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Hostetter Road Design Unit 09 Ready For Construction Specifications

SVBX C700

WEDNESDAY, NOVEMBER 21, 2012

4_DU-009 Hostetter Rd RFC Specifications 20121121.pdf

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P0728-C700-DU-009.RFC.R0

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B1211-F349

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Received SVBX PDCC November 26, 2012

TABLE OF CONTENTS

SECTION 02 41 00 DEMOLITION

SECTION 02 41 10 TREE PROTECTION AND REMOVAL

SECTION 03 05 15 PORTLAND CEMENT CONCRETE

SECTION 03 05 18 PRESTRESSED CONCRETE

SECTION 03 11 00 CONCRETE FORMING

SECTION 03 11 14 FALSEWORK

SECTION 03 15 00 CONCRETE ACCESSORIES

SECTION 03 15 13 WATERSTOPS

SECTION 03 20 00 CONCRETE REINFORCING

SECTION 03 30 00 CAST-IN-PLACE CONCRETE

SECTION 03 35 00 CONCRETE FINISHING

SECTION 03 41 00 STRUCTURAL PRECAST CONCRETE

SECTION 07 13 29 BUTYL RUBBER MEMBRANE WATERPROOFING

SECTION 07 94 00 STRUCTURAL JOINT SEALS AND ASSEMBLIES

SECTION 26 50 01 LIGHTING-STREETS

SECTION 31 00 00 EARTHWORK

SECTION 32 11 17 AGGREGATGE SUBBASE COURSES

SECTION 32 11 23 AGGREGATE BASE COURSE

SECTION 32 12 16 ASPHALT PAVING

SECTION 32 13 13 CONCRETE PAVING

SECTION 32 16 21 CONCRETE CURBS, GUTTERS, AND WALKS

SECTION 32 17 23 PAVEMENT MARKINGS

SECTION 32 31 13 CHAIN LINK FENCES AND GATES

SECTION 32 84 00 PLANTING IRRIGATION

SECTION 32 90 00 PLANTING

SECTION 34 71 15 CONCRETE BARRIERS AND RAILINGS


TECHNICAL SPECIFICATIONS

March 25, 2011October 9, 2012 07 94 00 - 1 Contract C700

Structural Joint Seals and Assemblies Request for ProposalRev. A

SECTION 07 94 00

STRUCTURAL JOINT SEALS AND ASSEMBLIES

PART 1 - GENERAL

1.01 SECTION INCLUDES

A. Constructing joints, joint seals and joint seal assemblies in concrete structures including:

Open joints

Filled joints

Sealed joints

Joint seal assemblies

1.02 RELATED SECTIONS

A. Section 01 45 00, Quality Control.

B. Section 03 15 13, Waterstops.

C. Section 03 30 00, Cast-in-Place Concrete.

D. Section 05 12 35, Structural Steel and Miscellaneous Metal for Bridges.

1.03 MEASUREMENT AND PAYMENT

Separate measurement or payment will not be made for Work required under this Technical

Specifications Section. All costs in connection with the Work specified in this Technical

Specifications Section will be considered to be included with the related item of Work in the Price

Schedule or incidental to the Work.

1.04 REFERENCES

A. American Association of State Highway and Transportation Officials (AASHTO):

AASHTO M160M/M160 Specification for General Requirements for Steel

Plates, Shapes, Sheet Piling, and Bars for Structural

Use

AASHTO M300 Specification for Inorganic Zinc-Rich Primer

B. American Institute of Steel Construction (AISC):

AISC 348 Specification for Structural Joints Using ASTM A325

or A490 Bolts



Contract C700 07 94 00 - 2 March 25, 2011October 9, 2012

Request for ProposalRev. A Structural Joint Seals and Assemblies

C. ASTM International (ASTM):

ASTM A6/A6M Specification for General Requirements for Rolled

Structural Steel Bars, Plates, Shapes, and Sheet Piling

ASTM A325 Specification for Structural Bolts, Steel, Heat Treated,

120/105 ksi Minimum Tensile Strength

ASTM A572/A572M Specification for High-Strength Low-Alloy

Columbium-Vanadium Structural Steel

ASTM D395 Test Methods for Rubber Property—Compression Set

ASTM D2240 Test Method for Rubber Property—Durometer

Hardness

ASTM D2628 Specification for Preformed Polychloroprene

Elastomeric Joint Seals for Concrete Pavements

ASTM D3363 Test Method for Film Hardness by Pencil Test

ASTM D4417 Test Methods for Field Measurement of Surface Profile

of Blast Cleaned Steel

ASTM D4541 Test Method for Pull-Off Strength of Coatings Using

Portable Adhesion Testers

ASTM D4752 Test Method for Measuring MEK Resistance of Ethyl

Silicate (Inorganic) Zinc-Rich Primers by Solvent Rub

D. Federal Standards (Fed Std):

Fed Std 595B Colors Used in Government Procurement

E. The Society for Protective Coatings (SSPC):

SSPC AB1 Mineral and Slag Abrasives

SSPC AB2 Cleanliness of Recycled Ferrous Metallic Abrasives

SSPC AB3 Newly Manufactured or Re-Manufactured Steel

Abrasives

SSPC QP1 Standard Procedure for Evaluating Painting Contractors

(Field Application to Complex Industrial Structures)

SSPC QP2 Standard Procedure for the Qualification of Painting

Contractors (Field Removal of Hazardous Coatings

from Complex Structures)





SSPC QP3 Standard Procedure for Evaluating Qualifications of

Shop Painting Applicators

SSPC SP10 Near-White Blast Cleaning

SSPC SP11 Power Tool Cleaning to Bare Metal

SSPC Painting Manual, Volume 1, “Good Painting Practice”

F. State of California Department of Transportation (Caltrans), Standard Specifications

(2006):

Section 6 Control of Materials

Section 51 Concrete Structures

Section 59 Painting

Section 75 Miscellaneous Metal

Section 91 Paint

1.05 SUBMITTALS

A. General: Submittals for joint seals and assemblies shall be made in accordance with the

provisions in Section 01 33 00, Submittal Procedures, and Section 01 33 23, Shop

Drawings, Product Data, and Samples.

B. Shop Drawings: Shop Drawings for joint seal assemblies shall show details of members,

including connections, sizes, and spacing of bolts and welds. Shop Drawings shall show

the marking and position of each member, erection plans and the limits of paint and

galvanizing applications. A complete anchor bolt setting plan for the execution of the work

shall be submitted.

C. Certificates of Compliance: Submit Certificates of Compliance for each batch of joint seal

material.

1. Certification in conformance with the requirements in SSPC QP 1, SSPC QP2,

and SSPC QP3 will not be required for cleaning and painting of joint seal

assemblies.

2. A Certificate of Compliance conforming to the provisions in Section 6-1.07,

"Certificates of Compliance," of the Caltrans Standard Specifications and a

Material Safety Data Sheet shall be furnished prior to use for each shipment of

blast cleaning material for steel.

D. Laboratory Test Reports:





1. Laboratory test reports shall show the name of testing agency, date of testing,

types of tests performed and shall be signed by a principal of the testing agency

who is a registered civil or structural engineer in the State of California.

2. Laboratory test reports shall be submitted for joint seals to show compliance with

appropriate ASTM Standards and these Technical Specifications.

1.06 QUALITY CONTROL

A. Codes and Standards: Comply with all applicable Federal, State and Local Codes and

Safety Regulations.

B. Submit to the VTA a separate Painting Quality Work Plan (PQWP) for each item of Work

for which painting or paint removal is to be performed, in conformance with Section 01 45

00 - Quality Control. As a minimum, each PQWP shall include the following:

1. The name of each subcontractor to be used.

2. One copy each of all current ASTM and SSPC specifications or qualification

procedures which are applicable to the painting or paint removal to be performed.

3. A copy of the coating manufacturer's guidelines and recommendations for surface

preparation, painting, drying, curing, handling, shipping, and storage of painted

structural steel, including testing methods and maximum allowable levels for

soluble salts.

4. Proposed methods and equipment to be used for paint application.

5. Proposed methods to control environmental conditions in accordance with the

manufacturer's recommendations and these Technical Specifications.

6. Proposed methods to protect the coating during curing, shipping, handling, and

storage.

7. A detailed paint repair plan for the repair of damaged areas.

8. No painting or paint removal shall be performed until the PQWP for that work is

reviewed by the VTA.

C. The VTA's review of the Contractor's PQWP shall not relieve the Contractor of any

responsibility under the Contract for the successful completion of the work in conformity

with the requirements of the Contract Documents.

D. Sampling, Testing and Inspection:

1. The Contactor’s approved independent testing laboratory shall perform sampling,

testing, and inspections specified herein in conformance with Section 01 45 00 -

Quality Control.





2. Notify the VTA at least 48 hours in advance of sampling, tests and inspections

being performed by the independent testing laboratory. The VTA may elect to

observe these procedures. Provide samples and facilities for inspection to the

VTA if requested.

3. The independent testing laboratory shall collect samples of materials for testing

in accordance with the provisions outlined herein and as directed by the VTA.

E. Submit a Quality Control Plan for the manufactured assemblies in accordance with Section

01 45 00 – Quality Control.

F. Qualifications of the independent testing laboratory and coating inspectors: Refer to

Section 01 45 00 - Quality Control.

PART 2 - PRODUCTS

2.01 MATERIALS

A. Materials for construction of joint seals and assemblies shall be in accordance with Section

51, "Concrete Structures," of the Caltrans Standard Specifications and these Technical

Specifications.

B. All metal parts of the joint seal assembly shall conform to the requirements in Section

75-1.03, "Miscellaneous Bridge Metal," of the Caltrans Standard Specifications. Bolts, nuts

and washers shall conform to ASTM A325.

C. Sheet neoprene shall conform to the requirements for neoprene in Section 51-1.14,

"Waterstops," of the Caltrans Standard Specifications. The sheet neoprene shall be

fabricated to fit the joint seal assembly accurately.

2.02 PAINTING

A. At the Contractor's option, cleaning and painting of all new metal surfaces of the joint seal

assembly, except stainless steel and anchorages embedded in concrete, may be substituted

for galvanizing. Cleaning and painting shall be in accordance with the provisions in

Sections 59-2, "Painting Structural Steel," 59-3, "Painting Galvanized Surfaces," and 91,

"Paint," of the Caltrans Standard Specifications.

B. Cleaning:

1. Fresh, potable water with a maximum chloride content of 75 ppm and a

maximum sulfate content of 200 ppm shall be used for water rinsing or pressure

washing operations. No continuous recycling of rinse water will be permitted. If

rinse water is collected into a tank and subsequent testing determines the

collected water conforms to the specified requirements, reuse may be permitted

by the VTA if no collected water is added to the tank after sample collection for

determination of conformance to specified requirements.





2. Mineral and slag abrasives used for blast cleaning steel surfaces shall conform to

the requirements for Class A, Grade 2 to 3 abrasives contained in SSPC AB 1,

and shall not contain hazardous material.

3. Steel abrasives used for blast cleaning steel surfaces shall comply with the

requirements of SSPC AB 3. If steel abrasive is recycled through shop or field

abrasive blast cleaning units, the recycled abrasive shall conform to the

requirements of SSPC AB 2.

C. Paint:

1. Blast cleaned surfaces shall receive a single undercoat, and a final coat where

specified, consisting of an inorganic zinc coating conforming to the requirements

in AASHTO M 300, Type I or Type II, except that: 1) the first three sentences of

Section 5.6, "Primer Field Performance Requirements," shall not apply for Type

II coatings, and 2) the entire Section 4.7.1 shall not apply for either type of

inorganic zinc coating.

2. The color of the final coat of inorganic zinc coating shall match Federal

Standard 595B No. 36373.

3. If the Contractor proposes to use a Type I coating, the Contractor shall furnish for

review documentation as required in Section 5.6 of AASHTO M300.

4. If the Contractor proposes to use a Type II coating, the coating shall be selected

from the qualified products list, which may be obtained from the Caltrans

Transportation Laboratory.

2.03 ALTERNATIVE JOINT SEAL ASSEMBLY

A. At the Contractor's option, an alternative joint seal assembly may be furnished and installed

provided: (1) that the quality of the alternative and its suitability for the intended

application are at least equal to that of the joint seal assembly shown on the Design

Drawings, (2) that acceptable Shop Drawings and a Certificate of Compliance are furnished

as specified herein and (3) that the alternative conforms to the following requirements:

B. The determination as to the quality and suitability of a joint seal assembly will be made in

the same manner as provided in Section 6-1.05, "Trade Names and Alternatives," of the

Caltrans Standard Specifications. The factors to be considered will include: the ability of

the assembly to resist the intrusion of foreign material and water throughout the full range

of movement for the application, and the ability to function without distress to any

component.

C. Alternative joint seal assemblies will not be considered for approval unless it can be proven

that the assembly has had at least one year of satisfactory service under conditions similar

to this application.





D. Submit complete Shop Drawings for each alternative joint seal assembly to the VTA. The

Shop Drawings shall show complete details of the joint seal assembly and anchorage

components and the method of installation to be followed, including concrete blockout

details and any additions or rearrangements of the reinforcing steel from that shown on the

Design Drawings.

E. The Shop Drawings shall be supplemented with calculations for the particular joint seal

assembly.

F. Calculations and Shop Drawings shall be stamped and signed by an engineer who is

registered as a civil or structural engineer in California.

G. Each shipment of joint seal materials shall be accompanied by a Certificate of Compliance

as provided in Section 6-1.07, "Certificates of Compliance," of the Caltrans Standard

Specifications. The certificate shall state that the materials and fabrication involved comply

in all respects to the specifications and data submitted in obtaining the approval.

H. The elastomer portion of the joint seal assembly shall be neoprene conforming to the

requirements in Table 1 of ASTM D2628 and the following, except that no recovery tests or

compression-deflection tests will be required:

Property Requirement ASTM Test Method

Hardness, Type A Durometer, points 55-70 D 2240 (Modified)

Compression set, 70 hours at 212° F,

maximum, percent

40 D 395 Method B (Modified)

I. All metal parts of an alternative joint seal assembly shall conform to the requirements

above for the joint seal assembly shown on the Design Drawings. At the Contractor's

option, metal parts may conform to ASTM A572/A572M.

J. The assembly and its components shall be designed to support the AASHTO HS20-44

loading with 100 percent impact. The tire contact area used to distribute the tire loads shall

be 9.6 inches, measured normal to the longitudinal axis of the assembly, by 20 inches wide.

The assembly shall provide a smooth riding joint without slapping of components or wheel

tire rumble.

K. The movement rating of the assembly shall be measured normal to the longitudinal axis of

the assembly. The dimensions for positioning the assembly within the movement rating

during installation shall be measured normal to the longitudinal axis, disregarding any skew

of the deck expansion joint.

L. The assembly shall have cast-in-place anchorage components forming a mechanical

connection between the joint components and the concrete deck.

M. The maximum depth and width of the recess shall be such that the primary reinforcement to

provide the necessary strength of the structural members is outside the recess. The





maximum depth of the recess at hinges shall be 10 inches. The maximum width of the

recess on each side of the expansion joint shall be 12 inches.

N. All reinforcement other than primary reinforcement shall continue through the recess

construction joint into the recess and engage the anchorage components of the assembly.

O. Horizontal angle points and vertical corners at curbs in assemblies shall consist of either

pre-molded sections or standard sections of the joint seal assembly that have been specially

miter cut or bent to fit the structure.

P. The elastomer portion of the assembly shall be installed in accordance with the

manufacturer's recommendations at such time and in such a manner that it will not be

damaged by construction operations. The joint and blockout shall be cleaned of all dirt,

debris and other foreign material immediately prior to the installation of the elastomer.

PART 3 - EXECUTION

3.01 GENERAL

A. Open and filled joints and appurtenances shall conform to the provisions in Section 51-

1.12A, "Open Joints," Section 51-1.12B, "Filled Joints," Section 51-1.12C, "Premolded

Expansion Joint Fillers," and Section 51-1.12D, "Sheet Packing, Preformed Pads and Board

Fillers," of the Caltrans Standard Specifications.

B. Joint Seals: Type A, AL and B seals shall conform to the provisions in Section 51-1.12F,

"Sealed Joints," of the Caltrans Standard Specifications.

1. When ordered by the VTA, a joint seal larger than called for by the Movement

Rating shown on the Design Drawings shall be furnished and installed.

2. One field splice per joint may be made at locations and by methods approved by

the VTA. The seals shall be manufactured full length for the intended joint, then

cut at the approved splice section and rematched before splicing. Submit splicing

details for approval prior to beginning splicing work.

3. Type A and AL joint seals shall consist of a groove in the concrete that is filled

with field-mixed silicone sealant. Polyurethane sealant shall not be used.

4. The type of seal to be used for the Movement Rating shown on the Design

Drawings shall be as follows:





Movement Rating (MR) Seal Type

MR 1 inch Type A or Type B

1 inch < MR 2 inches Type B

2 inches < MR 4 inches Joint Seal Assembly (Strip Seal)

MR 4 inches Joint Seal Assembly (Modular Unit)

or Seismic Joint

C. Joint Seal Assemblies: Joint seal assemblies shall conform to the provisions in Section 51-

1.12E, "Expansion Joint Armor," and Section 51-1.12F, "Sealed Joints," of the Caltrans

Standard Specifications.

1. Metal parts of the joint seal assembly shall be pre-assembled before installation to

verify the geometry of the completed seal.

2. The bridge deck surface shall conform to the provisions in Section 51-1.17,

"Finishing Bridge Decks," of the Caltrans Standard Specifications prior to placing

and anchoring the joint seal assembly.

3. The assembly shall be placed in a blocked out recess in the concrete deck surface.

The depth and width of the recess shall permit the installation of the assembly

anchorage components or anchorage bearing surface to the lines and grades

shown on the Design Drawings.

D. Sheet neoprene shall be installed at such time and in such manner that the sheet neoprene

will not be damaged by construction operations. The joint shall be cleaned of all dirt,

debris and other foreign material immediately prior to installation of the sheet neoprene.

E. Cleaning and Painting of Joint Seal Assemblies:

1. Cleaning:

a. The surfaces to be cleaned and painted shall be dry blast cleaned in

conformance with SSPC SP 10. Blast cleaning shall leave surfaces with a

dense, uniform, angular anchor pattern of not less than 1.6 mils nor more

than 3.5 mils as measured in conformance with ASTM D 4417.

b. Corners shall be chamfered to remove sharp edges.

c. Thermal cut edges (TCEs) to be painted shall be conditioned before

blast cleaning by shallow grinding or other method approved by the VTA to

remove the thin, hardened layer of material resulting from resolidification

during cooling.

d. Visually evident base metal surface irregularities and defects shall be

removed in accordance with ASTM A6/A6M or AASHTO M160M/M160

prior to blast cleaning steel. When material defects exposed by blast

cleaning are removed, the blast profile shall be restored by either blast

cleaning or by using mechanical tools in accordance with SSPC SP 11.





2. Painting:

a. Inorganic zinc coating shall be used within 12 hours of initial mixing.

b. Application of inorganic zinc coating shall conform to the provisions

for applying zinc-rich coating in Section 59-2.13, "Application of Zinc-Rich

Primer," of the Caltrans Standard Specifications.

c. The single undercoat of inorganic zinc coating shall be applied to the

required dry film thickness in two or more applications within 8 hours of the

start of blast cleaning. Abrasive blast cleaned steel shall not be exposed to

relative humidity exceeding 85 percent prior to application of inorganic zinc

coating.

d. The total dry film thickness of all applications of inorganic zinc,

including the surfaces of outside members within the grip under bolt heads,

nuts, and washers, shall be not less than 4 mils nor more than 8 mils, except

that the total dry film thickness on each faying (contact) surface of high

strength bolted connections shall be between one mil and the maximum

allowable dry film thickness for Class B coatings as determined by certified

testing in conformance with Appendix A of AISC 348. Unless otherwise

stated, all inorganic zinc coatings used on faying surfaces shall meet the slip

coefficient requirements for a Class B coating on blast-cleaned steel, as

specified in AISC 348. Provide results of certified testing showing the

maximum allowable dry film thickness for the Class B coating from the

qualifying tests for the coating chosen, and maintain the coating thickness

on actual faying surfaces of the structure at or below this maximum

allowable coating thickness.

e. Damaged areas and areas where mudcracking occurs in the inorganic

zinc coating shall be blast cleaned and repainted with inorganic zinc coating

to the specified thickness.

f. Metal surfaces coated with Type II inorganic zinc coating shall be

protected from conditions that may cause the coating film to dissolve.

Repair areas where the coating has dissolved by blast cleaning and

repainting with inorganic zinc coating to the specified thickness.

g. Dry spray, or overspray, as defined in the SSPC Painting Manual,

Volume 1, shall be removed prior to application of subsequent coats or final

acceptance. Removal of dry spray shall be by screening or other methods

that minimize polishing of the inorganic zinc surface. The dry film

thickness of the coating after removal of dry spray shall be in conformance

with the provisions for applying the single undercoat, as specified herein.

3.02 FIELD QUALITY CONTROL

A. Inspections: The independent testing laboratory shall perform the following inspections:





1. Inspect the joints and blockouts for joint seals and joint seal assemblies prior to

installation.

2. Inspect the installation of joint seals and joint seal assemblies.

B. Welding Quality Control: Inspection of welding shall be performed in accordance with the

requirements of Section 01 45 00 - Quality Control.

C. Sampling and Testing: The independent testing laboratory shall sample and test the joint

seal materials in accordance with the provisions in Section 51-1.12, "Expansion and Fixed

Joints and Bearings," of the Caltrans Standard Specifications.

D. Painting of Joint Seal Assemblies:

1. The independent testing laboratory shall test the inorganic zinc coating prior to

application of final coats. The locations of the tests shall be determined by the

independent testing laboratory. The VTA may observe testing and may select

additional test locations. The independent testing laboratory shall determine the

sequence of the testing operations. The testing for adhesion and hardness shall be

performed no sooner than 72 hours after application of the single undercoat of

inorganic zinc coating.

2. The inorganic zinc coating shall have a minimum adhesion to steel of 600 psi

when measured using a self-aligning adhesion tester in conformance with

ASTM D 4541. The independent testing laboratory shall select two locations per

assembly for adhesion testing. The VTA may observe testing and may select

additional test locations. If either of the locations tested fail to meet adhesion

requirements, the section will be rejected. Repair the rejected item by blast

cleaning and repainting with inorganic zinc to the specified thickness. Test

locations for areas of inorganic zinc meeting adhesion testing requirements shall

be repaired by application of organic zinc primer as specified in Section 91-1.04,

"Materials," of the Caltrans Standard Specifications to the specified minimum dry

film thickness.

3. Prior to application of final coats, the inorganic zinc coating shall exhibit a solid,

hard, and polished metal surface when firmly scraped with the knurled edge of a

quarter. Inorganic zinc coating that is powdery, soft, or does not exhibit a

polished metal surface, as determined by the independent testing laboratory, shall

be repaired by blast cleaning and repainting with inorganic zinc coating to the

specified thickness.

4. Dry to solvent insolubility for water borne inorganic zinc primers shall be

determined in conformance with ASTM D 4752, except that water shall be the

solvent. The resistance rating shall be not less than 4. Each assembly shall be

tested for solvent insolubility. Inorganic zinc coating that does not meet the

solvent insolubility requirements will be rejected. Repair rejected assemblies by

blast cleaning and repainting with inorganic zinc coating to the specified

thickness.





5. Surface hardness of inorganic zinc shall be a minimum 2H when measured in

conformance with ASTM D 3363. Each assembly shall be tested for surface

hardness. Inorganic zinc coating that fails to meet the surface hardness

requirements shall be repaired by blast cleaning and repainting with inorganic

zinc coating to the specified thickness.

6. The independent testing laboratory shall retest all rejected areas of inorganic zinc

coating after repairs have been completed.

END OF SECTION 07 94 00
