, and devices, shall also be submitted in a computerized file form as well as on Mylar reproduced as specified above. The computerized file form for all electronic files shall be in “.DGN” and “PDF” format. The electrical system vendor shall provide all pertinent drawings and data on CD ROM. The electrical system vendor shall verify the compatibility of his computerized file form prior to submission.
The preparation and submission of working drawings shall meet the provision for shop drawings in accordance with Subsection 105.04 of the Standard Specifications.
The Contractor shall submit for inspection and test, if directed by the Engineer and NJDOT MBEG, samples of any apparatus or devices that the Contractor proposes to use as a part of the electrical installation.
B. Instruction Books and Drawing Books. For all Instruction Books and Drawing Books, one copy of each shall be submitted to the Engineer and NJDOT MBEG for approval.
The Contractor shall furnish to the Engineer and NJDOT MBEG eight bound copies of an instruction book with the title "Operation and Maintenance Manual, Volume 1 – Bridge Operator's Manual". The manual shall contain non-technical information and instructions to operate the bridge. The manual shall be operator-oriented and recognize the technical limitations of the average operator. The manual shall contain suitably arranged chapters including, but not limited to, the following:
1. Table of Contents.
2. Introduction, including a general description of the bridge, its facilities and specifics of rehabilitation done under this contract.
3. Operating Procedure, including a simplified step-by-step, opening and closing procedure to normally operate the bascule span. Temporary Operation of the bascule span opening/closing shall also be included. This description shall be augmented and cross-referenced with a layout of the control desk, which shall be included in this section.
4. A description of the bridge's electric/mechanical power sources including methods and precautions for their selection.
5. Procedure for selecting drives and instrumentation to operate the bascule span.
6. A description of additional devices on the control desk, including the methods and operation of these devices.
7. A description of the bridge's instrumentation and controls including normal operating ranges of existing desk meters, operation of indicating lights, etc.
8. A detailed description of sequence interlocking including methods and precautions for use of the bypass switches.
9. A simplified description of how the bascule span normally operates under control of the PLC, both main and temporary, and how to recognize when there is a PLC/SLC malfunction. In addition, the procedure for operating the bascule span when the PLC/SLC is disabled shall be provided.
10. Detailed results of acceptance testing in a tabulation format. The Contractor shall submit the format before start of acceptance testing for approval.
11. A description of Abnormal Indications/faults such as, bascule span over-travel, bascule span drive permissive fault, etc.
The Contractor shall furnish to the Engineer eight bound copies of an instruction manual with the title "Operation and Maintenance Manual, Volume 2 - Operation of Electrical Equipment," containing the following:
1. Table of Contents.
2. Detailed, technical operating instructions, which shall cover bascule span operation, manual bascule span operation, temporary bascule span operation etc.
3. Detailed description of all control equipment including instructions to achieve optimum settings of all limit switches, detectors, etc.
4. Description of control, which shall describe in full the functions of all protective devices, limit switches, contactors, relays, PLC and associated equipment, existing and new and all other electrical equipment used, both in the power system and in the control system, in connection with each step in the operating sequence. Wire and apparatus numbers appearing on the wiring diagrams shall be used in this description for identifying the various devices and circuits.
5. To augment the description of control and operations, reference drawings showing locations of equipment, both existing and new, shall be included. A layout of control apparatus in the control house and operator's room shall be included. All descriptions shall be cross-referenced with reference drawings.
6. Complete bascule span motor flux vector drive manual, including all annotated drive parameters.
7. PLC/SLC manuals shall include but not necessarily be limited to:
a. System specifications
b. Electrical power requirements and special grounding
c. Application considerations
1) Assembly and installation procedures
2) Troubleshooting procedure.
3) Programming procedure
4) Explanation of internal fault diagnostics.
5) Shut down procedures.
The Contractor shall also furnish to the Engineer eight bound copies of a book with the title "Operation and Maintenance Manual, Volume 3 - Maintenance of Electrical Equipment," and the manual shall contain the following:
1. Table of Contents.
2. Maintenance instructions for the electrical equipment, including warnings and precautions to be observed during maintenance actions. All preventive maintenance procedures are to be outlined and a chart listing all maintenance procedures in chronological order shall be provided:
3. Set of descriptive catalog sheets, bulletins, maintenance instructions, and drawings covering all approved items of equipment furnished and installed under the item "Electrical Work”.
4. A troubleshooting flow chart for troubleshooting the bridge electrical system shall be provided to facilitate the diagnosing and correcting of malfunctions.
5. Reduced size (11” x 17”) prints of all approved working drawings, including all schematic wiring diagrams, control desk and control panel layouts and connection diagrams.
6. PLC/SLC schematic wiring, ladder diagrams, and electrical schematic.
7. A listing of all PLC/SLC inputs and outputs. The listing shall include:
a. Designation as symbol
b. Description of function
c. Drop where connected
d. Sheet number where used on wiring diagram
8. Composite schedule of electrical apparatus.
9. Complete spare parts list.
10. Test data, equipment, criteria, and performance curves for the bascule span drive motor.
11. Conduit layout and installation drawings.
12. Names, addresses, and telephone numbers of vendors and suppliers.
The material for the operation and maintenance manuals shall be assembled to form a booklet for each volume with heavy plastic covers. Each booklet shall be approximately 9 inches by 12 inches, three-ring binder with 3-inch "D" rings, and vinyl cover to allow insert type Title Sheets. Each booklet shall be neatly entitled with a descriptive title, the name of the bridge, the Owner, the location, year of installation, Contractor, and Designer. Copies of drawings shall be in black on a white background and shall be easily legible. Blue print drawings and/or hand drawn sketches are not acceptable. The arrangements of the booklets, the method of binding, material to be included, and the text shall all be as approved by the Engineer and NJDOT MBEG. The final bound volumes of the instruction books shall be completed and made available at the bridge site for use during the final acceptance testing period hereinafter specified for the electrical work.
All literature, descriptive materials for inclusion in any manual, shall have all sheets numbered and listed by section in the Table of Contents.
Each section/subsection shall be separated with tabbed divider sheets. Each tab shall be suitably titled.
All loose-leaf paper used for reproduction shall be 20 pound, 3-hole pre-punched and reinforced with plastic or cloth tape.
All copies of the Operations and Maintenance Manuals shall be distributed as follows:
1. One (1) copy each of Volume 1, Volume 2 and Volume 3 shall be distributed to the MBEG.
2. One (1) copy each of Volume 1, Volume 2, and Volume 3 shall be distributed to the Route 35 Operator House. The Contractor shall provide adequate additional shelving for all manuals in the Southeast operator house.
3. Two (2) copies of Volume 1 and six (6) copies each of Volume 2 and Volume 3 shall be distributed to the Bureau of Maintenance Engineering – Bridge Section, 1035 Parkway Avenue, Trenton, NJ 08625.
4. Three (3) copies of Volume 1 shall be distributed to the Bureau of Project Support and Engineering, Drawbridge Operations, 2436 Paynter’s Road, Manasquan, NJ 08736.
5. Additional volumes of Operations and Maintenance Manuals created from other sections shall be distributed to the Groups listed in subparagraphs 1, 2 & 3 above.
707.04 Construction Requirements.
A. Maintaining Existing Facilities. The Contractor shall conduct his operations in such a manner as to maintain the existing bridge electrical equipment and systems in operating condition at all times throughout the construction in accordance with the approved work schedule and all requirements for construction staging. This includes but is not limited to navigation lights, traffic signals, warning gates, barrier gates, roadway lights, heat trace cables for water and waste line and any other electrical facilities required for safe operation of the bascule span. The Contractor shall furnish and install any temporary facilities and equipment necessary to conform to the above requirements at no additional cost. The bridge operation during construction has been detailed on contract drawings and under “Temporary Bridge Operation during Construction”.
The Contractor shall be held responsible for the maintenance and repairs of the bridge components from the start of the project to the final acceptance. The Contractor shall be held responsible for the operation of the bascule span during periods defined in Section 107.13 “Construction over or adjacent to Navigable Waters”. The Contractor shall also be responsible for maintaining all bridge approaches lighting fixtures.
The maintenance shall include regular greasing, fluid change, electrical control maintenance, and repairs to any breakdowns during the construction period. Snow plowing and salt spreading both on the bridge and approaches, should be cleared away by the Contractor.
The Contractor, in the presence of the Engineer, shall examine all the required facilities on the bridge and he shall note items requiring modification and repair prior to the start of mandated maintenance. Upon receipt of a listing of non-operating items the Engineer will make arrangements with the Contractor or other parties to repair mal/non-functioning items. The Contractor shall be required to provide, at no additional cost to the NJDOT, temporary power for bridge facilities. As and if required, temporary power shall be provided by the Contractor at no additional cost to the State.
Additional items required to maintain facilities during construction can be found in Section 539 – “Temporary Bridge Operation During Construction”.
B. Construction Scheduling. The disconnecting and removal of existing facilities, the modification or rehabilitation of other existing equipment, the installation of new apparatus and equipment and the connections of all existing and new apparatus shall be coordinated with the structural, architectural, and mechanical work under this contract and shall be done in conformance with the requirements governing the sequencing and scheduling of construction as shown on the Plans and specified herein. Component sizes must be coordinated with existing or proposed access to their installed or temporary locations.
The Contractor shall prepare and maintain an updated progress schedule to indicate phases of work. The schedule shall be submitted to the Engineer and NJDOT MBEG for review and approval prior to the start of work and shall be in accordance with Section 108.04 of the Standard Specifications.
C. Removal of Existing Equipment. For demolition, removal, and salvage of existing equipment, refer to Section 540 “Demolition and Removal”.
D. Connections to Existing Facilities. The Contractor shall make all connections required between the rehabilitated and new equipment and the existing circuits and apparatus to provide for proper operation of the bascule span and its auxiliary equipment, in accordance with the requirements specified herein.
E. Cutting, Patching and Miscellaneous. The Contractor shall perform all necessary drilling, cutting, and patching required to install his work. All cutting of concrete, structural steel, sidewalks, floor slabs, walls, and other portions shall be done by skilled personnel. All conduits and pipe sleeves shall be properly grouted in the mortar.
After completion of the work, the Contractor shall repair all damages caused by either his installation to existing structure/bridge or facilities or existing damages/deformities, such as due to water leakage noticed while relocating equipment within structure/bridge or facilities and shall finish the job in a workman like manner satisfactory to the Engineer and NJDOT MBEG. Holes in the walls, ceiling, or floor shall be patched and finished to match the existing surfaces. Painted surfaces shall be repainted after being repaired. Any damage to windows, window framing, sash, sills, frames or any other architectural trim shall be repaired by the Contractor at his own expense.
F. Factory Inspection and Testing. The control and power distribution cabinets, motor flux vector drive cabinets, programmable logic controllers and other apparatus fabricated or assembled by the control system vendor shall be subjected to shop inspection to demonstrate compliance with all specified requirements. The shop inspection is intended as a means of facilitating the work and minimizing errors, with an understanding that it will not relieve the Contractor of responsibility for imperfect material or workmanship, both in the shop and at the bridge site.
The control cabinets, control desk, and enclosures with programmable controllers and all associated PLC-drops with all required interfacing equipment shall be assembled and temporarily interconnected for operational testing at the plant of the control system vendor. The testing shall demonstrate proper programmed operation of all bridge drives and auxiliary equipment in accordance with specified requirements for system functioning, including the programmable controllers, flux vector drives, and all control relays and motor starters etc.
The manufacturer's standard testing shall comprise at least the following:
1. Inspection of materials, fit of parts, finishes, adjustments, and conformance with catalog cuts.
2. Wire continuity tests, either visual or verified with continuity tester.
3. Operational check of circuits to determine proper interlocking of circuits and operator’s devices.
4. Polarity of connections to instruments and other polarity-sensitive devices.
5. Dielectric test in accordance with applicable NEMA standards.
The Engineer and NJDOT MBEG or authorized representative shall witness the factory inspection and special testing required herein, and no equipment shall be shipped from the factory until it has been approved by NJDOT MBEG and released for shipment by the Engineer. The Contractor shall provide notification thirty (30) days in advance of the date of the tests so that arrangements can be made for the Engineer and NJDOT MBEG to be present at the tests. The Contractor shall submit to the Engineer and NJDOT MBEG for review, ten (10) days prior to the testing date, a copy of all standard and all special tests to be performed, as well as actual test formats.
During the witnessed inspection, nameplate legends, conductor identifications, instrument scales, escutcheon plate engraving, and all other details of construction shall be checked for conformity with specified requirements.
G. Material Installation/Entry Clearance. To facilitate installation of the electrical and electrical related assemblies, the Contractor shall review all drawings to ensure that adequate installation space is available. Review of space installation shall be provided prior to manufacture or purchase. Units too large to fit through or into available space shall require the Contractor to enlarge the opening, relocate, or re-package the internal equipment at no additional expense to the New Jersey Department of Transportation.
The Contractor may arrange, furnish, and install hoisting equipment to facilitate installation and removal of various items. The Contractor shall ensure that the hoisting device, if used, has sufficient capacity to raise and lower the loads.
The cost to remove, hoist, and reconnect the bascule span motor, cabinets, enclosures, and associated equipment shall be paid for under Section 707, “Electrical Work”.
H. Manufacturer's Field Start-Up Service and Testing. Included with the furnishing of the major items of electrical equipment by the manufacturer shall be the furnishing of all necessary field supervisory start-up time by the manufacturer's service engineering department to facilitate proper adjustment of the drive equipment so as to achieve satisfactory functioning of the drives.
The manufacturer's field service engineering personnel shall be experienced in the adjustment and functioning of the particular control equipment furnished by the manufacturer. The personnel shall be capable of locating and correcting faults or defects and of obtaining from the manufacturer, without delay, new parts or replacements for apparatus that, in the opinion of the Engineer and NJDOT MBEG, does not perform satisfactorily.
Manufacturer’s Field Start-Up Service and Testing shall be for individual sub-systems and components. The final acceptance of the bridge electrical and control systems and peripherals shall be included and paid for under the “Acceptance Testing” Section of these specifications.
I. Field Testing. The Contractor shall arrange for and provide all the necessary field tests, including detailed bridge system acceptance testing, as directed by the Engineer and NJDOT MBEG, to demonstrate that the entire electrical system is in proper working order and in accordance with the Plans and Specifications. The tests shall include, but not be limited to, continuity and insulation resistance testing of conductors and operational testing of traffic signals, warning gates, barrier gates, lift bascule span, navigation lights, signals, existing automatic transfer switch, temporary manual transfer switch and complete PLC/SLC system. The Contractor shall arrange with the local power company to obtain, at his own expense, electric power during the testing period until the bridge has been accepted.
Should the acceptance tests show that any piece of equipment, cable or wiring connection, and interlocking, in the judgment of the Engineer and NJDOT MBEG, is defective or functions improperly, such adjustments and/or replacements shall be made by the Contractor as to make the installation satisfactory to the Engineer and NJDOT MBEG and at no extra cost.
The Contractor shall obtain final approval of the Operation and Maintenance Manual from the Engineer and NJDOT MBEG prior to final acceptance testing of the bridge.
Other field tests for specific equipment shall be as specified in the various sections of this Specification.
J. Electric Service. Utility electric power for operation of the bridge and its auxiliaries is supplied by one source. The source is the three-phase, 480/277-volt, 60-hertz, 4-wire, 225 KVA.
Normal power for operation of the bridge and its auxiliaries will be continued to be supplied by “Jersey Central Power and Light Company” from existing pole mounted transformers located near the parking lot at the southwest side of the bridge where shown on the Plans. The Contractor shall furnish and install 4” PVC schedule 80 conduits along the abutment wall and along approach bascule span stringers to the southeast house. The routing shall be as shown on the contract plans. Utility to ensure that a proper, solid, neutral to ground connection is furnished and installed at the transformers service point, and shall be connected to the bridge grounding system as shown on the Plans. The Utility Company provides, and maintains primary cables and the existing transformers.
The Contractor shall furnish and install, as shown on the plans wire with AWG size and quantity shall be as shown on the Plans. Standby power for the bridge and its auxiliaries shall be provided by a standby engine-generator set as indicated in “Diesel Engine Generator Rehabilitation”.
K. Louvers/Dampers. All existing generator room louvers shall be removed and replaced with new motor operated combination louvers/dampers. In addition, wall openings and the intake louver in the generator room shall be enlarged. The new enlarged intake louver/damper shall measure 48 inches high by 48 inches wide. The existing exhaust louver/damper shall be replaced with similar type combination louver of same size.
The louvers/dampers shall be the AC, 4” deep, 6063-T5 Aluminum Alloy Combination Louver manufactured by Ruskin Co. or the engineer and NJDOT MBEG approved equal. Front louver stationary blades shall be drainable type, rear adjustable blades shall be operable by concealed linkage, stainless steel sleeve bearings with locking louver quadrant, 120 V, direct coupled, spring return type actuator.
L. Bascule Span Brakes. Brakes – bascule span motor brakes and one machinery brakes, shall be furnished and installed in each machinery room as shown on the Plans. Each brake shall be a spring-set, thrustor-released, shoe-type, open brake, with a second mode for manual release, hydraulic set, and the brake shall be provided with corrosion-resisting fittings. The brakes shall be floor-mounted on structural supports. Each motor brake shall be rated 380 foot-pounds and shall be factory set to exert an actual retarding torque of - - - foot-pounds. Each machinery brake shall be factory set for 2150 ft.-lb. Brakes shall be manufactured by Mondel, or the Engineer and NJDOT MBEG approved manufacturer.
All motor and machinery brake wheels and couplings shall be furnished with the brakes by the brake manufacturer. The bores shall be left undersize, and the wheels shall be shipped to the machinery manufacturer who shall finish-bore and key seat the wheels and fit them onto the machinery shafts. For machinery brake wheels and couplings refer to plan sheets and mechanical specifications.
Each brake shall be equipped with a hand release that will not change the torque setting or require removable levers or wrenches. The hand release mechanism shall be located on the side of the brake away from the main reducer (right hand and left hand units are required). Each hand release shall be provided with a lever type limit switch for interlocking purposes as described under "interlocking." It shall not be possible to set the hand release of the brakes without tripping these switches. Switches shall be an approved equal to Square D Class 9007 with epoxy potted STOWA cable.
In addition to the hand release limit switch, two lever type limit switches shall be mounted on each brake. One shall indicate that the brake is fully set, the other that the brake is fully released. The brake released limit switch (which shall have two N.O. contacts) shall trip when the brake is electrically released or hand released. The brake set limit switch shall have two N.O. and two N.C. contacts and shall trip when the brake is fully set. Switches shall be an approved equal to Square D Class 9007 with epoxy potted STOWA cable.
The down-stroke (set) time delays of the thrustors shall be set in such a manner that the brakes will not be applied simultaneously should electric power fail or a stop is activated while the bascule span is in motion. The intervals between the setting of the brakes shall be adjusted to obtain smooth stopping of the bascule span in the shortest possible time as approved by the Engineer and NJDOT MBEG.
The oil used in the thrustor operating chambers of the brakes shall be a grade as approved by the Engineer and NJDOT MBEG. It shall have a free operating temperature range between -40 degrees and 150 degrees Fahrenheit.
The thrustors shall be actuated by 460-volt, three-phase, 60 Hertz, totally enclosed, squirrel cage motors controlled by magnetic contactors with manual-reset thermal overload relays. The rated stalled thrust of each thrustor shall be not less than 135 percent of the thrust actually required to release the brake with the torque adjusted to the continuous rated value.
Each thrustor shall include a 120-volt, single phase heater installed to maintain an acceptable oil temperature of 50 degrees Fahrenheit.
Each brake shall have nitriding finish on all ferrous parts and the brake covers shall be stainless steel.
The set, released, and hand-released status of each brake shall be indicated through the use of pilot light indicators on the control desk. Pilot lights to indicate excessive thrustor motor currents shall also be furnished.
To allow checking of the thrustor brake operation, key operated selector switches located on the control desk shall be furnished. Two position maintained one key operated switch per brake will allow brake testing with bascule span seated and motors not running. Only one brake may be tested at a time.
M. Provision for Gate Motors and Controls. Electric motors for operation of the Traffic Warning and barrier gates shall be furnished as part of the Traffic Warning and barrier gate machinery by the gate manufacturer and shall be installed under "Traffic Warning and Barrier Gates", Section 535.
Each Traffic Warning gate motor (total of two) and barrier gate motor (total of four motors) shall be of weatherproof, totally enclosed non-ventilated (TENV) type, 460-volt, three-phase, 60 Hertz, ball-bearing, squirrel cage motor capable of withstanding instant reversal when running at full speed. Each Traffic Warning and barrier gate motor shall be provided with a brake for stopping and holding the mechanism.
Each Traffic Warning and barrier gate motor shall be controlled by magnetic reversing type contactors, electrically and mechanically interlocked, and shall be protected by a three-element, thermal overload relay, automatic reset.
Each gate – two Traffic Warning gates and four barrier gates – shall be operated from individual raise and lower pushbuttons on the control desk. Pushbutton circuitry is arranged such that the gate in motion will stop immediately when the pushbutton is released. In addition, the group of two Traffic Warning gates is provided with a group raising pushbutton, and the four barrier gates are provided with a group raising pushbutton. All gates in a group shall travel to their respective limits after a momentary raise command of the group switch. The group shall stop immediately upon momentary contact of the group's respective stop pushbutton. The push-to-stop lamp shall illuminate when gates are in motion. While gates are in motion the raise or lower light will flash. When gate has been fully raised/lowered the light will be constantly illuminated. All existing pushbutton shall be interlocked in the new control scheme using Allen-Bradley controllers.
All electrical work to provide for the connection, operation, and control of the gate motors, including control apparatus, switches, conduits, boxes, cables, and other equipment, shall be furnished and installed under this item of "Electrical Work." The work shall also include adjustment of all apparatus and overload devices to provide proper functioning of the equipment.
Each gate furnished under the item of "Traffic Warning and Barrier Gates" shall include a 120/12-volt flasher and gate lights. Each barrier gate shall be equipped a proximity limit switch built into the gate housing. The limit switch shall provide contacts to control the limit of travel of the barrier gates in each direction and for indication and sequence interlocking. Adjustment of gate crank arms and limit switches for proper operation of the barrier gates shall be done under the item of "Traffic Warning and Barrier Gates.”
N. Bridge Control. The control circuits for operation of the bridge shall be made available through relays, encoders and programmable logic control for the leaf bascule span drives. The positions of the control selector switch shall be marked “Off” and “On. The control selector switch shall be kept in the “Off” position, except when operation of the bridge is required.
O. Bascule span Operation. Four modes of bascule span operation shall be provided to operate the bascule span. Normal bascule span operation shall be with utility power and the 40 horsepower vector duty squirrel cage motors. Backup bascule span operation shall be with generator power and the 40 horsepower vector duty squirrel cage motors. Emergency bascule span operation shall utilize the machinery room diesel engines to operate the bascule span, and utility or generator power to operate the traffic devices and utilities. The fourth mode will be two speed/two winding, brake/clutch integral assembly temporary motors powered either by the Utility power or Engine-generator power.
The flux vector drives can be selected from the drive selector switch on the control desk. The bascule span control pushbuttons shall provide for raising, lowering, or normal stop of the bascule span by momentary contact in the desired switch position. Depressing the “stop” pushbutton will cause the bascule span motor to decelerate to a reduced speed and then power will be removed from the motor and the brakes shall set. If an immediate stop is called for, the "Emergency Stop" pushbutton shall be depressed, causing power to be removed from all necessary bascule span drive and brake contactors. A fault reset pushbutton will reset the drives when pushed, a red pilot light will illuminate when a drive fault occurs.
P. Bascule Span Control.
1. Drive Selection. Flux vector drives for bascule span shall be provided as specified under “Flux Vector Drive Cabinets”. The flux vector drives shall be located in the switchboard room. Four, four-position pushbutton type selector switches are provided on the control desk to select push to stop, Raise, lower, or permissive fault.
If a drive is overloaded or failed or if a motor is disconnected, the bascule span shall come to a stop. The operator shall be alerted to this fault by displaying the message on the message display unit (the device that has been selected by the PLC). The fault light will continue to flash until the operator acknowledges the changeover in equipment by physically moving the appropriate selector switch to the second drive position or until the fault is corrected. The light shall then illuminate in the normal fashion.
2. Positional Measurement Devices: Bascule span position shall be indicated on the control desk by two modes; a digital resolver and selsyn-based system. The selsyn transmitter and receiver specifications are included in this Section.
a. Digital Angular Position Resolver. For the flux vector drives using PLC operation, position of the bascule span is to be measured by a digital position resolver. In each machinery room, there shall be mounted two (2) digital position resolvers connected to the operating machinery through gearing. Each digital position resolver shall produce an analog signal via a brushless resolver. This signal is converted to a 4-20mA analog signal format by a built-in ratiometric tracking converter. Each digital position encoder shall retain positional information, even in the event of a power failure to provide a fully absolute position encoder system. Each digital position encoder shall be a single-turn, heavy-duty, Size 40, and mounted in a NEMA 13 enclosure. The outputs shall be furnished with short-circuit proof PNP transistors. Output shall be 18 mA per 78 degrees of bascule span movement. Each digital resolver shall be furnished with a lockable, external toggle switch to allow changing of count direction without opening the housing, and be powered by a separate fused 5-volt D-C source and provide a TTL multiplexed digital output with end mount connected and multiconductor cable as recommended by the manufacturer. Mounting brackets and flexible couplings are to be used for mounting the encoders to the machinery supports. The Contractor shall include a single length of the multiconductor interconnecting cable and associated connectors between each encoder and the adjacent I/O drop.
Each resolver will produce approximately 17 mA for a full opening of 75 degrees.
At the seated position, the PLC software shall "initialize" the resolver count to a value “greater than 0”. As the bascule span raises, the resolver count shall increase. The PLC shall account for any rope stretch/slippage, etc., by taking the initial encoder count while the bascule span is seated into consideration during all manipulations and comparisons to the count during bascule span operation. This will provide exact limits of travel, deceleration points, etc.
Resolver failure shall immediately reduce the bascule span speed to creep and travel to full open or seated and set all brakes. At full open/closed position resolver count will reinitialize and bascule span shall be allowed to run at normal speed.
The PLC shall perform calibration error checks at seated, and at fully open to determine if the resolvers are properly measuring bascule span position. The checks shall be performed upon changing states of the fully seated limit switches. An error of 1 inch maximum will be tolerated for either resolver. If either resolver shall fail a calibration check during bascule span operation, the operator shall be alerted to this change by the flashing of the backup positional measurement indicating light and the extinguishing of the resolver’s indicating light. The light will continue to flash until the operator acknowledges the change by changing the selector switch position or when the bascule span becomes seated.
The control desk shall have two selector switches to select either of the two (2) digital resolvers. The digital resolvers shall be the DigiSolver, manufactured by Autotech, or Engineer and NJDOT MBEG approved equal.
Q. Sequence of Operation.
1. After a boat gives proper request signals for an opening, give the necessary signals with the air horns.
2. Turn the bridge control switch to "On.”
3. Turn the traffic signals switch from "Green" to "Red," to request traffic signals to turn off the green traffic lights and turn on the “Red Signal Ahead” sign flasher automatically. Approximately five (5) seconds after the “Red Signal Ahead” sign starts flashing, the traffic signals turn amber. After a short time delay of six (6) seconds, the amber lights shall be extinguished and the red traffic lights, gate warning lights, and gongs turned on.
4. Lower the warning gates for oncoming traffic one approach at a time.
5. Lower barrier gates in the proper sequence. Gongs will shut off when all gates are lowered.
6. Open the bascule span to the fully open position; bascule span navigation lights will turn from red to green. Sound horn to indicate span opening.
7. After the boat has passed, sound horn and lower the bascule span, bringing it to a full seat at all corners.
8. Raise barrier gates by means of the group raising or individual control. Gongs will begin ringing again.
9. Raise the warning gates by means of the group raising control.
10. As soon as all warning gates are raised, turn the traffic signals switch from "Stop" to "Go." Gongs will stop ringing. Bridge traffic signal will turn green and the “Red Signal Ahead” signs shall automatically stop flashing “Red.”
11. Turn bridge control switch to "off.”
R. Interlocking. The various control operations shall be so interlocked that they can be performed only in their proper sequence and that no damage can result from an incorrect operation. This interlocking shall be arranged as follows:
1. Contacts of the gate limit switches shall be so arranged that movement of any gate by 10 degrees from its fully raised position shall turn on the “Red Signals Ahead” signs, red traffic signals, warning lights, and gongs.
2. As soon as the warning gates are fully raised (after any one of them has been partly or fully lowered), the “Red Signals Ahead” signs, red traffic lights, warning lights, and gongs shall be turned off, provided the traffic signals switch has been returned to "Go”.
3. The warning gates cannot be operated electrically unless the bridge control is turned on, the “Red Signals Ahead” signs and "Stop" traffic signals have been turned on, and all barrier gates are fully raised.
4. The barrier gates cannot be operated electrically unless the “Red Signals Ahead” signs and "Stop" traffic signals have been turned on, the warning gates are down, and the bascule span is seated.
5. The bascule span cannot be operated electrically if more than one brake in the machinery room has been released by hand and barrier gates are not down and locked.
6. Sealed tumbler switches for bypassing the sequence interlocks in an emergency are provided and installed on the control desk. These switches shall be held in their open position by hinged plates at least 2 inches long, which have to be unlocked and turned over backwards in order to release the switch handles for bypassing. The underside of these plates shall be painted bright red. Provision shall be made so that each bypass switch can be locked in the "Off" position by means of a lockable brass cover plate. The bypass switches shall only be effective for a single close-open-close cycle. Operated switches must be turned off and back on to be effective.
S. Provisions for Laptop Computer, Printer and Data Logger. Under Section 536 – “Data Logging” the vendor (Link Control Systems, Inc. or NJDOT MBEG approved) shall supply a portable programming terminal printer and data logger assembly. The data logger assembly shall be delivered to the Contractor for installation in the Bridge Control House. The laptop computer and printer shall be delivered to a location as required by NJDOT MBEG.
Under “Raceway, Conductors, Terminations and Boxes”, the Contractor shall furnish and install all boxes, wires, cables to interconnect the printer and data logger. The Contractor shall also extend the necessary power for operation of these devices.
T. Maintenance Tests. The PLC shall store the various parameters described below for a total of one bridge opening/closing cycles. Subsequent bridge cycles shall overwrite any stored data so that the two most recent cycles' parameters are stored in memory at any given time.
The stored parameters for the one most recent bridge cycles shall be accessed using a designated code entered via the keyboard on the PLC user desk. The user shall have the option to print either or both groups of parameters on the printer.
The parameters listed below are to be recorded every 5 degree opening of bascule span. Tests for the bascule span drive system shall be conducted for the first and last five feet of travel and every five feet thereafter. The parameters to be measured are as follows:
1. Bascule span angular position against bascule span motor kilowatts, amps, and speed for both near and far leaves.
In addition, the drive used during the lifts shall be recorded and printed out with the above parameters as shall be the date and time of the lifts. The format for the printout of parameters shall be in tabular form with date, time, and drive identification heading the table. All parameters shall be measured and printed versus position of the bascule span as described in the acceptance test. The Vendor shall provide PLC software for additional maintenance test at the request of the Engineer and NJDOT MBEG.
1. Drift Test.
a. Used as a maintenance test to estimate bascule span balance.
Procedures for checking bascule span balance shall be as follows:
1. PLC Controlled
2. Initiated by a keyed switch located on the control desk.
3. Open the bascule span from fully closed at mid bascule span, the bascule span motors will automatically be disconnected keeping all bascule span brakes released.
4. PLC will record the amount of bascule span drift “angular position of bascule span when power was removed to angular position of bascule span stop position”. Bascule span will coast to stop.
5. Restart after bascule span stops and travel to full open.
6. Close bascule span and at mid bascule span, the bascule span motors will automatically be removed keeping all bascule span brakes released.
7. PLC will record the amount of bascule span drift.
8. Upon completion of bascule span raising and lowering drift test, the result of the test shall be displayed on the two-line display with indications drift raise (distance) drift lower (distance).
9. The bascule span balance is correct when the amount of drift while lowering is approximately 1½ times the amount of drift while opening.
The drift test shall be monitored by PLC logic. The PLC system shall monitor the bascule span speed and amount of drift time. Should either of these items become excessive, the drift test shall automatically reconnect the bascule span motors to regain control.
U. Position Indicator. The position of the bascule span during operation shall be shown by a position indicators mounted on the pinnacle of the control desk. The pointers shall be driven by a high-accuracy selsyn receivers connected to a high-accuracy transmitters mounted in the machinery rooms and geared to the operating machinery so that the input shaft of the transmitters shall rotate 280( for the maximum angular opening of 78 degrees.
The existing position indicators on the control desk will be reused.
Any changes in the ratios of gear sets provided as part of the rehabilitated operation machinery will affect the calibration of the position indicator. It shall be the Contractor’s responsibility to verify the actual rotation at the transmitter input shafts corresponding to the full-bascule span opening and to modify the position indicators’ design if necessary.
V. Limit Switches.
1. Fully Seated and Span Locks driven and pulled Limit Switches. The proximity sensor shall have a 5 mm nominal sensing range with a standard steel target as shown on the Plans with a 3-15% differential travel. The sensor shall be short circuit and overload protected. It shall be able to operate from 20-250VAC with a maximum voltage drop across a conducting sensor of 6 volts. Off state leakage current shall be less than or equal to 1.7mA. Minimum load current shall be no less than 3 mA. The sensor shall be repeatable within 2% of the nominal operating distance. It shall be able to operate within a +70C to -25C temperature range at a maximum of 10% drift. The sensor shall meet or exceed NEMA 6 and IP 67 enclosure ratings. The sensor shall be equipped with two LEDs, one to indicate power on and one to indicate sensing status with the power on LED also serving as Short Circuit Warning if flashing. The sensor shall be able to withstand a 30 g shock load for a maximum time of 11ms and be able to withstand a 55 Hz vibration 0.039 inch Amplitude in all three planes. The switch shall be provided with a minimum of one normally open contact. The switch shall be connected via a potted-in, watertight, PVC jacketed cable. The proximity switch shall be the B5-G18-ADZ3X2 Proximity Sensor as manufactured by Turck, or the Engineer and NJDOT MBEG approved equal
2. Traffic Warning and Barrier Gate Limit Switches. Limit Switches for each of the barrier gates shall be furnished as part of each respective gate. Each gate shall contain a rotary, cam operated, adjustable limit switch. A minimum of eight contacts is furnished, to provide gate motor control, interlocking, logic and indicating features. The warning gate and barrier gates limit switches shall be properly wired and used in the new PLC/SLC control system.
3. Over travel and Fully Open – Inclinometers. Two inclinometers, one for each leaf for over travel and fully open applications shall be provided and mounted to bascule girder web, near access cutout on the South and the North side as shown on the Plans.
Each inclinometer shall be waterproof, high performance model SI-701WPBIHP of Columbia Research Laboratories, Woodlyn, PA or NJDOT MBEG approved equal. The operational range shall be +/-5 degrees, with current output of 4-20 mA and Power requirement of 15 VDC. The sensor shall be encased in SS 316L material and shall satisfy IP 68 and NEMA 6P rating. Cables WC-2 and EC-5, with waterproof connectors shall be provided.
4. Overspeed Switches. Provide and install foot mount, NEMA 4 enclosed, euclide type C, AC overspeed protection switch on each of span motor shaft as shown on contract plans. Each switch shall have repetitive accuracy and temperature range from -50 degrees to + 120 degrees with 2 N.O./2 N.C. snap action contacts. The input shaft of the switch shall be 5/8” diameter, stainless steel.
Overspeed switches shall be Series 2210 – 122CD, NEMA 4 as manufactured by Hubbell or NJDOT MBEG approved equal.
W. Control Apparatus and Miscellaneous Equipment. Control apparatus shall conform to the applicable requirements of NEMA Publication No. ICS, latest revision, Industrial Control and Systems, rated as shown on the Plans or as required and to the following:
1. Circuit Breakers: All branch circuits where shown on the Plans shall be protected by molded-case circuit breakers mounted on the control panels. All breakers shall have quick-make and quick-break contacts, and the mechanism shall be trip-free and trip-indicating. Frame sizes shall not be less than 100 amperes and/or as shown on the Plans. The breakers shall be equipped with thermal-magnetic trips or adjustable, instantaneous, magnetic trip units, with trip rating as shown on the Plans or as required. Molded-case circuit breakers shall meet the requirements of NEMA Publication No. AB1, latest revision. Interrupting capacity shall be as shown on the contract documents. All circuit breakers shall be furnished with 2 N.O./2 N.C. contacts.
2. Motor Circuit Protectors: All branch circuits, where shown on the Plans, shall be protected by instantaneous trip motor circuit protectors (MCP). The MCP shall comply with UL 489 and IEC 157.1. The MCP shall be marked to permit proper electrical application within the assigned equipment ratings. The MCP shall be F-frame, 480 VAC maximum with alternate cam setting provision as manufactured by Cutler-Hammer, Square D FAL-frame, or Engineer and NJDOT MBEG approved equal.
3. Motor Starters and Magnetic Contactors: The continuous current rating of contactors and starters shall be adequate for the connected loads, and no starters shall be smaller than NEMA Size 1. All contact poles shall be provided with arc chutes, and contactors rated 150 amperes and above shall be equipped with magnetic blowouts. Contactors and overload relays shall be provided with a minimum of one normally open auxiliary contact and one normally closed auxiliary contact. Three-element, automatic reset, overload relays shall be provided for motor protection. Reversing contactors shall be electrically and magnetically interlocked.
4. Motor Disconnect Switches: Un-fused safety switches for use as disconnects, shall be installed within the range of view of each motor. The switches shall be lockable, non-fusible, heavy-duty, safety switches, rated as shown on the Plans, and in watertight and dust-tight NEMA 4X, stainless steel enclosures. Each disconnect shall be furnished with a 2 N.O/2 N.C. auxiliary contact and phenolic nameplate to identify corresponding motor or brake.
5. Overload Relays: Manual reset overload relays shall be provided to protect the brake motors, controllers, and wiring against overheating due to excessive current. Automatic reset overload relays shall be provided for bascule span motor and gate motors. Heater elements are to be selected based on motor full-load running current. Each O.L. shall provide a 2 N.O. and 2 N.C. contact.
6. Over-current Relay: Adjustable magnetically-operated/overload relays shall be set to trip at 180 percent full load current.
7. Control Relays: Auxiliary control relays shall be multi-contact magnetic industrial relays with contacts rated at 10 amperes, 600 volts, on a continuous basis. Relays that meet the specified requirements are the Square D 8501 Class X, Allen Bradley Bulletin 700 Type P, General Electric CR120B or Engineer and NJDOT MBEG Approved Equal.
8. Industrial Alternating Control Relays: Alternating relays shall be multi-contact magnetic relays with contacts rated at 10 amperes, 600 volts on a continuous basis. Alternating relays that meet the specified requirements are the Square D CA2SKE or Engineer and NJDOT MBEG approved equal.
9. Timing Relays: Time-delay relays shall be of the electro-pneumatic type providing time delay intervals as required with a linear timing range in the ratio of 1:10. Each timing relay shall be provided with a timing head calibrated in linear increments. The number and type of poles shall be as shown on the Plans.
10. Phase Failure and Reversal Relay: This relay shall prevent energizing the bridge controls in the event of reversed phase sequence, loss of one phase, or low voltage. Equipment that meets the specified requirements includes the Square D type MPD, Cutler Hammer Type D65, Westinghouse CP, or Engineer and NJDOT MBEG approved equal.
11. Selector switches and Pushbuttons: Control switches and pushbuttons on the control desk shall be heavy-duty, oil-tight contact blocks operated by selector knobs or pushbuttons as indicated on the Plans. Contacts shall be fine silver, capable of interrupting 6 amperes at 120 volts A-C and of continuously carrying 10 amperes.
12. Indicating Lights: Indicating lights shall be heavy-duty, oil-tight sockets provided with 6-watt lamps rated 135 volts. Indicating lights shall be of the remote test type. All lenses shall be glass or plastic, with color and escutcheon plates as shown on the Plans. Indicating lights shall be Square D Class 9001 Type K and Type J or Engineer and NJDOT MBEG approved equal.
13. Terminal Blocks: Terminal blocks for conductors of Size No. 8 AWG and smaller shall be one-piece blocks of phenolic material recognized under the UL Component Recognition Program. Barriers shall be not less than 1/2 inch high and 1/8 inch thick and shall be spaced 5/8 inch center-to-center. Straps and screws shall be of brass, nickel plated for use in highly corrosive atmospheres, and shall be rated for 50 amperes. The blocks shall provide a withstand voltage rating of 750 volts per IEEE switchgear standards. The terminal blocks shall provide strap screws suitable for use with ring tongue wire connectors. Corrosion resistant marking strips shall be provided for conductor identification. At least ten percent spare terminals shall be provided for use with power conductors and twenty percent for use with control conductors. Terminal blocks shall be Buchanan Type 2B112, General Electric Series CR 151B, Marathon series 1600 or Engineer and NJDOT MBEG approved equal. Screws shall be nickel plated brass construction.
14. Power Distribution Blocks: Power distribution blocks, for all conductors larger than No. 8 AWG, shall be constructed from a single piece of hard-drawn copper, machined and electro-tinned. All blocks shall be mounted on heavy-duty phenolic material and furnished with safety cover kits. Number and size of primary and secondary wire openings will be selected by the Contractor/Vendor and shall be approved equal to the 66000 series blocks as manufactured by Gould Shawmut or Series 145 by Marathon.
15. Control Transformer Bridge Control: The Contractor shall furnish and install a bridge control transformer in the power distribution and control cabinet which shall have the following characteristics: 5 KVA, 1-phase, 60 Hertz, 480V primary, 115(C temperature rise, two-5% FCBN full capacity 120/240 volt secondary, indoor enclosure arranged for floor mounting or wall mounting as required.
16. A warning gong shall be mounted on the traffic signal pole. Each warning gong shall be a weatherproof, motor-operated, vandal-proof, 12-inch gong mounted in a heavy-duty, cast-aluminum housing with hinged back door. Provide The gong shall be of cast silicon bronze, fire alarm metal. Gong shall operate on 120 Volts. Each gong shall be approved equal to model G-12, as manufactured by B&B Roadway, the Western-Cullen No. 555, or the Security Products Division of Federal Signal Corporation Type 555. Gongs shall be painted and mounted with hardware in such a way as to prevent theft.
17. Nameplates: Nameplates shall be provided for all aforementioned devices and shall be made of laminated phenolic plastic with white front and back and black core and shall be not less than 0.094 inch thick. The lettering shall be etched through the front layer to show black engraved letters on a white background. Lettering shall be not less than 1/4 inch high, unless otherwise detailed on the Plans. Nameplates shall be securely fastened to the equipment with stainless steel screws.
X. Transformers.
1. Bridge Lighting: The Contractor shall furnish and install a lighting transformer in the switchboard room, which shall have the following characteristics: 25 KVA , 480 delta primary voltage, 208/120 wye secondary voltage, dry type, energy efficient, electro-statically shielded. Sound level shall be below ANSI Std. C89.2 and shall not exceed 45DB, 2-20 FCAN and 4-20% FCBN primary taps. UL component recognized 220 C insulation with 80 C temp rise in accordance with NEMA Std. ST-20, 10-year warranty and mounted in accordance with UL standard 506 or 1561. The transformer shall be floor mount type where shown on the Plans.
Y. Equipment Labels. All electrical devices, disconnect switches and cabinet equipment shall have a label affixed to each unit. The label shall be similar in construction to the aforementioned nameplates. Each label shall be of suitable size and letter characteristics. Text shall indicate name/function of each item. Disconnect switches shall provide a label indicating the voltage within. Labels shall be securely attached using stainless steel screws. The Contractor shall submit to the Engineer and NJDOT MBEG for review, all signs, with sizes, location, and text.
Z. Bridge Control Cabinets. Control panels enclosed in free-standing cabinets shall be furnished and installed where shown on the Plans. All circuit breakers, switches, contactors, starters, relays, regulating equipment, and other apparatus for control of the bascule span and its auxiliaries shall be mounted on these enclosed panels. The arrangement and line-up of the individual control cabinets shall be as shown on the Plans.
All equipment in each control cabinet shall be mounted on painted sheet-steel bases, and each device shall be front-connected, front-wired, and removable from the front. The equipment in all cabinets shall be arranged for ease of access and for safety and convenience of operation. Special care shall be taken to obtain a systematic and neat arrangement of the equipment. Each device shall be suitably named and plainly marked by a laminated nameplate mounted near the device on the panel. Each nameplate shall show an approved descriptive title for the apparatus, together with the device designation appearing on the schematic wiring diagrams.
Each control cabinet shall be a NEMA Type 12 enclosure constructed of No. 12 gauge sheet-steel and shall be reinforced with steel angles or channels so as to provide a rigid, free-standing structure. The control cabinets shall be provided with stainless steel continuous hinged doors on the front of each panel section. Door panels shall have gaskets and shall be provided with three-point, vault-type latches. For cabinets with two (2) doors, the center support shall be removable. Ventilating louvers shall be provided at the front of each enclosure. All hardware shall be corrosion resistant. Thermostatically controlled strip heaters shall be provided in each cabinet to prevent build-up of excess moisture. Each panel shall be provided with suitable interior fluorescent light fixtures operated from a door operated switch and a duplex receptacle.
Each control panel enclosure shall permit mounting in the available space along the walls of the control house. If the final cabinet dimensions, as established by the manufacturer, should necessitate rearrangement or modification of the equipment in order to fit in the available space, such rearrangement or modifications shall be made and at no extra cost. The final arrangement of all equipment in the control house shall be subject to the approval of the Engineer and NJDOT MBEG.
The control panel enclosures and all metal reinforcing shall be painted inside with two coats and outside with three coats, consisting of one coat of primer followed by one coat of white enamel on the inside surfaces and two coats of gray enamel outside. The finish coat shall be ANSI 61 light gray enamel.
All contactors, relays, and other devices shall be of required current-carrying and interrupting capacity. All apparatus shall be of substantial construction and shall conform to the requirements of NEMA Standards Publications ICS 1 and 2, 1978, for industrial control devices.
All internal wiring between devices and/or terminal blocks shall be flame-retardant, ethylene-propylene insulated, switchboard wire, Type SIS. Control conductors shall be stranded copper not smaller than No. 14 American Wire Gauge.
For each assembled control panel, all outgoing wire, No. 8 AWG or smaller, shall be connected to terminal blocks installed at the sides of the cabinet. The control panels shall also provide sufficient extra terminals to allow connection of all wires coming from limit switches and other devices that go on to the bridge control desk and other locations as required, even though these wires do not connect to apparatus on the control panels. Spare terminals totaling at least 10 percent of those actually used shall be provided. Each terminal shall be identified per wire number shown on the Contractor's schematic wiring diagrams. All spare conductors entering any cabinet, terminal box shall be terminated on a terminal block.
All panel wiring shall be arranged systematically so that circuits can be readily traced. The internal cabinet wiring shall be installed in a network of troughs consisting of horizontal and vertical sections securely bolted to the panels. The troughs shall be fabricated from heavy-duty plastic shaped into a channel cross-section. After installation of the wiring, an insulated, flanged cover shall be snapped over the open side of each trough section. Each floor-mounted cabinet/panel shall be provided with 1/8 inch neoprene gasket between the cabinet and floor.
Control cabinets 48”x48”x12” for temporary system using integral motor/brake/clutch assembly to be located in the Southwest and Northeast rooms shall be as manufactured by Hoffmann or approved equal to NJDOT MBEG.
AA. Hardware and Supports. Supports for conduits, cables, boxes, cabinets, disconnect switches, small limit switches, and other separately mounted items of electrical equipment shall be fabricated from structural steel not less than 3/8-inch thick. Clip angles and other supporting members which are fabricated from structural steel plates and shapes, and bolted to the structural members, shall be included with the structural steel. All other supporting members shall be included under the electrical work.
Structural steel brackets, boxes, and other equipment mounted on concrete surfaces shall be provided with a full neoprene gasket not less than 1/16-inch thick between the equipment and the surface of the concrete.
Expansion anchors for fastening equipment or brackets to concrete surfaces shall be wedge type anchor bolts, which shall be locked in place by an expansion wedge as the nut is tightened. All parts of the expansion anchors shall be of Type 316 stainless steel. Holes for the anchors shall be drilled to the size and depth recommended by the manufacturer using carbide tipped masonry drills.
Mounting bolts, nuts, washers, and other detail parts used for fastening boxes, disconnect switches, small limit switches, conduit clamps, cable supports, brackets, and other electrical equipment shall be of stainless steel conforming to the requirements of ASTM Designation A276, Type 316. Bolt heads and nuts shall be hexagonal and shall be provided with medium-series lock washers. Bolts smaller than ½-inch in diameter shall not be used, except as may be necessary to fit the mounting holes in small limit switches, boxes, and similar standard devices.
Usage of beam clamps for supporting conduits, boxes, or other equipment shall not be acceptable without prior approval of the Engineer and NJDOT MBEG.
Preformed stainless steel metal framing channels, will be acceptable for mounting or supporting electrical equipment, conduits, or boxes. Prior to installation the Contractor shall submit to the Engineer and NJDOT MBEG for review, his design, and shall not install the channels without approval.
BB. Control of Traffic Devices. On each approach, traffic lights, warning gates, and gongs have been previously installed. Barrier gates are provided under the “Barrier Gates” item.
All equipment for controlling the operation of the “Red Signal Ahead” signs, traffic lights, warning gates and gongs, and barrier gates and all conduits, boxes, wiring, cables, and other equipment required to extend and connect the necessary circuits from the control house to the sign and signal equipment, warning gates, and gongs, and barrier gates on the approaches shall be done under this item "Bridge Electrical." The “Red Signal Ahead” sign and traffic signal operation shall be initiated by a two-position selector switch on the control desk. Red, amber, and green pilot lights on control desk indicate light status. The warning gates and barrier gates shall be controlled via pushbuttons on the control desk. Indicating lights on the control desk indicate gate arm status.
CC. “Red Signal Ahead” Signs”. “Red Signal Ahead” signs shall be furnished and installed as shown on the Plans. The signs shall be furnished with a flasher so that the word “Red” flashes when the sign is illuminated. The flasher shall flash the word off and on 30 times per minute.
The sign shall be turned on when the bridge operator turns the traffic signal selector switch to red, or if a warning or barrier gate is not fully raised. The sign shall be manufactured by NJDOT Traffic Operations approved manufacturer.
DD. Air Horns. Air horns for giving the necessary boat signals have been previously installed on the Bridge.
Under the item of “Electrical Work” the Contractor shall furnish and install all conduits, wiring, boxes, circuit breakers and any other equipment required to extend power to the air horns. Existing conduit and wiring shall be removed and new conduit and wires shall be installed.
EE. Bascule span and Fender Navigation Lights. Navigation lights have been previously installed on the bascule span and fender system. Before start of work under this item, the Contractor shall submit a report on condition of span and fender navigation fixtures. If, threads are found to be corroded, then, entire fixture assembly/lies will be replaced. Cost of providing and replacing fixtures will be included under this item.
Under the item of “Electrical Work” the Contractor shall furnish and install all conduits, wiring, boxes, circuit breakers and any other equipment required to extend power to the existing navigation lights. Existing conduit and wiring shall be removed and new conduit and wires shall be installed. Interconnection to the center lift bascule span navigation lights shall be through a new cable reel.
The lenses of all bascule span and fender navigation lights shall be cleaned, and if the lenses are cracked or damaged, new lenses shall be furnished and installed at no additional cost to NJDOT. New standard medium base cylindrical light emitting diode (LED) lamps, 120 volt, 8 watt power consumption, equivalent to 75 watt incandescent, shall be furnished and installed as a direct replacement of the existing standard incandescent 120 volt lamps. The LED lamps shall be B&B Roadway PLP-LED120-BG (green) or PLP-LED120-R (red) or Engineer approved equal.
At each fender walkway, the connections to the fender navigation lights shall be made with No. 10 AWG conductors in ¾-inch PVC-coated rigid metal conduit. A stainless steel NEMA 4X junction box shall be provided at each pier light. Conduits shall be securely clamped to the fender with two-hole conduit clamps of 3/8-inch thick bent stainless steel plate. The conduit clamps shall be fastened with stainless steel lag screws not less than 3/8-inch in diameter. Conduit clamp spacing shall not exceed 5 feet.
The connections to the center bascule span navigation lights shall be made with No. 10 AWG conductors in ¾-inch PVC-coated rigid metal conduit. One conductor shall ground the bascule span light housing.
The center bascule span navigation lights shall be controlled by the fully open position signal generated from the digital resolver, so that the green lights shall show when both ends of the bascule span are fully opened to 75 degrees feet or greater, and the red lights shall show when either end is not fully open. Loss of PLC output will force lift bascule span lights to red (fail-safe feature).
The navigation lights shall be controlled by a photoelectric control device mounted on the operator house roof. The photoelectric control unit shall be a completely self-contained, weatherproof device rated 1,800 VA at 120 volts and shall be provided with a time-delay feature and a deluxe, encapsulated lightning arrestor for protection against surges and lightning. The unit shall provide turn-on of the pier navigation lighting system at 1 foot-candle nominal. The unit shall be suitable for operation within a temperature range of 55 degrees Celsius below zero to 70 degrees Celsius above zero and shall have a fail-safe feature so that the lighting load remains energized in the event of component failure. The unit shall be suitable for installation in a twist lock receptacle with adapter for mounting on PVC-coated rigid metal conduit.
A three-position selector switch (OFF-PHOTO-ON) is installed on the control desk for operating the navigation lights. “red” position being a default position.
FF. Distribution/Lighting Panelboards. Distribution/Lighting panelboards, if required, shall be furnished and installed for distribution of the service lighting circuits. Existing house lighting and receptacles shall be reused. Panelboards shall be provided for at the locations as shown on the Plans.
Each distribution/lighting panelboard shall be of the dead-front type and shall be provided with quick-make, quick-break, thermal-trip, branch circuit breakers. Each breaker shall trip free of the operating handle, and the handle shall indicate the position of the breaker. Each panelboard shall be provided with a circuit breaker or lugs in the mains and with a full-sized neutral bar. All branch circuits shall be numbered, and a typewritten directory shall be provided on the inside of each door. Circuit breakers shall meet the requirements of UL Standard 489.
All distribution panelboards shall be 277/480 volts, 3 phase. 4 wire panels surface mounted at locations as shown on the plans. All lighting panelboards shall be 120/208 Volt, 3-phase, 4-wire panels surface mounted as shown on the Plans. Panelboard enclosures shall be code gauge galvanized steel with ANSI 61 light gray enamel finish. Distribution Panelboard shall be approved equal to Square-D Type NF. Lighting Panelboards shall be approved equal to Westinghouse Pow-R-Line Series, General Electric A Series, or Square-D Type NQOD and shall include a breaker/circuit location sheet.
GG. Provision for Air Conditioning. Air conditioning units have been previously installed in the operator house.
Under the item of "Electrical Work" the Contractor shall furnish and install all conduits, wiring, boxes, and other equipment required to extend power to the air conditioning units and connect thereto.
HH. Electric Heating. Either 3.6 KW or 5.0 KW Electric heaters have been previously installed in Near and Far Machinery Rooms and all four Tower Houses. The Contractor must confirm that a local three-pole disconnect switch has been installed near each heater. If not installed, the Contractor must install a local disconnect switch, in a NEMA 12 enclosure.
Under the item of "Electrical Work" the Contractor shall furnish and install all conduits, wiring, boxes, and other equipment required to extend power to the electrical heating units.
II. Provision For Outside Telephone. For telephone service in the operator and machinery houses, the Contractor shall furnish and install a 12-pair, shielded, 24 AWG telephone cable in the existing 1½-inch diameter conduit embedded in the southwest approach sidewalk. The cable shall be Anixter or Belden or Engineer and NJDOT MBEG approved equal. The existing pull box covers leading to the service point shall be removed and replaced with water-proof covers. The wire shall be terminated in the operator house. The installation shall be subject to the requirements of the Telephone Company and shall meet with its approval.
Conduit terminations shall be made in accordance with the Telephone Company’s requirements. A fish tape shall be furnished and installed in the conduit to facilitate pulling in the telephone cables. The minimum radius of conduit bends shall be 21 inches.
The Contractor shall arrange the pulling of telephone cables, and a total of twelve pair cables shall be installed. Five (5) pairs of wire shall be for functions indicated below. The remaining eight pair shall be for future use. The five outside phone lines required are:
1. Regular phone service
2. Dedicated PLC communication line
3. Dedicated SLC communication line
4. Fax machine
5. Fire Alarm Panel Line
The incoming telephone lines shall be terminated on an approved telephone terminal blocks. Each incoming line shall be protected from voltage spikes and surges utilizing spike preventive devices as recommended by the Telephone Company.
The Contractor shall extend the telephone lines to the phone in the operator’s room and machinery room, the data logging equipment, the fire alarm panel, and the fax machine unit. Each line shall terminate near the proposed phone system utilizing an approved telephone jack.
JJ. Provision for Channel Floodlights. Two weatherproof floodlight fixtures shall be furnished and installed on the exterior of each pier wall as shown on the Plans. It shall be aimed to illuminate the navigable channel at the bascule span.
Each floodlight shall be super-rough-service, halogen floodlight with multiplane lamp isolation diaphragm to absorb shock and vibration. The fixture shall accept PAR 56, sealed-beam, mogul end prong, 120-volt 500-watt lamps. The floodlight shall meet Standard 595 - Marine Outside Type ("Salt Water") Electric Fixture and Standard 844 - Electric Fixture for Hazardous Locations, Class 1, Division 2 (suitable for wet locations). The floodlight shall be furnished with copper-free, cast-aluminum housing with gray, baked-acrylic-enamel finish, heavy-duty, copper-free, aluminum mounting bracket, stainless steel exterior hardware, heat-resistant, tempered cover lens and a 500-watt, PAR 56, wide halogen floodlight. Floodlights shall be turned on/off from a light switch on the control desk manually or be controlled (on/off) through the use of a photo electric control unit. The photo control electric unit shall be the same as indicated in the Navigation Lights section hereinbefore.
KK. Provision for Water and Sewer Heat Trace. On the Southeast approach water and sewer lines have been installed with heat trace tapes and insulation.
Under the item of “Electrical Work” the Contractor shall furnish and install all conduits, wiring, boxes, circuit breakers and any other equipment required to extend power to the heat trace tape and control circuitry. Circuit breakers shall be GFCI. It shall be the responsibility of the Contractor to maintain power on the Heat Trace Lines. Temporary power, if required, shall be furnished and connected without additional cost to NJDOT.
LL. Painting. The requirements for painting machinery shall also apply to painting electrical equipment, unless otherwise specified.
1. Shop Painting: Electrical equipment such as conduits, boxes, supports, and other devices which have a galvanized finish and equipment such as motors, brakes, control desk, and control panel frames and enclosures which normally are given a factory finish need not be shop painted. All other electrical equipment shall be given one shop coat.
2. Field Painting: Electrical equipment which is normally given a factory painted finish suitable to the Engineer need not be field painted. All other electrical equipment, such as conduits, boxes, device enclosures, supporting clips and brackets, and other devices, shall be given two field coats of paint as specified under the requirements for painting machinery in Section 525. Before applying the two field coats, galvanized surfaces shall be cleaned free of all grease, oil, dirt, and foreign material and shall be etched with copper sulphate solution, after which the solution shall be applied. In lieu of etching and a coat of shop paint, the Contractor may use galvanizing primer as a first coat for galvanized surfaces. The final field coat on electrical equipment in the control house shall be of a color and type of paint to match the house interior.
MM. Spare Parts. The Contractor shall furnish the following spare parts:
1. Two packages of six fuses of each kind and size installed.
2. A full set of contacts and contact fingers for each type of limit switch. For rotary limit switches, furnish a total of eight contact assemblies. For lever actuated limit switches, furnish 1 spare complete assembly, and one lever arm and roller.
3. A set of contacts and contact fingers for each unit or fractional unit of five or less of each kind or size installed, including contactors and starters. Note: For units that do not incorporate replaceable contacts, furnish a complete unit with coil.
4. One coil for every five or less of each size relay/contactor, and motor starter installed.
5. One complete relay, timer, contactor, and starter for each unit or fractional unit of five or less of each kind and size installed.
6. Two heaters for overload relays of each size.
7. One complete vector duty squirrel cage bascule span motor identical to installed motor with encoders and overspeed switch installed. Spare motor and associated equipment shall be weather and dust-tight and shall be properly stored in the machinery room.
8. For the bascule span brakes:
a. 1 spare thrustor complete with heater and motor.
b. 1 limit switch for hand-release mechanism.
c. 1 limit switch for brake released.
d. 1 limit switch for brake set.
e. One (1) gallon of thrustor oil.
9. For the control desk:
a. 12 indicating lamps for each type and voltage
b. 1 package of 6 lamps for meters of each kind installed
c. 10 lens caps of each color
d. 1 lens for each desk unit
e. 4 selector switches of each type
f. 4 push buttons
g. 2 toggle switches
h. 1 bypass switches
10. For the PLC and SLC system:
a. 1 each type of input card and output card
b. 4 discrete input cards and 4 relay contact output cards (additional)
c. 1 PLC chassis power supply module
d. 1 Remote communication module
e. 1 CPU card
11. One single-turn digisolver
12. Any other spare-part listed in these specifications shall be included.
The Contractor shall arrange the spare parts in uniform size cartons of substantial construction, with typed and clearly varnished labels to indicate their contents, and store them where directed by the Engineer and NJDOT MBEG. Large spare parts shall be provided with moisture-proof wrapping. The Contractor shall also provide a directory of permanent type describing the parts. The directory shall state the name of each part, the manufacturer's number thereof, and the rating of the device for which the part is a spare. The spare parts shall also be marked to correspond with their respective item numbers as indicated on the elementary wiring diagram.
COMPENSATION
707.05 Method of Measurement.
Measurement will be on a lump sum basis.
707.06 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
Electrical Work Lump sum
SECTION 708 RACEWAY, CONDUCTORS, TERMINATIONS AND BOXES
708.01 DESCRIPTION.
The work shall consist of furnishing, installing, and placing in proper operating condition, acceptable to NJDOT and the Engineer, raceway, conductors, terminations and boxes, complete with all appurtenances, required for proper operation.
All conduits, boxes, wiring, cables, and other equipment required to extend the necessary circuits to and from electrical equipment and cabinets shall be furnished and installed under the item of "Raceway, Conductors, Terminations and Boxes." All internal equipment wiring shall be paid for under its respective Section, and shall conform to the requirements in this section.
It is the intent and purpose of these Specifications to cover and include all apparatus, appliances, material, plant and labor necessary to properly install, wire, connect, equip, test, adjust, and put in approved working order the respective portions of the work herein specified.
As shown on the Plans, the existing raceway, conductors, terminations, and boxes shall be abandoned or shall be disconnected, removed and salvaged in accordance with Section 539 “Demolition and Removal”.
MATERIALS
708.02 Materials and Equipment.
A. Conformance. All equipment and its installation shall conform to the requirements of the latest revision of the Standard Specifications for Movable Highway Bridges of the American Association of State Highway and Transportation Officials, except as may be otherwise provided herein.
Materials and construction shall conform to the requirements of the current National Electrical Code and to any applicable local rules and ordinances. The Contractor shall obtain any required permits and approvals of all Departments or Agencies having jurisdiction.
B. Equipment and Material Provisions. The conduit, wireway, conductors, terminations and boxes and all associated equipment and materials shall be new. All equipment, materials, and workmanship shall be first rate in every aspect of this project and shall be manufactured and erected to the satisfaction of the Engineer, and NJDOT MBEG and Maintenance Department. See Section 707, “Electrical Work” for Control System Vendor Requirements. The Contractor shall warrantee the in-service working of the raceway, conductors, terminations and boxes for one year following the date of project acceptance. If the Contractor has any objection to any feature of the equipment as designed and laid out, he must state his objection at once, in writing, to the Engineer and NJDOT MBEG; otherwise, his objection will be not be valid as an excuse for operational malfunctioning of the equipment or for defective or broken apparatus.
Each piece of electrical equipment and apparatus shall have a corrosion-resisting non-rusting metal nameplate, on which is stamped the name of the manufacturer, the rating or capacity, and all other relevant information of the equipment and/or apparatus.
All mounting hardware and all wire and cable terminals shall be vibration-proof and weather-proof.
If any changes from the Plans or these Specifications are deemed necessary by the Contractor, details of such departures and the reasons therefore shall be submitted for approval as soon as practicable before construction. No such changes shall be made without approval of the Engineer and NJDOT MBEG.
The raceway system and equipment drawings, operation, and maintenance procedures shall be included in the electrical Instruction Books and Drawing Books as described in Section 707, “Electrical Work”.
Material requirements for apparatus, equipment, and materials will be found in the articles under "Construction" in this item.
CONSTRUCTION
708.03 Construction.
A. Raceway/Wireways/Trough.
1. Conduits. All wiring shall be installed in conduit or wireways. See Section 707, “Electrical Work”, for telephone conduit and wire Specifications.
The PVC coated rigid metal conduit must be UL listed. The PVC coating must have been investigated by UL as providing the primary corrosion protection for the rigid metal conduit. Ferrous fittings for general service locations must be UL listed with PVC as the primary corrosion protection. Hazardous location fittings, prior to plastic coating must be UL listed. All conduit and fittings must be new, unused material. Applicable UL standards may include: UL 6 Standard for Safety, Fittings for Conduit and Outlet Boxes.
The conduit shall be hot dip galvanized inside and out with a clear urethane coating over hot galvanized threads.
A PVC sleeve extending one pipe diameter or two inches, whichever is less, shall be formed at every female fitting opening except unions. The inside sleeve diameter shall be matched to the outside diameter of the conduit.
The PVC coating on the outside of the conduit couplings shall have a series of longitudinal ribs 40 mils in thickness to protect the coating from tool damage during installation.
Form 8 condulets shall be supplied with plastic encapsulated stainless steel cover screws.
A green urethane coating shall be uniformly and consistently applied to the interior of all conduit and fittings. This internal coating shall be a nominal 2 mil thickness. Conduit or fittings having areas with thin or no coating shall be unacceptable.
The PVC exterior and urethane interior coatings applied to the conduit shall afford sufficient flexibility to permit field bending without cracking or flaking at temperatures above 30(F (-1(C).
All male threads on conduit, elbows, and nipples shall be protected by application of a urethane coating,
All female threads on fittings or conduit couplings shall be protected by application of a urethane coating.
Independent certified test results shall be available to confirm coating adhesion.
All conduits shall be standard weight, threaded, rigid steel conduit conforming to the requirements of ANSI Standard C80.1. All conduits shall be hot-dip galvanized, inside and out, to meet the requirements of the above standard for protective coating. Conduit couplings and fittings shall be made of malleable iron or steel, hot-dip galvanized.
All conduits to be installed in outdoor locations shall be plastic coated. Conduit fittings, including couplings, unions, elbows, expansion and deflection fittings, and other items, shall also be plastic coated. Conduits and fittings, which are to be plastic coated, shall be provided with a factory applied polyvinyl-chloride (PVC) coating. This internal coating shall be sufficiently flexible so as to permit field bending without cracking or flaking. The PVC coated, hot-dip galvanized steel conduit shall be UL labeled and listed. Conduits that meet above requirements are manufactured by Perma-Cote or Robroy, or the Engineer and NJDOT MBEG approved equal.
All hollow conduit and fittings that serve as part of the outdoor raceway shall be coated with the same exterior PVC coating and interior urethane coating. The plastic interior coating and the interior urethane coating shall be factory applied by the same manufacturer who produces the hot-dip galvanized conduit. PVC coated conduit shall be installed in accordance with the manufacturer's installation manual and shall be certified by the manufacturer or their certified representative.
Unions to connect sections of conduit that cannot be joined to each other or to boxes in the regular manner shall be of malleable iron or steel, hot-dip galvanized, PVC coated.
Conduits shall not be less than 3/4 inch in diameter. The interior surfaces shall have a smooth finish and be free of burrs or projections, which might cause injury to the cables. All conduits shall be free from blisters, cracks, or injurious defects and shall be reamed at each end after being threaded. Sections shall be connected to each other with screw couplings made up so that the ends of both conduits will butt squarely against each other inside of the coupling. Conduits shall be installed so as to be continuous and watertight between boxes or equipment. Conduits shall be protected at all times from the entrance of water or other foreign matter by being well-plugged overnight or when the work is temporarily suspended.
Conduit bends and offsets shall be made by cold bending using approved methods and equipment. The use of a pipe tee or vise for bending conduit will not be permitted. Conduit that has been crushed, or in any way deformed, shall be discarded. All bends shall be long sweep, free from kinks, and of such easy curvatures as to permit the drawing of conductors without injury. Conduit runs shall be made with as few couplings as standard lengths will permit, and the total angle of all bends between any two boxes or cabinets shall not exceed two quarter bends, unless otherwise approved by the Engineer and NJDOT MBEG. The radius of curvature of pipe bends shall not be less than eight times the inside diameter of said conduit. Long running threads will not be permitted. Pull boxes shall be used whenever necessary to facilitate the installation of the wire.
Except for installation indoors in the control house or where specifically permitted by the Engineer and NJDOT MBEG, condulets shall not be used for pulling conductors or for making turns in conduit runs or for branching conductors. Condulets, where permitted, shall consist of malleable iron castings with gasketed covers of the same material and fastened with brass cover screws. The bodies shall be hot-dip galvanized.
All new conduits shall, wherever practicable, be concealed in the walls, ceilings, or floors. Where conduits pass through the floors or walls of the houses, they shall be cast-in-place, or they shall be provided with galvanized pipe sleeves for free passage of the conduits. After the conduits are installed, the openings shall be caulked with an elastic compound and escutcheon plates provided on the interior walls, ceilings, and floors.
Conduits shall be securely clamped and supported at intervals not exceeding 5 feet in length, or other supporting lengths approved by the Engineer and NJDOT MBEG.
Conduit runs exposed on the steel structure shall be securely clamped to the steel work. The clamps, in general, shall consist of PVC coated U-bolts attached to structural steel supports bolted to the members. The minimum thickness of the structural supports shall be 3/8 inch. Supports shall be arranged so that conduits rest on top of the support and U-bolts rest on top of the conduits. The use of J-bolts to fasten structural supports or to clamp conduits will not be permitted.
All U-bolts shall be provided with medium-series lock washers and hexagonal nuts. The bolts, nuts, and washers shall be of stainless steel conforming to the requirements of the Standard Specification for Stainless and Heat-Resisting Steel Bars and Shapes, ASTM Designation A276, Type 316. U-bolts used for securing PVC coated conduits shall be manufactured from stainless steel with PVC coating.
Where conduits are to be mounted exposed on non-steel surfaces, they shall be securely clamped to the surface using bent plate pipe supports with back spacers held by not less than two bolts. The stock size for the bent steel plate supports shall be 1/4 inch thick by 2 inches wide. Back plates shall be of 3/8-inch thick steel. Supports and spacers shall be hot-dip galvanized. Bolts shall be not less than 1/2 inch in diameter and shall be of stainless steel conforming to the requirements specified for U-bolts.
At any point where a conduit crosses an expansion joint longitudinally or where movement between adjacent sections of conduit can be expected, conduit expansion fittings shall be installed. The fittings shall be bronze expansion fittings and shall be provided with flexible bonding jumpers to maintain the electrical continuity across the joints. The fittings shall permit a total conduit movement of 8 inches and shall be approved equal to the O.Z./Gedney Type AX, Spring City Type EF, or the Engineer and NJDOT MBEG approved equal.
At any point where a conduit crosses a joint laterally or where an offsetting type movement between adjacent sections of conduit can be expected, expansion and deflection fittings shall be installed. The fittings shall permit a movement of 3/4 inch from the normal in any direction. The fittings shall be the O.Z./Gedney Type DX, Spring City Type EDF, or the engineer and NJDOT MBEG approved equal.
Flexible conduits for the connections between the rigid conduit system, all motors, and limit switches shall be made with sections of PVC coated, flexible, metallic, liquidtight conduit. Each section shall not exceed 18 inches without prior approval of the Engineer and NJDOT MBEG.
All conduit embedded in concrete, insofar as possible, shall be completely encased by concrete of not less than 3 inches, measured in any direction, and shall be securely held in place during pouring and construction operations. A group of conduits terminating together shall be held in place by a template.
All conduit and fittings shall be carefully examined before being installed, and all pieces having defects shall be set aside and removed from the site. All bends shall be made with standard size conduit elbows. Bends and offsets can be made with a power bender or hickey without kinking or destroying the plastic surface or smooth bore of the conduit when approved by the Engineer and NJDOT MBEG. Conduit shall be assembled hand and tight and then using strap wrenches tightened two more turns. Wrench marks or chuck marks shall be touched up with the appropriate touch-up compound. All cuttings and threading shall be performed as recommended by the conduit manufacturer. All conduit, enclosures, and fittings shall be mechanically joined together to form a continuous electrical conductor to provide effective electrical continuity.
Ends of abandoned conduits, spare conduits, and empty conduits and stubs shall be capped during and after construction, and care shall be taken to ensure that no moisture or other matter is in or enters the conduits.
All conduits shall be pitched not less than 1 inch in 10 feet (except by special permission). Where conduits cannot be drained to pull boxes, a drain "T" with drain fitting shall be installed at the low point and drained to a 1-cubic foot dry well of broken stone. Drain fittings shall be of stainless steel and shall be capable of passing 25 cc of water per minute.
The ends of all conduits projecting into boxes and equipment enclosures shall be provided with bronze insulated grounding bushings. The insulated portion shall be of molded phenolic compound, and each fitting shall have a screw type combination lug for bonding. Insulated bushings shall be the O.Z./Gedney Type RBLG, or Engineer and NJDOT MBEG approved equal. All bushing in any box or enclosure shall be bonded together with No. 8 AWG bare copper wire.
All conduits shall be carefully cleaned both before and after installation. Upon completion of the conduit and box installation, the Contractor shall clear each conduit by snaking with a steel band, to which shall be attached an approved tube cleaner equipped with a mandrel of a diameter not less than 85% of the nominal inside diameter of the conduit and with a wire brush of the same diameter as the conduit, and shall then draw in the cables.
Both ends of each conduit run shall be provided with a brass tag having the same number stamped thereon in accordance with the conduit diagrams, and these tags shall be securely fastened to the conduit ends with No. 20 AWG brass wire.
For traffic devices and utility power conduit buried in the earth on the bridge approaches, UL listed PVC Schedule 80 conduit shall be used.
2. Wireways/Troughs. A wireway/trough shall be furnished and installed where shown on the Plans to provide for termination of conduits and to distribute the wiring to the various sections of the tower houses power and control cabinets.
A drawing showing the assembly and complete construction details of each trough shall be prepared and submitted for approval before each trough is fabricated. The Contractor shall follow the assembly and details of the trough as shown on the Plans.
The wiring trough shall be NEMA 12, constructed of No. 12 gauge sheet steel with No. 10 Gauge Flanges suitably reinforced with structural steel angels, and welded continuously at all seams and joints. It shall have a gasketed removable cover to provide access to the interior. Covers shall be secured by stainless steel screw clamps spaced no more than 8 inches apart. Wireways/troughs shall be supported every 5 feet. Details for hanging units shall be as shown on the Plans.
The wiring trough shall be painted inside and out with one coat of primer followed by one coat of white enamel on the inside surfaces and two coats of gray enamel on the outside. The finish coat shall be ANSI 61 Light Gray. Wireways shall be supported from adjacent ceilings using S.S. Hanger Rods and Angles or as shown on the Plans.
All sections of each wireway/trough shall be electrically connected to form an electrical bond and shall be tied to the Bridge Grounding System.
B. Hardware and Supports. Supports for conduits, cables, boxes, cabinets, disconnect switches, small limit switches, and other separately mounted items of electrical equipment shall be fabricated from structural steel not less than 3/8-inch thick. Clip angles and other supporting members which are fabricated from structural steel plates and shapes, and bolted to the structural members, shall be included with the structural steel. All other supporting members shall be included under the electrical work.
Structural steel brackets, boxes, and other equipment mounted on concrete surfaces shall be provided with a full neoprene gasket not less than 1/16-inch thick between the equipment and the surface of the concrete.
Expansion anchors for fastening equipment or brackets to concrete surfaces shall be wedge type anchor bolts, which shall be locked in place by an expansion wedge as the nut is tightened. All parts of the expansion anchors shall be of Type 304 stainless steel. Holes for the anchors shall be drilled to the size and depth recommended by the manufacturer using carbide tipped masonry drills.
Mounting bolts, nuts, washers, and other detail parts used for fastening boxes, disconnect switches, small limit switches, conduit clamps, cable supports, brackets, and other electrical equipment shall be of stainless steel conforming to the requirements of ASTM Designation A276, Type 316. Bolt heads and nuts shall be hexagonal and shall be provided with medium-series lock washers. Bolts smaller than ½-inch in diameter shall not be used, except as may be necessary to fit the mounting holes in small limit switches, boxes, and similar standard devices.
Usage of beam clamps for supporting conduits, boxes, or other equipment shall not be acceptable without prior approval of the Engineer and NJDOT MBEG and NJDOT Maintenance Department
Preformed stainless steel metal framing channels, will be acceptable for mounting or supporting electrical equipment, conduits, or boxes. Prior to installation the Contractor shall submit to the Engineer and NJDOT MBEG for review, his/her design, and shall not install the channels without approval.
C. Wiring and Cables. Except where otherwise noted, wiring in conduits shall be single-conductor.
All wires and their insulation and covering shall be of a nationally recognized brand, acceptable to the Engineer and NJDOT MBEG, and shall have marks always used on the particular brand for identifying it.
All wiring and cables shall conform to the requirements of NEMA Publication No. WC70, latest publication. Before wire and cable orders are placed with any manufacturer, the Contractor shall submit for approval typical published test data for the type of insulation proposed, showing that it meets the requirements of NEMA Publication No. WC70. All materials used to fabricate insulated wiring and cables shall be certified to be from stock not more than 1 year old.
All conductors shall be of stranded copper large enough to carry safely the maximum currents required without injurious heating or serious voltage drop. Conductors for all motors and power circuits shall not be smaller than No. 12 AWG, except as approved for control panel and desk wiring or for lighting fixtures. All conductors shall be soft-annealed copper wire conforming to the requirements of NEMA Publication No. WC70. All conductors shall have Class B concentric stranding, except for conductors in flexible cables.
The insulation shall be a chemically cross-linked, polyethylene compound conforming to the requirements of Part 3.6 of NEMA Publication No. WC70. The thickness of insulation shall be that required for 600 volts rated circuit voltage listed under the third Column of Table 3-3. The conductors shall be of the XHHW type.
Equipment ground conductors shall be bare, stranded, coated copper conforming to the requirements of NEMA Publication No. WC70, Part 2.
The conductor sizes and number of wires shown on the Plans are the minimum permissible. The Contractor shall provide wiring and cables of sufficient size and number as may be required for the installation in accordance with the wiring diagrams or his approved working drawings. In each conduit containing four or more conductors, at least one spare wire for each 4 conductors shall be provided. Conduits containing conductors No. 8 AWG or larger do not require spare conductors.
Wiring shall not be installed in any conduit before all joints are made up tightly and the conduits rigidly secured in place. The drawing of cables into conduits shall be done without any damage to the wires or their insulation or covering. No lubricant of any kind shall be used for the pulling of wires, unless specifically authorized by the Engineer and NJDOT MBEG. Sufficient slack shall be left in all cables to permit proper connections in boxes, cabinets, and enclosures.
Both ends of every single length of conductor shall be permanently and clearly tagged in accordance with the same numbers or designations appearing on the approved wiring diagrams.
Conductors inside terminal boxes, the control desk, and control panels shall be neatly formed into cables and laced with approved cable ties, with the individual conductors leaving the cable at their respective terminal points. These conductors shall be looped to allow not less than 3 inches of free conductor when disconnected. The formed cables shall be held securely away from the terminals and from contact with the enclosure by means of approved insulating supports.
All outgoing wires, No. 8 AWG or smaller, in the control desk and control panels and in terminal boxes shall be connected to terminal blocks of molded phenolic compound. Terminals shall be of screw type suitable for use with solderless, ring tongue, wire connectors. Connectors, which extend beyond the ends of terminal block barriers, shall be furnished with an insulating sleeve covering the metal part of the connector. Taping of extended terminals will not be permitted. Each block shall contain environmental contacts for Conductors No. 8 AWG or smaller and shall be the one piece terminal block series 200 as manufactured by Buchanan.
Each terminal of all terminal blocks shall be permanently marked to show the same number or designation as appears on the wire connected thereto.
Splicing of wires will not be permitted, except for wiring to service lighting fixtures and receptacles. Wherever it becomes necessary to joint or branch conductors, terminal blocks shall be used, and wires shall be clearly tagged.
D. Boxes. All boxes shall be sized, at a minimum, as per NEC Article 314. All boxes that contain both power and control conductors shall be provided with dividers. All outside location boxes not buried shall be stainless steel, NEMA 4X, 14-gauge, Type 316, and all buried boxes shall be precast polymer concrete UL tier 10 listed.
1. Precast Polymer Concrete. All approach pull and junction boxes mounted underground in the earth shall be precast polymer concrete with the cover flush with the ground at each location, and shall be provided with heavy-duty covers held with stainless steel hardware. The boxes shall be UL Tier 10 Listed, ANSI/SCTE 77 Tier 15 compliant, stackable PG box with heavy-duty HA covers and shall be manufactured by Quazite or Engineer and NJDOT MBEG approved equal.
All components of assembly (box and cover) shall be manufactured using matched surface tooling. All covers are required to have a minimum coefficient of friction of 0.50 in accordance with ASTM C1028. Independent third party verification or test reports stamped by a registered Professional Engineer certifying that all test provisions of this specification have been met are required with each submittal.
No box shall be provided with openings for more conduits or cables than actually enter it. The box and conduit entries shall be water and dirt tight. All boxes shall meet NJDOT requirements and shall be similar to NJDOT Approval Number EE-1236-94
2. Stainless Steel. Junction and terminal boxes and cabinets not indicated on the Plans as Polymer Concrete shall be NEMA 4X, 14-gauge, Type 316 stainless steel enclosures with hinged, 14-gauge stainless steel doors supported by a continuous stainless steel hinge with removable pin. Seams shall be continuously welded and ground smooth. Each enclosure shall be provided with stainless steel fast operating door clamp assemblies and oil-resistant gasket to insure a liquidtight seal. Boxes and cabinets shall be Bulletin A51S and A4S with clamp assemblies A-L23SS as manufactured by Hoffman Engineering Company, or equivalent as manufactured by Henessey or Weigmann or Engineer and NJDOT MBEG approved equal. Additional stainless steel box construction and sizes shall be as indicated on the Plans.
Surface mounted interior and exterior boxes shall be provided with external mounting lugs. No box shall be drilled for more conduits or cables than actually enter it. Exterior boxes shall be provided with ( inch combination drain and breather fittings.
Terminal boxes shall be of sufficient size to provide ample room for the terminal blocks and interior wiring, and for the installation of conduit terminations. Interior mounting buttons with tapped holes shall be provided for mounting the terminal blocks. Terminal blocks shall be provided in each terminal box for the connection of all conductors including spare conductors entering the box plus at least ten percent spare terminals. All terminal blocks and boards shall be mounted on suitable straps or structural steel brackets in such a manner as to permit routing the conductors behind the terminal blocks. Terminal blocks shall be one-piece blocks suitable for use in highly corrosive atmospheres and shall conform to the requirements hereinbefore specified.
Power terminal blocks for wires No. 8 AWG and larger shall be included in each terminal box as required for such conductors. Each terminal shall be a one-piece power distribution block of molded phenolic compound and shall conform to the requirements hereinbefore specified. A safety cover of insulating material shall be provided for each block.
E. Testing and Installation Guidelines. All testing and installation for the “Raceway, Conductors, Terminations and Boxes” and all associated equipment shall be paid for under this Section. The Contractor shall follow the testing and installation guidelines in paragraphs A through I in Section 707, “Electrical Work”.
COMPENSATION
708.04 Method of Measurement.
Measurement will be on a lump sum basis.
708.05 Basis of Payment.
Payment will be made under.
Pay Item Pay Unit
RACEWAY, CONDUCTORS, TERMINATIONS AND BOXEs lump sum
SECTION 709 - GROUNDING AND BONDING SYSTEM
709.01 DESCRIPTION.
The work shall consist of furnishing, installing, and placing in proper operating condition, acceptable to NJDOT and the Engineer, the grounding and bonding system, complete with all appurtenances, required for proper operation.
All conduits, boxes, wiring, cables, and other equipment required to extend the necessary circuits to and from the grounding and bonding system shall be furnished and installed under the item of "Raceway, Conductors, Terminations and Boxes." All grounding and bonding system wiring shall be paid for under this Section, and shall conform to the requirements in "Raceway, Conductors, Terminations, and Boxes.”
It is the intent and purpose of these Specifications to cover and include all apparatus, appliances, material, plant and labor necessary to properly install, wire, connect, equip, test, adjust, and put in approved working order the respective portions of the work herein specified.
MATERIALS
709.02 Materials and Equipment.
A. Conformance. All equipment and its installation shall conform to the requirements of the latest revision of the Standard Specifications for Movable Highway Bridges of the American Association of State Highway and Transportation Officials, except as may be otherwise provided herein.
Materials and construction shall conform to the requirements of the current National Electrical Code and to any applicable local rules and ordinances. The Contractor shall obtain any required permits and approvals of all Departments or Agencies having jurisdiction.
B. Equipment and Material Provisions. The grounding and bonding system, and all associated equipment and materials shall be new. All equipment, materials, and workmanship shall be first-rate in every aspect of this project and shall be manufactured and erected to the satisfaction of the Engineer, and NJDOT MBEG and Maintenance Department. See Section 707, “Electrical Work” for Control System Vendor Requirements. The Contractor shall warrantee the in-service working of the lightning protection and grounding and bonding systems, and associated equipment for one year following the date of project acceptance. If the Contractor has any objection to any feature of the equipment as designed and laid out, he must state his objection at once, in writing, to the Engineer and NJDOT MBEG; otherwise, his objection will be not be valid as an excuse for operational malfunctioning of the equipment or for defective or broken apparatus.
Each piece of electrical equipment and apparatus shall have a corrosion-resisting non-rusting metal nameplate, on which is stamped the name of the manufacturer, the rating or capacity, and all other relevant information of the equipment and/or apparatus.
All mounting hardware and all wire and cable terminals shall be vibration-proof and weather-proof.
If any changes from the Plans or these Specifications are deemed necessary by the Contractor, details of such departures and the reasons therefore shall be submitted for approval as soon as practicable before construction. No such changes shall be made without approval of the Engineer and NJDOT MBEG.
The grounding and bonding system and equipment drawings, operation, and maintenance procedures shall be included in the electrical Instruction Books and Drawing Books as described in Section 707, “Electrical Work”.
Material requirements for apparatus, equipment, and materials will be found in the articles under "Construction" in this item.
CONSTRUCTION
709.03 Construction.
A. Grounding and Bonding. The bridge steel work on each side of the channel and the towers shall be solidly bonded and grounded to ground rods installed in the piers and at the towers, using No. 4/0 AWG bare, stranded, tinned copper cable.
Exothermical welds shall be used to connect ground conductors to ground rods and ground bus bars The resistance to ground shall be no less than 5 ohms. Exothermic welds shall be molded fusion, type as required, as manufactured by Cadweld, Thermoweld, Metalweld, or approved equal.
Traffic signal poles, warning gates, barrier gates, standby generator neutral conductor and engine block, grounding conductors in conduits, navigation lighting units, all metal framing, cases, and enclosures of the electrical equipment, such as motors, control desk, control cabinets, boxes, and all other metal parts in the proximity of current carrying conductors or equipment shall be bonded together and solidly connected to a ground bus in the switchboard room, and another ground bus in the generator room. All electrical equipment ground busswork shall be connected to the closest main ground bus.
The utility service neutral conductor, the bridge grounding conductor and grounding electrode conductors shall all be exothermically welded together.
Grounding system terminals shall be solderless lugs and shall be secured by means of hexagonal-head, copper plated, steel machine bolts with lock washers or lock nuts. Ground system conductors shall be continuous non-spliced connections between terminal lugs. Paint, rust, and scale shall be removed over the contact area. All connections shall be made up as tightly as possible, and any bare metal or paint undercoat remaining exposed shall be spot painted to restore the surface with the same coating and number of coats as applied to the adjacent metal. Bolted connections shall be restricted to removable items (e.g., motors).
Equipment ground conductors shall be seven-strand, soft-drawn, bare, tinned copper wire conforming to ASTM B33 and not smaller than No. 8 AWG.
Ground rods shall be made of copper or copper-clad steel and shall not be less than 1 inch in diameter and 10-feet in length unless otherwise specified. A permanent, exothermic weld connection to the permanent steel sheet piling at the bridge towers is an acceptable grounding means at the indicated locations. If the steel sheet piling is not accessible, ground rods shall be used as grounding electrodes. Insulated green ground conductor shall be used when exposed to wet environment.
A minimum of two ground rods per pier, west towers and east towers shall be installed to establish the bridge grounding system. The utility service neutral conductor shall be grounded in accordance with the utility company’s standard requirements.
Upon completion of installation of electrical grounding and bonding system’s test ground resistance with ground resistance tester. Where tests show resistance-to-ground is over five (5) ohms, reduce resistance to five (5) ohms or less, by driving additional grounding electrodes. The test shall be repeated to demonstrate compliance.
B. Testing and Installation Guidelines. All testing and installation for the “Grounding Systems” and all associated equipment shall be paid for under this Section. The Contractor shall follow the testing and installation guidelines in paragraphs A through I in Section 707, “Electrical Work”, and all applicable paragraphs under this Section.
COMPENSATION
709.04 Method of Measurement.
Measurement will be on a lump sum basis.
709.05 Basis of Payment.
Payment will be made under.
Pay Item Pay Unit
GROUNDING AND BONDING SYSTEm lump sum
SECTION 710 - POWER DISTRIBUTION AND CONTROL CABINET
710.01 DESCRIPTION.
The work shall consist of furnishing, installing, and placing in proper operating condition, acceptable to NJDOT MBEG and the Engineer, the power distribution and control cabinet, complete with all appurtenances, required for proper operation.
All conduits, boxes, wiring, cables, and other equipment required to extend the necessary circuits to and from the power distribution and control cabinet shall be furnished and installed under the item of "Raceway, Conductors, Terminations and Boxes." All internal control desk wiring shall be paid for under this Section, and shall conform to the requirements in "Raceway, Conductors, Terminations, and Boxes.
It is the intent and purpose of these Specifications to cover and include all apparatus, appliances, material, plant and labor necessary to properly install, wire, connect, equip, test, adjust, and put in approved working order the respective portions of the work herein specified.
Existing power distribution and control cabinets shall be disconnected, removed, and salvaged in accordance with Section 539 “Electrical Demolition and Removal”.
MATERIALS
710.02 Materials and Equipment.
A. Conformance. All equipment and its installation shall conform to the requirements of the latest revision of the Standard Specifications for Movable Highway Bridges of the American Association of State Highway and Transportation Officials, except as may be otherwise provided herein.
Materials and construction shall conform to the requirements of the current National Electrical Code and to any applicable local rules and ordinances. The Contractor shall obtain any required permits and approvals of all Departments or Agencies having jurisdiction.
B. Equipment and Material Provisions. All power distribution and control cabinet equipment and materials shall be new. All equipment, materials, and workmanship shall be first-rate in every aspect of this project and shall be manufactured and installed to the satisfaction of the Engineer, and NJDOT MBEG and Maintenance Department. See Section 707, “Electrical Work” for Control System Vendor Requirements. The Contractor shall warrantee the in-service working of the power distribution and control cabinet for one year following the date of project acceptance. If the Contractor has any objection to any feature of the equipment as designed and laid out, the Contractor must state the objection at once, in writing, to the Engineer and NJDOT MBEG; otherwise, the Contractor’s objection will be not be valid as an excuse for operational malfunctioning of the equipment or for defective or broken apparatus.
Each piece of electrical equipment and apparatus shall have a corrosion-resisting non-rusting metal nameplate, on which is stamped the name of the manufacturer, the rating or capacity, and all other relevant information of the equipment and/or apparatus.
All mounting hardware and all wire and cable terminals shall be vibration-proof and weather-proof.
If any changes from the Plans or these Specifications are deemed necessary by the Contractor, details of such departures and the reasons therefore shall be submitted for approval as soon as practicable before construction. No such changes shall be made without approval of the Engineer and NJDOT MBEG.
The power distribution and control cabinet equipment drawings, operation, and maintenance procedures shall be included in the electrical Instruction Books and Drawing Books as described in Section 707, “Electrical Work”.
Material requirements for apparatus, equipment, and materials will be found in the articles under "Construction" in this item.
CONSTRUCTION
710.03 Construction.
A. The Contractor shall field verify all dimensions of equipment and cabinets to be installed. If relocation is necessary, it will be at no cost to the State.
B. Cabinet. Control panels enclosed in free-standing cabinets shall be furnished and installed where shown on the Plans. All circuit breakers, switches, contactors, starters, relays, regulating equipment, and other apparatus for control of the bascule span and its auxiliaries shall be mounted on these enclosed panels. The arrangement and line-up of the power distribution and control cabinet shall be as shown on the Plans.
All equipment in the cabinet shall be mounted on painted sheet-steel bases, and each device shall be front-connected, front-wired, and removable from the front. The equipment in the cabinet shall be arranged for ease of access and for safety and convenience of operation. Special care shall be taken to obtain a systematic and neat arrangement of the equipment. Each device shall be suitably named and plainly marked by a laminated nameplate mounted near the device on the panel. Each nameplate shall show an approved descriptive title for the apparatus, together with the device designation appearing on the schematic wiring diagrams.
The cabinet shall be a NEMA Type 12 enclosure constructed of No. 12 gauge sheet-steel and shall be reinforced with steel angles or channels so as to provide a rigid, free-standing structure. The cabinet shall be provided with stainless steel continuous hinged doors on the front of each panel section. Door panels shall be gasketed and shall be provided with three-point, vault-type latches. For this cabinet with two (2) doors, the center support shall be removable. Ventilating louvers shall be provided at the front of each enclosure. All hardware shall be corrosion resistant. Thermostatically controlled strip heaters shall be provided in each cabinet to prevent build-up of excess moisture. Each panel shall be provided with suitable interior fluorescent light fixtures operated from a door operated switch and a duplex receptacle.
The cabinet shall permit mounting in the available space along the railing in the switchboard room of the SE house or wall mount type in the SW and NE houses. If the final cabinet dimensions, as established by the manufacturer, should necessitate rearrangement or modification of the equipment in order to fit in the available space, such rearrangement or modifications shall be made and at no extra cost. The final arrangement of all equipment in all houses shall be subject to the approval of the Engineer and NJDOT MBEG.
The enclosure and all metal reinforcing shall be painted inside with two coats and outside with three coats, consisting of one coat of primer followed by one coat of white enamel on the inside surfaces and two coats of gray enamel outside. The finish coat shall be ANSI 61 light gray enamel.
All contactors, relays, and other devices shall be of required current-carrying and interrupting capacity. All apparatus shall be of substantial construction and shall conform to the requirements of NEMA Standards Publications ICS 1 and 2, 1978, for industrial control devices.
All internal wiring between devices and/or terminal blocks shall be flame-retardant, ethylene-propylene insulated, switchboard wire, Type SIS. Control conductors shall be stranded copper not smaller than No. 12 American Wire Gauge.
For the assembled control panel, all outgoing wire, No. 8 AWG or smaller, shall be connected to terminal blocks installed at the sides of the cabinet. The control panels shall also provide sufficient extra terminals to allow connection of all wires coming from limit switches and other devices that connect to the bridge control desk and other locations as required, even though these wires may not connect to apparatus on the control panels. Spare terminals totaling at least 10 percent of those actually used shall be provided. Each terminal shall be identified per wire number shown on the Contractor's schematic wiring diagrams. All spare conductors entering any cabinet, terminal box shall be terminated on a terminal block.
All panel wiring shall be arranged systematically so that circuits can be readily traced. The internal cabinet wiring shall be installed in a network of troughs consisting of horizontal and vertical sections securely bolted to the panels. The troughs shall be fabricated from heavy-duty Noryl plastic shaped into a channel cross-section. After installation of the wiring, an insulated, flanged cover shall be snapped over the open side of each trough section. Each floor-mounted cabinet/panel shall be provided with 1/8 inch neoprene, Fabreeka type gasket between the cabinet and floor.
C. Equipment Labels. All cabinets shall have a label affixed to each unit. The label shall be similar in construction to the nameplates. Each label shall be of suitable size and letter characteristics. Text shall indicate name/function of each item. Labels shall be securely attached using stainless steel screws. The Contractor shall submit to the Engineer and NJDOT MBEG for review, all signs, with sizes, location and text.
D. Power and Control Apparatus. Control apparatus shall conform to the applicable requirements of NEMA Publication No. ICS, latest revision, Industrial Control and Systems, rated as shown on the Plans and/or as specified in Section 707 – “ELECTRICAL WORK” – subsection W – “CONTROL APPARATUS AND MISCELLANEOUS EQUIPMENT”.
E. Power Distribution / Automatic Transfer Switch. The feeders from the utility power and standby power source shall be connected to a power distribution system through main circuit breakers and an automatic transfer switch. The utility power supply is to be the preferred source of bridge power. In the event of failure of the preferred source, the automatic transfer switch shall operate automatically to start and connect the standby engine-generator to the power distribution system. Sub-feeders protected by circuit breakers shall distribute power from the main breaker to all motors and controls for operation of the bridge, auxiliaries, climate control systems, and lighting systems.
F. Testing and Installation Guidelines. All testing and installation for the “Power Distribution and Control Cabinet” and all associated equipment shall be paid for under this Section. The Contractor shall follow the testing and installation guidelines in paragraphs A through I in Section 707, “Electrical Work”.
COMPENSATION
710.04 Method of Measurement.
Measurement will be on a lump sum basis.
710.05 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
POWER DISTRIBUTION AND CONTROL CABINET LUMP SUM
SECTION 711 - TRAFFIC WARNING GATES AND BARRIER GATES
711.01 DESCRIPTION.
The work shall consist of furnishing, installing, and placing in proper operating condition, acceptable to NJDOT and consultant, the Traffic Warning Gates and Barrier Gates, complete with all appurtenances, including anchor bolts, required for proper operation. The Traffic Warning gates shall be VW-5 as manufactured by B&B Roadway or equal if, acceptable to NJDOT MBEG, the Engineer, and NJDOT Maintenance Department. The Barrier Gates shall be VR-7 as manufactured by B&B Roadway or equal if, acceptable to NJDOT MBEG, the Engineer and NJDOT Maintenance Department.
All apparatus for controlling the operation of the Traffic Warning and Barrier Gates and all conduits, boxes, wiring, cables, and other equipment required to extend the necessary circuits from the operator’s house to the gates shall be furnished and installed under the item of "Electrical Work." Platforms, brackets, and foundations for mounting the Traffic Warning and Barrier Gates are as shown on the structure plans and shall be paid for under the Pay Item “Platforms for Barrier Gates and WARNING Gates”.
It is the intent and purpose of these Specifications to cover and include all apparatus, appliances, material, plant and labor necessary to properly install, wire, connect, equip, test, adjust, and put in approved working order the respective portions of the work herein specified.
Existing Traffic Warning and Barrier Gates shall be disconnected, removed, and salvaged in accordance with Section 539 - “Demolition and Removal”.
The existing Barrier Gates shall remain in service until replacement items have been installed. The existing Traffic Warning Gates shall remain in service until replacement items have been installed and are operational. Traffic Warning gate arm lengths shall be different during construction stages. The arm lengths shall be as shown on the Traffic Warning and Barrier Gates drawings.
MATERIALS
711.02 Materials.
A. Conformance. All equipment and its installation shall conform to the requirements of the latest revision of the Standard Specifications for Movable Highway Bridges of the American Association of State Highway and Transportation Officials, except as may be otherwise provided herein.
Materials and construction shall conform to the requirements of the current National Electrical Code and to any applicable local rules and ordinances. The Contractor shall obtain any required permits and approvals of all Departments or Agencies having jurisdiction.
B. Equipment and Material Provisions. All Traffic Warning and Barrier Gates equipment and materials shall be new. All equipment, materials, and workmanship shall be first rate in every particular aspect and shall be manufactured and installed to the satisfaction of the Engineer, NJDOT MBEG and Maintenance Department. The Contractor shall warrantee the in-service working of the Traffic Warning and Barrier Gates for one year following the date of project acceptance. If the Contractor has any objection to any feature of the equipment as designed and laid out, he must state his objection at once, in writing, to the Engineer and NJDOT MBEG; otherwise, his objection will be not be valid as an excuse for operational malfunctioning of the equipment or for defective or broken apparatus.
Each piece of electrical equipment and apparatus shall have a corrosion-resisting non-rusting metal nameplate, on which is stamped the name of the manufacturer, the rating or capacity, and all other relevant information of the equipment and/or apparatus.
All metal parts of the installation shall be of corrosion-resisting, non-rusting material such as aluminum, bronze, or stainless steel. Proposed material shall be approved by the Engineer and NJDOT MBEG prior to construction. Malleable iron, or steel with a hot-dip galvanized finish, shall be used where specified herein or permitted by the Engineer and NJDOT MBEG. Structural steel shall conform to the requirements given under this Contract.
All mounting hardware and all wire and cable terminals shall be vibration-proof and weather-proof.
If any changes from the Plans or these Specifications are deemed necessary by the Contractor, details of such departures and the reasons therefore shall be submitted for approval as soon as practicable before construction. No such changes shall be made without approval of the Engineer and NJDOT MBEG.
Material requirements for apparatus, equipment, and materials will be found in the articles under "Construction" in this item.
CONSTRUCTION
711.03 Construction.
A. Working Drawings and Samples. The Contractor shall prepare and submit for review, within 30 days after the award of the Contract, the following working drawings executed in accordance with the provisions of the Contract:
1. Assembly drawings of the barrier gate stands locating and identifying all apparatus and equipment inside.
2. Arrangement and complete construction details of the Traffic Warning and Barrier Gates operating machinery.
3. Detail drawings showing the construction of gate arms, including provisions for guying and bracing.
4. Traffic Warning and Barrier Gates construction details.
5. Wiring diagrams of all Traffic Warning and Barrier Gates electrical equipment, including development diagrams for the gate limit switches. All wires shall be suitably numbered.
6. Certified dimension prints of apparatus shall state in the certification the name of the job, the application of the apparatus, device designation, number required, right-hand or left-hand assembly, electrical rating, number of poles or contacts, material, finish, and any other pertinent data to show that the apparatus meets the specified requirements.
The preparation and submission of the electrical working drawings shall meet the provisions for Shop Drawings given in Section 105.04 of the New Jersey Standard Specifications.
The Contractor shall also furnish eight copies of complete operation and maintenance and servicing data for the Traffic Warning and Barrier Gates. The first copy shall be submitted for approval by NJDOT MBEG before all copies are made. This data shall be incorporated in the instruction books provided under the item of Section 707, “Electrical Work”.
B. Inspection and Testing. The Contractor shall arrange for and provide all necessary field tests, as directed by the Engineer and NJDOT MBEG, to demonstrate that the Traffic Warning and Barrier Gates are in proper working order and in accordance with the Plans and Specifications. Should the tests show that any piece of equipment or apparatus, in the judgment of the Engineer and NJDOT MBEG, is defective or functions improperly, such adjustments or replacements shall be made by the Contractor as to make the installation satisfactory to the Engineer and NJDOT MBEG and at no extra cost to the State of New Jersey.
During the field/acceptance testing period, the Contractor shall arrange to have at the site the barrier gate manufacturer representative. This representative shall be capable of supervising all adjustments to the equipment; of locating faults or defects and correcting them if possible; and of obtaining from the manufacturer, without delay, new parts or replacements for apparatus, which, in the opinion of the Engineer and NJDOT MBEG, does not perform satisfactorily.
Field operational testing of the gates shall demonstrate the balance condition of the gate arms such that a stationery arm remains in the same position when the brake is released, proper manual operation and operational features specified herein.
C. Traffic Warning Gates. Two (2) motor operated Traffic Warning Gates shall be furnished and installed on the approaches where shown on the plans. The Traffic Warning Gates shall be B&B Roadway VW-5 or Engineer and NJDOT MBEG approved equal.
Each gate shall have an arm of the length shown on the Plans, which shall open through an angle of 90 degrees from the horizontal to the vertical. Each gate shall have a welded steel stand arranged to provide a weathertight housing for the motor, disconnect switch, gear train, limit switch, and fuses for warning lights. The gate stands shall be hot-dip galvanized after fabrication. The transmission gearing for each gate shall be enclosed. Weathertight, gasketed doors shall be provided for access to the operating equipment. A hand crank shall be provided for manual operation of each gate and stored inside the gate housing.
The gate arms shall be made of double rail, 4” square, 6005-T5 aluminum extruded tubing. Each gate arm shall be adequately braced transverse to its motion to resist wind loads and to reduce whipping and shall be guyed to prevent sagging. Each assembled gate arm shall be designed for a 75 miles-per-hour wind load. Stainless steel truss cables and a damping type bumper rod with compression spring shall be provided near the end of each gate arm to stop the travel at the closed position without undue shock. Gate arms shall be equipped with guy wires configured in such a way that they do not project beyond the gate housing into the sidewalk when the gate is in the vertical position.
All bolts, screws, or other fastenings used in the gate arm assembly and for connection to the gate stand shall be of stainless steel.
The number of warning lights on the gate arms shall be as shown on the wiring diagrams. Each warning light shall be a weatherproof, two-way, cast-aluminum unit with red Fresnel lenses, front and back. The lights shall be interconnected and grounded with four-conductor portable cord using watertight connectors at the fixtures. A 12 volt, clear traffic LED signal lamp shall be installed in each fixture. The lights shall be connected so that adjacent units will flash alternately. Fuses for the warning lights shall be 5-ampere midget cartridge fuses installed in molded rubber connection kits. Each gate housing shall include a 120/12V solid state flasher.
An 8-circuit limit switch shall be provided in each gate operated by the gate mechanism. Each limit switch shall be a rotary, cam-type, switch; and it shall be gear driven from the transmission. The contacts shall be quick-break with silver alloy buttons. The limit switch shaft shall be stainless steel, and cams shall be secured thereto with set screws. A hand crank limit switch with 2 NO and 2 NC contacts shall be provided to prevent electrical operation of gates while hand cranking.
The motor for each warning gate shall be sized as shown on the Plans and furnished as part of the gate by the gate manufacturer. Each motor shall be a totally-enclosed, 460-volt, three-phase, 60-cycle, ball-bearing induction motor and shall be capable of withstanding instant reversal when running at full speed. Each motor and gear train shall be capable of opening and closing the gate in about 13 seconds. A motor-mounted, spring-set, magnetically-released, disc brake shall be provided for stopping and holding the mechanism. A watertight disconnect switch shall be provided to permit disconnecting the motor and brake from the incoming power.
All internal wiring for each gate shall be brought to numbered terminal blocks inside the housing for the connection of external circuits.
Each gate arm shall be striped on both faces with alternate red and white reflectorized stripes 6 inches wide measured parallel to the edge of the gate arm. The stripes shall slope downward at an angle of 45 degrees toward the center line of the roadway. The gate stands shall be painted in accordance with the requirements hereinbefore specified under the item of "Bridge Electrical" - Painting. Gate arm channels and supports shall be galvanized or painted in accordance with the requirements specified herein for painting structural steel.
Each warning gate shall be bolted to its concrete base as indicated on the Plans. In erecting the gates, the arms shall be carefully attached to the supporting members so as to make a rigid connection. The arms shall be counterbalanced and the limit switches and crank arms adjusted so that the arms are stopped in a truly vertical or horizontal position, within 1 degree. All gate anchor bolts and mounting templates shall be furnished by the gate manufacturer.
All components of the gate operating mechanism shall be housed in a welded steel housing, hot-dip galvanized inside and out after fabrication. Doors shall be provided on the roadway and sidewalk side of the housing, large enough for convenient removal of the largest component of the operating mechanism. Doors shall be provided with neoprene gaskets, stainless steel swing bolts and catches, and safety interlock switches.
Each gate housing shall be equipped with a thermostatically controlled heater; switched service light; and duplex, 15-ampere, 120-volt, Specification Grade GFI receptacle. A 15-ampere circuit breaker shall protect the above units and be mounted in the gate housing. Provisions for hand cranking, including crank, and limit switch, shall be furnished.
Each warning gate shall be furnished with lockable doors and chain-attached bronze padlocks. All locks shall be keyed alike, identical to the barrier gate housing locks.
D. Positive Resistance Barrier Gates. Four (4) motor operated, positive resistance (vertical) Barrier Gates shall be furnished and installed on the approaches where shown on the Plans. The Barrier Gates shall be B&B Roadway VR-7 or Engineer and NJDOT MBEG approved equal. The double arms shall be arranged to lock together at the tips of the arms to provide a resistance barrier to traffic. Location of the male-female end locking device shall be as shown on the Plans.
The operating mechanism shall move the gate arm through 90 degrees of travel in about 16 seconds against a wind load of 15 PSF. The motor for each barrier gate arm shall be a 460-volt, 60-cycle, three-phase, high-slip, NEMA Design C, ball-bearing, totally enclosed, non-ventilated (TENV), weatherproof, squirrel-cage type rated for not less than 2-horsepower. The barrier gate arm shall be held at each end of travel by a mechanically set, electrically released, motor mounted brake. The drive mechanism and motor brake shall be capable of holding the gate arm vertical against a wind load of 30 PSF.
Gear reducers for driving the arms shall be totally enclosed in oil-tight steel housings and shall be automatically lubricated. Oil sight gauges shall be provided. All driving components shall be proportioned so that the maximum stress in any part does not exceed 50 percent of the yield point of the material at the stalled torque of the motor.
The transmission shall be a fully enclosed, all gear, direct drive unit running in an oil bath. The drive train shall not use belts or chains and shall be connected to the arm shaft with an adjustable connecting rod having self-aligning ball ends. The connecting rod material shall be ASTM A311 Class B high strength, fatigue resistant steel.
A 10-circuit rotary cam limit switch with adjustable cams, driven by the gear train, shall be provided for control of the barrier gate and for interlocking. A motor disconnect switch shall be installed in the barrier gate housing. Reversing contactors shall be mounted on the bridge control panels under the item of “Electrical Work”.
Provisions shall be made for hand operation, and a hand crank shall be furnished for each barrier gate. Insertion of the crank shall release the brake and make the electrical components inoperative. The hand crank limit switch shall contain two N.O. contacts.
All conductors shall be brought to numbered terminal blocks for connection of incoming wiring.
For each barrier gate, all components of the operating mechanism shall be housed in a welded steel housing having a minimum plate thickness of .375 inches. The entire housing shall be hot-dip galvanized, inside and out, after fabrication. All external fasteners 0.5” and above shall be stainless steel. Arm shaft openings shall incorporate “O” rings.
Doors shall be provided in the roadway side and back side of the housing, large enough for convenient removal of the largest component of the operating mechanism. Doors shall be equipped with neoprene gaskets, silicon bronze hinges with stainless steel pins, stainless steel catches and bolts, safety interlock switches with two normally open and two normally closed contacts, and chain-attached bronze padlocks with common keys. The doors shall be equipped with a DPDT door safety switch. Opening of a housing door shall disable the electrical motor and controls, and cancel any barrier gate operation and group operation, as described in the “Electrical Work” item.
An opening shall be provided for inserting the hand crank. There shall be a minimum of three (3) feet around the hand crank to provide an adequate operation area. Insertion of the crank shall release the brake and make the electrical controls inoperative. Safety interlock switches with two normally open and two normally closed contacts shall be provided. An easily accessible, but secure hand crank insertion shall automatically cancel any group operation.
Arm supports and counterweights shall be carried on a horizontal trunnion supported on trunnion bearings mounted on the housing.
Each barrier gate housing shall be equipped with a thermostatically controlled heater, switched service light, duplex, 15-ampere, 120-volt, specification grade GFCI receptacle. A 175-watt, 15-ampere, 120-volt circuit breaker shall be installed to protect the above units.
The barrier gate arm design shall be double rail aluminum tube. The double rail barrier gate arms shall be fabricated of extruded, round aluminum tube, manufactured from high-strength, 6061-T6, aluminum tubes as shown on the Plans. Length of the barrier gate arms shall be as shown on the Plans and shall be fabricated in accordance with requirements of the American Welding Society Structural Welding Code – Aluminum D1.2. The arms shall be so fabricated that the out-of-straight of any tube from end to end shall not exceed ¾ inch. A bumper rod with compression spring shall be provided to stop the travel at the lowered position without undue shock. The bumper shall be of a heavy-duty design.
The Barrier Gates shall be capable of absorbing the energy of a 5,000-pound vehicle traveling up to 50 mph. The barrier gate shall utilize energy absorption cables to assist in diffusing the kinetic energy of an impacting vehicle. The barrier gate arms shall have three ½ inch diameter minimum energy absorption cables, one inside each tube and a third hung along the centerline of the arm. Cables shall be 6x25 300-series stainless steel, annealed. The rope shall be kept straight in the annealing furnace and shall not be coiled before installation in the gate arms.
In the event of a collision, the energy absorption cables shall be anchored at both ends of the bascule span in the closed to traffic position. The cables shall engage end anchorages in front of each housing and connect to each other through a jaw and toggle at the ends of the arms. The cables shall be strung with the minimum amount of tension required to hold the cables in position without excessive sag. The end lock assembly shall facilitate locking the barrier to another barrier.
The number of warning lights on the gate arms shall be as shown on the wiring diagrams on the Plans. Each warning light shall be a weatherproof, two-way, molded plastic unit with 7 inch red plastic lenses, front and back. The lights shall be interconnected with three-conductor portable cord using watertight connectors at the fixtures. A 12 Volt, 21 candle power LED traffic signal lamp shall be installed in each fixture. The lights shall be connected so that adjacent units shall flash alternately. Fuses for the warning lights shall be 10-ampere midget cartridge fuses installed in molded rubber connection kits. In each gate shall include a 120/12 volt flasher. Gate lights will be connected to flash alternate 0.5 seconds on and 0.5 seconds off with light at tip to burn constantly. Wiring for warning light shall be wired in such a way as to not affect pedestrian traffic. It must be in a safe and secured position.
Barrier gate delineators shall be mounted on brackets on the barrier gate arms as shown on the Plans. Two delineators shall be provided for each gate arm.
The barrier gate housings shall be set first. The Barrier shall be fixed to a suitable foundation, by using, eight, minimum 1” diameter anchor bolts. Before the anchor bolts are tightened and the housings permanently set, their position shall be verified by checking that the axis of rotation is parallel to the bridge centerline, that the housings of the gate is on the same centerline, and that the support arms are correctly spaced apart for mounting the gate arms. Each barrier gate shall be bolted to its concrete foundation as indicated on the Plans.
After the housings are set, the gate arms shall be attached using the nominal shim thickness at the support arms and the center jaw and toggle. The shims at the support arms and the backstays shall be adjusted so that the arms are truly horizontal in the down position and meet the end lock on the exact centerline. The center jaw and toggle shall then be shimmed so that the toggle is exactly centered in the jaw at 69 degrees Fahrenheit ambient temperature. The counterweights shall then be adjusted so that the arms are exactly balanced in all positions.
After completion of the gates, the end anchorages for the restrainer cables shall be set to provide the clearances shown on the Plans for engaging the end toggles, and the ring nuts at the center jaw. Toggle shall be set to provide the clearances shown on the Plans. A limit switch at the end of one gate in each pair shall be furnished to indicate when both gate arms are down and locked.
To detect locking of the Barrier Gates, a magnetic proximity switch is to be attached to the two female end lock assemblies, and a flexible cable shall be run between the proximity switch and the terminal blocks in the barrier gate housing. An adjustable target assembly shall be attached to the two male end lock assemblies.
When the gates are electrically operable, they shall be operated as in normal use and the limit switches adjusted so that each arm is stopped within 1 degree of the vertical or horizontal position. The manufacturer of the gate shall provide all required anchor bolts and templates for gate and dog units.
Each gate arm shall be striped on both faces with alternate red and white reflectorized stripes 6 inches wide, measured parallel to the edge of the gate arm. The stripes shall slope downward at an angle of 45 degrees toward the centerline of the roadway. The galvanized gate stands shall be left unpainted so that the galvanized surfaces can weather. Gate arms, channels, and supports shall be painted in accordance with the requirements specified for painting structural steel and moving parts, except the arms shall be painted red as required under “Mechanical Work”.
Each barrier gate shall be operated from individual momentary pushbuttons on the control desk. In addition, the group of four Barrier Gates shall be provided with a group raising pushbutton. After a momentary contact of the pushbutton, all Barrier Gates shall travel to their fully raised limits. The group shall stop immediately upon momentary contact of the group’s stop pushbutton.
D. Grounding. All metallic conduits, equipment enclosures, frames, housing, and all other metal parts of electrical systems installed or connected under this item, in the proximity of current-carrying conductors or equipment shall be bonded to the bridge ground system. Grounding and bonding shall conform to the requirements given under the item of “Lightning Protection and Grounding Systems”.
E. Spare Parts. The following Traffic Warning and Barrier Gates spare parts shall be furnished and packed in suitable cartons for storage at the bridge:
1. 2 barrier gate arms (one male locking type, one female locking type), complete with restrainer cables, jaws, toggles, and fittings, but without lights and wiring. Gate arms shall be suitably crated, labeled, and delivered as hereinafter indicated.
2. 6 warning light fixtures, complete
3. 12, 21 candle power, 12-volt, signal lamps
4. 3 limit switch contacts
The Contractor shall arrange the spare parts in uniform-size cartons of substantial construction, with typed and clearly varnished labels to indicate their contents. All spare parts shall be furnished and delivered where directed by the Engineer and NJDOT MBEG at no additional cost.
711.04 NJDOT Acceptance.
The Contractor shall not deviate from the Engineer’s design, in any way, without written authorization from the Engineer and NJDOT MBEG. All aspects of the Traffic Warning and Barrier Gates and warning light assemblies installation must be approved by the Engineer and NJDOT MBEG prior to construction. All aspects of Traffic Warning and Barrier Gates and warning light assemblies must be completely and fully operational and accepted by NJDOT MBEG and Maintenance. Payment to the Contractor will only be warranted when complete acceptance has been given in writing by NJDOT MBEG and Maintenance.
COMPENSATION
711.05 Method of Measurement.
Measurement will be on a lump sum basis.
711.06 Basis of Payment.
Payment will be made under.
Pay Item Pay Unit
TRAFFIC WARNING AND BARRIER GATEs LUMP SUM
SECTION 712 - CONTROL DESK MODIFICATIONS
712.01 DESCRIPTION.
The work shall consist of furnishing, installing, and placing in proper operating condition, acceptable to NJDOT MBEG and the Engineer, on the existing control desk, two resolver selector switches and red flasher fault reset pushbutton complete with all appurtenances, required for proper operation.
All conduits, boxes, wiring, cables, and other equipment required to extend the necessary circuits to and from the control desk shall be furnished and installed under the item of "Raceway, Conductors, Terminations, and Boxes." All internal control desk wiring shall be paid for under this Section, and shall conform to the requirements in "Raceway, Conductors, Terminations, and Boxes.
It is the intent and purpose of these Specifications to cover and include all apparatus, appliances, material, plant and labor necessary to properly install, wire, connect, equip, test, adjust, and put in approved working order the respective portions of the work herein specified.
MATERIALS
712.02 Materials and Equipment.
A. Conformance. All equipment and its installation shall conform to the requirements of the latest revision of the Standard Specifications for Movable Highway Bridges of the American Association of State Highway and Transportation Officials, except as may be otherwise provided herein.
Materials and construction shall conform to the requirements of the current National Electrical Code and to any applicable local rules and ordinances. The Contractor shall obtain any required permits and approvals of all Departments or Agencies having jurisdiction.
B. Equipment and Material Provisions. The existing control desk additional equipment and materials shall be new. All workmanship shall be first-class in every aspect of this project and shall be manufactured and erected to the satisfaction of the Engineer, and NJDOT MBEG and Maintenance Department. See Section 707, “Electrical Work” for Control System Vendor Requirements. The Contractor shall warrantee the in-service working of the modified control desk for one year following the date of project acceptance. If the Contractor has any objection to any feature of the equipment as designed and laid out, the Contractor must state the objection at once, in writing, to the Engineer and NJDOT MBEG; otherwise, the Contractor’s objection will be not be valid as an excuse for operational malfunctioning of the equipment or for defective or broken apparatus.
New piece of electrical equipment and apparatus, to be installed under this section, shall have a corrosion-resisting non-rusting metal nameplate, on which is stamped the name of the manufacturer, the rating or capacity, and all other relevant information of the equipment and/or apparatus.
All mounting hardware and all wire and cable terminals shall be vibration-proof and weather-proof.
If any changes from the Plans or these Specifications are deemed necessary by the Contractor, details of such departures and the reasons therefore shall be submitted for approval as soon as practicable before construction. No such changes shall be made without approval of the Engineer and NJDOT MBEG.
The control desk and equipment drawings, operation, and maintenance procedures shall be included in the electrical Instruction Books and Drawing Books as described in Section 707, “Electrical Work”.
Material requirements for apparatus, equipment, and materials will be found in the articles under "Construction" in this item.
CONSTRUCTION
712.03 Construction.
A. Control Desk. The existing control desk shall be modified by furnishing and installing additional selector switches, pushbuttons etc. in the operator's room of the Southeast house. On the desk shall be mounted additional devices for controlling operation of the bascule span and its auxiliaries. The modified desk shall be of neat, substantial construction. All metal hardware shall be of substantial construction and shall have a satin-chrome plate finish. All equipment mounting screws and bolts shall be stainless steel.
Special care shall be taken throughout the construction to insure that the existing control desk equipment mounted thereon are completely protected from damage or defacement at all times while the control desk modification is being carried on.
Existing two fluorescent desk interior service lights, 15 amp duplex receptacle and thermostatically controlled strip heater installed in the desk interior may have to be located while new PLC drop and required terminal strips are being installed. It is the responsibility of the Contractor that the Contractor minimizes the relocation of the existing reusable equipment.
Digital Meters.
1. The existing digital meters are:
a. Main Power Bus – Volts, Amps & Kilowatts
b. Lighting Power Bus – Volts, Amps & Kilowatts
c. Bascule span Motor – RPM
All meters are powered at 120 VAC. – Each meter shall provide a separate 4-20 mA output to allow interconnection to the new PLC. The vendor shall provide connection cables and plugs of sufficient length to interconnect the meters and the adjacent new I/O drop in the desk.
A new two? InView panel mount two line display unit, Allen Bradley Catalog Number 2706-P22R shall be installed in the vicinity of the existing control desk. Proposed location of the InView unit shall be to the left of the existing digital clock mounted on the top of the desk pinnacle, after field verification by the Contractor/control system vendor.
A12-key sealed numeric keypad shall be mounted semi-flush on the control desk top. The keypad and message display unit shall permit the bridge operator and maintenance personnel to inquire about and verify various parameters of the bridge control system. The message display unit shall also annunciate faults and malfunctions such as blown input fuses, causes of bascule span drive permissive faults and other abnormal events. Various codes shall be entered by the user via the keypad and the appropriate information shall be displayed on the message display unit and/or sent to the printer for a hard copy as desired. The codes and their functions shall be documented in the Operation and Maintenance Manual.
Message Display Unit:
The InView message display unit to be furnished shall be a two-line, 20 characters per line, LED matrix Window based programmable unit. The characters are to be 0.7 inch high requiring 24 V dc power supply. The InView unit shall be in a NEMA 4X, 316 L stainless steel enclosure.
The unit shall be capable of displaying up to two hundred fifty (250) 20-character messages or 150 40-character messages. Single or multiple messages may be displayed simultaneously, scrolled, chained, blinked, or overlaid. Menu driven program shall allow viewing of messages on the display screen during programming. An external printer port shall be provided to allow interconnection of the printer. Connection of the printer cable to the display unit's printer port shall be made external to the PLC user console via a semi-flush mounted socket furnished on the interior of the desk The data liner message display shall be as indicated on the plan sheets and any additional messages required by the Engineer and NJDOT MBEG. The message display shall be powered from the UPS to prevent the loss of clock time.
The Vendor shall furnish and deliver to the MBEG office, all required computer hardware, InView P22R windows-based software, and interconnect cables to provide programming of the “Programmable Message Unit”.
Keyboard Unit:
A sealed numeric keyboard unit shall be furnished and installed on the control desk. The NEMA 13 keyboard shall contain 12 jam-proof keys wired so there will be one output per key plus one common. Plastic buttons with 0.190-inch high, engraved legend are to be covered with black neoprene. Contacts shall be rated 6-20 MA at 4-12 VDC, and operating force shall be 16 oz. nominal. Buttons shall be gray, with black legends having the marking 0-9, E and CE. Wiring to the terminals shall be of the quick-connect type. RFI shielding shall be incorporated into the keyboard. The keyboard shall be approved equal to PN No. PX1P12K10A2A-013 as manufactured by Micro Switch.
The message display unit and keypad shall be interconnected with the PLC via I/O cards in the remote rack located inside the bridge control desk. The Contractor shall provide all conduits, conductors and multiconductor cables necessary to render the PLC user console operable. In addition, the Contractor shall furnish and install all wiring plugs, connectors and power supplies to allow the keyboard unit and message display to be functional.
Sockets for testing lamps used in meters and in the position indicator shall be installed inside the control desk. The desk interior shall be suitably lighted and controlled by a switch mounted near the front doors. One duplex receptacle shall be mounted in the desk's interior.
All contact blocks for control switches, pushbuttons, and other control devices shall be mounted within the body of the desk. The operators for these devices shall protrude through the desk top. The indicating lights for each operation shall be incorporated with the control device governing that operation.
The escutcheon plates of all new control switches, pushbuttons, tumbler switches and bypass switches shall be made of a hot-polished, laminated phenolic compound no less than 3/16-inch thick. The compound shall have a white surface 1/32-inch thick, an intermediate black layer 1/32-inch thick, and a white back 1/8 inch thick. All corners shall be rounded, and the edges of the plates shall be chamfered. All engraving shall be upper case, standard gothic characters, cut through the surface into the intermediate layer. All plates shall be securely fastened to the desk top with stainless steel screws.
The existing wiring within the control desk shall be replaced with new insulated switchboard wire Type SIS. Wire shall not be smaller than #14 AWG except all power wiring for lights, heaters and major power feeds shall not be smaller than 12 gauge. The wiring shall be arranged systematically so that all circuits can be readily traced. All conductors shall be terminated on easily accessible terminal blocks mounted inside the desk at the rear. Spare terminals totaling at least 10 percent of those actually used shall be provided. Wiring shall be identified at equipment terminals by marking the adjacent area with bright yellow painted numbers to correspond to conductor designations appearing on the Contractor's wiring diagrams.
Indicating lamps shall be replaced with new in-kind type and shall be mounted on the control desk to show that the various steps in the sequence of operation have taken place so that the operator may proceed to subsequent steps at the proper time. The functions to be indicated and the color of the lenses shall be as shown on the Plans.
A remote PLC I/O rack and all associated equipment shall be mounted within the desk to incorporate the selector switches, pushbuttons, indicating lights, relays, and desk meters with the PLC.
B. Testing and Installation Guidelines. All testing and installation for the “Control Desk” and all associated equipment shall be paid for under this Section. The Contractor shall follow the testing and installation guidelines in paragraphs A through I in Section 707, “Electrical Work”.
COMPENSATION
712.04 Method of Measurement.
Measurement will be on a lump sum basis.
712.05 Basis of Payment.
Payment will be made under.
Pay Item Pay Unit
CONTROL DESK MODIFICATIONS LUMP SUM
SECTION 713 - FLUX VECTOR DRIVE AND CABINET
713.01 DESCRIPTION.
The work under this section shall include furnishing, installing, and placing in proper operating condition, acceptable to NJDOT MBEG and the Engineer, four flux vector drives and four cabinets, dynamic braking modules, resistors, and bascule span motor assemblies, complete with all required appurtenances.
All conduits, boxes, wiring, cables, and other equipment required to extend the necessary circuits to and from the flux vector drive cabinets shall be furnished and installed under the item of "Raceway, Conductors, Terminations, and Boxes." All modified internal control desk wiring shall be paid for under this Section, and shall conform to the requirements in "Raceway, Conductors, Terminations, and Boxes.
It is the intent and purpose of these Specifications to cover and include all apparatus, appliances, material, plant and labor necessary to properly install, wire, connect, equip, test, adjust, and put in approved working order the respective portions of the work herein specified.
Existing thyristor drive cabinets and bascule span motors shall be disconnected, removed, and salvaged in accordance with Section 540 “Demolition and Removal”.
MATERIALS
713.02 Materials.
A. Conformance. All equipment and its installation shall conform to the requirements of the latest revision of the Standard Specifications for Movable Highway Bridges of the American Association of State Highway and Transportation Officials, except as may be otherwise provided herein.
Materials and construction shall conform to the requirements of the current National Electrical Code and to any applicable local rules and ordinances. The Contractor shall obtain any required permits and approvals of all Departments or Agencies having jurisdiction.
B. Equipment and Material Provisions. All flux vector drive cabinets equipment and materials shall be new. All equipment shall be UL approved, materials, and workmanship shall be first-class in every aspect of this project and shall be manufactured and erected to the satisfaction of the Engineer, and NJDOT MBEG and Maintenance Department. See Section 707, “Electrical Work” for Control System Vendor Requirements. The Contractor shall warrantee the in-service working of the flux vector drives and associated equipment for one year following the date of project acceptance. If the Contractor has an objection to any feature of the equipment as designed and laid out, he must state his objection, in writing, to the Engineer and NJDOT MBEG; otherwise, his objection will not be valid as an excuse for operational malfunctioning of the equipment or for defective or broken apparatus.
Each piece of electrical equipment and apparatus shall have a corrosion-resisting non-rusting 316 L, stainless steel nameplate, on which is stamped the name of the manufacturer, the rating or capacity, and all other relevant information of the equipment and/or apparatus.
All mounting hardware and all wire and cable terminals shall be vibration-proof and weather-proof.
If any changes from the Plans or these Specifications are deemed necessary by the Contractor, details of such departures and the reasons therefore shall be submitted for approval as soon as practicable before construction. No such changes shall be made without approval of the Engineer and NJDOT MBEG.
The flux vector drive cabinets and equipment drawings, operation, and maintenance procedures shall be included in the electrical Instruction Books and Drawing Books as described in Section 707, “Electrical Work”.
Material requirements for apparatus and equipment, will be found in the articles under "Construction" in this item.
CONSTRUCTION
713.03 Construction.
A. Cabinets. Flux Vector Drive panels enclosed in free-standing floor cabinets shall be furnished and installed where shown on the Plans. All circuit breakers, switches, contactors, flux vector drives, regulating equipment, and other apparatus for control of the bascule span shall be mounted on these enclosed panels. The arrangement and line-up of the flux vector drive cabinets shall be as shown on the Plans.
All equipment in the cabinet shall be mounted on painted sheet-steel bases, and each device shall be front-connected, front-wired, and removable from the front. The equipment in the cabinet shall be arranged for ease of access and for safety and convenience of operation. Special care shall be taken to obtain a systematic and neat arrangement of the equipment. Each device shall be suitably named and plainly marked by a laminated nameplate mounted near the device on the panel. Each nameplate shall show an approved descriptive title for the apparatus, together with the device designation appearing on the schematic wiring diagrams.
The cabinets shall be NEMA Type 12 enclosures constructed of No. 12 gauge sheet-steel and shall be reinforced with steel angles or channels so as to provide a rigid, free-standing structure. The cabinets shall be provided with stainless steel continuous hinged doors on the front of each panel section. Door panels shall be gasketed and shall be provided with three-point, vault-type latches. Ventilating louvers shall be provided at the front of each enclosure. All hardware shall be corrosion resistant. Thermostatically controlled strip heaters shall be provided in each cabinet to prevent build-up of excess moisture. Each panel shall be provided with suitable interior fluorescent light fixtures operated by a door operated switch and a duplex receptacle.
The cabinets shall permit mounting in the available space along the walls of the switchboard room If the final cabinet dimensions (84”x30”x20”), as established by the manufacturer, should necessitate rearrangement or modification of the equipment in order to fit in the available space, such rearrangement or modifications shall be made and at no extra cost to NJDOT. The final arrangement of all equipment in the control house shall be subject to the approval of the Engineer and NJDOT MBEG.
The enclosures and all metal reinforcing shall be painted inside with two coats and outside with three coats, consisting of one coat of primer followed by one coat of white enamel on the inside surfaces and two coats of gray enamel outside. The finish coat shall be ANSI 61 light gray enamel.
All contactors, relays, and other devices shall be of required current-carrying and interrupting capacity. All apparatus shall be of substantial construction and shall conform to the requirements of latest NEMA Standards Publications ICS 1 and 2, for industrial control devices.
All internal wiring between devices and/or terminal blocks shall be flame-retardant, ethylene-propylene insulated, switchboard wire, Type SIS. Control conductors shall be stranded copper not smaller than No. 14 American Wire Gauge.
For the assembled panel, all outgoing wire, No. 8 AWG or smaller, shall be connected to terminal blocks installed at the sides of the cabinet. The panels shall also provide sufficient extra terminals to allow connection of all wires coming from limit switches and other devices that go on to the bridge control desk and other locations as required, even though these wires do not connect to apparatus on the control panels. Spare terminals totaling at least 10 percent of those actually used shall be provided. Each terminal shall be identified per wire number shown on the Contractor's schematic wiring diagrams. All spare conductors entering any cabinet, terminal box shall be terminated on a terminal block.
All panel wiring shall be arranged systematically so that circuits can be readily traced. The internal cabinet wiring shall be installed in a network of troughs consisting of horizontal and vertical sections securely bolted to the panels. The troughs shall be fabricated from heavy-duty Noryl plastic shaped into a channel cross-section. After installation of the wiring, an insulated, flanged cover shall be snapped over the open side of each trough section. Each floor-mounted cabinet/panel shall be provided with 1/8 inch neoprene gasket with switchboard matting between the cabinet and floor platform.
B. Equipment Labels. All electrical devices and cabinet equipment shall have a label affixed to each unit. The label shall be similar in construction to the nameplates. Each label shall be of suitable size and letter characteristics. Text shall indicate name/function of each item. Labels shall be securely attached using stainless steel screws. The Contractor shall submit to the Engineer and NJDOT MBEG for review, all signs, with sizes, location and text.
C. Power and Control Apparatus. Power and control apparatus required for the flux vector drive assemblies shall meet the requirements stated in Section 527, “Power Distribution and Control Cabinet”.
D. Bascule Span Motor Control System. The Contractor shall furnish four (4) Flux Vector-Controlled Variable Frequency Drives (VFD’s) with operating voltages and current ratings as shown on the Plans. VFD Systems shall be UL508 listed. The complete VFD system shall be manufactured and warranted by the VFD manufacturer. Third party assemblers will require prior approval, in writing, of the engineer and NJDOT MBEG.
It is the intent of this specification to describe the minimum performance requirements of the VFD system. Any deviation shall be detailed in writing and submitted to the Engineer and NJDOT MBEG for approval at least two (2) weeks prior to bid time. The drive manufacturer shall visit the installation site prior to bid.
The VFD System shall be compatible with the vector duty, squirrel-cage type, induction motor and shall be sized to ensure the motor full load amps (FLA) do not exceed the VFD's continuous current rating, with an overload capability of 180% of full load torque for 20 seconds and 150% for 60 seconds. The continuous output current rating of the drive shall be 112 Amps. The VFD drive shall be capable of providing 180% starting torque capability. If the VFD manufacturer's standard product is current rated at 8 khz carrier frequency or below, a de-rating factor of 20% minimum shall be used to derive the maximum continuous current rating of the VFD. The VFD shall maintain full performance without de-rating for up to 300 feet long motor feeders. The drive manufacturer shall also include output load reactors to minimize insulation stress on the bascule span motors.
The VFD's shall be IEEE 519 compliant for allowable harmonic distortion at the power distribution point of service, including line notching and transients. In the event that the VFD's produce Total Harmonic Distortion (THD) in excess of the prescribed limits of the utility company, the Contractor shall take all necessary steps at no additional expense to NJDOT to reduce such harmonics to the allowable limits. Total Current Harmonic Distortion (THD) measured at the power input terminals of VFD shall be 20% or less at 50% or higher load. The Contractor shall also include voltage and current THD calculations at the point of service for the particular drive system when submitting the VFD System for approval.
To minimize the impact during construction and make optimum use of training and spare parts resources, vendor responsibilities shall be as follows:
1. Specified VFD's shall be supplied by one manufacturer.
2. Like components of all VFD Systems, although for different services, shall be interchangeable products of one manufacturer.
3. All VFD Systems shall be the same model series of one manufacturer. The complete VFD system shall be manufactured and warranted by the VFD manufacturer.
VFD Systems shall be 32 bit microprocessor based, closed loop vector, fully transistorized 3 phase, full wave diode bridge input and a PWM sine-coded output waveform type. The input diode bridge shall offer complete immunity against voltage dips, line noise and harmonics. The output transistors must be of the IGBT type (Insulated Gate Bipolar Transistor) to facilitate noiseless motor operation. The VFD's shall be tested and rated for a minimum of 100 years Mean Time Between Failure (MTBF). The Contractor shall provide manufacturer’s typical test results or calculations with submittal to verify MTBF.
The VFD’s shall be capable to run in speed and torque mode with adjustable torque limits in all four quadrants. VFD’s will be supplied with a quadrature type encoder feedback card compatible with a vector duty, squirrel-cage type induction motor. The drive shall be capable of auto-tuning to the actual motor without any unwarranted service interruption during normal drive operation.
To minimize electrical and acoustical noise, and to eliminate low speed cogging, a minimum switching frequency of 8 kHz shall be used at 460VAC. The VFD shall not "cog" at any frequencies with a 1,000:1 speed regulation. There shall be no sudden frequency shifts and associated acoustical noise shifts as the output frequency is varied between 0 and 60Hz. Motor and VFD shall be able to produce full torque at zero speed.
The VFD's input displacement power factor shall be 0.98 or better over the entire operating frequency and load range. Efficiency shall be measured 96% minimum at rated load. The Contractor shall provide manufacturers typical test results or calculations with submittal to verify efficiency and power factor.
The VFD's shall be 6-pulse configured to effectively minimize harmonic distortion content.
The VFD's shall have, but not be limited to the following protective features:
1. Solid state output ground fault protection shall be provided.
2. Adaptive electronic motor overload protection shall be provided which shall protect both the motor and the VFD’s at all frequencies. This overload must be UL approved. Electronic thermal overload circuits, which only protect the motor at full speed, shall not be acceptable. The VFD’s shall sense the load and speed and shall recalibrate the thermal trip curve to ensure low speed motor protection. The initial trip point shall be adjustable from at least 40% of the VFD’s continuous rating to account for motor magnetizing current.
3. Input surge protection shall be performed by MOV'S (metal oxide varistors) in accordance with latest ANSI Specification C63.41.
4. Input and output phase loss detection must be provided to protect the VFD’s.
5. Input and output short circuit protection must be provided.
Opto-coupled isolated control inputs shall be provided with 11-bit D/A converter. The motor speed shall be directly proportional, to 4-20mA, and variable resistance signals. In addition, the VFD shall have independent settings adjustable on the fly for input reference offset (positive and negative) and gain to facilitate signal setting/matching. Three analog inputs shall be available.
The VFD shall employ modular PC board design for ease of troubleshooting. All connectors must be polarized type and clearly marked on both the connector and PC board to ensure proper connection.
VFD operation options shall be programmable via a door mounted digital keypad, and include as a minimum the following functions:
1. VFD operation options shall be programmable via a door mounted digital keypad, and include as a minimum the following functions.
2. DC injection braking at start for energizing the flux before starting with independently adjustable current and time.
3. Adjustable hand jog.
4. Automatic voltage reduction with load reduction, adjustable on the fly to maximize energy savings, without sacrificing acceleration and deceleration torque.
5. Electronic motor reversing.
6. Three independently adjustable prohibited frequencies with adjustable bandwidths.
7. Independently adjustable levels to engage stall prevention function during acceleration, deceleration, or running.
8. True PID set point control embedded in the microprocessor programmable by the operator via the digital keypad.
9. “Speed search” transfer. The VFD’s shall have the ability to start into a spinning load without stopping the motor or creating a fault condition. The VFD’s shall match the motor’s speed and then drive the motor to its proper speed reference. This must be performed without the use of a digital input.
10. Minimum of 1000:1 controllable constant torque speed range. Speed regulation shall be 0.02% or better over the entire speed range. Motor and drive combination shall develop 100% motor torque at zero speed.
11. Minimum of 2-second power loss ride-through capability. In the event of a loss of three-phase power lasting 2 seconds or less, the VFD must remain operational and prevent nuisance trips upon return of power.
12. Password security as specified by New Jersey Department of Transportation.
The door mounted digital keypad shall be removable and transferable to the second drive. The door mounted digital keypad shall also be capable of storing the drive program parameters and transfer them automatically to the other drives by simply connecting it to the drive to be programmed.
The flux vector drive systems shall be provided with, as a minimum, the following inputs and outputs:
1. Five (5) programmable contact inputs.
2. Eight (8) programmable digital inputs and an additional spare 8 programmable discrete input card.
3. Four (4) programmable digital open collector outputs and a dry contact output.
4. Two analog outputs for remote indication of output power and RPM.
5. Three programmable analog inputs with a minimum of 11 bit resolution.
6. Two preset torque limits activated by a contact closure. The torque limits must be able to be set through a PC and/or the digital operator.
The VFD shall be suitable for installation under the following conditions:
1. +14 to +122 degrees F (-10 to +50 degrees C) ambient temperature (non-freezing).
2. –13 to +149 degrees F (-25 to +65 degrees C) storage temperature.
3. 95% Relative Humidity, non-condensing.
4. Input voltage shall be 3-phase, nominal voltage 460 VAC with +10% -15%.
5. Acceptable power and control wiring from the drive to the motor shall be minimum 800 feet with no loss of functionality. The manufacturer must also guarantee the motor/drive system, with motor cable lengths of up to 800 feet without motor or drive de-rating. This must be in writing with the submittal at the time of bid.
6. Restart feature shall be programmable.
When a fault occurs, the Drive shall have a controlled shut down sequence. The reason for the fault condition shall be enunciated on the LED display, and the LCD graphic screen shall display the current, temperature, frequency, and voltage at the time of the fault as well as potential reasons for the condition. The Drive shall monitor, sense, and display the following fault conditions (remote annunciation shall be available with a form “C” fault contact):
1. Blown Fuse.
2. Instantaneous over-current trip.
3. DC bus over-voltage.
4. DC bus under-voltage.
5. VFD internal over-temperature condition.
6. External fault input.
7. Internally diagnosed, control failure.
8. Motor thermal overload.
9. VFD thermal overload.
10. Programmable “Shear pin” current trip.
The drive shall be provided with a Programming/Operating Station with the following features:
1. Drive operator (keypad) shall have an English LCD back-lit display as well as an English LED display of frequency reference, output frequency, output current (accurate +/- 3% regardless of output frequency), output voltage, DC bus voltage, output power (kW), elapsed time meter, input terminal status, output terminal status, LED lamp check, and all programming parameters, motorized pot.
2. Alpha-numeric display of faults. Up to 4 sequential faults shall be retained in non-volatile memory (maintained even after removal of input power).
Each VFD system shall be mounted in a NEMA 12 cabinet with dimensions no larger than as shown on the Plans. Each VFD shall be provided with a door-mounted digital operator control station with the following features:
1. Local/Remote switch for selecting operation either from the digital operators control station or from a remote location. Both start/stop and speed reference signals shall be selected by a single switch.
2. Jog push button.
3. Reset push button.
4. Start push button.
5. Stop push button.
6. Red LED’s shall be supplied as a standard on the digital operators station for indication of hand, auto, running, stopped, and drive running with no speed reference signal applied (zero speed).
The VFD’s shall be supplied with AC input line reactors with minimum impedance of 5%, or an impedance value as recommended by the drive manufacturer, to smooth the input current waveform and reduce harmonics content. Output reactors shall also be 5% impedance or an impedance value as recommended by the drive manufacturer. The VFD’s shall also be supplied with DC choke reactors to further minimize total harmonic distortion on the DC VFD bus.
The VFD’s shall be supplied with fully NEMA rated, mechanically interlocked input and output contactors to disconnect the drive from the line and load, respectively, when the drive is not running.
The VFD shall be capable of operating in two distinct torque-limiting modes as dictated by a discrete input contact command. With the discrete input contact open, the motor torque shall be limited by the capability of the drive. With the discrete input contact closed, the torque of the motor shall be limited to 50%-80% nameplate full load torque of the 40-HP motor. This reduced torque limit shall be field adjustable through a PC or a field digital operator. The drive manufacturer shall provide all hardware and programming necessary to provide this reduced torque function.
A dynamic braking module and power resistor shall be furnished and installed for each flux vector drive to regulate the DC bus voltage and dissipate the excess power across the dynamic braking resistors in the form of heat. The resistors shall be sized as recommended by the manufacturer to provide 150% braking torque and 30% duty cycle. The dynamic braking modules shall be located in the flux vector drive cabinets, and the power dissipating resistors shall be floor mounted in the house foyer storage area adjacent to the stairs.
The VFD cabinet shall be equipped with auxiliary controls and wiring to automatically start the enclosure fan blower in conjunction with motor operation to prevent heat buildup. The controls shall consist of a motor starter and motor overloads as specified elsewhere in this specification. The equipment shall be located in the VFD cabinet. A red indication light shall be provided on the cabinet panel to indicate blower failure. The dynamic braking module shall be equipped with thermal overload protection to prevent VFD and dynamic brake module malfunction.
The VFD cabinet shall be equipped with an internal fluorescent light activated by a door switch. The VFD cabinet shall be equipped with an internal 120VAC duplex receptacle.
The VFD shall have a default condition of zero speed, such that when a fault is detected the drive will switch to zero speed following a smooth “normal stop” deceleration ramp. The Contractor shall coordinate this feature with the VFD system manufacturer.
The VFD shall have a "Power Off" feature, such that when a designated control input contact closes, the VFD inverter output to the drive motor is turned off. The Contractor shall coordinate this feature with the VFD system manufacturer. This feature is necessary to implement “drift” test.
The VFD cabinet shall contain a digital display, which will indicate the speed in RPM of each motor.
The Contractor shall coordinate with the drive manufacturer the parameters for the VFD specified on the drawings.
VFD Systems shall be furnished with the options listed on the contract drawings and as specified herein. VFD Systems shall be VG-10 Drive as manufactured by Saftronics, Inc., or Engineer and NJDOT MBEG approved equal.
E. Lift Bascule span Motor. Four, electric, vector duty, squirrel cage, inverter type motors shall be furnished and installed to operate the bascule span. In addition, an identical motor shall be furnished and properly stored in the machinery room as a spare motor.
Each bascule span driving motor shall be a 40 horsepower, vector duty, horizontal squirrel cage motor rated 460 volts, three-phase, 60 Hertz, 600 RPM, and 1.0 service factor. The motor shall be totally enclosed, non-ventilated and shall be rated on a basis of 60 minutes for use in 40 degrees Celsius ambient temperature. Insulation shall be Class B or better, with special treatment to retard decrease in insulation resistance due to excessive moisture.
Each motor shall develop a full-load torque of not less than 564 lb-ft and a 275% maximum torque of not less than 1550 lb-ft. Each motor shall be capable of carrying a torque equal to twice its full-load torque for 2 minutes
Each bascule span motor shall be provided with front C-face bell housing, adapter, and two (2) new quadrature encoder ring kits installed. An over speed assembly shall be installed on a suitable motor mounted bracket and coupled directly to the motor shaft extension. The over speed switches shall have independent adjustable settings.
Each bascule span motor shall be provided with a heater. The heater shall be a single-phase, 120-volt unit and shall be suitable for continuous operation under the conditions of installation. The motor heater shall be disconnected when either the motor disconnect switch has been turned off or when the motor is running.
Each motor shall be connected to the operating machinery by a flexible coupling furnished with the operating machinery. The motor half of each coupling shall be pressed on the motor shaft at the plant of the manufacturer of the motors.
The bascule span motor shall be installed with approved sizes and types of wire terminals and splice fittings for the connection of the motor to the circuit wiring. The motor shall be furnished with oversize cast-iron conduit boxes. Connections between the rigid conduit system and the motor shall be made with flexible conduit sections not exceeding 18 inches in length.
The bascule span motor shall be an approved equal to the vector duty squirrel cage motor manufactured by Rueland Electric, GE, or Allen Bradley.
F. Motor Speed. Two (2) dual pickup, bearingless, heavy-duty encoders shall be furnished and installed as shown on the Plans. The encoders shall be of the industrial type (aluminum and glass encoder wheels are not acceptable). The encoders shall have a resolution of 1024 ppr and be compatible with the flux vector drives. Encoder shall be the SL 56 Slim Tach manufactured by Northstar or Engineer and NJDOT MBEG approved equal, and shall be installed on the motor shaft C face, with an identical encoder installed on a C face mounted on the first encoder.
G. Motor Test. A complete set of speed-torque-current curves at 0%, 25%, 50%, 75%, and 100% load for each bascule span motor and spare shall be prepared and submitted to the Engineer and NJDOT MBEG for approval. Motor current and torque curves corresponding to full speed, half speed, quarter speed, and no-load speed shall be provided at rated voltage. The curves shall cover the interval from 200 percent braking torque to breakdown driving torque, referred to as full-load motor torque.
The bascule span motor and spare shall include a megger test. Insulation resistance values and test voltage shall be included on the test report. Testing shall be between each lead and ground.
Tests shall be reported on the standard forms for induction motors of the National Electrical Manufacturers Association. All test reports and curve sheets shall be certified by the manufacturer, and seven copies of each shall be submitted. Motors shall not be shipped from the plant of the manufacturer until the test reports have been approved by the Engineer and NJDOT MBEG.
F. Testing and Installation Guidelines. All testing and installation for the “Flux Vector Drive Cabinets” and all associated equipment shall be paid for under this Section. The Contractor shall follow the testing and installation guidelines in paragraphs A through I in Section 707, “Electrical Work”.
COMPENSATION
713.04 Method of Measurement.
Measurement will be on a lump sum basis.
713.05 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
FLUX VECTOR DRIVE AND CABINEts lump sum
SECTION 714 - PROGRAMMABLE LOGIC CONTROLLER SYSTEM
714.01 DESCRIPTION.
The work shall consist of replacing the existing Square-D, SYMAX programmable logic controller system by furnishing, installing, programming, testing, and placing in proper operating condition, acceptable to the Engineer and NJDOT MBEG, Allen Bradley PLC-5 programmable logic controller (PLC) system and cabinets, complete with all appurtenances, required for proper operation. Existing control scheme, that is, sequence of bridge operation will be maintained during and after rehabilitation.
All conduits, boxes, wiring, cables, and other equipment required to extend the necessary circuits to and from the PLC cabinets shall be furnished and installed under the item of "Raceway, Conductors, Terminations, and Boxes." All new internal PLC cabinet wiring shall be paid for under this Section, and shall conform to the requirements in "Raceway, Conductors, Terminations, and Boxes.”
It is the intent and purpose of these Specifications to cover and include all apparatus, appliances, material, plant and labor necessary to properly install, wire, connect, equip, test, adjust, and put in approved working order the respective portions of the new Allen Bradley PLC-5, programmable logic controller system herein specified.
MATERIALS
714.02 Materials and Equipment.
A. Conformance. All equipment and its installation shall conform to the requirements of the latest revision of the Standard Specifications for Movable Highway Bridges of the American Association of State Highway and Transportation Officials, except as may be otherwise provided herein.
Materials and construction shall conform to the requirements of the current National Electrical Code and to any applicable local rules and ordinances. The Contractor shall obtain any required permits and approvals of all Departments or Agencies having jurisdiction.
B. Equipment and Material Provisions. The Allen Bradley PLC-5 system, cabinets, and all associated equipment and materials shall be new. All equipment, materials, and workmanship shall be first-class in every aspect of this project and shall be manufactured and installed to the satisfaction of the Engineer, and NJDOT MBEG and Maintenance Department. See Section 707, “Electrical Work” for Control System Vendor Requirements. The Contractor shall warrantee the in-service working of the PLC system and associated equipment for one year following the date of project acceptance. If the Contractor has any objection to the equipment layout, he must state his objection at once, in writing, to the Engineer and NJDOT MBEG; otherwise, his objection will be not be valid as an excuse for operational malfunctioning of the equipment or for defective or broken apparatus.
Each piece of electrical equipment and apparatus shall have a corrosion-resisting non-rusting metal nameplate, on which is stamped the name of the manufacturer, the rating or capacity, and all other relevant information of the equipment and/or apparatus.
All mounting hardware and all wire and cable terminals shall be vibration-proof and weather-proof.
If any changes from the Plans or these Specifications are deemed necessary by the Contractor, details of such departures and the reasons therefore shall be submitted for approval as soon as practicable before construction. No such changes shall be made without approval of the Engineer and NJDOT MBEG.
The PLC system, cabinets and equipment drawings, operation, and maintenance procedures shall be included in the electrical Instruction Books and Drawing Books as described in Section 707, “Electrical Work”.
Material requirements for apparatus, equipment, and materials will be found in the articles under "Construction" in this item.
714.03 Construction.
A. Cabinets. PLC system equipment panels enclosed in free-standing cabinets shall be furnished and installed where shown on the Plans. All circuit breakers, switches, contactors, starters, relays, regulating equipment, and other apparatus for control of the bascule span and its auxiliaries shall be mounted on these enclosed panels. The arrangement and line-up of the PLC cabinets shall be as shown on the Plans. Redundant PLC CPU shall be installed in the right side existing cabinet. After temporary system is installed and operational, all PLC drops located inside the control desk shall be disconnected and removed. New PLC drop “one” having sixteen slot chassis shall be installed inside the control desk.
All new equipment in the cabinets shall be mounted on painted sheet-steel bases, and each device shall be front-connected, front-wired, and removable from the front. The equipment in the cabinet shall be arranged for ease of access and for safety and convenience of operation. Special care shall be taken to obtain a systematic and neat arrangement of the equipment. Each device shall be suitably named and plainly marked by a laminated nameplate mounted near the device on the panel. Each nameplate shall show an approved descriptive title for the apparatus, together with the device designation appearing on the schematic wiring diagrams.
The cabinet shall be a NEMA Type 12 enclosure constructed of No. 12 gauge sheet-steel and shall be reinforced with steel angles or channels so as to provide a rigid, free-standing structure. The cabinet shall be provided with stainless steel continuous hinged doors on the front of each panel section. Door panels shall be gasketed and shall be provided with three-point, vault-type latches. For cabinets with two (2) doors, the center support shall be removable. Ventilating louvers shall be provided at the front of each enclosure. All hardware shall be corrosion resistant. Thermostatically controlled strip heaters shall be provided in each cabinet to prevent build-up of excess moisture. Each panel shall be provided with suitable interior fluorescent light fixtures operated from a door operated switch, and a duplex receptacle.
The cabinets shall permit mounting in the available space along the walls of the operator house and machinery houses. If the final cabinet dimensions, as established by the manufacturer, should necessitate rearrangement or modification of the equipment in order to fit in the available space, such rearrangement or modifications shall be made and at no extra cost. The final arrangement of all equipment in the control house shall be subject to the approval of the Engineer and NJDOT MBEG.
The enclosure and all metal reinforcing shall be painted inside with two coats and outside with three coats, consisting of one coat of primer followed by one coat of white enamel on the inside surfaces and two coats of gray enamel outside. The finish coat shall be ANSI 61 light gray enamel.
All contactors, relays, and other devices shall be of required current-carrying and interrupting capacity. All apparatus shall be of substantial construction and shall conform to the requirements of NEMA Standards Publications ICS 1 and 2, 1978, for industrial control devices.
All internal wiring between devices and/or terminal blocks shall be flame-retardant, ethylene-propylene insulated, switchboard wire, Type SIS. Control conductors shall be stranded copper not smaller than No. 14 American Wire Gauge.
For the assembled control panel, all outgoing wire, No. 8 AWG or smaller, shall be connected to terminal blocks installed at the sides of the cabinet. The control panels shall also provide sufficient extra terminals to allow connection of all wires coming from limit switches and other devices that go on to the bridge control desk and other locations as required, even though these wires do not connect to apparatus on the control panels. Spare terminals totaling at least 10 percent of those actually used shall be provided. Each terminal shall be identified per wire number shown on the Contractor's schematic wiring diagrams. All spare conductors entering any cabinet, terminal box shall be terminated on a terminal block.
All panel wiring shall be arranged systematically so that circuits can be readily traced. The internal cabinet wiring shall be installed in a network of troughs consisting of horizontal and vertical sections securely bolted to the panels. The troughs shall be fabricated from heavy-duty Noryl plastic shaped into a channel cross-section. After installation of the wiring, an insulated, flanged cover shall be snapped over the open side of each trough section. Each floor-mounted cabinet/panel shall be provided with 1/8 inch neoprene, Fabreeka type gasket between the cabinet and floor.
B. Equipment Labels. All electrical devices and cabinet equipment shall have a label affixed to each unit. The label shall be similar in construction to the nameplates. Each label shall be of suitable size and letter characteristics. Text shall indicate name/function of each item. Labels shall be securely attached using stainless steel screws. The Contractor shall submit to the Engineer and NJDOT MBEG for review, all signs, with sizes, location, and text.
C. Programmable Logic Controller System (PLC). Bridge control logic functions shall be performed by a programmable logic controller system, which shall provide for operation of the bridge and its auxiliaries in accordance with the system functioning specified herein and the control logic shown on the Plans.
The system shall be fully redundant, with two identical processing units arranged so that either unit can be manually selected from a two (2) position maintained selector switch on the control desk. A pilot light will indicate which PLC is on line. Hot transfer of PLC’s shall not be utilized. A built-in delay between PLC selection shall be utilized. Each programmable logic controller shall be approved equal to PLC-5/40 as manufactured by Allen Bradley/Rockwell Automation and shall be furnished with all modifications and auxiliary equipment required to provide the desired functions as described in these specifications and as shown on the Plans. Wiring arrangements shall be made to ensure that the CPU’s are powered on-line and off-line.
The PLC system and associated components shall be the products of a single manufacturer and shall comply with applicable provisions of NEMA Standards ICS 2-Z30, IEEE/ANSI C37.90A, and UL 508. Equipment shall be suitable for operation at voltages from 102-132 volts A-C, 57 to 63 Hertz, and at 0 to 95 percent relative humidity (non-condensing). All PC equipment (CPU, UPS, I/O frames, input cards, output cards, multiplexers, cables, etc.) shall undergo a minimum of 100 hours of continuous burn-in prior to shipment. Burn-in shall be done while operating at temperatures within rated limits and cycling equipment through a program. PC equipment shall be tested to assure proper operation in the presence of both radio frequency and electrical noise, meeting RFI immunity per FCC Class A, EMI immunity per MIL-STD-4618, and capable of withstanding 2,500-volt surges.
Central processor units (CPU) shall permit programming capabilities as required and as shown on elementary wiring diagrams, including, but not limited to, internal delay equivalents, counters, timers, real time calendar clock, data functions such as data compare and data transfer, transitional coils which allow an output to remain on for a single processor scan only, latch/unlatch relays, storage registers, etc. Program memory shall be metal oxide, semi-conductor (CMOS-RAM), battery backup power system. Batteries shall be able to support the memory for not less than 3 months without external power, and the system shall have a low battery voltage alarm indication. The backup battery shall be capable of being replaced without interruption of memory integrity with A-C power on and shall be provided with a visual indication of battery status. CPU shall have a key operated selector switch for preventing changes in the stored program while in the "operate" position.
The status of inputs and outputs shall be checked at the time they are called in for the program, and outputs shall be available to be turned "on" or "off" as soon as the associated logic rung has been scanned. CPU shall check the parity of each word at the time it is scanning that word. An alarm contact shall permit indication of trouble whenever a failure occurs in the system. An audible and visual signal permitting an automatic transfer by a suitable selector switch located on the control desk to the backup processor shall be provided. This backup processor shall permit continued operation of the bridge from the point of failure. CPU shall have trouble lights to indicate memory parity errors or processor malfunction. Operating logic shall be contained in plug-in cards for ease of replacement. Memory unit shall have spare program and data storage capacity equal to at least 20 percent of the memory used but total capacity of not less than 8K.
The power input to all programmable logic controller power supply units shall be provided with line conditioning equipment comprising an on-line uninterruptible power supply (UPS) of capacity not less than the connected load. It shall completely protect the equipment from the A-C line and provide stand-alone power at rated load to the connected equipment for at least ten (10) minutes to retain PLC system continuity during bridge power transfer. The UPS shall incorporate internal batteries with battery charger. The UPS unit shall provide 5.0 KVA output with 115 VAC, 42 Amp input. The UPS shall be hardwired. The ferrups unit shall allow hot battery exchange and provide "“bulletproof” protection against the effects of surges, spikes, sags, noises and lightning.
Input/output (I/O) frames shall be required for a full complement of boards. Facilities for the addition in the field of additional boards up to the full capacity of the PLC shall be provided. Design shall be such that each I/O card module type is unique so that a card cannot be inadvertently installed in a slot programmed for a different unit. I/O cards shall be replaceable without removal of any panel wiring and shall provide at least one common terminal for every two inputs or outputs. Inputs and outputs shall be optically isolated for internal circuitry and shall be provided with reed and power relays rated 2 amperes minimum at 120 volts, 60 Hertz, suitable for operating motor starters up to NEMA Size 4, including associated surge characteristics. Where ever shown on the contract documents interposing relays shall be provided.
Analog inputs and outputs shall have a range of 4 to 20 mili-amperes, with conversion between external analog signals and internal numeric values providing at least 12-bit resolution. Timing shall be available in seconds and tenths of seconds. Arithmetic capability shall include add, subtract, multiply, and divide.
Status LED lights shall be provided for each input or output, indicating a signal is present to turn the input or output to "on." Outputs shall be fused as shown on the Plans or as required, with fuses removable without the use of special tools and with indication of blown fuses.
Each remote I/O chassis module shall be in a dedicated NEMA rated cabinet. The machinery room remote I/O chassis module cabinet shall be equipped with an air conditioner package. The cooling fan package, if provided, shall consist of a 4 inch fan, powered by 120 volt AC 60 Hz., single phase motor, air filter, composite air plenum, composite finger guard, stainless steel grille, exhaust grille, and filter with a temperature control switch. The fan assembly shall be located on the lower side of the cabinet and the exhaust grille shall be positioned near the top of the opposite side of the cabinet.
Remote I/O racks and associated peripherals shall be furnished, wired, and installed at locations shown on the Plans. Fiber optic cable and an optical communication module are utilized for Inter I/O rack communications.
For interconnection of the PLC drops “remote I/O” communication module is required to accept twisted shielded pair cable to Communicate. A remote I/O module is required to communicate between drops.
D. System Hardware: Provide power supply units, cables, and auxiliary equipment as required; and install all components in PLC cabinet in space as shown on Drawings. Complete Allen Bradley PLC system shall be wired in accordance with manufacturer's instructions and external wiring terminated on suitably marked terminals on the control desk. Data communications equipment (DCE) shall include a manual selector switch with three ports and converter cables as required to interface the switching device with the PLC's and the programming unit or modem. Modem shall consist of a synchronous line driver suitable for operating over twin standard telephone company cable pairs. Unit shall be rack mounted and suitable for operating at data rates up to 9,600 BPS, four-wire and two-wire full-duplex operation with RS232 terminal interface. Modem shall be Micom, Gandalf, or Engineer and NJDOT MBEG approved equal. Components shall be readily removable for replacement and/or repair. The modem shall be installed in such a manner that future connection to telephone company cable pair(s) is viable and convenient. The locations of each remote and local I/O Chassis module and data logger shall be as shown on the Plans.
It shall be possible to connect programming equipment to the CPU while the CPU is running without interfering with the operation of the CPU.
It shall be possible to record programs stored in a CD. The Contractor shall provide CD hardware.
It shall be possible to copy programs stored on CD into the CPU memory.
It shall be possible to verify programs stored on CD against memory stored in the CPU memory.
It shall be possible to monitor the contents of the various timer and analog registers shown on the Plans.
For each I/O rack furnished, a minimum of one spare input module and one spare output module (where applicable) shall be furnished and/or pre-wired to terminals in the rack's enclosure or cabinet ready for use.
Programming: The programming shall be entered prior to delivery of program cards using a programming panel and can be monitored and revised as required at the site using a portable programming unit. Each of the following logic symbols shall take no more than one word of CPU memory.
1. Coil with address.
2. Normally closed contact with address.
3. Normally open contact with address.
4. Branch open.
5. Branch closed.
6. The CPU shall automatically close gaps in memory when logic statements are removed, thus reducing memory size.
7. It shall be possible at any time by means of a permissive key interlock to modify an existing program in memory by inserting one or more ladder diagram rungs between any two existing (previously programmed) rungs. This ability to insert rungs of unspecified work length shall be accomplished by the technique of automatic "gap open," not by the imprecise method of reversing "contingency" blocks of memory for future changes.
System Wiring: Wiring shall be placed in a systematic way to minimize electrical noise caused by data transfer between I/O lines. Arrangement shall be as follows where possible:
All incoming power lines shall be kept separate from low-level D-C lines, I/O power supply cables, and all I/O rack interconnect cables.
Low-level D-C I/O lines, such as TTL and analog, shall be routed in the same duct in parallel with A-C signals.
I/O rack interconnect cables and I/O power cables shall be routed together in a common duct not shared by other wiring, or they shall be routed with low-level D-C lines or routed externally to all ducts and held in place using tie wraps or some other fastening method.
I/O wiring and A-C power lines shall be placed at right angles to each other to minimize possibility of electrical noise pickup.
At least 2 inches shall be allowed between the I/O modules and any wire duct and terminal strips.
The wires connected to a single module shall be bundled by using a tie wrap and shall be routed with other bundles of the same signal characteristics. The input power and output bundles carrying the same type of signals shall be kept separate whenever possible to avoid interference.
The placement of various components inside enclosures shall be away from the PLC components to minimize the effects of noise or heat generated by these devices.
Disconnect switches and/or circuit breakers and surge suppressors shall be located near the top or bottom of the enclosures.
Magnetic components (contactors, relays, and other electro-mechanical components) shall be mounted near the top or bottom of the enclosure in an area segregated from the PLC components. Barriers shall be placed with at least 6 inches separation between the magnetic area and the PLC.
Thermostatically controlled blowers shall be used for cooling the components inside any enclosure containing PLC equipment and shall be placed in a location not close to the heat generating device.
D. Testing and Installation Guidelines: All testing and installation, including software testing and debugging, for the new Allen Bradley “Programmable Logic Controller System” and all associated equipment shall be paid for under this Section. The Contractor shall follow the testing and installation guidelines in paragraphs A through I in Section 707, “Electrical Work”.
COMPENSATION
714.04 Method of Measurement.
Measurement will be on a lump sum basis.
714.05 Basis of Payment.
Payment will be made under.
Pay Item Pay Unit
PROGRAMMABLE LOGIC CONTROLLER SYSTEm lump sum
SECTION 715 – DATA LOGGING
715.01 DESCRIPTION.
The work under this section shall include providing data logging capabilities at the bridge site, transmitting data via a modem and telephone lines to the NJDOT MBEG.
It is the intent and purpose of these Specifications to cover and include all apparatus, appliances, material, and labor necessary to properly install, wire, connect, equip, test, adjust, and put in NJDOT approved working order the respective portions of the work herein specified.
All work, plant, field testing, supplying of appurtenant devices, providing necessary manuals and documentation shall be provided by a sole source. The vendor shall be Link Control Systems, Inc.
MATERIALS
715.02 Materials.
A. Bridge Data Logging System. The Contractor shall provide a Data Logging System capable of storing operational, failure data, and all aspects of bridge operation in a memory at the bridge site. The records in memory shall be able to be extracted thru a remote access bridge computer off-site operated by NJDOT MBEG. While accessing data remotely from the bridge’s PLC, the data accessed must be identified from the PLC. The computer program shall also have the capability of troubleshooting the bridge PLC from the office of NJDOT MBEG. The system shall include all necessary hardware, programming and appurtenant equipment to provide functioning as hereinafter specified. The Data Logging System shall be compatible with all equipment previously installed at NJDOT MBEG’s offices and must be in operating condition and approved by NJDOT MBEG. The system vendor must demonstrate that the printer connected to the State’s Data Logging Station prints both Allen Bradley and Square-D programs.
The Data Logging System shall monitor all malfunctions or failures in the programmable control equipment. It shall record failure of either power source and any alarm triggered by impending failure conditions. It shall record phase failure or reversal of the main power source.
The Data Logging System shall be mounted in a cabinet in the Operator’s Room. The unit shall be a stand-alone unit with processor rack, power supply, power supply cable, Allen Bradley PLC 5/40 processor, or an Allen Bradley processor with adequate memory to store all data required within these specifications, interface card, and data controller module. A maintained, 2-position key operated selector switch capable of providing data logging with switch in the left hand position and remote programming in right position. The remote Programming/Data Log key switch shall be keyed the same as the power switch on the Operator’s control desk. The two switches shall be each a key operated selector switch with key removable in the off center position and shall be mounted on the operators consoles. Procurement of the bridge data logging system shall be from Link Controls System, Ronkonkoma, New York 11779.
The following list of data will be monitored and software programmed for storage and recovery of the data at the option of NJDOT – MBEG:
1. Time Date Stamp
2. Time of red light (start of operation)
3. Monitored for faults
a. Time & Date (Default)
b. Near Side Warning Gate Overload
c. Far Side Warning Gate Overload
d. Near Side Barrier Gate 1 Overload
e. Near Side Barrier Gate 2 Overload
f. Far Side Barrier Gate 1 Overload
g. Far Side Barrier Gate 2 Overload
h. Span Lock 1 Overload
i. Span Lock 2 Overload
j. Near Side Motor 1 Brake Overload
k. Near Side Motor 2 Brake Overload
l. Near Side Machinery Brake 1 Overload
m. Near Side Machinery Brake 2 Overload
n. Far Side Motor 1 Brake Overload
o. Far Side Motor 2 Brake Overload
p. Far Side Machinery Brake 1 Overload
q. Far Side Machinery Brake 2 Overload
r. Near Side Motor 1 Overload
s. Near Side Motor 2 Overload
t. Far Side Motor 1 Overload
u. Far Side Motor 2 Overload
v. Near Side Warning Gate Hand Crank
w. Far Side Warning Gate Hand Crank
x. Near Side Barrier Gate 1 Hand Crank
y. Near Side Barrier Gate 2 Hand Crank
z. Far Side Barrier Gate 1 Hand Crank
aa. Far Side Barrier Gate 2 Hand Crank
ab. Near Side Motor 1 Brake Hand Released
ac. Near Side Motor 2 Brake Hand Released
ad. Near Side Machinery 1 Brake Hand Released
ae. Near Side Machinery 2 Brake Hand Released
af. Far Side Motor 1 Brake Hand Released
ag. Far Side Motor 2 Brake Hand Released
ah. Far Side Machinery 1 Brake Hand Released
ai. Far Side Machinery 2 Brake Hand Released
aj. Near Side Resolver 1 Calibration Error
ak. Near Side Resolver 2 Calibration Error
al. Far Side Resolver 1 Calibration Error
am. Far Side Resolver 2 Calibration Error
an. Traffic Signal Bypass On
ao. Warning Gate Bypass On
ap. Barrier Gate Bypass On
aq. Span Lock Bypass On
ar. Brake Bypass On
as. PLC 1 Selected
at. PLC 2 Selected
au. Speed 100%
av. Speed 50%
aw. Near Side Motor 1 Overspeed
ax. Near Side Motor 2 Overspeed
ay. Far Side Motor 1 Overspeed
az. Far Side Motor 2 Overspeed
ba. Near Side Motor 1 Deceleration Failure
bb. Near Side Motor 2 Deceleration Failure
bc. Far Side Motor 1 Deceleration Failure
bd. Far Side Motor 2 Deceleration Failure
be. Near Side Drive 1 Undervoltage
bf. Near Side Drive 2 Undervoltage
bg. Far Side Drive 1 Undervoltage
bh. Far Side Drive 2 Undervoltage
bi. Near Side Drive 1 Overtemperature
bj. Near Side Drive 2 Overtemperature
bk. Far Side Drive 1 Overtemperature
bl. Far Side Drive 2 Overtemperature
Near Side Drive 1 Overload
bm. Near Side Drive 2 Overload
bn. Far Side Drive 1 Overload
bo. Far Side Drive 2 Overload
bp. Near Side Warning Gate Arm Malfunction Red Traffic Signal
bq. Far Side Warning Gate Arm Malfunction Red Traffic Signal
br. Near Side Barrier Gate 1 Arm Malfunction Red Traffic Signal
bs. Near Side Barrier Gate 2 Arm Malfunction Red Traffic Signal
bt. Far Side Barrier Gate 1 Arm Malfunction Red Traffic Signal
bu. Far Side Barrier Gate 2 Arm Malfunction Red Traffic Signal
bv. Near Side Warning Gate Raising Fault
bw. Far Side Warning Gate Raising Fault
bx. Near Side Barrier Gate 1 Raising Fault
by. Near Side Barrier Gate 2 Raising Fault
bz. Far Side Barrier Gate 1 Raising Fault
ca. Far Side Barrier Gate 2 Raising Fault
cb. Near Side Warning Gate Lowering Fault
cc. Far Side Warning Gate Lowering Fault
cd. Near Side Barrier Gate 1 Lowering Fault
ce. Near Side Barrier Gate 2 Lowering Fault
cf. Far Side Barrier Gate 1 Lowering Fault
cg. Far Side Barrier Gate 2 Lowering Fault
ch. Near Side Motor 1 Brake Release Fault
ci. Near Side Motor 2 Brake Release Fault
cj. Near Side Machinery Brake 1 Release Fault
ck. Near Side Machinery Brake 2 Release Fault
cl. Far Side Motor 1 Brake Release Fault
cm. Far Side Motor 2 Brake Release Fault
cn. Far Side Machinery Brake 1 Release Fault
co. Far Side Machinery Brake 2 Release Fault
cp. Near Side Motor 1 Brake Set Fault
cq. Near Side Motor 2 Brake Set Fault
cr. Near Side Machinery Brake 1 Set Fault
cs. Near Side Machinery Brake 2 Set Fault
ct. Far Side Motor 1 Brake Set Fault
cu. Far Side Motor 2 Brake Set Fault
cv. Far Side Machinery Brake 1 Set Fault
cw. Far Side Machinery Brake 2 Set Fault
cx. Bridge Operating Time Over 20 Minutes
cy. Emergency Stop Activated.
cz. Generator Power Online
da. PLC 1 Battery Low
db. PLC 2 Battery Low
dc. Near Side Drive 1 CB Tripped
dd. Near Side Drive 2 CB Tripped
de. Far Side Drive 1 CB Tripped
df. Far Side Drive 2 CB Tripped
dg. Fuse Check
dh. Spare
Incremental Information:
1. Total failures for the current month
2. Total bridge operations for the current month
3. Total delay to vehicular traffic for the month
4. Total use of all bypass switches for the month
5. Total use of traffic light bypass
6. Total use of warning gate bypass
7. Total use of barrier gate bypass
8. Total use of bascule span bypass
9. Total drive permissive faults for the month
10. Total delayed openings for the month
11. Total incomplete openings for the month
The system shall also monitor the actuation of all limit switches and desk operating switches for proper sequenced operation. If contact operation is normal, there shall be no input to memory; if contact operation is abnormal, the failure shall be identified and stored in memory. Actuation of any bypass switch shall also be identified and recorded in memory.
The Data Logging System located in the bridge operator’s room shall be able to maintain 30 days of operational data. At the end of 30 days, data shall replace day #1. The Data logging system shall incorporate modem interfacing equipment as required to allow access to the contents of the data log operational data memory for a 30 day period by NJDOT MBEG using a standard telephone line via modem 24/7. It shall be possible for NJDOT MBEG to make a permanent record for storage by portable USB flash memory drive having a storage capacity of 1024 MB (or best/latest available) and CD at NJDOT MBEG offices. Following transfer of the data log for permanent storage, it shall be possible to erase the temporary local memory so as to make space available for data storage for a 30 day period of time. All new equipment shall be compatible with all existing data logging equipment currently being used by NJDOT MBEG and must be in a working condition satisfactory to the NJDOT MBEG.
Wiring and extending power and other necessary connections shall be provided and paid for under “Raceway, Conductors, Terminations, and Boxes”.
B. Remote Access Bridge Programming System. The New Jersey Department of Transportation, MBEG in New Jersey is equipped with a remote access bridge programming system with the ability to interface between the SQUARE-D and Allen Bradley programs. The data retrieval system software shall be modified to incorporate data logging information compatible with all existing Allen Bradley control systems on New Jersey movable bridges. Sufficient registers shall be available with the software for maximum monthly openings (for 2003, maximum was 250 openings/month). Upgrading of the software shall be furnished by Link Control Systems, Inc., Ronkonkoma, N.Y. 11779.
C. Portable Data Access Systems. For programming and editing existing and new programs/data requires two (2) portable data access systems each unit shall be a “DELL Latitude D800” latest version and shall contain as a minimum the following:
1. All standard variables of the latest DELL LATITUDE D810 (advanced version, as per WWW.)
2. Leather Carrying Case
3. Allen Bradley RS-Logix and RS-View Full Version Software Packages Installed
Top server software and other required software/hardware necessary to communicate with the control and data logging systems as described herein for the purpose of troubleshooting and data retrieval.
D. Miscellaneous Units/Devices
Quantity Material Description
1 Hewlett Packard Deskjet 9800d Color Inkjet Printer
2 USB 2.0 Printer Cable
4 Super Talent Flash – USB 2.0 Flash Drive 1GiB capacity, Model: STF_O_USB2.
2 Belkin F3U133-06-APL USB 2.0 Device Cable 6 feet
10 Hewlett Packard 96 Black Inkjet Print Cartridge
6 Hewlett Packard 97 Photo Inkjet Print Cartridge
6 Hewlett-99 Photo Inkjet Print Cartridges, Tri-Color
6 Hewlett Packard 100 Photo Inkjet Print Cartridge, Grey
20 Hewlett Packard Premium Plus Photo Paper, High Gloss (50 sheets 8½ x 11)
CONSTRUCTION
715.03 Construction.
All hardware and software shall be acceptable to the MBEG prior to purchase and installation. All software shall be compatible with the computer’s operating system.
The Integrator shall forward all manuals, instructions, documentation, software and literature received with the bridge computer system to the MBEG, and shall supply all cables and connections for the computer system.
Link Control Systems, Inc., the Integrator, shall supply Automatic Retrieval Programs for Allen-Bradley PLC Systems and shall supply all software, programs, cables, and cards (keys) necessary for system to download Allen-Bradley retrieval systems automatically a minimum of once per month.
Due to the volatility of current technology, the Integrator shall be required to submit catalog cuts for all items prior to procurement to Mr. Roy Bill at the NJDOT MBEG office. All items, devices, or units except the data logger shall be shipped to NJDOT MBEG intact. All Square-D cards in the data logging cabinet shall be removed, cleaned, carefully packaged, and delivered to the NJDOT MBEG in Freehold.
715.04 Field Testing.
After installation of the data logger at the bridge site and the data retrieval updated software at the MBEG Office, the vendor shall provide all necessary tests to show that the system is operating satisfactorily. System discrepancies or non-functional items shall be corrected and the systems shall be retested at no additional cost.
715.05 NJDOT Acceptance.
The Contractor and Subcontractors shall not deviate from the Engineer’s design in any way, without written authorization from the Engineer, and NJDOT MBEG. All aspects of the data logger equipment and software installation must be stamped and approved by the Engineer and NJDOT MBEG prior to construction. All aspects of data logger equipment and software must be completely functional and fully operational and accepted by the Engineer and NJDOT MBEG. Payment to Contractor and subcontractor will only be warranted when complete acceptance has been given in writing by the Engineer and NJDOT MBEG.
COMPENSATION
715.06 Method of Measurement.
Measurement will be on a lump sum basis.
715.07 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
DATA LOGGING LUMP SUM
SECTION 716 - DIESEL ENGINE GENERATOR REHABILITATION
716.01 DESCRIPTION.
The work shall consist of rehabilitating, and placing in proper operating condition, acceptable to NJDOT MBEG, NJDOT Maintenance Department and the Engineer, the existing 100 KW diesel engine generator in the generator room of the Southeast house, complete with all appurtenances, required for proper operation.
All conduits, boxes, wiring, cables, and other equipment required to extend the necessary circuits to and from the diesel engine generator shall be furnished and installed under the item of "Raceway, Conductors, Terminations and Boxes." All internal generator wiring shall be paid for under this Section, and shall conform to the requirements in "Raceway, Conductors, Terminations and Boxes.”
It is the intent and purpose of these Specifications to cover and include all apparatus, appliances, material, plant and labor necessary to properly rehabilitate, wire, connect, equip, test, adjust, and put in approved working order the respective portions of the work herein specified.
The existing components of the diesel engine generator to be replaced shall be disconnected, removed, and/or salvaged in accordance with Section 539 “Demolition and Removal”.
MATERIALS
716.02 Materials and Equipment.
A. Conformance. All equipment and its installation shall conform to the requirements of the latest revision of the Standard Specifications for Movable Highway Bridges of the American Association of State Highway and Transportation Officials, except as may be otherwise provided herein.
Materials and construction shall conform to the requirements of the current National Electrical Code and to any applicable local rules and ordinances. The Contractor shall obtain any required permits and approvals of all Departments or Agencies having jurisdiction.
B. Equipment and Material Provisions. The diesel engine generator and all associated equipment and materials shall be new or refurbished only as required. All equipment, materials, and workmanship shall be first-class in every aspect of this project and shall be manufactured and erected to the satisfaction of the Engineer, and NJDOT MBEG and Maintenance Department. See Section 707, “Electrical Work” for Control System Vendor Requirements. The Contractor shall warrantee the in-service working of the diesel engine generator for one year following the date of project acceptance. If the Contractor has any objection to any feature of the equipment as designed and laid out, he must state his objection at once, in writing, to the Engineer and NJDOT MBEG; otherwise, his objection will be not be valid as an excuse for operational malfunctioning of the equipment or for defective or broken apparatus.
Each piece of replaced or rehabilitated electrical equipment and apparatus shall have a corrosion-resisting non-rusting metal nameplate, on which is stamped the name of the manufacturer, the rating or capacity, and all other relevant information of the equipment and/or apparatus.
All mounting hardware and all wire and cable terminals shall be vibration-proof and weather-proof.
If any changes from the Plans or these Specifications are deemed necessary by the Contractor, details of such departures and the reasons therefore shall be submitted for approval as soon as practicable before construction. No such changes shall be made without approval of the Engineer and NJDOT MBEG.
The diesel engine generator and equipment drawings, operation, and maintenance procedures shall be included in the electrical Instruction Books and Drawing Books as described in Section 707, “Electrical Work”.
Material requirements for apparatus, equipment, and materials will be found in the articles under "Construction" in this item.
CONSTRUCTION
716.03 Construction.
A. Existing Standby Diesel Engine Generator Rehabilitation. Under this item, the Contractor shall rehabilitate, upgrade, and re-test the existing standby generator set operating at 480V/277 Volts, 150 kW nominal electrical generating power. The engine generator shall provide complete backup power for the bridge bascule span motor and the remaining load. See Section 533, “Mechanical Work”, for emergency bascule span operation, machinery room diesel engine operation system, and rehabilitation. Under this item, the Contractor shall rehabilitate, upgrade, and re-test the existing standby generator set operating at 480V/277 Volts, 150 kW nominal electrical generating power. The engine generator shall provide complete backup power for the bridge bascule span motor and the remaining load. See Section 533, “Mechanical Work”, for emergency bascule span operation, machinery room diesel engine operation system, and rehabilitation.
It is the intent and purpose of the existing standby diesel generator set rehabilitation provisions to cover and include all apparatus, appliances, material, and labor necessary to properly rehabilitate, install, wire, connect, equip, test adjust, and put in approved working order the respective portions of the standby generator work herein specified.
The standby generator set rehabilitation work shall include the following:
1. Refurbish the generator set Diesel engine including engine block, crankshaft and pistons, valves, hoses, belts, filters, fuel indicator, cooling system including radiator and radiator fan, engine controls, governing system, starting system, exciter system, fuel lines, manifold, vibration isolators, exhaust pipes, and all other worn out components. Existing block heater shall be replaced with new in-kind block heater and shall be connected to the auxiliary power supply. For new intake and exhaust combination louvers, refer to Section 707 – “Electrical Work”:
2. Refurbish the electrical synchronous generator. The refurbishing of the generator shall include cleaning and painting, upgrade to new electronic voltage regulator controls with +/-0.5% voltage regulation capability, replacement of electrical conductors with damaged insulation, replacement of control relays and all other in-operational or obsolete control electro-mechanical components. The generator set shall also be retrofitted with a remote annunciator installed in the operator’s room. At present, none of the control components in the control box, mounted on the engine generator are connected. The Contractor shall connect the local alarm kit also.
3. The generator set exhaust system rehabilitation shall also include furnishing and installing a new silencer to satisfactorily reduce engine and exhaust noise minimum 25 dBA.
4. The Contractor shall ensure that a proper, solid, neutral to ground connection is furnished and installed at the generator service point, and shall be connected to the bridge grounding system as shown on the Plans.
5. Remote-control circuits for starting and stopping of the engine-generator shall be so arranged that the engine is automatically controlled by contacts of an automatic transfer switch.
6. The Contractor shall furnish all equipment, conduits, wiring, supports, and fittings required to extend the standby power feeder and grounding conductor from the engine-generator control panel to the bridge transfer switch cabinet as shown on the Plans. The Contractor shall furnish and install all conduits, wiring, operators room annunciator, and other equipment required for remote starting and stopping of the engine-generator for the battery charger, jacket heater, and associated controls. The connections of these circuits at the engine control panel shall be made as described in the Plans.
The rehabilitated generator set controls must be capable of detecting the following conditions, indicate if the condition will shutdown the generator or provide a warning, and annunciate the situation.
1. Emergency stop
2. High coolant temperature
3. High oil temperature
4. Controller internal fault
5. Locked rotor
6. Low coolant level
7. Low oil pressure
8. Overcrank
Remote Annunciator: A repetitive alarm annunciator panel will be supplied complying with the NFPA110 requirements. The remote annunciator shall be wall mounted in the operator room, in sight from the bridge control desk. The NFPA requires audible and visual signal drives, powered by an electrical storage battery, be provided to give warning of derangement or alarm conditions in the alternate electric power source. (Standby Electric Generator Set) In accordance with NFPA110, the alarm annunciator audible system allows for a first alarm to be silenced and if a second alarm occurs, the alarm system will again sound the alarm. The annunciator panel will include the following features:
1. Low battery voltage
2. Low oil pressure
3. Engine overspeed
4. Engine overcrank
5. Low water temperature
6. High engine temperature - pre-alarm
7. Low fuel
Site Tests: Following the generator rehabilitation work, the Contractor shall perform an installation check, start-up, and load test using only one leaf at a time. The Engineer and NJDOT MBEG, bridge operators, and the maintenance staff shall be notified of the time and date of the site test. The tests shall include:
Fuel, lubricating oil, and coolant shall be checked for conformity to the manufacturer's recommendations, under the environmental conditions present and expected:
Accessories that normally function while the set is standing by shall be checked prior to cranking the engine. These shall include: block heaters, battery charger, generator strip heaters, remote annunciator, etc.
Start-up under test mode to check for exhaust leaks, path of exhaust gases outside the building, cooling air flow, movement during starting and stopping, vibration during running, normal and emergency line-to-line voltage and frequency, and phase rotation.
Automatic start-up by means of simulated power outage to test remote-automatic starting, transfer of the load, and automatic shutdown. Prior to this test, all transfer switch timers shall be adjusted for proper system coordination. Engine coolant temperature, oil pressure, and battery charge level along with generator voltage, amperes, and frequency shall be monitored throughout the test. An external load bank shall be connected to the system if bascule span load is unavailable to load the generator.
Should the tests show that the engine-generator or any component piece of equipment or apparatus, in the judgment of the Engineer and NJDOT MBEG, is defective or functions improperly, such adjustments and/or replacements shall be made by the Contractor as to make the installation satisfactory to the Engineer and NJDOT MBEG at no extra cost.
Warranty and Maintenance: The rehabilitated diesel engine generator set shall be guaranteed against defective material and workmanship for one year from date of start-up. Optional warranties shall be available upon request.
B. Testing and Installation Guidelines. All testing and installation for the “Diesel Engine Generator Rehabilitation” and all associated equipment shall be paid for under this Section. The Contractor shall ensure that the diesel engine generator is in proper working condition prior to final acceptance testing included in Section 537. The Contractor shall follow the testing and installation guidelines in paragraphs A through I in Section 707, “Electrical Work”.
COMPENSATION
716.04 Method of Measurement.
Measurement will be on a lump sum basis.
716.05 Basis of Payment.
Payment will be made under.
Pay Item Pay Unit
DIESEL ENGINE GENERATOR REHABILITATION LUMP SUM
SECTION 717 – TEMPORARY BRIDGE OPERATION DURING CONSTRUCTION
717.01 DESCRIPTION.
To maintain bridge operation during construction: temporary (emergency) span motor assembly, bascule span control, lighting, and associated safety features shall be installed and made operational prior to the demolition and removal of the existing systems. The closed circuit television system, lighting, and all traffic devices, i.e., traffic signals, traffic warning gates and barrier gates shall be operational at all times during temporary operation. The existing barrier gates will not be operational during Stage IB, when the movable span is in the down position except for Sunday openings. The new barrier gates will be hand cranked into position during these Sunday openings to protect the traveling public from approaching/striking the open span during these times. Utility service will be un-interrupted during various stages of construction, except while a switch-over from the existing embedded utility service wiring to the new installed service wiring, either in pre-stage or Stage I, service will be disrupted for a few hours. During that period, an engine generator shall be used to power essential devices.
Temporary operation of the bridge bascule span during construction shall be as follows:
A. Pre-Stage I – Normal Bascule span Operation. Bridge bascule span will continue operation as before, using existing electric bascule span motor and thyristor drive system.
B. Stage I - Normal Bascule span Operation in the beginning with switch over to Direct Diesel Drive/Temporary Span Motor assembly operation. Traffic devices will be operated normally in Stage IA, but barrier gates will be hand crank operated in Stage IB.
C. Stage II – Diesel Drive/Temporary Span Motor assembly operation. Bridge bascule span operation using rehabilitated diesel engines or temporary span motor assembly located in the SW and NE tower houses. Traffic devices will be operated by either Utility service or rehabilitated diesel engine generator set and controlled by temporary programmable controller system.
D. Stage III – Diesel Drive/Temporary Span Motor assembly operation. Bridge bascule span operation using rehabilitated diesel engines or temporary span motor assembly located in the SW and NE tower houses. Traffic devices will be operated by either Utility service or rehabilitated diesel engine generator set and controlled by temporary programmable controller system.
E. Stage IV - Diesel Drive/Temporary Span Motor assembly operation. Bridge bascule span operation using rehabilitated diesel engines or temporary span motor assembly located in the SW and NE tower houses. Traffic devices will be operated by either Utility service or rehabilitated diesel engine generator set and controlled by temporary programmable controller system.
During Stage IV, new permanent span operation system, using VFD’s will be tested for acceptance. End of Stage IV, the bridge bascule span will be operated by new flux vector drives/motors assemblies.
717.02 Control System Vendor (Integrator).
The Bridge Control System Vendor (Integrator) prerequisites shall be as indicated in Section 707, and the Vendor shall be Link Controls, Inc or NJDOT MBEG approved equal. The Integrator shall provide a field test for the temporary system and the Contractor shall provide the necessary field start-up service in accordance with Section 707. The Integrator shall provide 10 copies of a “Bridge Operators Manual – Temporary System” including wiring and schematic diagrams, SLC software ladder logic diagrams and complete catalog cut sheets of all temporary system products.
MATERIALS
717.03 Materials and Workmanship.
All electrical equipment and its installation shall conform to the requirements of the current standard specifications for movable highway bridges of the American Association of State Highway and Transportation Officials, except as may be otherwise provided herein.
All work shall conform to the requirements of the current National Electrical Code, and to any applicable local rules and ordinances. The Contractor shall obtain any required permits and approvals of all departments or agencies having jurisdiction.
All equipment and materials except those designated to be reused shall be new. All equipment, materials and workmanship shall be first rate in every aspect of the project, and shall be manufactured and installed to the satisfaction of the Engineer and NJDOT MBEG. The Plans and Specifications contain a proposed method of maintaining bridge operation during construction.
CONSTRUCTION
717.04 Working Drawings.
The Contractor shall prepare and submit for review and approval within thirty (30) days after the award of the contract the following working drawings, for the SW and NE tower rooms Direct Drive Diesel Engine and Temporary Span Motor assembly, executed in accordance with the provisions of the contract.
717.05 Construction Existing Facilities.
A. Maintaining Existing Facilities. The Contractor shall conduct his operations in such a manner as to maintain the existing bridge electrical equipment and systems in operating condition at all times throughout the construction in accordance with the approved work schedule and all requirements for construction staging. This includes but not limited to navigation lights, traffic signals, warning and barrier gates, roadway lights, lighting and heating and any other electrical facilities required for safe operation of the bascule span. The Contractor shall furnish and install any temporary facilities, equipment, and personnel necessary to conform above requirements. The arrangement of any temporary facilities and controls shall be approved by the Engineer and NJDOT MBEG. Lane closures shall be in accordance with the requirements listed on the maintenance of traffic plan sheets.
The Contractor shall be held responsible for the maintenance and repairs of the bridge components from the start of the project to the final acceptance. Maintaining all electrical facilities for tower houses, including heaters, lighting (lamp and/or ballast replacement, fixture cleaning etc.) shall be Contractor’s responsibility. The Contractor shall be held responsible for the operation of the bascule span during periods defined in Section 107.13 “Construction over or adjacent to Navigable Waters”.
The maintenance shall also include regular greasing every month, fluid change, electrical control maintenance and also repairs to any breakdowns during the construction period. All open gearing, bearings, and lock bars shall be greased monthly. All enclosed gear reducers and flexible couplings shall be drained/purged and refilled annually. For a list of approved lubricants see Subsection 533.03.
The Contractor and NJDOT Personnel shall examine all the required facilities on the bridge and he shall note items requiring modification prior to start of mandated maintenance.
Upon issuance of a report of non-operating items to the Engineer and NJDOT MBEG he shall make arrangements with the General Contractor or other parties to repair mal/non-functioning items.
B. Bridge Operating Personnel. During the reconstruction period it shall be the Contractors responsibility to maintain the bridge in a suitable manner to ensure unbroken service.
During the construction staging period and when the bridge is operational to navigation traffic, the Contractor shall provide qualified operators with previous movable bridge operational experience for each opening. One NJDOT Bridge operator will be present 24 hours per day to operate the bridge and supervise the Contractors’ operators. Bridge openings are based on a five (5) minute notice. The bridge shall be manned 24 hours per day, 7 days per week.
Bridge opening time for construction and test purposes, shall be limited to a total roadway closure to traffic of no more than 15 minutes at a time, with traffic allowed to completely clear prior to allowing another opening.
During the normal working day, the Contractor shall have in attendance at the bridge two personnel who are knowledgeable as to the bridge workings and be able to perform electrical troubleshooting. At all other times he or she shall be available to report at the bridge within half an hour, after verbal notification by the Engineer or other duly appointed representative.
717.06 Temporary Operation System.
A. Description.
1. Temporary (emergency) Span Motor: The span drive motors shall be reversible, crane and hoist duty design D, 2 speed, 2 winding motors. They shall be built in accordance with NEMA publication MG-1. The motors shall be 3 phase, 60 hertz, with moisture resistant insulation, 40 degree C ambient temperature.
a. Horse power: 15/7.5 HP
b. Nominal Voltage: 480_ VAC
c. Nominal speed: 1800/900 RPM
d. Duty: 60 minute
e. Insulation: BBB
f. Service Factor: 1.0
The motors shall be totally enclosed, non-ventilated type, with re-greaseable ball bearings, moisture resistant insulation with internal space heater. The motor shafts shall be Cadmium plated. A drain hole of not less than 1/2 inch diameter shall be provided at the bottom of the motor.
The motor shall be capable of having a minimum locked rotor torque of 260%.
All winding shall be copper. The conduit boxes shall be sized in accordance with the requirements of the NEMA MG 1-1987 PART 11 and NEC requirements and located to avoid interference with the machinery.
Each motor shall be subjected to a full load test in accordance with the current requirements of the NEMA MG 1-1987 PART 12, and IEEE STD 112-1984. The data shall be certified and submitted to the Engineer on the IEEE forms. The Engineer shall be notified of the time and place of the testing at least two weeks in advance of the testing. The Engineer shall determine if the motors are as specified and in accordance with requirements.
All motors must be manufactured to the following standards:
1. IEEE Marine Standards No. 45.
2. American Bureau of Shipping (A.B.S.).
3. U.S. Coast Guard Inspection Service.
Modifications needed to meet the requirements of these specifications are as follows:
1. All aluminum parts - chemical film (MIL-C-5541) and zinc chromate primer
(MIL-P- 8595).
2. Cadmium plate shaft and hardware (FED-QQ-P-416).
3. Re-greaseable ball bearings.
4. Screens over all openings - 3 x 3 mesh - galvanized (drip-proof protected only).
5. Seal all joints and eye bolt holes.
6. Sealed leads in terminal box (waterproof - TENV and TEFC).
7. Shaft seals (waterproof - TENV and TEFC).
8. Removable drain plugs (waterproof - TENV and TEFC).
9. Final coat of epoxy paint.
10. Corrosion resistant coating - rotor and stator laminations.
11. Stainless steel nameplate.
12. Insulation to protect against fungus growth per MIL-V173B.
The motor frame shall be finished with a corrosion-resistant paint or coating. Exposed unpainted metal surfaces shall be of a corrosion-resistant material. Motors shall be exposed to outdoor conditions with no harmful effects top the motor.
Both motors shall be furnished with rear (opposite drive end) mounted brakes. Each brake shall be of the disc type. A micro switch, with 2 N.O. and 2 N.C. contacts shall be provided for brake release/ set controls and indication. They shall be energized by 460/3/60 electrical service. Brakes shall be sized according to the engineer’s specifications as shown on the drawings.
A 3.23:1 gearbox with a minimum efficiency of 95% shall be mounted in-line with the brake-motor. The gearbox shall have a 2.0 S.F. A clutch, with a micro switch having 2 N.O. and 2 N.C. contacts shall be mounted to the output of the gearbox and rated for 465 ft-lbs. The complete motor-brake-clutch assemblies shall be provided by the motor manufacturer.
After entire motor, brake, clutch, gearbox and control system installation, the Contractor shall perform a load test and plot Speed/Torque/Amp. curves to demonstrate that the motor functions properly and has the specified operating characteristics. The data shall be recorded on a chart recorder and include acceleration, deceleration, full speed, reduced speed and creep speed.
The complete temporary motor assembly with controls will be installed at locations as shown on the contract plans.
Specified Motor assemblies shall be manufactured by Reuland Electric or the engineer and NJDOT MBEG approved equal.
2. Temporary Control System. Allen Bradley small logic controller (SLC) shall be used, as a temporary control system to operate the bascule span. The SLC system shall be controlling the temporary 15/7.5 H.P. motor assembly. The SLC central processing units, a redundant system, shall be furnished and installed in a traffic control/SLC cabinet having all traffic control devices, brakes, selector switches, indicating lights, on/off switches, In View message display and other miscellaneous devices as shown on the contract plans. The cabinet shall be located in the operator’s room. Two SLC input/output drops chassis shall be located in the southwest and northeast house rooms located at sub-level one, near temporary motor assembly control cabinet. The integrator shall furnish, assemble and put into operation the entire temporary control system.
The temporary control system shall be completed and operational by the middle of stage one. The Contractor shall provide a necessary temporary electrical panel board and wiring to operate traffic devices. The integrator shall schedule a factory acceptance test, as described under Section 707 – “Electrical Work” and get approval from the engineer, before shipping the equipment out to the bridge site.
B. Control System Integrator. The Control System Integrator, Link Control Systems Inc., or NJDOT MBEG approved integrator shall be responsible for ensuring all components of the traffic devices are intact and that missing or damaged items are replaced. Power supplies and system appurtenant items shall be checked.
The integrator shall also be responsible for training the NJDOT Maintenance Department and Bridge operators temporary system operation. The integrator shall also offer courses, similar/ or same, as listed below:
1. CCP122 PLC-5/SLC 500 Fundamentals Using RSLogix
2. CCPS65 SLC 500/PLC-5 Communications
3. CCPS41 SLC 500 Programming
4. CCPS43 SLC 500 Maintenance & Troubleshooting
5. CCPS42 SLC 500 Advanced Programming
6. CCPS45 SLC 500 Advanced Maintenance & Troubleshooting
The above listed courses are offered by Allen Bradley. The cost of temporary system training shall be included under this Section 536 – “Temporary Bridge Operation During Construction”.
Emergency Control Desk
An emergency bridge control desk shall be furnished and installed in the operator’s room of the control house next to the existing main control desk as shown on contract plans. On the desk shall be mounted all devices for controlling operation of the lift span and its auxiliaries during construction and for emergency operational purposes. The desk shall be of neat, substantial construction. It shall be fabricated from No. 10 gauge sheet-steel, properly formed and suitably reinforced to provide adequate strength. The desk top shall be fabricated of No. 10 gauge, Type 304 stainless steel sheet with a non-glare, satin finish. Removable doors shall be provided in the front pivoted on 90 degrees hinges, and secured with flush type, three-point vault type latches. Side of the desk adjacent to the main control desk shall have a cut-out for easy access to the main control desk interior. The emergency desk shall be neatly fitted up with close joints, and all rough edges or corners shall be ground off smoothly, and all projecting edges rounded off. All metal hardware shall be of substantial construction and shall have a satin-chrome plate finish. All equipment mounting screws and bolts shall be stainless steel.
The sheet-steel portions of the desk and all metal reinforcing shall be painted inside wit two coats and outside with three coats of paint, consisting of one coat of primer followed by two coats of enamel on the outside surfaces and one coat of white enamel inside. The finish coat shall be of a color to match the house interior. Color samples shall be subject to approval by the Engineer. The stainless steel desk top shall not be painted.
Special care shall be taken throughout the construction to insure that the stainless steel desk top and the equipment mounted thereon are completely protected from damage or defacement at all times.
One fluorescent desk interior service light, 15 amp duplex receptacle and thermostatically controlled strip heater shall be furnished and installed in the desk interior.
All contact blocks for control switches, pushbuttons, and other control devices shall be mounted within the body of the desk. The operators for these devices shall protrude through the desk top. The indicating lights for each operation shall be incorporated with the control device governing that operation.
The escutcheon plates of all control switches, pushbuttons, and by pass switches shall be made of a hot-polished, laminated phenolic compound no less than 3/16-inch thick. The compound shall have a white surface 1/32-inch thick, an intermediate black layer 1/32-inch thick, and a white back 1/8-inch thick. All corners shall be rounded, and the edges of the plates shall be chamfered. All engraving shall be upper case, standard gothic characters, cut through the surface and into the intermediate layer. All plates shall be securely fastened to the desk top with stainless steel screws.
The wiring within the control desk shall be insulated switchboard wire Type SIS. Wire shall not be smaller than #14 AWG except all power wiring for lights, heaters and major power feeds shall not be smaller than 12 gauge. The wiring shall be arranged systematically so that all circuits can be readily traced. All conductors shall be terminated on easily accessible terminal blocks mounted inside the desk at the rear. Spare terminals totaling at least 20 percent of those actually used shall be provided. Wiring shall be identified at equipment terminals by marking the adjacent area with bright yellow painted numbers to correspond to conductor designations appearing on the Contractor’s wiring diagrams.
Indicating lights, Square-D class 9001, type k, 30mm shall be mounted on the control desk to show that the various steps in the sequence of operation have taken place so that the operator may proceed to subsequent steps at the proper time. The functions to be indicated and the color of the lenses shall be as shown on the Plans.
A SLC I/O rack and all associated equipment shall be mounted within the desk to incorporate the selector switches, pushbuttons, indicating lights, relays and desk meters with the SLC.
It shall be the Contractor’s responsibility to ensure control desk will fit into the operator’s room prior to manufacture. It shall be the Contractor’s responsibility to provide any hoisting devices required. Patching any damaged areas, including windows shall be the Contractor’s responsibility. The Contractor shall submit to the Engineer the method of bringing the emergency desk and any additional work required.
C. Demolition/Salvage
The cost of the Demolition/Salvage of all temporary equipment shall be included in the lump sum price of Section 539, “Demolition and Removal”.
717.07 Temporary/Emergency System Testing:
Before temporary system commissioning, the Contractor shall perform acceptance testing to the satisfaction of the Engineer, MBEG, and NJDOT maintenance and submit a report of the tests performed and the results obtained. Format of the report and the tabulations must be approved by the Engineer and MBEG. The temporary system will be operational after construction is completed and will be used as an emergency system.
COMPENSATION
717.08 Method of Measurement.
Measurement for all other items will be on a lump sum basis.
717.09 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
TEMPORARY BRIDGE OPERATION DURING CONSTRUCTION LUMP SUM
SECTION 718 - ACCEPTANCE TESTING
718.01 DESCRIPTION.
The work shall consist of testing and placing in proper operating condition, acceptable to NJDOT MBEG and the Engineer, the complete rehabilitated bridge electrical and peripheral systems.
It is the intent and purpose of these Specifications to cover and include all apparatus, appliances, material, plant and labor necessary to properly install, wire, connect, equip, test, adjust, and put in approved working order the respective portions of the work herein specified.
MATERIALS
718.02 Materials.
A. Conformance. All equipment and its installation shall conform to the requirements of the latest revision of the Standard Specifications for Movable Highway Bridges of the American Association of State Highway and Transportation Officials, except as may be otherwise provided herein.
Materials and construction shall conform to the requirements of the current National Electrical Code and to any applicable local rules and ordinances. The Contractor shall obtain any required permits and approvals of all Departments or Agencies having jurisdiction.
B. Equipment and Material Provisions. All acceptance testing equipment, including infrared thermographical camera for loose connections, materials, and workmanship shall be first-class in every aspect of this project and shall be manufactured and installed to the satisfaction of the Engineer, and NJDOT MBEG and Maintenance Department. See Section 707, “Electrical Work” for Control System Vendor Requirements. If the Contractor has any objection to any feature of the equipment as designed and laid out, he must state his objection at once, in writing, to the Engineer and NJDOT MBEG; otherwise, his objection will be not be valid as an excuse for operational malfunctioning of the equipment or for defective or broken apparatus.
If any changes from the Plans or these Specifications are deemed necessary by the Contractor, details of such departures and the reasons therefore shall be submitted for approval as soon as practicable before construction. No such changes shall be made without approval of the Engineer and NJDOT MBEG.
CONSTRUCTION
718.03 Construction.
A. Control System Testing. The Contractor shall show, by testing using properly calibrated meters, that all control equipment is working within the manufacturer’s published limits.
The Control System Vendor shall show, step-by-step using the PLC software, that the bascule span operates per specifications and has all interlocks included in the software. The following equipment shall be tested for acceptance according to the specifications:
1. Traffic signals and “Red Signal Ahead” signs
2. Warning gates
3. Barrier gates
4. All types of limit switches
5. Complete PLC system
6. Flux Vector Drives
7. Bridge Lighting
8. Miscellaneous Equipment
B. Diesel Engine Generator. The Contractor shall test the generator room rehabilitated diesel engine generator to show that the bridge bascule span can be operated, one leaf at a time, using the diesel engine generator. All control system interlocks must be active and operational during this phase.
C. Diesel Engine. The Contractor shall operate the diesel engine, and show that should both other modes of bascule span operation fail, the bascule span can be lifted as per the specifications.
D. Test Procedure. The Contractor shall submit the detailed testing procedure to the Engineer for approval. The information shall also include the information on meters and infrared thermographical camera to be used while testing.
COMPENSATION
718.04 Method of Measurement.
Measurement will be on a lump sum basis.
718.05 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
ACCEPTANCE tESTING LUMP SUM
SECTION 719 – TRAINING
719.01 DESCRIPTION.
Under this section, training for bridge operators, maintenance staff and engineering staff shall be provided. The training shall include on-site as well as off-site locations. Topics shall include variable frequency drive control, PLC-installation, programming, hardware, software and peripheral items, PLC maintenance and troubleshooting, closed circuit television system, barrier gates, stand-by engine generator, thrustor brake operation and maintenance, resolvers/encoders, proximity switch and limit switch settings, topics on fiber optics-installation, connection and testing shall also be included.
719.02 Training.
A. Bridge Operator’s Training. When the bridge has been completed, tested and approved by the Engineer, and NJDOT MBEG and Maintenance, the Contractor shall provide bridge operator training for a period of eight (8) consecutive working days. The Contractor’s trainer shall be a skilled person with training experience relative to bridge operation, and competent to operate the bridge and be completely familiar with the equipment used in the bridge operation and its auxiliaries. The Contractor shall submit the name of the skilled personnel for approval by NJDOT MBEG and the Engineer. He or she shall also be required to make any adjustments required to the electrical or mechanical equipment within the scope of the contract.
During the 8-day period specified above the approved trainer shall be in attendance at the bridge site for a normal working period of 8-hours per day. At other times, during the 8-day period, he or she shall be available to report to the bridge within 1 hour after verbal notification from the NJDOT Engineer or his or her appointed representative.
B. Bridge Operator’s Manual. The Contractor shall provide to NJDOT ten (10) copies of the Bridge Operating Instruction Manual as indicated in Section 527.04-B. This manual shall be furnished to the bridge operators one (1) week prior to starting of the training session. The Contractor’s trainer shall describe to the bridge operators in detail all salient features contained on the control desk units and how they operate. Operation of each switch and pilot light shall be described. All phases of operations and the bridge operator’s responsibility to maintain the bridge in operation shall be described.
C. Training for Service Personnel and Engineers. In addition to the bridge operators training, the Contractor/Vendor shall arrange through the NJDOT, MBEG additional training sessions as indicated hereinafter.
Each training session shall be limited up to 10 trainees. The training sessions shall include, but not be limited to: theory, installation, operation, set up procedures, adjustments, troubleshooting and repair.
The bridge control system vendor and Contractor shall organize and prepare necessary training sessions for the following topics:
1. Flux Vector Drive – Theory, Programming, Troubleshooting 2 Days
2. Engine Generator Set and Diesel Bascule span Engine 1½ Days
3. PLC training – See Section 538.03
4. Brakes, Limit Switches, Resolvers and Associated Control
5. Devices Related to the Current Contract 2 Days
6. Barrier Gates and Warning Gates 1 Day
7. Mechanical/Machinery Work 2 Days
D. Training Materials. Each training vendor shall submit the course outline of the topics to be presented at the training sessions. All courses shall be presented by competent instructors with relevant experience. Each training vendor shall submit the instructor’s qualifications for approval prior to the training session.
E. Space Procurement. It shall be the Contractor’s responsibility to procure adequate space for the training program. The Contractor shall coordinate the training schedule with each training vendor and supply any necessary items to properly allow the training vendor to conduct his courses. Supplying notebooks, paper for the students, visual aid devices, blackboards, and projection equipment shall be the responsibility of the Contractor.
719.03 PLC Training.
One four day training session will be provided by the PLC Manufacturer (Allen Bradley/Rockwell Automation) at their off-site training facilities at Rockwell Automations, 299 Cherry Hill Road, Suite 200, Parsippany, New Jersey 07054. The PLC training sessions shall be as follows:
1. one (1) 2-day Basic/Intro course – CCP101.
2. one (1) 4-day Programming course – CCP410.
3. one (1) 5-day Advanced Programming course – CCP411.
4. one (1) 4-day Maintenance and Troubleshooting course – CCP412.
The Contractor shall make arrangements with Allen Bradley/Rockwell Automation to provide the training sessions to run concurrently with the Bridge Operator’s training.
Arrangements for the PLC Training sessions shall be made through: ROCKWELL AUTOMATION – GLOBAL TECHNICAL SERVICES”.
A. Course Purpose. This course provides the most effective procedures for isolating and correcting problems with 1785 PLC-5 systems using RS Logix 5, RS Who, and RS Linx software. Instructors will demonstrate each procedure in detail; then provide realistic situations that require attendees to do relevant practice exercises and demonstrate proficiency in each procedure. In addition, students will learn how to perform program editing, saving and restoring memory.
This course covers all of the PLC-5 processors.
B. Course Objectives. Upon completion of this course, all attendees should be able to perform the following tasks:
1. Make changes to PLC-5 programs and hardware as specified by others using RS Logix 5 Software.
2. Isolate and safely correct the most common problems in the 1785 PLC-5 system.
C. Topical Outline. Subject Topics of Allen Bradley’s Course CCP101.
1. What is a Control System.
2. Identifying Common Features of Programmable Controllers.
3. Identifying Functionality of an I/O System.
4. Distinguishing I/O Configurations.
5. Identifying the Functionality of a Programming System.
6. Interpreting the Memory Structure of a PLC-5 Processor.
7. Identifying PLC-5 I/O Addressing.
8. Interpreting Ladder Logic.
9. Entering Ladder Logic.
10. Interpreting TON and CTU Instructions.
Subject topics from customized PLC Basic’s & Maintenance & Troubleshooting with the 1785 PLC-5 system:
1. Copying, Restoring and Saving Programs.
2. Searching and Replacing Programs Elements.
3. Modifying Ladder Programs.
4. Modifying Data Table Information.
5. Troubleshooting (including interpreting program logic for the purpose of troubleshooting).
6. All as applied to Movable Bridges.
D. Recommended Attendee Prerequisites. Each attendee should have experience troubleshooting and maintaining control systems and be familiar with basic control and electrical principles.
E. Each Attendee will Receive:
1. Student manual
2. Product documentation manuals
3. Hands-on experience
4. Practice exercises
5. Personalized certificate of completion
F. Facility Requirements:
1. Provided by Allen Bradley
2. Provisions for lunch
G. Logistics:
1. 4 days of class instructions per session. One session required
2. Allen Bradley will provide materials and workstations for up to 10 attendees per session
3. Class must be held during normal working hours/day (Monday through Friday, 8 AM – 5 PM)
H. Future Training. Available from Allen Bradley/Rockwell Automation – to be included in Training Session – furnish two (2) 10-unit packs of future training coupons (each pack of coupons shall be usable for a period of three (3) years from date of acceptance).
719.04 Training Schedule.
The Contractor shall prepare a written training schedule, and submit it to the NJDOT MBEG for approval 90 Days prior to the start of the training. At the request of the NJDOT time schedules may have to be modified to properly accommodate all trainees. The NJDOT shall supply to the Contractor a list of the training session attendees. The Contractor shall forward a copy of the training schedule to all concerned personnel. Each of the above vendors shall provide on-site training sessions for their installations. The subjects shall include maintenance, repair, adjustment, operation programming and other related topics.
COMPENSATION
719.05 Method of Measurement.
Measurement will be on a lump sum basis.
719.06 Basis of Payment.
The Contractor shall submit to the Engineer and NJDOT MBEG a detailed breakdown of his costs under this item within thirty (30) days of award of the Contract. The contract bid price for the item “Training” is a not-to-exceed fixed sum of ninety thousand dollars ($90,000.00). This breakdown will be evaluated by the Engineer and NJDOT MBEG and an equitable basis of payment established.
Payment will be made under:
Pay Item Pay Unit
training lump sum
SECTION 720 - DEMOLITION AND REMOVAL
720.01 DESCRIPTION.
The work under this item shall consist of furnishing all labor, materials, plant and equipment and performing all work necessary to provide temporary openings in the machinery room and operator house; disconnect, remove and dispose of existing electrical equipment as shown on the plans and in the specifications; and to maintain the bascule span as required and as indicated on the plans, or called for in these specifications.
CONSTRUCTION
720.02 Construction Requirements.
The work at the existing bridge under this item shall be done in conformance with all requirements governing the sequencing, schedule of construction and conditions included under “Temporary Bridge Operation during Construction” and other sections within these specifications.
The existing equipment to be removed shall be disposed of at the discretion of the Engineer, NJDOT Maintenance Department and NJDOT MBEG.
The work at the existing bridge site shall include, but not be limited to disconnecting, removing, transporting, and disposing of the following equipment at the discretion of the Engineer and NJDOT Maintenance Department:
A. All bridge wiring in ducts, raceways and conduits on the bridge as well as gate and traffic signal wiring on both bridge approaches, disconnected and removed under this contract.
B. Incoming service wiring, circuit breakers and transformer (150 KVA) and other appurtenant devices.
C. Bridge service feeders and all associated wiring between control panels and JCP&L service location.
D. Motor Control Center 3 in a proper construction sequence, control panels, enclosures and associated mounting supports in the switchboard room and in the machinery room.
E. Wound rotor motors secondary resistors and associated enclosures and supporting framework as indicated on Mechanical drawings.
F. Bascule span thrustor brakes. (See Mechanical Work, Section 525, and Mechanical Drawings for temporary bascule span operation details.)
G. Bascule span rotary limit switches.
H. Instrumentation drives/gear boxes.
I. Selsyn transmitters.
J. Bascule span and pier navigation lamps.
K. Exiting deteriorated conduits.
L. Existing swing barrier gates, Traffic Warning gates and all associated equipment on each approach (six total).
M. Seated limit switches.
N. Wound rotor motors (4 units). Motors shall be transported to a location as specified by NJDOT.
O. Demolition and removal of temporary bridge operation materials.
In general, all apparatus to be removed shall be disconnected by removing existing bolts, nuts and screws. The work shall include removal of all brackets, hangers, clamp fittings and other hardware no longer needed.
All existing facilities, apparatus, cables, wiring and other equipment which are to remain in place on the bridge, shall be protected at all times from damage or defacement caused by the Contractor’s operations. Any such damage or defacement shall be promptly repaired or cleaned to the satisfaction of the Engineer and NJDOT MBEG at no extra cost. If, in the opinion of the Engineer and NJDOT MBEG, the Contractor’s rehabilitation work requires temporary removal of existing equipment for proper protection, such removal and remounting shall be done at no extra cost.
Prior to removal of previously listed items the Contractor shall confer with the Engineer, NJDOT Maintenance Department and NJDOT MBEG as to which items are to be retained. The Contractor shall remove these items, properly store in a protected area, and deliver to a location specified by the Engineer and NJDOT MBEG. At no additional cost, all remaining exiting materials and equipment removed under this item shall become the property of the Contractor, and shall be removed from the site and disposed of properly.
The following equipment is to be salvaged from the demolition and delivered to NJDOT:
Materials:
1. Distribution Transformer and Power Distribution Panelboard with Circuit Breakers.
2. Wound Rotor Span Motors
3. Thrustor Brakes
4. Limit Switches
5. SCR drives
720.03 Maintaining Existing Facilities.
The Contractor shall conduct his operation in such a manner as to maintain certain electrical facilities required for bascule span operation during all construction stages. The span must be operational at all times, even though on limited basis during winter months.
Temporary electric service, to operate the bridge or maintain any existing electrical facilities on the existing bridge shall be furnished by the Contractor at no additional expense to NJDOT.
720.04 Removal of Previously Painted Assemblies.
Existing interior paint may contain lead and asbestos. The Contractor shall take extreme precautions while removing existing painted electrical devices, mechanical assemblies, structural members, equipment and exterior wall panels. The Contractor shall refrain from using blast cleaning, and torch cutting techniques.
The Contractor shall determine if any airborne concentrations of lead or asbestos are released during a sample removal of painted assemblies. The “Task Trigger” method outlined in OSHA Document 29 CFR 1926.62(D)(2) may be used until actual exposure assessment is documented. Additional documentation can be obtained from OSHA Publication No. 3126, “Working with Lead in the Construction Industry”.
The Contractor shall keep all work areas clean and free of lead to the extent that the work process allows. Cleaning with compressed air is prohibited. Use only a vacuum with a HEPA filter or wet cleaning methods when removing lead dust (Reference 29 CFR 1926.62(H), 29 CFR 1926.25 and 1926.20).
All workmen handling lead based paint shall be required to wear work gloves and washing of hands should be stressed upon completion of work.
Respiratory protection shall be furnished and provided by the Contractor in accordance with OSHA Publication 29 CFR 1926.62F.
The Contractor shall obtain the following documents and be in compliance with the aforementioned items:
1. 29 Code of Federal Regulations, (CFR) 1926.
2. 29 Code of Federal Regulations, (CFR) 1910.
3. OSHA Publication No. 3126, “Working with Lead in the Construction Industry”.
4. State of New Jersey, Department of Health, Hazard Alert, “Persons Engaged in Abrasive Blasting, Welding and Torch Cutting, Grinding and Spray Paint Operations on Lead Painted Steel Surfaces are at Risk of Lead Poisoning”.
5. Section 5(a) (1) of the OSHA Act.
The Contractor may request “OSHA” assistance on the required lead abatement from the U.S. Department of Labor/OSHA.
Prior to painting, the Contractor shall remove all visible oil, grease and salts by solvent cleaning in accordance with SSPC-SP1. All existing paint left on the surface after cleaning shall be adequately roughened prior to paint application. Existing surfaces to be prepared for painting shall be in accordance with SSPC-SP2 and SSPC-SP3 respectively.
After cleaning surrounding areas, the Contractor shall paint the cleaned area with a color to match the surrounding area.
720.05 Scaffolding.
It shall be the Contractor’s responsibility to furnish, erect, and dismantle at end of project all scaffolding for removal of existing and installation of new equipment.
A special steel sheeting ceiling will be required to cover all machinery room electrical equipment during various stages of construction. It is Contractor’s responsibility to mount and protect from weather all temporary electrical equipment.
The Contractor shall design and submit, for approval by the Engineer and NJDOT MBEG, all required scaffolding. The Contractor shall dismantle and remove all installed scaffolding at the project’s end without any additional cost to the NJDOT.
COMPENSATION
720.06 Method of Measurement.
Measurement will be on a lump sum basis.
720.07 Basis of Payment.
Payment will be made under:
Pay Item Pay Unit
DEMOLITION AND REMOVAL LUMP SUM
DIVISION 800 – LANDSCAPING
SECTION 808 - FERTILIZING AND SEEDING
808.05 BASIS OF PAYMENT.
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PAYMENT WILL NOT BE MADE FOR AREAS OF FERTILIZING AND SEEDING DISTURBED BY CONSTRUCTION OPERATIONS, BEYOND THE PRESCRIBED GRADING LIMITS IN ISLANDS AND MEDIANS, AND BETWEEN PRESCRIBED GRADING LIMITS AND THE RIGHT-OF-WAY LINE, EXCEPT AS FOLLOWS:
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*****OR*****
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DIVISION 900 - MATERIALS
SECTION 901 - AGGREGATES
901.08 DENSE-GRADED AGGREGATE.
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6.
THE second SENTENCE IS CHANGED TO:
WHEN AASHTO T 310 (DIRECT TRANSMISSION METHOD, NUCLEAR GAUGE METHOD FOR MEASURING DENSITY AND MOISTURE CONTENT) IS USED TO PERFORM COMPACTION ACCEPTANCE TESTING (SUBSECTION 301.05, SUBPART 2), A REPRESENTATIVE SAMPLE OF FIVE TESTS FOR EACH 5,000 SQUARE YARDS LOT WILL BE TAKEN.
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A.
the first sentence of the FIRST paragraph is changed to:
COARSE AGGREGATE SHALL BE BROKEN STONE OR WASHED GRAVEL CONFORMING TO SUBSECTION 901.04 OR 901.05 RESPECTIVELY EXCEPT THAT CARBONATE ROCK SHALL NOT BE USED FOR CONCRETE SURFACE COURSES OR BRIDGE DECKS.
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902.02 POSTS AND SPACERS.
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SUPPLIERS FOR OBTAINING RECYCLED/SYNTHETIC ROUTED SPACERS WILL BE IDENTIFIED IN THE STANDARD INPUT. ACCORDING TO THE PROVISIONS OF 105.04, THE WORKING DRAWING SUBMISSION SHALL PROVIDE EVIDENCE THAT THE SPACERS THAT ARE TO BE USED DO SATISFY THE ABOVE CRITERIA. STEEL SPACERS SHALL CONFORM TO AASHTO M 270 GRADE 36 AND SHALL BE GALVANIZED ACCORDING TO AASHTO M 111. STEEL PIPE SPACERS SHALL BE SCHEDULE 40 GALVANIZED PIPE.
Wood timber spacers and posts shall conform to Subsection 918.01.
Steel posts shall be structural steel that conforms to AASHTO M 270 Grade 36 and shall be galvanized according to AASHTO M 111.
To verify suppliers for obtaining recycled/synthetic routed spacers (Polymer & Composite Blockouts), the Contractor is advised to study the “Bureau of Material’s Approved List” on the following NJDOT website:
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903.01 COMPOSITION OF MIXTURES.
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*****OR*****
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904.01 ASPHALT BINDER.
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ASPHALT BINDER SHALL CONFORM TO AASHTO M320, “PERFORMANCE-GRADED ASPHALT BINDER”.
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TEMPERATURE-VOLUME CORRECTION FACTORS THAT SHALL BE USED TO CONVERT THE VOLUME OF BITUMINOUS MATERIALS, MEASURED AT THE TEMPERATURE AT THE POINT OF USE, TO THE VOLUME AT 60 ºF ARE FOUND IN THE FOLLOWING TABLES:
Table 904-1 Temperature-Volume Correction Factors
for Bituminous Materials
Asphalt Binder, All Grades.
Cut-Back Asphalt, Grades RC-800, RC-3000, MC-800, and MC-3000.
Inverted Emulsified Asphalt, Grade IEMC-800.
see bdc03s-08 for tables.
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905.02 CHEMICAL ADMIXTURES.
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CORROSION INHIBITOR PRODUCTS THAT ARE TO BE USED IN THE FABRICATION OF CONCRETE ITEMS SHALL BE AS FOLLOWS:
Calcium Nitrite Based as produced by
W.R. Grace & Company
2133 85th Street
North Bergen, NJ 07047
Telephone: 201-869-5220
Calcium Nitrite Based as produced by
The Euclid Chemical Company
5 Joanna Court
East Brunswick, NJ 08816
Telephone: 732-390-9770
Calcium Nitrite Based as produced by
Master Builders Inc.
798 Welsh Road
Huntingdon Valley, PA 19006
Telephone: 215-938-7501
Calcium Nitrite Based as produced by
SIKA Corporation
201 Polito Avenue
Lyndhurst, NJ 07071
Telephone: 800 - 933 - SIKA (7452)
Calcium Nitrite Based as produced by
Great Eastern Technologies, LLC
“Chem Strong CI”
515 Route 528
P. O. Box 3015
Lakewood, NJ 08701
Telephone: 888 - 452 – 9348
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905.06 DETECTABLE WARNING SURFACES.
Materials for Detectable Warning Surfaces shall be safety red and appear uniform in color after curing. The surface coating material shall be an abrasion, UV and chemical resistant and shall be capable of adhering to existing or new Portland cement concrete surfaces. The minimum final dry coat thickness shall be 40 mils.
The cured coating shall exhibit the following minimum coefficients of friction when tested according to ASTM D 1894.
Static coefficient of friction Dynamic coefficient of friction
Dry 0.95 – 0.99 Dry 0.91 – 0.95
Wet 1.39 – 1.42 Wet 1.27 – 1.36
The Detectable Warning Surfaces shall be installed according to the manufacturer’s recommendations.
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SECTION 906 – ELECTRICAL MATERIALS
906.15 PEDESTALS, POLES, TRANSFORMER BASES, AND MAST BRACKET ARMS.
THE FOLLOWING IS ADDED TO THIS SUBSECTION:
ALL LIGHTING STANDARDS SHALL BE FURNISHED WITH AN INTERNAL VIBRATION DAMPER MOUNTED AT A HEIGHT RECOMMENDED BY THE MANUFACTURER.
SECTION 908 – Joint materialS
908.02 JOINT SEALERS.
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HOT-POURED JOINT SEALER FOR JOINTS AND CRACKS IN BOTH HMA AND PORTLAND CEMENT CONCRETE SURFACE COURSE SHALL BE SEALANT CONFORMING TO SUBSECTIONS 908.06, 908.07, AND ASTM D 6690 AS FOLLOWS:
1. Type II Sealant shall be used when sealing cracks in HMA.
2. Type IV Sealant shall be used when sealing joints and cracks in Portland cement concrete pavements and HMA saw and seal applications.
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The second sentence is changed to:
THE MATERIAL SHALL CONFORM TO THE PHYSICAL PROPERTIES SPECIFIED IN TABLE 1 OF ASTM D 3542 AND AS MODIFIED HEREIN. THE COMPRESSION-DEFLECTION PROPERTIES SPECIFIED IN TABLE 1 OF ASTM 3542 SHALL BE REPLACED WITH NJDOT TEST METHOD J-2 AS PROVIDED WITHIN THESE SPECIFICATIONS. THE REQUIREMENT FOR PRESSURE DEFLECTION SHALL BE 3.5 PSI.
The first sentence of the fifth paragraph is changed to:
THE WIDTH TO HEIGHT RATIO OF THE COMPRESSION SEALER SHALL NEVER BE LESS THAN 90%.
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1. Scope.
The first sentence is changed to:
THIS SPECIFICATION COVERS THE MATERIAL REQUIREMENTS FOR GLANDULAR TYPE STRIP SEAL DECK JOINT SYSTEMS CONSISTING OF AN EXTRUDED NEOPRENE RUBBER GLAND SEAL MECHANICALLY LOCKED IN THE CAVITIES OF TWO PARALLEL STEEL RAIL SECTIONS.
3. Metal Components and Adhesive.
The first and second sentences are changed to:
STEEL RAIL SECTIONS SHALL CONFORM TO AASHTO M 270 GRADE 36 OR 50. STEEL FOR PLATES, SHAPES AND OTHER STRUCTURAL STEEL USED IN THE DECK JOINT SYSTEM SHALL CONFORM TO AASHTO M 270 GRADE 36 OR 50.
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Polymerized joint adhesive shall be hot-applied asphaltic joint adhesive/sealer and shall conform to the physical properties in Table 908-6 below.
Table 908-6 Tests for Identification
|Property |ASTM |Physical Requirements |
| |Test Procedure | |
|Brookfield Viscosity, 400ºF |D 2669 |3,000 – 10,000 cp |
|Cone Penetration, 77ºF |D 5329 |60-100 |
|Flow, 140ºF |D 5329 |1/4 inch maximum |
|Resilience, 77ºF |D 5329 |30% minimum |
|Ductility, 77ºF |D 113 |1 foot minimum |
|Ductility, 39.2ºF |D 113 |1 foot minimum |
|Tensile Adhesion, 77ºF |D 5329 |500% minimum |
|Softening Point |D 36 |170ºF minimum |
|Asphalt Compatibility |D 5329 |Pass |
The manufacturer of the joint adhesive shall provide documentation of recommended pour temperature and safe heating temperature for the material and shall submit certifications of compliance according to Subsection106.04.
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909.10 TOPSOIL.
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ITEM 1. IS CHANGED TO:
1. SOILS HAVING LESS THAN 4.1 PH VALUE, OR GREATER THAN 8.0 PH VALUE.
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910.07 GRANITE FACING FOR PIER SHAFTS.
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THE NUMBER OF CORES TO BE FURNISHED FOR SUCH TESTS SHALL BE SIX.
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912.10 PAVEMENTS STRIPES OR MARKINGS.
C. Thermoplastic.
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2. FOR WHITE, THE COMPOSITION OF THE MIXTURE SHALL BE AS FOLLOWS:
Component Percent by weight
Resin/Binder 22-26 percent
Glass Beads (pre-mix) 30 percent minimum
WhitePigment 10 percent minimum
Calcium Carbonate and Inert Fillers
(shall not contain silica other than as glass beads) 34-38 percent
3. Only yellow non-lead formulas shall be used, the composition of the mixture shall be as follows:
Component Percent by weight
Resin/Binder 22-26 percent
Glass Beads (pre-mix) 30 percent minimum
Yellow Pigment 2 percent minimum
Calcium Carbonate and Inert Fillers
(shall not contain silica other than as glass beads) 42-46 percent
The yellow material’s combined totals of lead, cadmium, mercury, and hexavalent chromium shall not exceed 100 parts per million.
The thermoplastic manufacturer shall certify, according to Subsection 106.04, that the material will meet the requirements specified.
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D. PREFORMED TRAFFIC TAPE. PREFORMED TRAFFIC TAPE FOR PERMANENT AND TEMPORARY APPLICATIONS SHALL BE FROM THE NJDOT APPROVED PRODUCTS LIST MAINTAINED BY THE BUREAU OF MATERIALS ENGINEERING AND TESTING.
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912.12 REMOVABLE WET WEATHER PAVEMENT MARKING TAPE AND REMOVABLE BLACK LINE MASKING TAPE.
A. Removable Wet Weather Pavement Marking Tape. The removable wet weather pavement marking tape shall consist of polymeric, conformable backing materials with a retroreflective surface designed to provide retroreflectivity in wet conditions. The underside of the tape shall be precoated with a pressure sensitive adhesive which bonds the tape to the roadway surface so as to be able to withstand traffic immediately after installation. Primers shall be used to promote tape adhesion to the pavement only in accordance with the tape manufacturers recommendations.
Daylight color of the white tape shall be no darker than color No. 37778 of FED-STD-595B. Daylight color of the yellow tape shall conform to the FHWA color tolerance chart for highway yellow.
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WHEN MEASURED WITH A LTL-2000 RETROMETER, THE TAPE SHALL HAVE INITIAL, MINIMUM RETROFLECTANCE VALUES CONFORMING TO:
Dry Condition – ASTM E 1710
Entrance Angle = 88.76(
|Observation Angle |Specific Luminance |
|(Degrees) |White |Yellow |
| |(Millicandelas per square foot per |(Millicandelas per square foot per |
| |footcandle) |footcandle) |
|1.05 |750 |450 |
Note: The angular aperture of both the photoreceptor and the light projector shall be six minutes of arc. The reference axis shall be taken perpendicular to the test sample.
Continuous Wet Condition – ASTM E 2176
Entrance Angle = 88.76(
|Observation Angle |Specific Luminance |
|(Degrees) |White |Yellow |
| |(Millicandelas per square foot per |(Millicandelas per square foot per |
| |footcandle) |footcandle) |
|1.05 |750 |350 |
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A COMPLETE COATING SYSTEM OF AN INORGANIC ZINC RICH PRIMER, A HIGH BUILD EPOXY INTERMEDIATE COAT AND A URETHANE FINISH COAT SHALL BE SELECTED FROM ONE OF THE APPROVED COATING SYSTEMS LISTED ON THE FOLLOWING WEBSITE:
All products for the complete system, including thinners and solvents, shall be from the same manufacturer and shall be from the Qualified Paint List.
Drying time between coats shall be per the manufacturer’s recommendations.
The following information shall be submitted for the system selected at least one month before painting is anticipated:
1. A 1-gallon sample for each coat of paint in the system.
2. Infrared curves (0.1 to 0.6 mils) for each coat. Curves for the dry film of the vehicle (binder) of each component and for the mixed paint shall be included.
3. Weight per gallon, at 77 (F, for each coat. Variance shall be within plus or minus 1.8 ounces of the normal weight per gallon of the sample that was approved and placed on the QPL.
4. Viscosity in Krebs Units, at 77 (F, for each coat. Variance shall be within plus or minus 5 Krebs Units, or equivalent units of another viscometer, of the viscosity of the sample that was approved and placed on the QPL.
5. Percent of solids by weight of each coat.
6. Percent of metallic zinc by weight in the dry film of the cured zinc primer coat. This percentage shall be greater than or equal to that of the sample that was approved and placed on the QPL.
7. Percent of metallic zinc by weight in the zinc pigment component.
8. Finish coat color chips for selection of color by the Engineer.
9. The required curing time and dry film thickness for the qualification of the zinc primer for slip-critical connections in conformance with the requirements of AASHTO, Division I, Table 10.32.3C for Class of Surface B. A certified test report with the slip coefficient tested according to AASHTO Division 1, Article 10.32.3.2.3.
10. Technical data sheets, MSDS, and specific application instructions for all coats. In the event of a conflict between the data/instruction sheets and these Specifications, with the approval of the Engineer, the manufacturer’s requirements shall govern. Work shall not be allowed to proceed until the information is received and approved.
11. Mixing and thinning directions.
12. Recommended spray nozzles and pressures.
The Contractor shall submit the manufacturer’s recommended repair procedures to correct damage such as that caused in handling and shipping, deficient or excessive coating thickness, removal of zinc salts and other contaminants that would be detrimental to succeeding coats, and procedures for surface preparation and painting of rust spots.
The Contractor shall provide the services of a paint or a painting technical representative from the paint manufacturer at the beginning of operations and whenever required during operations.
Each container of paint shall be labeled to show the name of the manufacturer, the trade name designation of the contents, the lot or batch number, the date of manufacture, and the volumetric contents in gallons or the weight of zinc powder in pounds. Each container shall be labeled according to the Code of Federal Regulations for flammables and shall contain all information necessary to comply with NJSA 34:5A-1 New Jersey Worker and Community Right To Know Act.
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A COMPLETE COATING SYSTEM OF AN ALUMINUM EPOXY MASTIC PRIMER AND A URETHANE FINISH COAT SHALL BE SELECTED FROM ONE OF THE APPROVED COATING SYSTEMS LISTED ON THE FOLLOWING WEBSITE:
All products for the complete system, including thinners and solvents, shall be from the same manufacturer and shall be from the Qualified Paint List.
Drying time between coats shall be per the manufacturer’s recommendations.
The following information shall be submitted for the system selected at least one month before painting is anticipated:
1. A 1-gallon sample for each coat of paint in the system.
2. Infrared curves (0.1 to 0.6 mils) for each coat. Curves for the dry film of the vehicle (binder) of each component and for the mixed paint shall be included.
3. Weight per gallon, at 77 (F, for each coat. Variance shall be within plus or minus 1.8 ounces of the nominal weight per gallon of the sample that was approved and placed on the QPL.
4. Viscosity in Krebs Units, at 77 (F, for each coat. Variance shall be within plus or minus 5 Krebs Units, or equivalent units of another viscometer, of the viscosity of the sample that was approved and placed on the QPL.
5. Percent of solids by weight of each coat.
6. Finish coat color chips for selection of color by the Engineer.
7. Technical data sheets, MSDS, and specific application instructions for all coats. In the event of a conflict between the data/instruction sheets and these Specifications, with the approval of the Engineer, the manufacturer’s requirements shall govern. Work shall not be allowed to proceed until the information is received and approved.
8. Mixing and thinning directions.
9. Recommended spray nozzles and pressures.
The Contractor shall submit the manufacturer’s recommended repair procedures to correct damage such as that caused in handling and shipping, deficient or excessive coating thickness, removal of zinc salts and other contaminants that would be detrimental to succeeding coats, and procedures for surface preparation and painting of rust spots.
The Contractor shall provide the services of a paint or a painting technical representative from the paint manufacturer at the beginning of operations and whenever required during operations.
Each container of paint shall be labeled to show the name of the manufacturer, the trade name designation of the contents, the lot or batch number, the date of manufacture, and the volumetric contents in gallons or the weight of zinc powder in pounds. Each container shall be labeled according to the Code of Federal Regulations for flammables and shall contain all information necessary to comply with NJSA 34:5A-1 New Jersey Worker and Community Right To Know Act.
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A COMPLETE COATING SYSTEM OF AN ORGANIC ZINC RICH PRIMER, A HIGH BUILD EPOXY INTERMEDIATE COAT AND A URETHANE FINISH COAT SHALL BE SELECTED FROM ONE OF THE APPROVED COATING SYSTEMS LISTED ON THE FOLLOWING WEBSITE:
All products for the complete system, including thinners and solvents, shall be from the same manufacturer and shall be from the Qualified Paint List (QPL).
Drying time between coats shall be per the manufacturer’s recommendations.
The following information shall be submitted for the system selected at least one month before painting is anticipated:
1. A 1-gallon sample for each coat of paint in the system.
2. Infrared curves (0.1 to 0.6 mils) for the zinc primer, intermediate, and finish coats to include curves for the dry film of the vehicle (binder) of each component and for the mixed paint.
3. Weight per gallon, at 77 (F, for the zinc primer, intermediate, and finish coats. Variance shall be within plus or minus 1.8 ounces of the nominal weight per gallon of the sample that was approved and placed on the QPL.
4. Viscosity in Krebs Units, at 77 (F, for the zinc primer vehicle and the intermediate and finish coat paints. Variance shall be within plus or minus 5 Krebs Units, or equivalent units of another viscometer, of the viscosity of the sample that was approved and placed on the QPL.
5. Percent of solids by weight of the zinc primer vehicle and the intermediate and finish coat paints.
6. Percent of metallic zinc by weight in the dry film of the cured zinc primer coat. This percentage shall be greater than or equal to that of the sample that was approved and placed on the QPL.
7. Percent of metallic zinc by weight in the zinc pigment component.
8. Finish coat color chips for selection of color by the Engineer.
9. The required curing time and dry film thickness for the qualification of the zinc primer for slip-critical connections in conformance with the requirements of AASHTO, Division I, Table 10.32.3C for Class of Surface A. A certified test report with the slip coefficient tested according to AASHTO Division 1 Article 10.32.3.2.2.
10. Technical data sheets, MSDS, and specific application instructions for all coats. In the event of a conflict between the data/instruction sheets and these Specifications, with the approval of the Engineer, the manufacturer’s requirements shall govern. Work shall not be allowed to proceed until the information is received and approved.
11. Mixing and thinning directions.
12. Recommended spray nozzles and pressures.
The Contractor shall submit the manufacturer’s recommended repair procedures to correct damage such as that caused in handling and shipping, deficient or excessive coating thickness, removal of zinc salts and other contaminants that would be detrimental to succeeding coats, and procedures for surface preparation and painting of rust spots.
The Contractor shall provide the services of a paint or a painting technical representative from the paint manufacturer at the beginning of operations and whenever required during operations.
Each container of paint shall be labeled to show the name of the manufacturer, the trade name designation of the contents, the lot or batch number, the date of manufacture, and the volumetric contents in gallons or the weight of zinc powder in pounds. Each container shall be labeled according to the Code of Federal Regulations for flammables and shall contain all information necessary to comply with NJSA 34:5A-1 New Jersey Worker and Community Right To Know Act.
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6. ALTERNATE PAVEMENT REFLECTORS AND CASTINGS. ALTERNATE PAVEMENT REFLECTORS AND CASTINGS SHALL BE FROM THE NJDOT APPROVED PRODUCTS LIST MAINTAINED BY THE BUREAU OF MATERIALS ENGINEERING AND TESTING.
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913.03 DUCTILE IRON WATER PIPE.
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DUCTILE IRON WATER PIPE SHALL CONFORM TO ANSI/AWWA C151/A21.51.
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913.11 HIGH DENSITY POLYETHYLENE (HDPE), PVC DRAINAGE PIPE.
Corrugated HDPE drainage pipe shall conform to AASHTO M 252 or AASHTO M 294M. PVC drainage pipe shall conform to ASTM D 2729.
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SECTION 914 – PORTLAND OR BLENDED HYDRAULIC CEMENT CONCRETE, MORTOR, AND GROUT
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914.01 COMPOSITION OF PORTLAND OR BLENDED HYDRAULIC CEMENT CONCRETE.
Portland cement concrete shall be composed of Portland cement or blended hydraulic cement, coarse aggregate, fine aggregate, admixtures, and water. Portland cement concrete except white concrete may include fly ash, Ground Granulated Blast Furnace Slag or Silica Fume. Materials shall conform to the following Subsections:
Aggregates 901.12
Admixtures:
Air-Entraining 905.01
Chemical 905.02
Mineral:
Fly Ash 919.07
Silica Fume 919.10(b)
Ground Granulated Blast Furnace Slag 919.18
Portland Cement 919.11
Water 919.15
Chemical admixtures conforming to the requirements of Subsection 905.02 may be used in the mix design of structural concrete items.
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914.02 PORTLAND OR BLENDED HYDRAULIC CEMENT CONCRETE DESIGN, CONTROL, AND ACCEPTANCE TESTING REQUIREMENTS.
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E.
|STANDARD ITEM |DESCRIPTION |UNIT |BASE PRICE |
|5A13C |CONCRETE IN SUPERSTRUCTURE, DECK SLABS |CY |$460.00 |
|5A14C |CONCRETE IN SUPERSTRUCTURE, DECK SLABS, |CY |$525.00 |
| |W/ CORR. INHB. ADMIXTURE | | |
|5A33C |CONCRETE IN SUPERSTRUCTURE, PARAPETS |LF |$305.00 |
|5B30E |PRESTRESSED CONCRETE SLAB BEAMS, (TYPE SII-36), 36" X 15" |LF |$125.00 |
|5B32E |PRESTRESSED CONCRETE SLAB BEAMS, (TYPE SIII-36), 36" X 18" |LF |$130.00 |
|5B33D |PRESTRESSED CONCRETE BOX BEAMS, (TYPE BI-36), 36" X 27" |LF |$170.00 |
|5B34E |PRESTRESSED CONCRETE SLAB BEAMS, (TYPE SIV-36), 36" X 21" |LF |$160.00 |
|5B35D |PRESTRESSED CONCRETE BOX BEAMS, (TYPE BII-36), 36" X 33" |LF |$170.00 |
|5B37D |PRESTRESSED CONCRETE BOX BEAMS, (TYPE BIII-36), 36" X 39" |LF |$175.00 |
|5B39D |PRESTRESSED CONCRETE BOX BEAMS, (TYPE BIV-36), 36" X 42" |LF |$185.00 |
|5B45C |PRETENSIONED PRESTRESSED CONCRETE BEAMS, 45" |LF |$155.00 |
|5B54C |PRETENSIONED PRESTRESSED CONCRETE BEAMS, 54" |LF |$155.00 |
|5B60E |PRESTRESSED CONCRETE SLAB BEAMS, (TYPE SII-48), 48" X 15" |LF |$160.00 |
|5B62E |PRESTRESSED CONCRETE SLAB BEAMS, (TYPE SIII-48), 48" X 18" |LF |$135.00 |
|5B63C |PRETENSIONED PRESTRESSED CONCRETE BEAMS, 63" |LF |$185.00 |
|5B63D |PRESTRESSED CONCRETE BOX BEAMS, (TYPE BI-48), 48" X 27" |LF |$215.00 |
|5B64E |PRESTRESSED CONCRETE SLAB BEAMS, (TYPE SIV-48), 48" X 21" |LF |$215.00 |
|5B65D |PRESTRESSED CONCRETE BOX BEAMS, (TYPE BII-48), 48" X 33" |LF |$185.00 |
|5B67D |PRESTRESSED CONCRETE BOX BEAMS, (TYPE BIII-48), 48" X 39" |LF |$220.00 |
|5B69D |PRESTRESSED CONCRETE BOX BEAMS, (TYPE BIV-48), 48" X 42" |LF |$230.00 |
|5B72C |PRETENSIONED PRESTRESSED CONCRETE BEAMS, 72" |LF |$200.00 |
|5E18E |PRESTRESSED CONCRETE PILES, DRIVEN |LF |$90.00 |
|5E30C |CAST-IN-PLACE CONCRETE PILES, DRIVEN, 12" DIAMETER |LF |$30.00 |
|5E30D |PRECAST CONCRETE PILES, DRIVEN, 12" X 12" |LF |$90.00 |
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tHE SECOND SENTENCE OF THE THIRD PARAGRAPH IS CHANGED TO:
AT LEAST SIX 4 BY 8 INCH TEST CYLINDERS SHALL BE PREPARED FROM EACH BATCH AND CURED ACCORDING TO AASHTO T 23 OR AASHTO T 126.
THE FIRST sentence OF THE TENTH PARAGRAPH IS CHANGED TO:
CLASSES A AND B CONCRETE MAY BE DESIGNED TO ACHIEVE EARLY STRENGTH REQUIREMENTS BY INCREASING THE CEMENT CONTENT.
C. Acceptance Testing Procedures for Slump and Air Entrainment.
THE FIRST SENTENCE OF THE FOURTH PARAGRAPH IS CHANGED TO:
FOLLOWING ANY PERMITTED ADDITIONS, THE DRUM SHALL BE ROTATED AT THE RECOMMENDED MIXING SPEED FOR A MINIMUM OF 30 REVOLUTIONS WITHOUT EXCEEDING 300 TOTAL REVOLUTIONS, THE ORIGINAL TEST RESULTS SHALL BE DISREGARDED, AND A SINGLE TEST FOR BOTH SLUMP AND AIR ENTRAINMENT PERFORMED.
D. General Acceptance Testing Requirements for Strength.
THE FOLLOWING IS ADDED AFTER THE SECOND PARAGRAPH:
CONCRETE TEST SPECIMENS WHICH ARE TO BE USED FOR DETERMINATION OF EARLY STRENGTHS FOR FORM REMOVAL, OPENING TO TRAFFIC, OR OTHERWISE PLACING THE CONCRETE INTO SERVICE SHALL BE CURED ACCORDING TO THE FIELD CURING PROVISIONS IN AASHTO T 23.
E. Acceptance Testing for Strength for Pay-Adjustment Items.
THE ENTIRE TEXT OF THIS SUBPART after the first paragraph IS CHANGED TO:
THE AMOUNT OF PAY-ADJUSTMENT IN DOLLARS IS THE PRODUCT OF THE PAY ITEM BASE PRICE TIMES THE LOT QUANTITY TIMES THE PERCENT PAY-ADJUSTMENT (EXPRESSED AS A DECIMAL) GIVEN BY EQUATION 1 OR EQUATION 2.
Equation 1 and Equation 2:
Quality Pay-adjustment (Percent)
PD < 50 PPA = 3.0 - 0.3 PD Equation 1
PD ( 50 PPA = 26.0 - 0.76 PD Equation 2
Where: PPA = Percent Pay-adjustment
PD = Percent Defective (Estimate of percent of lot below the class design strength
by the use of Equation 3 and Subsection 914.05, Table 914-5)
Equation 3:
Q = (ALS - CDS) / S
Where: Q = Quality index for pay-adjustment computations
ALS = Average lot strength in psi
CDS = Class design strength in psi
S = Standard deviation of the strength test results in psi
for the lot as computed by Equation 4
Equation 4:
S = [pic]
Where: ( = Summation
Xi = Individual test result (average strength of a test cylinder pair)
N = Number of test results for the lot
Note: When only a single test result is available, the standard deviation "S" is assumed to equal 200 psi.
For lots having percent defective (PD) levels less than 10 percent, Equation 1 provides positive adjustments to the contract price. For lots having exactly 10 percent defective, there is no adjustment to the contract price. For lots having greater than 10 percent defective, Equations 1 or 2, as appropriate, subtract progressively larger amounts from the contract price.
If, based on the initial series of tests, the lot quality of a pay-adjustment item is estimated to be PD = 50 or greater, or if any individual test value (average of a cylinder pair) falls below the retest limit for non-pay-adjustment concrete in Subsection 914.05, Table 914-4, the Engineer has the option to reevaluate by coring or other suitable means. When this provision is applied to Class P concrete, each beam or pile in the steam bed will be evaluated separately.
If the Department elects not to core, the Contractor may accept the pay-adjustment of (PPA) calculated by Equation 2 or, when approved by the Engineer, may take cores according to Subsection 914.05, Table 914-4 at no cost to the Department. The Contractor must take the cores within 60 days from notification of the option to core. As an aid in making this decision, the Contractor will be permitted to perform nondestructive testing using a method or device approved by the Engineer.
When re-evaluation is accomplished by a method other than coring, the results will be used only to determine what further action is to be taken. If any of the non-core tests results are below the class design strength, the Engineer has the option to core. If this option is waived, the Contractor may elect to core, at no cost to the State and within 60 days after being presented with this option, or to accept the pay-adjustment computed from the initial test cylinder results. If the Contractor elects to core, the coring shall be performed as directed and the Department will test the cores. If none of the non-core test results is below the class design strength, the Engineer may elect either to core or to accept the lot at 100 percent payment.
If, based on the core results, the lot is determined to be at a quality level of PD < 75, the pay-adjustment shall be computed by Equation 1 or Equation 2, as appropriate. If the lot is confirmed to be at a quality level of PD = 75 or greater, the lot is considered to be rejectable and the Engineer may:
1. Require the Contractor to remove and replace the defective lot at no cost to the State,
2. Allow the Contractor to leave the defective lot in place and receive a percent pay-adjustment (PPA) computed by Equation 2, or
3. Allow the Contractor to submit a plan, for approval, for corrective action to be performed at no cost to the State. If the plan for corrective action is not approved, either option 1 or 2 above may be applied.
F. Acceptance Testing for Strength for Non-Pay-Adjustment Items.
THE ENTIRE TEXT OF THIS SUBPART IS CHANGED TO:
ALL CONCRETE ITEMS NOT SPECIFICALLY DESIGNATED AS PAY-ADJUSTMENT ITEMS AS DESCRIBED IN SUBSECTION 914.02, SUBPART E ARE CONSIDERED TO BE NON-PAY-ADJUSTMENT ITEMS, BUT MAY BE ACCEPTED BY PAY-ADJUSTMENT UNDER CERTAIN CIRCUMSTANCES. SUCH AN ITEM IS ELIGIBLE FOR 100 PERCENT PAYMENT (PA = 0) PROVIDED THE RETEST LIMIT OF SUBSECTION 914.05, TABLE 914-4 IS MET. IF THIS REQUIREMENT IS NOT MET, THE ITEM WILL BE TREATED AS A PAY-ADJUSTMENT ITEM ACCORDING TO SUBSECTION 914.02, SUBPART E, AND ALL PAY-ADJUSTMENT PROVISIONS SHALL APPLY EXCEPT THAT THE ITEM BID PRICE WILL BE USED INSTEAD OF AN ITEM BASE PRICE IN THE COMPUTATION OF THE PAY-ADJUSTMENT.
When a pay-adjustment is computed for any of the following items, which are only partially composed of concrete, the amount of pay-adjustment, if any, will be multiplied by the Estimated Percentage of Concrete (expressed as a decimal) as indicated below:
Pay Item Estimate Percentage
of Concrete
INLETS, TYPE 30
INLETS, TYPE , USING EXISTING CASTING 30
INLETS, TYPE B- 40
INLETS, TYPE B- , USING EXISTING CASTING 40
INLETS, TYPE MODIFIED 40
INLETS, TYPE MODIFIED, USING EXISTING CASTING 40
INLETS, TYPE ES 50
INLET CASTINGS, TYPE ES 40
MANHOLES 30
MANHOLES, ‘ DIAMETER 30
MANHOLES, USING EXISTING CASTING 30
MANHOLES, SANITARY SEWER 30
MANHOLES, SANITARY SEWER, USING EXISTING CASTING 30
GRANITE CURB 25
RESET GRANITE CURB 25
BEAM GUIDE RAIL ANCHORAGES 25
CHAIN-LINK FENCE, ‘ HIGH 25
CHAIN-LINK FENCE, ALUMINUM-COATED STEEL, ‘ HIGH 25
CHAIN-LINK FENCE, PVC-COATED STEEL, ‘ HIGH 25
CHAIN-LINK FARM-TYPE FENCE 25
GATES, CHAIN-LINK FENCE, ‘ WIDE 25
GATES, CHAIN-LINK FENCE, ALUMINUM-COATED STEEL, ‘ WIDE 25
GATES, CHAIN-LINK FENCE, PVC-COATED STEEL, ‘ WIDE 25
GATES, CHAIN-LINK FARM-TYPE FENCE, ‘ WIDE 25
RESET FENCE 25
TEMPORARY CHAIN-LINK FENCE, ‘ HIGH 25
GUIDE SIGNS, TYPE GA, BREAKAWAY SUPPORTS 20
GUIDE SIGNS, TYPE GA, NON-BREAKAWAY SUPPORTS 20
THE AMOUNT OF PAY-ADJUSTMENT FOR PAY ITEMS NOT LISTED ABOVE IS THE PRODUCT OF THE UNIT BID PRICE TIMES THE LOT QUANTITY TIMES THE PERCENT PAY-ADJUSTMENT GIVEN BY EQUATION 1.
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G. MIX DESIGN, FABRICATION AND FURNISHING OF HIGH PERFORMANCE CONCRETE (HPC) FOR DECK
SLABS, SIDEWALKS, CONCRETE RAILINGS AND SUBSTRUCTURE MEMBERS.
1. Fabrication Requirements. For the construction of deck slabs, sidewalks, concrete railings and substructure concrete, the HPC shall be fabricated in accordance with the requirements of these specifications.
2. Mix Design Verification. In the development of the HPC mix design, the following performance requirements, in accordance with the indicated test method, shall be achieved. A report to document these results shall be provided to the NJDOT Regional Materials Office. The Contractor shall obtain the results of these standard tests from an AASHTO Accredited testing agency, that is approved for Portland Cement concrete testing, at no cost to the Department.
Performance Requirements for Deck Slabs, Sidewalks, Concrete Railings
|Performance Characteristic |Standard Test Method |Performance Required |
|Scaling Resistance |ASTM C 672 |x = 3 max |
|(x = visual rating of the surface after 50 cycles) | | |
|Freeze-Thaw Durability |AASHTO T 161 |x = 80% minimum |
|(x = relative dynamic modulus of elasticity after 300 |ASTM C 666 | |
|cycles) |Proc. A | |
|Chloride Permeability |AASHTO T 277 |1000 maximum |
|56 days (coulombs) |ASTM C1202 | |
|56 Day Compressive Strength |AASHTO T 22 |5400 psi minimum |
|(Verification Strength) |ASTM C 39 | |
Performance Requirements for Substructure Protection Concrete
|Performance Characteristic |Standard Test Method |Performance Required |
|Abrasion Resistance |ASTM C 944 |x = 0.04 inches maximum |
|(x = average depth of wear ) | | |
|Freeze-Thaw Durability |AASHTO T 161 |x = 80% minimum |
|(x = relative dynamic modulus of elasticity after 300 |ASTM C 666 | |
|cycles) |Proc. A | |
|Chloride Permeability |AASHTO T 277 |1000 maximum |
|56 days (coulombs) |ASTM C1202 | |
|56 Day Compressive Strength |AASHTO T 22 |5400 psi minimum |
|(Verification Strength) |ASTM C 39 | |
Note: For the Scaling Resistance performance testing, as prescribed in the Standard Test Method, specimens shall be moist cured for 14 days and then air cured for 14 days.
a. If the compressive strength requirement has been achieved in 28 days, the strength requirement shall be considered acceptable. If the required compressive strength is not achieved in 28 days, the HPC sample shall be tested at 56 days.
b. If the chloride permeability requirement has been achieved in 28 days, the chloride permeability shall be considered acceptable. If the required chloride permeability is not achieved in 28 days, the HPC sample shall be tested at 56 days.
c. At least 90 calendar days prior to the planned start of the concrete placement, the mix design shall be submitted for approval and verification in accordance with Subsection 914.02. The submission shall include the results of the required Performance testing specified above.
d. In accordance with the above referenced AASHTO T277 test, at 28 and 56 day intervals, the Department will perform chloride permeability testing to document the quality of the HPC mix design and to verify the results submitted in the above referenced Report.
e. The Contractor shall submit four (4) additional cylindrical samples to the Department Laboratory, for performance of this testing. These samples shall be 4 inches in diameter and at least 8 inches in length. The test value shall be the result of the average value of tests on two (2) specimens for each mix design.
3. Production HPC.
a. As per the provisions of 501.12, Subpart 5., a plan of operation for placement of the HPC deck slab, shall be submitted for review and approval by the Engineer. Additionally, a pre-placement meeting shall be held at least seven days prior to the start of placement.
b. During production, the components of the mix design shall not be changed in any way from the approved mix design. If for some reason, the components must be changed, the mix design shall be re-verified according to the requirements stated herein.
4. HPC Acceptance Requirements.
a. With the exception that compression testing may be conducted at 56 days, the requirements specified in Subsection 914.02 for control and acceptance testing of Class A concrete shall be adhered to in the fabrication of the HPC elements.
b. Testing for the Chloride Permeability requirements stated below will not be performed for the sidewalk and parapet HPC.
c. Acceptance testing performance measures shall consists of the following parameters:
|Performance Characteristic |Standard Test Method |Performance Required |
|Percent Air Entrainment * |AASHTO T 152 |6.0 ± 1.5 (#57 Aggregate) |
| | |6.0 ± 1.5 (#67 Aggregate) |
| | |7.0 ± 1.5 (#8 Aggregate) |
|Slump (inches) * | |3 ± 1 |
|Chloride Permeability ** |AASHTO T 277 |2000 maximum |
|56 days (coulombs) |ASTM C1202 | |
|56 Day Compressive Strength *** |AASHTO T 22 |4400 psi |
|(Retest Limit) |ASTM C 39 |minimum |
Notes: * As per the guidance stated in Subsection 501.03, a Type F water-reducing, high range admixture will be permitted in accordance with Subsection 905.02 and Subsection 914.02, Subparts B and C. When a Type F admixture is used, the Slump and Air Content values for the HPC shall be as follows:
Slump: 6 ± 2 inches
Air Content: increase both the target value and tolerance percentages by 0.5
** For chloride permeability testing, 4 additional cylinders shall be provided to the Department Laboratory. Two cylinders each from two randomly selected delivery trucks shall be taken for testing at 28 day and 56 day intervals.
*** For compressive strength testing, the Initial Sampling Rate for the HPC shall be 6/Lot.
d. The HPC shall be a Non-Pay-Adjustment Item. In accordance with the provisions of Subsection 914.02 F., the HPC shall be accepted for strength according to the strength performance requirements stated herein.
e. A test for chloride permeability shall consist of two test specimens. The results of the two specimens shall be averaged to determine the test result. There will be two tests performed on each lot from samples taken from two randomly selected delivery trucks.
f. The lot is eligible for 100 percent payment provided that all test results are equal to or below 2000 coulombs.
g. Whenever one or more individual test results exceed 2000 coulombs at 28 days, the lot shall be re-evaluated at the same testing rate at 56 days. If, upon testing at 56 days, one or more individual test results exceed 2000 coulombs, the Engineer may:
(1) Require the Contractor to remove and replace the defective lot at no cost to the State,
(2) Permit the Contractor to submit a plan, for approval, for corrective action that is to be performed at no cost to the State.
5. Surface cracks Surface cracks that may develop in deck slabs and do not exceed 3/8 inch in depth shall be sealed with a low viscosity epoxy sealer or a low viscosity methacrylate monomer penetrating sealer that is to be approved by the Engineer. Cracks exceeding 3/8 inch in depth shall be repaired by methods that are to be approved by the Engineer. All such corrective work shall be at the Contractor’s expense.
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T303 STANDARD TEST METHOD FOR ACCELERATED DETECTION OF POTENTIALLY DELETERIOUS
Expansion of Mortar Bars Due to Alkali-Silica Reaction.
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TABLE 914-1 REQUIREMENTS FOR ROADWAY CONCRETE ITEMS
| |Concrete |Slump |Percent Air Entrainment for Coarse Aggregate Size Numbers |
| |Class |(inch) | |
| | | |357 |467 |57 |67 |8 |
|Cast-in-Place Items | | | | | | | |
|Surface Course, Bridge Approach Slabs, Bridge Approach Transition |B |2±1 |5.0±1.5 |5.0±1.5 |6.0±1.5 |6.0±1.5 |7.0±1.5 |
|Slabs | | | | | | | |
| | | | | | | | |
|Base Course |B |2±1 |5.0±1.5 |5.0±1.5 |6.0±1.5 |6.0±1.5 |7.0±1.5 |
| | | | | | | | |
|Inlet and Manhole Walls, Headwalls, Miscellaneous Concrete |B |3±1 |---- |---- |6.0±1.5 |6.0±1.5 |7.0±1.5 |
| | | | | | | | |
|Inlet and Manhole Top Slabs, Sidewalks, Driveways, Islands |B |3±1 |---- |---- |6.0±1.5 |6.0±1.5 |7.0±1.5 |
| | | | | | | | |
|Slope Gutters, Vertical Curb, Sloping Curb, Barrier Curb and Base |B |4±1 |---- |---- |6.0±1.5 |6.0±1.5 |7.0±1.5 |
| | | | | | | | |
|Concrete and White Concrete Vertical, Sloping and Barrier Curb, |B |4±1 |---- |---- |7.0±2.0 |7.0±2.0 |8.0±2.0 |
|Concrete and White Concrete Islands | | | | | | | |
| | | | | | | | |
|Foundations for: | | | | | | | |
|Inlets and Manholes |B |3±1 |6.5 max |6.5 max |7.5 max |7.5 max |8.5 max |
|Electrical Items |B |3±1 |---- |---- |7.5 max |7.5 max |8.5 max |
|Signs |B |3±1 |---- |---- |6.0±1.5 |6.0±1.5 |7.0±1.5 |
|Junction Boxes |B |3±1 |---- |---- |7.5 max |7.5 max |8.5 max |
Table 914-1 (Continued)
|Concrete |Slump |Percent Air Entrainment for Coarse Aggregate Size Numbers |
|Class |(inch) | |
| | | |357 |467 |57 |67 |8 |
|Cast-in-Place Items (continued) | | | | | | | |
|Footings for Fence Posts, Guide Rail End Treatment |B |3±1 |---- |---- |7.5 max |7.5 max |8.5 max |
|Culverts |A |3±1 |---- |---- |6.0±1.5 |6.0±1.5 |7.0±1.5 |
|Monuments |A |3±1 |---- |---- |7.5 max |7.5 max |8.5 max |
|Slope Protection |B |2±1 |---- |---- |6.0±1.5 |6.0±1.5 |7.0±1.5 |
|Precast Items | | | | | | | |
|Culverts |A |3±1 |---- |---- |6.0±1.5 |6.0±1.5 |7.0±1.5 |
| | | | | | | | |
|Inlets and Manholes, Junction Boxes, Headwalls, Reinforced |B |3±1 |---- |---- |6.0±1.5 |6.0±1.5 |7.0±1.5 |
|Concrete End Sections (See note 2) | | | | | | | |
| | | | | | | | |
|Concrete and White Concrete Barrier Curb |B |3±1 |---- |---- |7.0±2.0 |7.0±2.0 |8.0±2.0 |
Note 1: According to Subsection 501.03, a Type F water-reducing, high range admixture will be permitted according to Subsection 905.02 and Subsection 914.02, Subparts B and C. When a Type F admixture is used, the table Slump and Air Content values for the given concrete item shall be changed as follows:
Slump: 6 ± 2 inches
Air Content: Increase both the target value and tolerance percentages by 0.5.
Note 2: For the items in this category, the slump may be reduced to zero (dry cast) provided that adequate consolidation, acceptable to the Engineer, is achieved.
Table 914-3 Mix Design Requirements
| |Class of Concrete |
| | | | | | | |
| |A |B |S |P |P-1 |P-2 |
| | | | | | | |
|Class Design Strength |4600 |3700 |2000 |5500 |6000 |6500 |
|(28 days, psi Note 3) | | | | | | |
| | | | | | | |
|Verification Strength |5400 |4500 |-- |6000 |6500 |7000 |
|(28 days, psi Note 3) | | | | | | |
| | | | | | | |
|Maximum | | | | | | |
|Water/Cement Ratio (Note 2) | | | | | | |
|lb/lb |0.443 |0.488 |0.577 |Note 1 |Note 1 |Note 1 |
|gals/bag |5.0 |5.5 |6.5 |Note 1 |Note 1 |Note 1 |
| | | | | | | |
|Minimum | | | | | | |
|Cement Content | | | | | | |
|lb/cy |611 |564 |658 |Note 1 |Note 1 |Note 1 |
|Bags/cy |6.5 |6.0 |7.0 |Note 1 |Note 1 |Note 1 |
Note 1: According to PCI Manual, except as indicated in Note 2.
Note 2: The maximum water/cement ratio for all classes of concrete except for Classes P, P-1 and P-2, when a Type F water-reducing, high range admixture is used according to Tables 914-1 and 914-2, shall be reduced by 0.043 lb/lb (4.5 gals/bag).
Note 3: All concrete test results shall be recorded to the nearest 10 psi.
Note 4: To successfully meet the requirements of this specification, the target production strength must be higher than the Class Design Strength by an amount proportional to the Producer’s within-lot standard deviation.
Table 914-4 Lot Sizes, Sampling Rates and Retest Limits
| |Class of Concrete |
| | | | | | | |
| |A |B |S |P |P-1 |P-2 |
| | | |
|Lot Size (maximum) |One Day's Production |One Day's Production of a Single Steam |
| | |Bed |
|Pay-Adjustment Items |
| Initial Sampling Rate |5/Lot |5/Lot |-- |5/Lot |5/Lot |5/Lot |
| Retest Sampling Rate |5/Lot |5/Lot |-- |5/Unit or Load Test |
|(minimum) | | | | |
|Non-Pay-Adjustment Items |
| Initial Sampling Rate |3/Lot |2/Lot |1/Lot |3/Lot |3/Lot |3/Lot |
| Retest Limit (psi) |4400 |3600 |2000 |5400 |5900 |6400 |
| Retest Sampling Rate |5/Lot |5/Lot |5/Lot |5/Lot |5/Lot |5/Lot |
Note 1: The lot sizes are maximums and, at the option of the Engineer, any lot may be subdivided into two or more smaller lots. When such a subdivision is made, the specified sampling rate applies to each of the smaller lots.
Note 2: An initial strength test result is defined as the average strength of two 4 inch by 8 inch compression test cylinders, cured for 28 days, and tested in the Department Laboratory except for Classes P, P-1, and P-2 cylinders which may be tested at the fabricator's plant under the supervision of the Engineer.
Note 3: A retest result is defined as the strength of an individual test result obtained by coring or other suitable means. If retest is performed by coring, each retest result is defined as the corresponding nominal core strength divided by 0.85.
Note 4: The specified sampling rates shall apply except that no more than one test per truckload or batch of concrete will be required (except for air and slump tests when retempering). It is expected that each structural component will have a representative sample taken. At the option of the Engineer, nonstructural concrete lots consisting of 20 cubic yards or less may be accepted without strength tests.
Note 5: No lot shall include more than one class of concrete nor include concrete of the same class having different specified levels of slump or air entrainment.
Note 6: For prestressed concrete, if more than one bed is used or if more than 80 cubic yards of concrete are used, the production shall be subdivided as equally as possible into two or more lots.
Note 7: Retest limit for non-pay-adjustment roadway and structural items requiring the use of Class B, white concrete, shall be 3000 psi.
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915.02 PRESTRESSING REINFORCEMENT.
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The first sentence is changed to:
GRIT IMPREGNATED EPOXY-COATED PRESTRESSING STEEL STRANDS SHALL CONFORM TO THE REQUIREMENTS OF ASTM A 882 AND TO THE CRITERIA SPECIFIED IN 502.06.
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916.04 RETROREFLECTIVE SHEETING.
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AS STATED HEREIN, THE TERMS REFLECTIVE SHEETING AND RETROREFLECTIVE SHEETING ARE SYNONYMOUS.
Retroreflective sheeting shall conform to ASTM D 4956 based upon results obtained and reported through testing performed by the National Transportation Product Evaluation Program (NTPEP).
Fluorescent retroreflective sheeting shall be selected from the approved products list as provided in the Special Provisions.
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a. Retroreflectance. All retroreflective sheeting shall have the minimum coefficient of retroreflection (RA) in conformance with ASTM D 4956.
b. Color. The colors of the retroreflective sheeting, except for fluorescent colors shall conform the color requirements of ASTM D 4956.
c. Fluorescent Colors. The daytime fluorescent color of retroreflective sheeting shall be determined according to ASTM E 991.
In addition, the color shall be equally distinguishable in daylight and at night under artificial headlight illumination. The color shall have a consistent chromaticity across all signs of the same color. Noticeable deviation from the shades that would affect the required performance shall be a cause for rejection of any sheeting or completed sign at any time before acceptance. For sheeting that is directional, the datum mark (arrow) imprinted on the face of the sheeting shall be the datum mark for test purposes.
d. Product Performance Requirements. The retroreflective sheeting manufacturer shall meet the following requirements for their products.
(1) Type III Sheeting – Sheeting shall be required to have a service life span of at least 12 years.
(2) Types VI, VII, VIII AND IX Sheeting – Sheeting shall be required to have a service life span of at least 10 years.
(3) The performance requirements shall be such that there is: no loss of retroreflectivity; no loss of colorfastness; no cracking; and no other conditions inherent to the sheeting including inks and overlay film that causes it to be incapable of performing as required.
2. Certification of Compliance. The manufacturer shall submit a certification of compliance according to Subsection 106.04 for each lot of sheeting supplied for use on the Project.
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ALL FINISHED SIGNS SHALL BE CLEAR AND LEGIBLE WITHOUT SMUDGING, BLISTERS, DELAMINATION, LOOSE EDGES OR OTHER BLEMISHES.
1. Type A Demountable.
THE FIRST AND SECOND PARAGRAPHeS ARE CHANGED TO:
THE DEMOUNTABLE SIGN LETTERS, DIGITS, ARROWS, BORDERS, AND ALPHABET ACCESSORIES SHALL BE REFLECTORIZED AND SHALL CONSIST OF ASTM D 4956 TYPE VIII OR IX WIDE ANGLE PRISMATIC RETROREFLECTIVE SHEETING APPLIED TO ⅜-INCH CUTOUT ALUMINUM PLATES CONFORMING TO ASTM B 209, ALLOY 6061-T6 OR 5052.
All shields and symbols to be mounted to sign types GO, GOX, and GA on breakaway tubular posts shall consist of ASTM D 4956 Type VIII OR IX wide angle prismatic retroreflective sheeting applied to 3/16-inch cutout aluminum plates conforming to ASTM B 209, Alloy 6061-T6.
2. Type B Direct and Permanently Applied Retroreflective Sheeting Copy.
SUBPART D, E, & F ARE DELETED and C IS CHANGED TO:
C. WHEN THE BACKGROUND IS ASTM D 4956 TYPE III SHEETING, ASTM D 4956 TYPE III SHEETING SHALL BE USED FOR COPY.
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a. Application.
THE LAST SENTENCE IN THE THIRD PARAGRAPH IS CHANGED TO:
SHEETING APPLIED TO EXTRUDED SECTIONS SHALL EXTEND OVER TOP EDGES AND DOWN SIDE LEGS A MINIMUM OF 1/16 INCH; EXCEPT THAT WHERE ASTM D 4956 TYPE VIII OR IX SHEETING IS USED, IT SHALL BE CUT AT THE TOP EDGES ACCORDING TO THE MANUFACTURER’S RECOMMENDATION.
c. Screen Process Printing.
THE THIRD SENTENCE IN THE FIRST PARAGRAPH IS CHANGED TO:
TRANSPARENT SCREEN PROCESS PAINT, AFTER APPLICATION TO THE RETROREFLECTIVE SHEETING AND THOROUGHLY DRY SHALL CONFORM TO THE COLOR REQUIREMENTS ASTM D 4956.
9. Packaging, Storage, and Shipping.
THE FIRST SENTENCE IN THE FIRST PARAGRAPH IS CHANGED TO:
PACKAGING, STORAGE, AND SHIPPING OF SIGNS PRODUCED USING RETROREFLECTIVE SHEETING SHALL BE ACCORDING TO THE SHEETING MANUFACTURER’S RECOMMENDATIONS.
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916.10 STEEL “U” POST SIGN SUPPORTS.
The steel “U” post sign supports shall conform to ASTM A499. Signs shall be secured to the steel “U” post by means of 18-8 stainless steel 5/16 x 18 UNC hexagonal headed bolts and nuts conforming to ASTM A 320, Grade B8, Class 1. Sign mounting bolts shall extend beyond the end of each nut but not more than ¾ inches when fully tightened.
The steel “U” posts shall be straight and have a smooth finish, free of burrs.
The list of the approved products will be provided by the Bureau of Materials Engineering and Testing.
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THE FIRST PARAGRAPH IS CHANGED TO:
FOR GROUND MOUNTED FLEXIBLE DELINEATORS, THE PORTION OF THE DELINEATOR ABOVE GROUND SHALL BE ONE COMPONENT, OR SHALL BE BONDED TOGETHER IF IT CONSISTS OF TWO OR MORE COMPONENTS. THE SHAPE OF THE DELINEATOR POST WHERE THE RETROREFLECTIVE SHEETING IS APPLIED SHALL HAVE A CROSS SECTION THAT PROTECTS THE SHEETING FROM ABRASION UPON IMPACT.
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THE ENTIRE subpart is DELETED.
11. SAMPLING RATE
the Subpart number is changed to:
10. SAMPLING RATE.
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917.01 BOLTS AND BOLTING MATERIAL.
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The following is added:
C. DIRECT TENSION INDICATORS SHALL COMPLY WITH ASTM F 959 AND SHALL BE ACCEPTED AND INSTALLED ACCORDING TO TEST METHOD S-3, “PROCEDURE FOR IDENTIFICATION AND INSTALLATION OF HIGH STRENGTH BOLTS WITH DIRECT TENSION INDICATORS (DTI’S)”.
3. Manufacturing.
a. Bolts.
The first sentence is changed to:
HARDNESS FOR BOLT DIAMETERS ¼ INCH TO 1 ½ INCHES, INCLUSIVE, SHALL BE AS NOTED:
The following is added:
WHEN ATMOSPHERIC CORROSION RESISTANT WEATHERING STEEL IS TO BE USED, TYPE 3 BOLTS SHALL BE USED.
The following is added:
D. DIRECT TENSION INDICATORS (DTI’S). WHEN GALVANIZING OF THE BOLT ASSEMBLY IS REQUIRED, DTI’S SHALL BE MECHANICALLY GALVANIZED IN ACCORDANCE WITH AASHTO M 298, CLASS 50 (ASTM B 695, CLASS 50). DTI’S TO BE USED FOR TYPE 3 BOLTS SHALL BE EPOXY COATED WITH A BLACK COLOR.
4. Testing.
The following is added:
G. DIRECT TENSION INDICATORS (DTI’S). DTI’S SHALL BE TESTED ACCORDING TO ASTM F 959.
7. Installation.
The Subpart a. is change to:
A. BOLTS SHALL BE INSTALLED ACCORDING TO THE APPROPRIATE AASHTO SPECIFICATIONS. DIRECT TENSION INDICATORS (DTI’S) SHALL BE USED WITH HIGH STRENGTH BOLTS TO VERIFY THE REQUIRED TENSION. THE PROVISIONS OF ARTICLE 11.5.6.4.7 OF DIVISION II OF THE AASHTO STANDARD SPECIFICATIONS OR OF ARTICLE 11.5.6.4.7 OF THE AASHTO LRFD BRIDGE CONSTRUCTION SPECIFICATIONS SHALL BE FOLLOWED. IF WARRANTED AND AS DIRECTED BY THE ENGINEER, THE FACE OF THE NUT SHALL BE SMEARED WITH WAX BEFORE IT IS INSTALLED. THE CASTRAL STICK WAX LUBRICANT, BEESWAX OR A WATER WAX EMULSION; SUCH AS, THE MACDERMID “TORQUE ’N TENSION CONTROL FLUID” MAY BE USED.
The following is added at the end of the Subsection:
ANCHOR BOLTS, ROCK ANCHORS, AND HARDWARE SHALL CONFORM TO AASHTO M 270 GRADE 36 AND SHALL BE GALVANIZED AFTER FABRICATION, INCLUDING THREADING, ACCORDING TO ASTM A 153.
Dowels used to anchor prestressed concrete voided slabs and box beams to abutments and piers shall conform to AASHTO M 270 Grade 36 and shall be galvanized to ASTM A 153. Threading of dowels is not required.
Welded steel shear connectors shall conform to Division II, Section 11 of the AASHTO Standard Specifications for Highway Bridges or Section 11 of the AASHTO LRFD Bridge Construction Specifications.
Stainless steel bolts, nuts, and washers shall conform to ASTM A 320, Class 1, Grade B8 (AISI Type 304).
For overhead and cantilever sign support structures, bolts, nuts and washers for steel to steel chord splices shall conform to AASHTO M 164 and be hot-dip galvanized as per ASTM A 153.
As an alternate, bolts, nuts and washers conforming to AASHTO M 164 may be substituted for bolts, nuts, and washers of the same diameter, length, and thickness conforming to ASTM A 307.
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ALL INLET AND MANHOLE CASTINGS, GRATES, EXTENSION RINGS, EXTENSION FRAMES AND COVERS SHALL BE CAPABLE OF WITHSTANDING THE PROOF LOAD TESTING REQUIREMENTS SPECIFIED IN AASHTO M 306 WHEN THEY ARE TESTED AS A COMPLETE ASSEMBLED UNIT AND SHALL CONFORM TO THE FOLLOWING:
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919.02 BEARING PADS.
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The first paragraph is changed to:
ELASTOMERIC BEARING PADS FOR BRIDGE BEAMS SHALL CONFORM TO DIVISION II, SECTION 18 OF THE AASHTO STANDARD SPECIFICATIONS FOR HIGHWAY BRIDGES OR SECTION 18 OF THE AASHTO LRFD BRIDGE CONSTRUCTION SPECIFICATIONS.
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FLY ASH FOR PORTLAND CEMENT CONCRETE SHALL CONFORM TO ASTM C 618, CLASS C OR CLASS F EXCEPT THAT THE LOSS ON IGNITION SHALL NOT BE MORE THAN THREE PERCENT. FLY ASH USED TO CONTROL ALKALI-SILICA REACTIVITY SHALL BE CLASS F. BEFORE EACH SOURCE OF FLY ASH IS APPROVED, CERTIFIED RESULTS OF TESTS CONDUCTED BY A TESTING AGENCY SHALL BE SUBMITTED TO AND VERIFIED BY THE DEPARTMENT. ACCOMPANYING THE CERTIFICATION SHALL BE A STATEMENT FROM THE SUPPLIER LISTING THE SOURCE AND TYPE OF COAL, THE METHODS USED TO BURN, COLLECT, AND STORE THE FLY ASH, AND THE QUALITY CONTROL MEASURES EMPLOYED.
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919.11 PORTLAND OR BLENDED HYDRAULIC CEMENT.
Portland cement shall conform to the following:
Masonry Cement ASTM C 91
Portland Cement, Type I, II, and Type III (see Note 1) ASTM C 150
White Portland Cement, Type I and III (see Note 2) ASTM C 150
Blended Hydraulic Cement (see Note 3) ASTM C 595
Note 1: Type III may be used only for prestressed or precast items.
Note 2: Shall not contain more than 0.55 percent by weight of ferric oxide (Fe2O3).
Note 3: Only types IS, I(PM), and I(SM) may be used. Portland cement, may be pre-blended with a maximum of 15 percent fly ash, by weight, or a maximum of 10 % silica fume by weight, or with a maximum of 50% GGBFS by weight. If more than 30% GGBFS is used, a scaling test conforming to ASTM C 672 must be completed on the mix design and the concrete must have a visual rating less than 3 as based on ASTM C672 10.1.5 after 50 cycles.
When blended Portland cement is used, no additional mineral admixtures shall be added.
Different brands of cement, the same brand of cement from different mills or different types of cement shall not be mixed.
Suitable means shall be provided for storing and protecting the cement against dampness. Cement which for any reason has become partially set or which contains lumps of caked cement will be rejected. The temperature of the cement at the time of delivery to the mixer shall not exceed 160 °F.
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GROUND, GRANULATED BLAST FURNACE SLAG MAY BE USED AS A REPLACEMENT FOR PORTLAND CEMENT AS SPECIFIED IN SUBSECTION 919.11 UP TO A MAXIMUM REPLACEMENT LEVEL OF 50 PERCENT BY WEIGHT. REPLACEMENT OF PORTLAND CEMENT GREATER THAN 30 PERCENT WILL REQUIRE A SCALING TEST ON THE MIX DESIGN CONFORMING TO ASTM C 672 WITH A VISUAL RATING LESS THAN 3.
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MINERAL ADMIXTURES 8 POUNDS FROM EACH SOURCE
Blended Hydraulic Cement ASTM C 595
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919.22 CONTROLLED LOW STRENGTH MATERIAL (CLSM).
CLSM shall conform to the following:
Fine Aggregate 901.12
Chemical Admixtures 905.02
Portland Cement, Type I, II, III 919.11
Water 919.15
CLSM shall consist of a mixture of Portland cement, water, fine aggregate and chemical admixtures. Fly ash shall not be permitted in mixes intended for trench backfilling. The CLSM mixture shall be proportioned to provide a backfill material that is self-compacting and capable of being excavated with hand tools at a later date. CLSM shall be proportioned to produce a 28-day compressive strength of 50 to 150 pounds per square inch. An accelerating admixture shall be used to produce a fast setting flowable mixture as required. The CLSM shall have a permeability of 1.7 x 10-3 ( 0.2 x 10-3 centimeters per second according to ASTM D5084 for backfilling of conduits and piping.
At least 45 days prior to the start of any CLSM placement, trial batches of CLSM shall be prepared of the same materials and proportions proposed for use on the project. Each mix design shall be submitted on Portland cement concrete mix design forms furnished by the Department, naming the sources of materials and test data.
Department personnel will be present at the time of verification batching to confirm that the proportions and materials batched are according to the proposed mix designs. At least six 6 X 12 inch compression test cylinders shall be prepared for each batch according to ASTM 5971-96 for 28-day strengths except for fast setting mixes, which shall be tested at the specified cure time.
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SECTION 921 – FIBERGLASS REINFORCED PLASTIC LUMBER
THE FURNISHING OF FIBERGLASS REINFORCED PLASTIC LUMBER (FRPL) SHALL CONFORM TO THE FOLLOWING MATERIAL PROPERTIES:
1. Plastic. The plastic for FRPL shall be a mixture of one or more of the following recycled post consumer or post industrial thermoplastics: high-density polyethylene, medium-density polyethylene or, low-density polyethylene. The plastic shall be mixed with appropriate colorants, UV inhibitors and antioxidants so that the resulting product meets the material property requirements specified in Table I below.
FRPL shall not absorb moisture, corrode, rot, warp, splinter or crack. The outer skin shall be smooth and black in color unless otherwise specified in the contract plans. It shall contain hindered amine light stabilizers to provide sufficient resistance to ultraviolet light degradation so as to meet the requirements in Table I below.
2. Manufacturing. Manufacture FRPL as one continuous piece with no joints or splices to the dimensions and tolerances in accordance with Table 2 and consisting of a dense outer skin surrounding a less dense core. Interior voids shall not exceed 0.75 inch in diameter. FRPL shall be free of twist and curvature.
3. Reinforcement. FRPL shall be reinforced by fiberglass reinforcing rods spaced inside the four corners of the timber. Reinforce 10”x10” FRPL with a minimum of four 1.5 inch diameter reinforcing rods placed in the corners of the section. Reinforce 12”x12” FRPL with a minimum of four 1.5 inch diameter reinforcing rods placed in the corners of the section. Reinforcing rods must be continuous and offer a minimum flexural strength of 70 ksi when tested in accordance with ASTM D 4476 and a minimum compressive strength of 40 ksi when tested in accordance with ASTM D 695. Steel reinforcing rods shall not be permitted. All FRPL used for constructing platforms, blocking and wales shall have a minimum of 15% (by weight) chopped glass reinforcement added to the polyethylene. No fiberglass rebar will be required for the smaller dimensional FRPL.
4. Structural Properties. 10”x10” and 12”x12” FRPL shall meet the minimum structural properties (+/- 10%) listed in Tables 3A and 3B. Smaller, dimensional FRPL for platforms and blocking shall meet the minimum structural properties listed in Table 4.
TABLE 1: PLASTIC MATERIAL PROPERTIES
|Density (ASTM D792) |Skin |55-63-lbs/ft3 |
|Density (ASTM E1547) |Core |34-48-lbs/ft3 |
|Water Absorption (ASTM D570) |Skin |2 hrs: ................
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