HomeMy WebLinkAboutBID - 6024 PRECAST PRIMARY JUNCTION VAULTS (3)THE CITY OF FORT COLLINS UTILITIES
Electric Department
CONSTRUCTION SPECIFICATION NO: 366-101
TITLE: Precast Primary Junction Vaults
APPROVED BY:
Kraig Bader
Standards Engineering Division Manager
ORIGINATED: 8-16-73
REVISED: 1 December 2006
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PREVIOUS REVISION DESCRIPTIONS ON FILE
REVISION DESCRIPTION APPROVED
Revision F:
• Paragraph 3.2.6: Change drawings, design calculations to be addressed to
Design Engineer rather than Distribution Engineering.
Sagen/Coram
4/25/89
Revision G:
• Paragraphs 2.2 and 3.1.2.1: Drop year.
• Paragraphs 2.5 and 3.1.2.2: Update AASHO to AASHTO.
• Paragraph 2.6: Update from Prestressed Concrete Institute to National Precast
Concrete Association.
• Paragraph 3.1.1: Add NPCA certification requirement and right to cancel statement.
• Paragraph 3.1.2.6: Correct Distribution to Design Engineering.
• Paragraphs 3.1.4.1, 3.2.4, 4.2.1 and 4.5.2: Drop year and section.
• Paragraph 3.1.4.7: Add Dayton Superior inserts. Note eye bolts supplied by City.
Sagen/Coram
10/2/92
Revision H:
• Paragraph 3.2.6: Added painting requirement
Sagen/Westhuis
- March 99
Revision I :
• Replace Window knockouts with Duct Terminations.
• Ground rods replaced with #2 bare copper bonded to the vault’s internal steel
superstructure. #2 bare copper leads are brought out of the vault wall so that
ground bus can be bonded to it.
• All vaults will be manufactured with the same duct terminator configurations, so
they are no longer job-specific.
Bader /
Pendleton –
October 2005
Revision J :
• Paragraph 3.2.8: Change quantity from one to two 6” thick grade rings to be
consistent with current construction practices. This allows for future grade
changes and proper cover over duct banks.
Bader /
Dahlgren –
January 2006
Revision K :
• Paragraph 3.1.4.2: Add Type I-II LA to cement types. Removed reference to
withdrawn ASTM Standard C-175.
• Paragraph 3.1.4.4: Add A-706 for Weldable.
• Paragraph 4.1.1: Change “acceptable to” wording to “approved by”.
• Paragraph 4.6: Add last sentence regarding other sample monitoring systems.
• Appendix B: Add Colorado Precast to Suggested Manufacturers List
Bader /
Dahlgren -
May·2006
Revision L :
• Add a 7’ X 12’ Vault option that can be used for switch placement or as a 20K non-
impact rated splice vault that will not be placed in the roadway.
• Ground connections changed from #2 bare copper to #2 insulated Copper wire
bonded to the rebar structure.
Bader /
Dahlgren – Dec
2006
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TABLE OF CONTENTS
PREVIOUS REVISION DESCRIPTIONS ON FILE .............................................................................................................. 2
1 SCOPE .......................................................................................................................................................................................
4
2 APPLICABLE DOCUMENTS................................................................................................................................................ 4
2.1 ASTM STANDARDS .............................................................................................................................................................. 4
2.2 AMERICAN CONCRETE INSTITUTE A.C.I. 318, LATEST REVISION ......................................................................................... 4
2.3 AMERICAN WELDING SOCIETY AWS D12.1-61.................................................................................................................... 4
2.4 FORT COLLINS UTILITIES ELECTRIC DRAWING 366-101 ....................................................................................................... 4
2.5 AASHTO STANDARD SPECIFICATIONS FOR HIGHWAY BRIDGES .......................................................................................... 4
2.6 NATIONAL PRECAST CONCRETE ASSOCIATION'S QUALITY CONTROL MANUAL FOR PRECAST CONCRETE PLANTS .............. 4
3 REQUIREMENTS.................................................................................................................................................................... 4
3.1 GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION........................................................................... 4
3.2 SPECIFIC REQUIREMENTS FOR DESIGN AND CONSTRUCTION ............................................................................ 8
4 QUALITY ASSURANCE......................................................................................................................................................... 9
4.1 GENERAL ...........................................................................................................................................................................
9
4.2 QUALIFICATION TESTS .................................................................................................................................................. 9
4.3 FUNCTIONAL TESTS...................................................................................................................................................... 10
4.4 FINISH .................................................................................................................................................................................
10
4.5 DEFECTS .............................................................................................................................................................................
10
4.6 TEST METHODS - QUALIFICATION TESTS................................................................................................................ 10
4.7 TEST METHODS - FUNCTIONAL TESTS ..................................................................................................................... 10
5 DELIVERY..............................................................................................................................................................................
10
APPENDIX A – 10’ X 10’ VAULT DETAIL DRAWING..................................................................................................... 11
APPENDIX A – 7’ X 12’ VAULT DETAIL DRAWING....................................................................................................... 12
APPENDIX B – APPROVED MANUFACTURERS ............................................................................................................. 13
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SPECIFICATIONS FOR PRECAST PRIMARY JUNCTION VAULTS
1 SCOPE
This specification sets forth minimum requirements for the design, construction, delivery and
offloading of precast primary junction vaults as detailed on Drawing 366-101. Excavation and
installation will be by Utilities.
2 APPLICABLE DOCUMENTS
2.1 ASTM Standards
2.2 American Concrete Institute A.C.I. 318, Latest Revision
2.3 American Welding Society AWS D12.1-61
2.4 Fort Collins Utilities Electric Drawing 366-101
2.5 AASHTO Standard Specifications for Highway Bridges
2.6 National Precast Concrete Association's Quality Control Manual for Precast Concrete
Plants
3 REQUIREMENTS
3.1 GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION
3.1.1 QUALIFICATIONS
Manufacture, transportation, and offloading shall be by a Company specializing in
providing precast products and services normally associated with precast/prestressed
concrete construction. The manufacturer shall demonstrate the ability to provide
appropriately skilled workers, tools, equipment, and facilities. To assure proper quality
control and supervision, all concrete products associated with the vault shall be
produced in the same National Precast Concrete Association (NPCA) certified
manufacturing facility. The manufacturer shall comply with the requirements set by the
NPCA's Quality Control Manual for Precast Concrete Plants. If the manufacturer is not
NPCA certified at the time bids are awarded, three weeks will be allowed to obtain
certification. If certification is not obtained within the allotted three-week period, the
award will be made to the next low bidder that is NPCA certified.
Utilities reserves the right to cancel the contract if the product does not meet
specifications, even if a non-conforming vault has been accepted.
3.1.2 DESIGNS
3.1.2.1 Design shall be in accordance with the provisions of the American Concrete
Institute A.C.I. 318 for reinforced concrete. The effect of openings in the
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sides, top, and bottom shall be taken into account, together with all possible
loads or combinations thereof.
3.1.2.2 Wheel loading for vaults installed in roadways shall be HS25 as prescribed
by the American Association of State Highway and Transportation Officials
(AASHTO). Wheel loading for vaults installed behind the curb with torsion
assist hatches shall be HS10-44.
3.1.2.3 No structure shall be designed for soil pressure less than an equivalent fluid
pressure of 50 pounds per cubic foot.
3.1.2.4 All structures shall be designed for a minimum hydrostatic pressure of 5
feet measured from the base of the structure.
3.1.2.5 Floors shall be designed for a minimum load of 20 pounds per square foot
and a single concentrated load equal to the area in feet of the floor times 35
pounds placed at any point on the floor.
3.1.2.6 All designs shall bear the seal of an engineer licensed by the State of
Colorado. Three sets of design calculations shall be submitted to the City of
Fort Collins Utilities Electric Department Engineering Standards for approval.
3.1.3 DRAWINGS
3.1.3.1 All drawings and specifications shall be submitted at the time of bid and
shall clearly indicate the loads for which the vaults are designed. These loads
shall include soil loads, hydrostatic loads, and live loads which can safely be
imposed upon the vault simultaneously.
3.1.3.2 Copies of structural drawings, specifications, and typical details shall be
provided to Utilities by the manufacturer at the time of bid and shall bear the
seal of an engineer licensed by the State of Colorado. These drawings shall
show the size and position of all structural elements and reinforcing steel,
together with the location of all inserts, openings, and attachments that are a
part of the vault, and shall show the dead weight of the complete unit.
3.1.3.3 All plans shall clearly show the specified compressive strength of the
concrete at 28 days in pounds per square inch (psi) for which each part of the
vault is designed.
3.1.4 MATERIALS
3.1.4.1 Concrete
Concrete shall be mixed and placed in accordance with A.C.I. 318. Concrete
quality shall conform to the provisions of A.C.I. 318.
3.1.4.2 Cement
Cement shall be Portland Cement Type II or Type I/II , conforming to ASTM C-
150. Low alkali (LA) formulations may be used.
3.1.4.3 Concrete Aggregate
Concrete aggregate shall conform to ASTM C-33. The maximum size of the
aggregate shall not be more than 3/4 inch.
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3.1.4.4 Reinforcing Steel
Reinforcing bars shall conform to ASTM A-615 (Standard Specification for
Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement) Grade 60,
latest revision, or A-706 (Specification for Low-Alloy Steel Deformed and Plain
Bars for Concrete Reinforcement) where weldable reinforcing bars are needed.
Welded wire fabric shall conform to ASTM A-185, latest revision. Rebar shall be
wire tied, not welded.
An insulated #2 Copper wire shall be bonded to the rebar structure using an
appropriately sized mechanical clamp. The connection shall be sealed using 3M
Scotch Seal #2229 or equivalent. Wire, clamp and rebar shall be wire brushed
before installation.
3.1.4.5 Air-Entraining Agents
Air-entraining agents shall conform to ASTM C-260.
3.1.4.6 Gaskets
Gaskets shall be of a resilient material resistant to attacks by acids of alkali
conditions in soils, and shall form a continuous watertight seal.
3.1.4.7 Embedded Items and Anchorage Devices
All embedded items, inserts, and anchorage devices exposed to view, moisture or
weather shall be hot-dipped galvanized steel. Anchorage devices shall be
fabricated from ASTM A36 steel.
Lifting devices shall have a minimum safety factor of 4. Lifting devices for vault
top shall be Dayton Superior, 4-ton P-52 SL Anchors, with recess plugs. Inserts
shall be Richmond 1" LEL-SH single end lift inserts or Dayton Superior 1" T-1
single pick-up inserts. Richmond LEB lifting eye bolts, size 1" x 3½" with 3" thread
will be provided by City of Fort Collins Utilities.
3.1.5 MANUFACTURE
3.1.5.1 Casting
Casting shall be accomplished by methods and equipment that are in
conformance with generally acceptable systems for this type of work.
Forms shall conform to the shape, lines, and dimensions of the members as called
for on the plans, and shall be substantial and sufficiently tight to prevent leakage.
They shall be properly braced so as to maintain position and shape.
All precast concrete shall be manufactured by a plant thoroughly experienced in
this type of work. The manufacturer shall meet all production schedules. Surfaces
on which units are cast shall be level and free from any imperfections detrimental
to the surface appearance of the finished units. Parting compound shall be
applied evenly as per manufacturer's recommendations.
Concrete shall be so handled as to prevent segregation of materials and shall be
continuously vibrated during casting, either internally or externally, to achieve proper
compaction, finish and distribution of concrete. All precautions must be taken to
keep the reinforcing steel in the proper locations during placing and consolidation of
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the concrete. Unless shown otherwise, all reinforcing steel shall have a minimum
cover of 1½". Embedded items shall be accurately placed and maintained in their
proper location during the casting operation. Special inserts or other devices for
handling of panels for the convenience of the manufacturer shall not be exposed to
view after members are erected. Embedded anchors, inserts, plates, angles and
other cast-in items shall have sufficient anchorage and embedment for design
requirements.
3.1.5.2 Curing
Concrete shall be protected from the weather and maintained at 50oF to 75 oF in a
moist condition for at least the first seven (7) days after placing unless steam
curing is employed.
Concrete may be steam cured after an initial set has taken place. The steam
temperature shall not exceed 160 oF, and shall not be raised from the ambient
temperature at a rate exceeding 40 oF per hour. The steam cured unit shall not be
removed from the forms until sufficient strength is obtained for the unit to withstand
any structural strain that may be imposed during the form stripping process. After
the stripping of forms, further curing by means of water spraying or a membrane
curing compound may be used. This compound shall conform to ASTM C-309.
3.1.5.3 Dimensional Tolerances
The dimensional tolerances of structural members shall not be greater than 3% of
the specified dimensions. The internal dimensions of the vault shall be held to
within 1% of the designed dimension. When a structure is composed of one or
more components, the space in the joint between elements shall be uniform to a
maximum tolerance of 1/16".
3.1.5.4 Inserts
All threaded inserts placed in the concrete for use by the purchaser shall be free of
dirt to a depth of 2-1/2 times the thread diameter, and shall be protected from rust.
The manufacturer shall specify the maximum allowable loads that may be placed
on all inserts.
3.1.5.5 Gaskets
Structures composed of one or more elements and provided with gasket seals
between the elements, shall when assembled exert uniform pressure on the
gasket through its entire length sufficient to provide a watertight seal upon test.
3.1.6 GUARANTEE
The contractor shall guarantee the vault and lid for a period of two years after
completion against defective workmanship and materials. The determination of the
necessity during such guarantee period for the contractor to repair said vaults and lids
shall rest entirely with the Light and Power Utility, and the decision upon the matter
shall be final and obligatory upon the contractor.
3.1.7 Non-Conforming Material
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Purchase orders are contingent on conformance with these specifications and
attachments. Utilities reserves the right at any time to cancel a purchase contract, if in
Utilities’ opinion, the product or delivery does not meet specifications, even if a
nonconforming vault has previously been accepted. At Utilities’ discretion, a supplier
providing non-conforming material may be removed from the Approved Suppliers list
for an indefinite re-evaluation period of not less than two (2) years.
3.2 SPECIFIC REQUIREMENTS FOR DESIGN AND CONSTRUCTION
3.2.1 Vaults shall be built according to drawings in 366-101 (see Appendix A) showing the
location of all openings and inserts.
3.2.2 Shop Drawings
If the manufacturer has not previously done so, he shall prepare and submit to Utilities
three (3) sets of shop drawings for approval on a given vault design and shall not
proceed with the manufacture prior to approval of the drawings by Utilities. Utilities
must also review and approve any changes made to the original shop drawings.
3.2.3 Design Calculations
If the manufacturer has not previously done so, he shall obtain and submit to Utilities
three (3) sets of design calculations for approval. All vault designs shall bear the seal
and signature of an engineer registered in the State of Colorado.
3.2.4 Precast Members -Each precast member shall conform to all provisions of A.C.I. 318.
3.2.5 Openings and Inserts in Walls
Detail drawings (see Appendix A for example) will be issued with the release for
construction. Openings of the size and shape indicated on the detail drawings shall be
cast in the walls within ½" of the centerline location shown on the drawings. Inserts for
pulling eyes shall be cast within 1" of the centerline location on the drawings.
3.2.6 Identification for Billing, Correspondence, Drawings, and Other Data.
All invoices, and billing correspondence shall include the Utility vault numbers for
which the invoices are being submitted and shall be addressed to:
City of Fort Collins Utilities, Electric Department,
Post Office Box 580,
Fort Collins, Colorado 80522,
Attention: Doug Martine, Distribution Engineering
All drawings, design calculations and other correspondence shall be addressed to:
City of Fort Collins Utilities , Electric Department,
Post Office Box 580,
Fort Collins, Colorado 80522,
Attention: Kraig Bader, Standards Engineering
All invoices and correspondence shall show the City of Fort Collins Utilities purchase
order number.
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3.2.7 Gaskets
Gaskets (joint compound) shall be installed by the manufacturer at the job site during
the final placement of the vault, if final placement is performed by the manufacturer.
3.2.8 Grade Rings
The manufacturer shall provide, as standard equipment, one 6" thick grade ring with
manhole frame, and two 6" thick grade rings with each vault as shown on drawing 366-
101.
3.2.9 Paint
A flat white vinyl latex paint shall be applied to the complete interior of each vault.
Paint shall not be used to cover defects or flaws in the concrete. Any such discovery
will result in immediate rejection of that specific vault.
4 QUALITY ASSURANCE
4.1 GENERAL
4.1.1 Responsibility for Inspection
Unless otherwise specified, the vendor is responsible for the performance of all
inspection requirements as specified herein. Except as otherwise specified, the
vendor may utilize his own facilities or any commercial laboratory approved by the City
of Fort Collins Utilities. The Utilities or its authorized representatives shall have access
to the manufacturing plant at any time during working hours and reserves the right to
perform or witness any of the inspections set forth in this specification where such
inspections are deemed necessary.
4.1.2 Drawings
The manufacturer shall maintain accurate and up-to-date drawings available for the
inspection of the placement of reinforcing steel and other dimensional characteristics
of the structure.
4.1.3 Notice of Manufacturing Schedule
Utilities shall be informed two (2) days in advance of the construction of each vault, in
order that Utilities may, at the Utility’s option, have an inspector at the plant during
construction.
4.2 QUALIFICATION TESTS
4.2.1 Concrete
The manufacturer shall test concrete in accordance with A.C.I. 318 and in addition
shall for each vault make two (2) cylinders which shall be cured under field conditions.
All cylinders shall be tested by an approved independent testing laboratory and a
certificate of these tests shall be a part of the manufacturer's permanent record. In
addition, one (1) copy of the certificate shall be provided to the Utility's representative
at the time of delivery.
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4.3 FUNCTIONAL TESTS
4.3.1 Dimensions
All dimensions shall conform to the drawings with allowable tolerances as specified in
Paragraphs 3.1.5.3 and 3.2.5 of this specification.
4.4 Finish
The finish shall be the result of casting against approved forms using care in the cleaning
of forms, design of concrete mix, placing, and curing.
4.5 Defects
Small surface holes caused by air bubbles, normal form joint marks, and minor chips and
spalls will be tolerated. Honeycomb (due to lack of proper consolidation by vibration) will
be cause for rejection. All cracks which penetrate the thickness of any member shall be
deemed evidence of partial failure and shall be cause for rejection of the member.
4.6 TEST METHODS - QUALIFICATION TESTS
Concrete samples shall be taken in accordance with ASTM C172. Concrete cylinders
shall be molded and laboratory cured in accordance with ASTM C31 and tested in
accordance with ASTM C39. Field cured cylinders shall be in accordance with Section
9(c) of ASTM C31. Other sample monitoring systems may be used if approved by City of
Fort Collins Utilities.
4.7 TEST METHODS - FUNCTIONAL TESTS
4.7.1 Dimensions
All dimensions and location of inserts and openings shall be checked using a standard
tape measure.
4.7.2 Finish and Defects
A visual inspection shall be deemed adequate to determine the quality of the finish and
the extent of the defects. Where cracks of questionable nature exist, the manufacturer
may be required to load test the member in accordance with ACI 318. In any event, all
members shall be watertight.
5 DELIVERY
Manufacturer is responsible for delivery and final placement of vaults at job site. Care shall be
taken in loading, transportation, and setting precast vaults. Members shall be handled in such a
manner as to prevent excessive stresses, spalling, or cracking. Edges shall be protected from
staining, chipping or spalling.
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Appendix B – Approved Manufacturers
Amcor Precast
8392 Riverview Parkway
Littleton, CO 80215-9790
Toll Free: 800-742-4538
Fax: 303-791-1120
www.oldcastle-precast.com
Firebaugh's Pre-Cast Concrete Co
3090 E Las Vegas
Colorado Springs, CO 80906 - 8000
Ph: (719) 392-9036
Fax: (719) 392-0066
Attention: Kevin Gregg
General Email: mmcclain@firebaughprecast.com
Rinker Materials (formerly Carder Concrete Products)
8311 W. Carder Ct
Littleton, CO 80125-9705
Telephone 303-791-1600
bspatz@rinker.com
Colorado Precast
1820 SE 14th Street
Loveland, CO 80537 - 8805
970-669-0535
970-669-0674 Fax
www.coloprecast.com