SYSTEMS STANDARD SPECIFICATIONS

Transcription

1 DALLAS AREA RAPID TRANSIT LIGHT RAIL PROJECT SYSTEMS STANDARD SPECIFICATIONS CONTRACT Number C Systems Standard Specifications Prepared by: DALLAS SYSTEMS CONSULTANTS, A Joint Venture of PARSONS and Paragon Project Resources, Inc. 17 March 2006

2 DALLAS AREA RAPID TRANSIT LIGHT RAIL PROJECT SYSTEMS STANDARD SPECIFICATIONS BASELINE I hereby certify that the following Specifications Sections were prepared under my direct supervision System Safety Program No Additional Items DIVISION 1 - GENERAL REQUIREMENTS DIVISION 5 - METALS Overhead Contact System Steel Poles - Wide Flange Overhead Contact System Fabricated Metal Supports Overhead Contact System Steel Tubular Poles No Additional Items DIVISION 16 - ELECTRICAL Conduit and Raceways Traction Power System Substation Installation Overhead Contact System Basic Electrical Materials And Methods Overhead Contact System Grounding and Bonding Overhead Contact System No Additional Items DALLAS SYSTEMS CONSULTANTS, A Joint Venture of THE SEAL APPEARING ON THIS DOCUMENT WAS AUTHORIZED BY FRANK R. DeLlZZA P.E ON CONTRACT NO. C Parsons Corporation and m PARSONS ISSUE pcracon Paragon Project Resources, Inc. DATE: 17 MAR 2006

3 DALLAS AREA RAPID TRANSIT LIGHT RAIL PROJECT SYSTEMS STANDARD SPECIFICATIONS BASELINE I hereby certify that the following Specifications Sections were prepared under my direct supervision. DIVISION 16 - ELECTRICAL Basic Technical Requirements - Communications System Miscellaneous Components And Products - Communications System Communications Facilities - Communications System Communications Interface Cabinet - Communications System Communications Cable - Communications System Fiber Optic Cable Subsystem - Communications System Basic Electrical Materials And Methods - Communications System Telephone Subsystem - Communications System Public Address Subsystem - Communications System Visual Message Board Subsystem - Communications System Fire Alarm Subsystem - Communications System Intrusion Alarm Subsystem - Communications System Fare Collection Local Area Network - Communications System Grounding and Bonding - Communications System Communications Transmission Subsystem - Communications System Power Supplies and Distribution - Communications System Manuals and Training - Communications System Technical Support and Spares - Communications System No Additional Items DALLAS SYSTEMS CONSULTANTS, A Joint Venture of Parsons Corporation and CONTRACT NO. C ISSUE poraicon Paragon Project Resources. Inc. ACEx Technologies, Inc DATE: 17 MAR 2006

4 DALLAS AREA RAPID TRANSIT LIGHT RAIL PROJECT SYSTEMS STANDARD SPECIFICATIONS BASELINE I hereby certify that the following Specifications Sections were prepared under my direct supervision. DIVISION 16 - ELECTRICAL Basic Technical Requirements - Signal System Block Design Criteria - Signal System Drawings - Signal System External Cable - Signal System Power Cable - Signal System Power Switch-and-Lock Movements - Signal System Embedded Power Switch-and-Lock Movements - Signal System Signals and Indicators - Signal System Audio Frequency Main Line Track Circuits - Signal System Power Frequency Track Circuits - Signal System Train-To-Wayside Communications - Signal System Cab Signal and B-Point Loops - Signal System Impedance Bonds - Signal System Train Stops - Signal System Rail Bonding - Signal System Automatic Highway Crossing Warning System - Signal System Power System - Signal System No Additional Items DALLAS SYSTEMS CONSULTANTS, A Joint Venture of Parsons Corporation and CONTRACT NO. C ISSUE POXSCON Paragon Proiect Resources. Inc. DATE: 17 MAR 2006

5 DALLAS AREA RAPID TRANSIT LIGHT RAIL PROJECT SYSTEMS STANDARD SPECIFICATIONS BASELINE I hereby certify that the following Specifications Sections were prepared under my direct supervision. DIVISION 16 - ELECTRICAL Instrument Houses - Signal System Wayside Cases - Signal System Junction Boxes - Signal System Instrument Racks - Signal System Internal Wire and Cable - Signal System Plug Connectors - Signal System Relays - Signal System Vital Microprocessor Interlocking System - Signal System Transformers - Signal System Local Control Panels - Signal System Event Recorders - Signal System Grounding of Equipment - Signal System Electromagnetic Compatibility - Signal System Reliability and Maintainability - Signal System Wayside Signs - Signal System Miscellaneous Components and Products - Signal System Test and Inspection - Signal System No additional items DALLAS SYSTEMS CONSULTANTS, A Joint Venture of Parsons Corporation and PARSONS CONTRACT NO. C ISSUE DATE: 17 MAR 2006 Paragon Project Resources, Inc. 3 - ' 7 - <><>

6 SYSTEMS STANDARD SPECIFICATIONS 17 March 2006 TABLE OF CONTENTS Page 1 of 2 DIVISION 1 - GENERAL REQUIREMENTS System Safety Program DIVISION 5 - METALS Overhead Contact System Steel Poles - Wide Flange Overhead Contact System Fabricated Metal Supports Overhead Contact System Steel Tubular Poles DIVISION 16- ELECTRICAL Conduit and Raceways Traction Power System Substation Installation Overhead Contact System Basic Electrical Materials And Methods Overhead Contact System Grounding and Bonding Overhead Contact System Basic Technical Requirements - Communications System Miscellaneous Components And Products - Communications System Communications Facilities - Communications System Communications Interface Cabinet - Communications System Communications Cable - Communications System Fiber Optic Cable Subsystem - Communications System Basic Electrical Materials And Methods - Communications System Telephone Subsystem - Communications System Public Address Subsystem - Communications System Visual Message Board Subsystem - Communications System Fire Alarm Subsystem - Communications System Intrusion Alarm Subsystem - Communications System Fare Collection Local Area Network - Communications System Grounding and Bonding - Communications System Communications Transmission Subsystem - Communications System Power Supplies and Distribution - Communications System Manuals and Training - Communications System Technical Support and Spares - Communications System

7 SYSTEMS STANDARD SPECIFICATIONS 17 March 2006 TABLE OF CONTENTS Page 2 of 2 DIVISION 16- ELECTRICAL, Continued Basic Technical Requirements - Signal System Block Design Criteria - Signal System Drawings - Signal System External Cable - Signal System Power Cable - Signal System Power Switch-and-Lock Movements - Signal System Embedded Power Switch-and-Lock Movements - Signal System Signals and Indicators - Signal System Audio Frequency Main Line Track Circuits - Signal System Power Frequency Track Circuits - Signal System Train-To-Wayside Communications - Signal System Cab Signal and B-Point Loops - Signal System Impedance Bonds - Signal System Train Stops - Signal System Rail Bonding - Signal System Automatic Highway Crossing Warning System - Signal System Power System - Signal System Instrument Houses - Signal System Wayside Cases - Signal System Junction Boxes - Signal System Instrument Racks - Signal System Internal Wire and Cable - Signal System Plug Connectors - Signal System Relays - Signal System Vital Microprocessor Interlocking System - Signal System Transformers - Signal System Local Control Panels - Signal System Event Recorders - Signal System Grounding of Equipment - Signal System Electromagnetic Compatibility - Signal System Reliability and Maintainability - Signal System Wayside Signs - Signal System Miscellaneous Components and Products - Signal System Test and Inspection - Signal System

8 SECTION SYSTEM SAFETY PROGRAM PART 1 - GENERAL 1.1 DESCRIPTION A. The Work to be done under this Section consists of establishing and maintaining a Contractor System Safety Program (CSSP). This safety program shall be developed by the Contractor and integrated into all Work phases relating to Communications, Traction Electrification, i.e., Overhead Contact System and Traction Power Substations, Signals, and Fare Collection, and these Contract Work elements shall be known collectively as "Systems." The CSSP requirements shall be applied to subcontractors, suppliers, and vendors. B. The CSSP shall prescribe a formal approach to hazard control through engineering, design, education, management policy, and supervisory control of conditions and practices. The procurements and guidelines established in MIL-STD-882D, Standard Practice For System Safety, shall be applied to the CSSP. C. The CSSP shall supplement the fail-safe and fault tolerant design requirements of these Specifications, but shall not, in any way, relieve the Contractor of design responsibility. 1.2 REFERENCES A. Military Standards 1. MIL-STD-882D - Standard Practice For System Safety B. Dallas Area Rapid Transit (DART/Authority) 1. DART Light Rail Transit, Systems Safety and Security Program Plan, May 2004, Revision 7 (SSPP) 1.3 OBJECTIVES A. The Contractor's objectives shall be in compliance with Authority's System Safety and Security Program Plan (SSPP). B. The primary objective of the CSSP shall be to eliminate hazards from the "Systems" equipment and facilities provided under this Contract. These are hazards which could result in personal injury, damage, or loss of a portion of the subject facilities, see Paragraph 1.6, "Hazard Risk Assessment and Resolution" of this Section. Hazard risk assessment applies both directly and indirectly, (i.e., whether the injury, damage, or loss, were to be caused directly by a subject facility malfunction or indirectly by the resultant unsafe operation of one or more trains.) C. The secondary objective of the CSSP shall be to minimize the extent and seriousness of injury to personnel and damage to equipment and property due to any malfunction of the facilities provided under this Contract. 1.4 SUBMITTALS A. System Safety Program Plan 1. The Contractor shall submit for Authority approval, a Contract System Safety Program Plan (CSSP) within 60 days after Contract NTP in accordance with the requirements of these Specifications. The CSSP shall include all of the requirements of this Section and the intent of the Authority SSPP. It shall describe how the CSSP is to be implemented, managed, and documented to achieve the objectives of the CSSP The functions, responsibilities, and authority of all personnel associated with the implementation, management, and operation of the CSSP shall be clearly identified in the Contractor's CSSP. The relationship between line, staff, project, and management shall be shown. The process by which the Contractor shall monitor and supervise subcontractors, suppliers and vendors, to assure their conformance to the applicable requirements of the CSSP shall also be discussed. 3. The Contractor proposed PHA format shall be shown and described in the CSSP. The Contractor's PHA format shall be submitted for Authority approval as part of the CSSP. 4. The Contractor may submit a CSSP for Authority approval that has been successfully implemented on a similar rail transit project. In this case, the CSSP shall include: a. A reference contact for the other project including name, title, address and telephone number. b. Definition of equipment and processes that are new or different between the Authority Project and the other project. c. Approach for evaluating the system safety impacts of these new and different elements. 5. The Authority approved CSSP shall be maintained throughout the life of the Contract. B. Monthly Progress Reports 1. The Contractor shall submit to the Authority Monthly System Safety Reports, commencing no later than 60 days after Contract NTP, as a part of the Monthly Progress Report. The Monthly System Safety Reports shall include the following: DART - October

9 SYSTEM SAFETY PROGRAM a. A list of in-progress System safety tasks and the status of each. b. Evaluation of design changes on the System safety. c. A list of open items relevant to System safety. d. A list of System safety tasks to be accomplished in the next reporting period. e. An updated schedule showing the significant milestones of the CSSP, with expected dates of completion. Preliminary Hazard Analysis (PHA) 1. The Contractor shall submit the PHA in quarterly increments beginning no later than six months after Contract NTP. Each submittal shall include the following information: a. The PHA, in the current state of completion. b. Perform the PHA and ensure compliance with the relevant portions of the Authority's SSPP Chapter 5 and the CSSP and these Specifications. c. Identification of changes, additions, or deletions since the previous submittal. d. Status of all known system hazards. Operating Hazard Analysis (OHA) 1. The Contractor shall submit the OHA in quarterly increments, beginning no later than six months after Contract NTP. Each submittal shall include the following information: a. The OHA, in the current state of completion. b. Perform the OHA and ensure compliance with the relevant portions of the Authority's SSPP Chapter 5 and the CSSP and these Specifications. c. Identification of changes, additions, or deletions since the previous submittal. d. Status of all known operating hazards. Failure Mode Effects Analysis (FMEA) 1. The Contractor shall submit the FMEA in quarterly increments, beginning no later than six months after Contract NTP. Each submittal shall include the following information: a. The FMEA, in the current state of completion. b. Perform the FMEA and ensure compliance with the relevant portions of the Authority's SSPP Chapter 5 and the CSSP and these Specifications. c. Identification of changes, additions, or deletions since the previous submittal. d. Status of all known operating hazards. F. Fault Tree Analysis (FTA) 1. The Contractor shall submit the FTA in quarterly increments, beginning no later than six months after Contract NTP. Each submittal shall include the following information: 1.5 REQUIREMENTS A. Management a. The FTA, in the current state of completion. b. Perform the FTA and ensure compliance with the relevant portions of the Authority's SSPP Chapter 5 and the CSSP and these Specifications. c. Identification of changes, additions, or deletions since the previous submittal. d. Status of all known operating hazards. 1. The Contractor shall be responsible for the CSSP management and operation. The responsibilities and functions of those directly associated with System Safety policies and implementation of the program shall be clearly defined. The authority delegated to this organization and the relationship between line, staff, interdepartmental, project, functional and general management organizations shall be identified. It is not the intent of this Section to prescribe or imply organizational structure, management methodology, implementation procedures, or internal documentation. Pertinent aspects of the CSSP Management shall be reported in the monthly reports. B. The Contractor shall designate an employee as "System Safety Supervisor or Manager" to manage all aspects of the Contractor's and subcontractors' CSSP. The requirements for the System Safety Supervisor or Manager shall be: DART - October 2005

10 SYSTEM SAFETY PROGRAM 1. Minimum of three years experience in performing operating hazard analyses and preliminary hazard analyses. 2. Knowledge in "Systems" technology. 3. Knowledge of Light Rail or Transit control system software safety characteristics. 4. The Contractor shall submit the designated Safety Manager/Supervisor employee and resume and credentials for Authority approval. Preliminary Hazard Analysis 1. The Contractor shall conduct a complete and comprehensive PHA to identify, classify, evaluate and resolve hazards in the System. The PHA shall include consideration of all "Systems" subsystems, assemblies and components. The PHA shall include the following information: a. Hazard Index Number b. Description of the hazard. c. Effects of the hazard. d. Initial hazard risk. e. Controls for the hazard. f. Final hazard risk. g. Status of the hazard. Operating Hazard Analysis 1. The Contractor shall conduct a complete and comprehensive OHA. Interface With the Authority System Safety Activities 1. The Authority will perform System Safety Activities as defined in Authority's SSPP. Included in these activities are PHA and OHA. The Contractor shall support these activities by providing: a. Technical data related to the Contract requested by the Authority. b. Response to System Safety questions for equipment, procedures or other material related to the Contract. c. The Contractor shall disclose, analyze, explain, and discuss designs with the Authority that impact or potentially impact the safety, operation, or reliability where the Contractor's designs deviate from the Authority's current configuration and equipment complement and potentially compel the Authority to review the system safety impact. F. Interface With the Authority Operations 1. Contractor employees that are required to work in and around the Authority revenue operations shall attend an Authority sponsored safety class prior to commencing any Work. 1.6 HAZARD RISK ASSESSMENT AND RESOLUTION A. Hazard Risk is comprised of two elements: severity and frequency. Severity is a qualitative measure of the injury and damage resulting from a mishap. Frequency is a qualitative measure of how often a mishap occurs. B. Hazard severity shall be classified and assigned a relative quantitative severity in accordance with the Authority's SSPP Paragraph C. Hazard frequency shall be assigned a relative frequency of occurrence in accordance with the Authority's SSPP Paragraph D. The Contractor shall take immediate action to control hazards in accordance with the requirements of Authority's SSPP Paragraph TASKS AND PROCEDURES A. The CSSP shall specifically describe the procedures that the Contractor shall follow in order to accomplish CSSP tasks. These tasks shall include the following: 1. Adequately control entire system hazards in the design phase as early as possible. 2. Eliminate from the System any identified false Signal proceed aspects or the evoking of any false proceed aspects. 3. Identify any single failure in the Communication and Control System, Signal System, and Overhead Contact System (OCS), Traction Power Substation, Fare Collection or their interfaces that may cause an unsafe condition. 4. Minimize the number of false signal stop aspects and other false communications control indications due to equipment design, installation, or operating procedure. 5. Evaluate design changes and the impact these changes will have on the safety of the complete System. 6. Establish and maintain the required backup data, information and material to assure and support System Safety Certification of the Communications and Control, OCS, and Signals Systems. DART - October

11 SYSTEM SAFETY PROGRAM PART 2 - PRODUCTS 2.1 CONTRACTOR FURNISHED MATERIALS A. The Contractor shall provide all the materials, tools, equipment, computer time, reference literature and any such required items that are essential to meet the CSSP requirements. PART 3 - EXECUTION 3.1 PERFORMANCE A. The System Safety Supervisor / Manager, identified in this Section shall have the following responsibilities: 1. Direct the activities of the CSSP and assigned personnel to complete all required CSSP tasks in accordance with the Contract Documents, while maintaining and staying within schedule and budget. 2. Supervise the Contractor's "PHA" of the Communications, OCS, Traction Power Substation, Fare Collection, and Signal Systems and its individual subsystems and interface areas. 3. Maintain records of all changes to the CSSP. These records shall be available to the Authority upon 48 hours notice. 4. Determine potential changes that could be made in the Systems, operating rules, training procedures, equipment, maintenance procedures, physical structure, or other systems outside this Contract to eliminate critical and marginal hazard conditions or to reduce their effect to a negligible status and recommend these changes to the Authority. 5. Implement those safety changes approved or required by the Authority, which fall within these Specifications. 6. Prepare and submit the Monthly System Safety Reports to the Authority as required in Paragraph 1.4.B of this Section. PART 4 - MEASUREMENT AND PAYMENT 4.1 GENERAL A. The Work specified in this Section will not be measured separately for payment. 4.2 PAYMENT A. In accordance with Section "General Requirements." END OF SECTION DART - October 2005

12 SECTION OVERHEAD CONTACT SYSTEM STEEL POLES - WIDE FLANGE PART 1 - GENERAL 1.1 DESCRIPTION A. The Work specified in this Section includes providing and delivering new wide flange steel poles and installation by the Contractor, as part of the Overhead Contact System (OCS) shown on the Contract Drawings and specified herein. 1.2 REFERENCE STANDARDS A. American Society of Mechanical Engineers International (ASME) 1. ASME SEC II SA-53/SA-53M - Specification for Pipe, Steel, Black and Hot-Dipped, Zinc- Coated, Welded and Seamless - ASTM A53/A53M-99 B. American Institute of Steel Construction, Inc. (AISC) 1. Specifications for the Design, Fabrication and Erection of Structural Steel for Buildings 2. Code of Standard Practice for Steel Buildings and Bridges C. ASTM International (Formerly known as American Society for Testing and Materials) (ASTM) 1. ASTM 123/A 123M - Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products 2. ASTM 143/A 143M - Safeguarding Against Embrittlement of Hot-Dip Galvanized Steel Products and Procedure 3. ASTM A153 /153 M - Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware 4. ASTM A194/A194M - Specifications for Carbon and Alloy Steel Nuts 5. ASTM A283 - Low and Intermediate Tensile Strength Carbon Steel Plates 6. ASTM A307 - Carbon Steel Externally Threaded Standard Fasteners 7. ASTM A370 - Methods and Definitions for Mechanical Testing of Steel Products 8. ASTM A384 - Safeguarding Against Warpage and Distortion During Hot-Dip Galvanizing of Steel Assemblies 9. ASTM F436 - Specifications for Hardened Steel Washers D. E. F. G. H. 1.3 A. B. 10. ASTM A500 - Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes 11. ASTM A501 - Hot-Formed Welded and Seamless Carbon Steel Structural Tubing 12. ASTM A563 - Carbon and Alloy Steel Nuts 13. ASTM A572 - High-Strength Low-Alloy Columbium-Vanadium Steels of Structural Quality 14. ASTM A992/ A992 M Rev A - Standard Specification for Structural Steel Shapes 15. ASTM B6 - Standard Specification for Zinc 16. ASTM E Standard Definitions of Terms Relating to Magnetic Particle Examination 17. ASTM E709 - Standard Recommended Practice for Magnetic Particle Examination 18. ASTM F593 - Stainless Steel Bolts, Hex Cap Screws, and Studs American Welding Society (AWS) AWS D1.1/D1.1M; Structural Welding Code, Steel AWS Wl Ch 12 - Computerization of Welding Inspection and Quality Department of Defense Specifications (DOD) 1. DOD-P-21035A Paint, High Zinc Dust Content, Galvanizing Repair Military Standard 1. NAVY MIL DTL 24441/20A - Primer coating, zinc dust-zinc oxide (for galvanized surfaces) Federal, State and Local Authorities 1. All applicable codes and regulations Corps of Engineers Publications 1. CRD-C588 Non-shrink Grout SUBMITTALS Refer to these Specifications for submittal procedures. Within 45 days of commencing Work, the Contractor shall submit shop drawings for review giving complete information required for fabrication of the poles. The shop drawings shall be to scale and shall indicate all DART - October

13 OVERHEAD CONTACT SYSTEM STEEL POLES - WIDE FLANGE fittings, holes and accessories, and the locations, sizes and types of all welds. C. Shop drawings shall be prepared under the signature and seal of a Licensed Texas Professional Engineer. D. Within 45 days of commencing welding Work, the Contractor shall submit for acceptance: 1. Specifications for welding procedures in accordance with AWS D Certificates of qualifications of welders, welding operators and tackers in accordance with AWS W1 CH Certificate of qualification of welding inspectors in accordance with AWS W1 CH12. E. Before commencing fabrication, the Contractor shall submit for review the manufacturer's certificates of compliance, or certified laboratory test reports demonstrating the compliance of all raw materials and fabricated products with paragraph 2.2, "Fabrication," of this Section. Included shall be a listing of the ASTM standards designated by the manufacturer, as indicated. F. Six copies of certified laboratory test reports shall be submitted prior to delivery of poles. 1.4 QUALITY ASSURANCE A. The Contractor shall perform the Work included in this Section in strict accordance with the requirements of the Authority approved Contractor Quality Control Program. B. The Contractor shall comply with the requirements of these Specifications and the codes and regulations of jurisdictional authorities. C. The Contractor's Quality Control Program shall include the following requirements: 1. Material qualification testing and certification for acceptance of materials, components and assemblies. 2. Job control testing of in-progress work being performed in shops, factories and on-site. 3. On-site inspection of specified work elements. 1.5 POLE TESTING AND INSPECTION A. Material Testing 1. The chemical compositions and required mechanical properties of all materials used shall be determined, either by obtaining manufacturer's certificates of compliance or by laboratory testing at a facility acceptable to the Authority. Embrittlement 1. Fabrication shall conform to ASTM A143 to prevent embrittlement of the steel. Weld Testing 1. The services of an AWS Certified Welding Inspector shall be provided by the pole fabricator: a. Inspect Fabrication Operations b. Inspect Welding Procedures c. Inspect Welding Personnel Qualifications d. Perform Ultrasonic and Magnetic Particle Testing 2. A visual inspection of all welds shall be performed in conformance with the AWS Code. 3. Weld testing shall be performed on a sample number of each type of pole, selected at random by the Authority, comprising five percent of the total number of poles. All poles selected for testing shall be tested by the ultrasonic and magnetic particle methods. 4. Equipment, procedures and personnel for weld testing, and test reports, shall conform to the requirements of AWS D1.1, Section 6 - Inspection. 5. Weld testing shall consist of: a. Ultrasonic testing conforming to the AWS D1.1, Section 6 requirements. b. Magnetic particle testing conforming to the ASTM E709 requirements. 6. Ultrasonic testing shall be performed on the complete penetration welds between the pole shaft and base. 7. For each tested pole that is found to be unacceptable, weld testing shall be performed on a further sample of two poles, selected at random by the Authority from the remaining untested pole population. 8. Results of weld testing shall be deemed acceptable or unacceptable in accordance with AWS D1.1, Sections 8, 9, or Welds found to be unacceptable shall be repaired in accordance with AWS D1.1, Section 3, and retested DART - October 2005

14 OVERHEAD CONTACT SYSTEM STEEL POLES - WIDE FLANGE D. Galvanizing Testing 1. All galvanized items shall be inspected for conformance with the requirements of the following ASTM Specifications, as applicable: a. b. c. E. Impact testing: Galvanizing Compliance: A153 Embrittlement: A143 Distortion: A384 A123 or 1. Structural steel materials for base plates and pole shafts shall be tested for impact toughness in accordance with the Charpy V- notch test as specified in ASTM A370. The minimum energy value shall be 15 feetpounds at 0 degrees F. F. Inspection 1. Provisions shall be made for inspection of the fabrication and testing by the Authority. The Contractor shall provide two weeks advance notice for the Authority inspection. Inspection by the Authority at the point of manufacture shall not constitute acceptance of the work as specified. 1.6 PRODUCT DELIVERY, STORAGE AND HANDLING A. During fabrication and delivery, the poles shall be handled and transported in a manner to preclude damage to either the structural steel or the zinc coating. PART 2 - PRODUCTS 2.1 MATERIALS A. Wide Flange Poles 1. Wide Flange Pole shaft and components (base plates, stiffeners, bracket arms) shall be fabricated using ASTM A992 steel. The pole shaft shall be fabricated from one piece (no splicing). B. Weld Filler 1. Zinc 1. Weld filler metal shall be selected in compliance with the welding procedures of AWSD1.1. Zinc used for hot-galvanized coating shall be Prime Western Grade, or approved equal, conforming to ASTM B6. D. Zinc rich paint shall conform to Federal Specification TT-P-641, Type II; and shall be Tnemec-Zinc Series as manufactured by Tnemec Co., Inc.; Carbo- Zinc SP81 as manufactured by Carboline; or approved equal. E. Galvanizing repair compound shall conform to Federal Specification No. DOD-P-21035A, Galvalloy by Metalloy Products Co., Hardhat 2185 by Rust- Oleum, ZRC by ZRC Chemical Products, or approved equal. 2.2 FABRICATION A. Poles, fittings, and accessories shall be fabricated to the dimensions shown on the Contract Drawings. B. Methods and Tolerances 1. Poles, fittings, and accessories shall be fabricated by methods and within tolerances conforming to the AISC Specifications, except as specified herein. C. Wide Flange base plates tolerances: 1. Bolt Circle+/-1/16 inch. 2. Hole Diameter + 1/16, - 0 inch 3. Location of Holes + 1/16 inch in each direction. D. Welding Procedures 1. Welding procedures, welders, welding operations and tackers shall conform to the provisions of AWS D1.1, Section 2, Design of Welded Connections; Section 3, Workmanship; Section 4, Technique; and Sections 8, 9, and 10. E. Weld Repair 1. Welds found to be unacceptable shall be repaired in conformance with the provisions of AWS D1.1, Section 3, Workmanship. F. Surface Grinding G. Pole Straightening Before galvanizing, all penetration welds shall be ground flush with base metal to eliminate surface cracks. All other welds and cut edges shall be ground to eliminate sharp edges and burrs. Before galvanizing, the poles shall be straightened as required to conform to the specified requirements. Straightening methods shall not require heating of the poles. H. Galvanizing DART - October

15 OVERHEAD CONTACT SYSTEM STEEL POLES - WIDE FLANGE 1. After fabrication, the poles, fittings and accessories shall be hot-dip galvanized inside and out, in conformance with ASTM A123 or ASTM A153, as required. All pole fabrications shall be galvanized for their entire length, at one time, in a single hot-dip galvanizing bath. Galvanizing by successive dippings of partial pole lengths shall not be permitted. I. Pole Identification Plate 1. A stainless steel pole identification plate shall be attached to each pole at 24 inches above the base plate. The plate shall show the pole type, structure number, and the manufacturer's name and date of manufacture. The identification plate shall be 4 inches by 1.5 inches and embossed with 0.75 inch high letters and numbers. The plate design, style of lettering and method of attachment shall be Authority approved. J. Pole Type Assembly Mark 1. Pole type assembly number shall be hard marked with a minimum height of 3/4 inch and a minimum indentation of 1/16 inch. The hard mark shall be stamped on the top of the base plate and shall be visible after painting. PART 3 - EXECUTION 3.1 DELIVERY AND STORAGE A. Poles shall be delivered complete with associated fittings and accessories, properly packed and protected against damage and loss of parts. Poles shall be protected from damage during storage and handling, and during moving from the storage facility to the installation sites. 3.2 FIELD QUALITY CONTROL A. Delivered poles, fittings, and accessories shall be inspected for conformance with requirements of this Section. Poles not acceptable will be removed and replaced at no additional expense to the Authority. 3.3 POLE SETTINGS A. General 1. Wide flange steel poles shall be installed where shown on the Contract Drawings. Anchor bolts, nuts, and washers shown as cast-in-place will be provided and installed by the Contractor. Additional provisions prior to installation of the poles are as follows: a. The Contractor shall inspect each OCS pole foundation for suitability of installing the designed pole. Any deficiencies with the OCS foundation shall be corrected by the Contractor at no additional cost to the Authority. b. Perform any preparatory work required to install the pole such as chipping of concrete and cleaning of bolt threads. Cleaning of the bolt threads will generally require the use of the required chaser. Caution shall be exercised to prevent damage to the anchor bolts. 1) The Contractor shall repair the damage incurred at no extra cost to the Authority. c. Straighten bent anchor bolts and or replace damaged ones as directed by the Authority. The Contractor shall be required to straighten or replace all bent or broken OCS foundation anchor bolts at no additional cost to the Authority. d. The Contractor shall submit for Authority approval a procedure for straightening or replacing bent anchor bolts. The Contractor shall obtain Authority approval prior to commencing Work. Pole Installation 1. All catenary poles shall be raked and/or adjusted to a plumb condition to compensate for the static load deflection induced by the wire and equipment. The final erected pole plumb (perpendicular) position shall not exceed one in 50 of true vertical with the pole fully loaded as measured within eight feet of its base and corrected for taper where applicable. Any pole lean shall be against the direction of the static loads. 2. The poles shall be raked in the unloaded position by adjusting the double nuts provided with the foundation. A minimum of two full threads shall protrude above the nut. The bottom nut shall clear the top of concrete a minimum of 3/4 inch and a maximum of 2-1/2 inches. All nuts shall be tightened by applying the required torque with a wrench. Pole Fittings 1. The Contractor shall provide and install all fittings required for the specific installation, including, but not limited to, the following items: a. Counterweight Holes b. Brackets for Down Guys Feeder Poles (Wide Flange Poles) 1. Wide flange feeder poles shall be fitted with cable support clamps as shown on the Contract Drawings. The Contractor shall DART - October 2005

16 OVERHEAD CONTACT SYSTEM STEEL POLES - WIDE FLANGE verify that any stiffener plates used on the feeder poles are installed in such a manner to allow correct routing of the feeder conduit risers. Bracket Arms 1. Bracket arms shall be installed at the locations shown on the Contract Drawings. Installation shall conform to the following requirements: a. OCS support bracket arms shall be mounted and adjusted so that the contact wire can be installed at the wire heights, and within the tolerance limits, specified in this Specification. b. Bracket arm installation shall allow for pole rake and deflection caused by applied dead loads and wire tension loads. After overhead contact systems are installed and fully adjusted to the specified tensions, bracket arms and mountings shall be inspected, and readjusted as required. 3.4 TOUCH-UP A. Areas of damaged galvanizing shall be coated with a compound such as Galvalloy by Metalloy Products Co., Hardhat 2185 by Rust-Oleum, ZRC by ZRC Chemical Products, or Authority approved equal. PART 4 - MEASUREMENT AND PAYMENT 4.1 GENERAL A. The Work specified in this Section will not be measured separately for payment. 4.2 PAYMENT A. All costs connected herewith will be considered incidental to the Work specified under Section "Overhead Contact System." END OF SECTION F. Grounding and Bonding 1. All steel poles installed by the Contractor shall be electrically bonded to the foundation ground, or as shown on the Contract Drawings. Damage to the steel pole base plate galvanized coating shall be repaired in accordance with Paragraph 3.4, "Touch-Up," of this Section. G. Additional Requirements 1. If original foundations are replaced before poles are set, the poles shall be set not less than seven days after foundations are installed, and loaded to design requirements either not less than twenty-eight days after foundations are installed or until required concrete strength verified by test has been attained. 2. The Contractor shall exercise care during erection of poles to prevent damage and disfigurement. Nylon slings and chokers or other non-marking material shall be used for handling of poles. All imperfections on the steel poles shall be repaired as required to restore poles to a condition acceptable to the Authority. Damage to galvanized coatings shall be touched up as specified in Paragraph Caution is advised during steel pole erection to prevent contact with other overhead, and possibly energized, utilities. DART - October

17 SECTION OVERHEAD CONTACT SYSTEM FABRICATED METAL SUPPORTS PART 1 - GENERAL 1.1 DESCRIPTION A. The Work specified in this Section includes the following: 1. Design, fabrication and installation of metal fabrications for pole attachments, tunnel roof supports and over bridge supports required to secure the Overhead Contact System (OCS), as shown on the Contract Drawings and specified herein. 2. The fabricated items specified herein consist of steel and iron shapes, plates, bars, pipes, tubes, casting and roll-formed shapes, hot-dip galvanized after fabrication, which are not a part of an overall system specified in other sections of these Specifications. 3. Pole attachments and over bridge supports shall be fabricated as complete units, and hotdip or electrogalvanized after fabrication in order to avoid the need for field painting, or for any finishing at the work site except for touchup of damaged surfaces. Each unit shall be delivered complete with anchorage devices, ready for installation as specified in these Specifications, without requiring cutting or drilling at the work site. Units shall be protected against damage during shipment and handling. 1.2 REFERENCE STANDARDS A. American Hot-Dip Galvanizers Association, Inc. (AHDGA) 1. Inspection Manual for Hot-Dip Galvanized Products B. American Institute of Steel Construction (AISC) 1. AISC - Design, Fabrication and Erection of Structural Steel for Buildings 2. AISC - Code of Standard Practice for Steel Buildings and Bridges C. American Iron and Steel Institute (AISI) 1. AISI - Stainless Steel Cold-Formed Structural Design Manual 2. AISI - Specifications for the Design, Fabrication and Erection of Structural Members 3. AISI - Design of Cold Formed Steel Structural Members D. ASTM International (Formerly known as American Society for Testing and Materials) (ASTM) 1. ASTM A6/A6 M - Standard Specification for General Requirements for Rolled Structural Steel Bars, Plates, Shapes, and Sheet Piling 2. ASTM A 29/A 29M - Standard Specification for Steel Bars, Carbon and Alloy, Hot-Wrought, General Requirements for 3. ASTM 36 - Standard Specification for Carbon Structural Steel 4. ASTM A 477 A 47M - Standard Specification for Ferritic Malleable Iron Castings 5. ASTM A 487 A 48M - Standard Specification for Gray Iron Castings 6. ASTM A 53/A 53M REV A - Standard Specification for Pipe, Steel, Black and Hot- Dipped, Zinc-Coated, Welded and Seamless 7. ASTM Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished 8. ASTM A 123/A 123M - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products 9. ASTM A143/ A 143M - Safeguarding Against Embrittlement of Hot-Dip Galvanized Structural Steel Products and Procedure for Detecting Embrittlement 10. ASTM A153/A 153M - Zinc Coating (Hot- Dip) on Iron and Steel Hardware 11. ASTM A283/A 283M - Standard Specification for Low and Intermediate Tensile Strength Carbon Steel Plates 12. ASTM A325 REV B - High Strength Bolts for Structural Steel Joints, including Suitable Nuts and Plain Hardened Washers 13. ASTM A 384/A384M-Standard Practice for Safeguarding Against Warpage and Distortion During Hot-Dip Galvanizing of Steel Assemblies 14. ASTM A385 - Standard Practice for Providing High-Quality Zinc Coatings (Hot-Dip) 15. ASTM A501 - Standard Specification for Hot- Formed Welded and Seamless Carbon Steel Structural Tubing 16. ASTM A563 REV A - Carbon and Alloy Steel Nuts DART - October

18 OVERHEAD CONTACT SYSTEM FABRICATED METAL SUPPORTS 17. ASTM A 5697 A 569M - Standard Specification for Steel, Carbon (0.15 Maximum, Percent), Hot-Rolled Sheet and Strip Commercial 18. ASTM A 568/ A 568M - Standard Specification for Steel, Sheet, Carbon, and High-Strength, Low-Alloy, Hot-Rolled and Cold-Rolled, General Requirements for 19. ASTM A575 - Standard Specification for Steel Bars, Carbon, Merchant Quality, M-Grades 20. ASTM 576 REV B - Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special Quality 21. ASTM B6-Standard Specification for Zinc 22. ASTM D Preparation of Zinc-Coated Steel Surfaces for Painting E. American Railway Engineering and Maintenance-of- Way Association (AREMA) F. American Welding Society (AWS) 1. AWS D1.1/D1.1M - Structural Welding Code 2. AWS W1 CH12 - Qualifications of Welders and Welding Operators G. The Society of Protective Coating (SSPC) 1. SSPC - Systems and Specifications, Steel Structures Painting Manual, Volume SUBMITTALS A. Refer to these Specifications, for submittal procedures. B. Within 45 days of commencing Work, submit Shop Drawings for the fabrication and erection of assemblies of metal work that are not completely shown by manufacturer's data sheets. Include plan elevations at not less than 1 inch to 1-foot scale, and include details of sections and connections at not less than 3-inch to 1-foot scale. Show anchorage and accessory items. C. Shop drawings shall be prepared under the signature and seal of a Licensed Texas Professional Engineer. D. Within 45 days of commencing Work, submit manufacturer's product data, load tables, dimension diagrams, and anchor details indicating compliance with the Contract Specifications and Drawings requirements, and for products installation instructions to be used in the metal work fabrication, including paint products. E. Within 45 days of commencing Work, submit welder certifications and qualifications, as required by AWS W1 CH QUALITY CONTROL A. The Contractor shall perform the Work included in this Specification in strict accordance with the requirements of the Contractor's Quality Control Program as Authority approved. The Contractor shall comply with the requirements of these Specifications. B. The Contractor shall perform the following in accordance with these Specifications: 1. Material qualification testing and certification for acceptance of materials, components and assemblies. 2. Job control testing of in-progress work being performed in shops, factories and work site. 3. On-site inspection of specified work elements. C. Qualifications: Provide major items of work fabricated by a firm that has been specializing in custom type metal fabrication for a minimum of five years on work of similar scope. Employ experienced workers for both fabrication and installation, who are capable of producing work of the highest standards of quality in the industry. D. Inspection and Tests: 1. Inspections, tests, and samples shall conform to listed ASTM Specifications and Standards. 2. Inspection rights and privileges, procedures, and acceptance or rejection of galvanized steel materials shall conform to ASTM A Inspection and tests include the following: a. Visual examination of samples and finished products. b. Tests to determine weight or mass of zinc coating per square foot of steel surface. c. Tests to determine distribution and uniformity of zinc coating. d. Tests to determine thread fittings of units, washers to bolts. 1.5 PRODUCT DELIVERY, STORAGE AND HANDLING A. Packaging 1. Shall be of the type to prevent damage to galvanized surfaces and distortion of steel materials and components. B. Handling and Storage: 1. Conform to ASTM A DART - October 2005

19 OVERHEAD CONTACT SYSTEM FABRICATED METAL SUPPORTS 2. Protect galvanized materials from damage to zinc coating. 3. To avoid humid storage stain, space surfaces of galvanized materials to permit free circulation of air. C. Damaged Materials: 1. Repair material showing evidence of damage to zinc coating. 2. If not repairable, material with damaged coating will be subject to rejection. PART 2 - PRODUCTS 2.1 FASTENERS AND ANCHORAGE MATERIALS A. Fasteners shall be stainless steel or epoxy-coated to prevent rusting or staining. B. Items listed below are indicated for minimum general conditions, and may be superseded by Section 2.2 A. 1. Machine Bolts: ASTM A307, Grade A, or ASTM A325, High Strength Steel Bolts. 2. Machine Screws: FS FF-S-92, cadmiumplated steel. 3. Expansion Anchor Bolts: Toothed steel or lead shield expansion devices to the type and size indicated, with galvanized bolts, except do not use lead shield type anchor bolts for overhead anchorage. 4. Lag Bolts: FS FF-B-561, type and grade as required. 5. Through Bolts or Eye Bolts, ASTM A193, Grade B7. 6. Nuts: Standard Hex Nut, ASTM A563, Grade A. 7. Washers: Carbon steel; plain, round complying with FS FF-W-92; locking, helical spring complying with FS FF-W-84, all galvanized. 8. Concrete Inserts: Unit-type inserts of the type and size indicated, of hot-dip zinc-coated steel. 9. Non-shrink, Nonferrous Grout: POR-ROK Anchoring Cement, Lehn & Fink Industrial Products, Division of Sterling Drug, or Authority approved equal. 2.2 FABRICATION, GENERAL A. For the fabrication of metal work which will be exposed to view, use only materials which are smooth and free of surface blemishes including pitting, seam marks, roller marks, grinding, or by welding and grinding, prior to cleaning, treating and application of finishes including zinc coatings. B. Use materials of the size and thicknesses indicated, or if not indicated, of the required sizes and thickness to produce adequate strength and durability in the finished product for the intended use. Work to the dimensions shown or accepted on shop drawings, using proven details of fabrication and support. Use the type of materials indicated or specified for the various components of work. C. Form exposed work true to line and level with accurate angles and surfaces and straight sharp edges. Ease exposed edges to a radius of approximately 1/32 inch unless otherwise indicated. Form bent-metal corners to the smallest radius possible without causing grain separation or otherwise impairing the Work. D. Verify dimensions by accurate field measurement before fabrication, wherever work adjoins other work that precedes it in construction. However, do not delay job progress; allow for trimming and fitting of metal work wherever the taking of field measurements before fabrication might delay the work. On shop drawings, note which dimensions have been verified by field measurement. E. Weld corners and seams continuously and in accordance with the recommendations of AWS D1.1. Grind exposed welds smooth and flush to match and blend with adjoining surfaces. F. Form exposed connections with hairline joints that are flush and smooth, using concealed fasteners wherever possible. Use exposed fasteners of the type indicated, or if not indicated, use Phillips flathead (countersunk) screws or bolts. G. Pre-drill bolt holes and tapped holes for screws as indicated as required for attachment of metal work and for the attachment of adjacent materials. H. Provide inserts and anchoring devices that must be set in concrete for the installation of metal work. Coordinate delivery of such devices with other work to avoid delay. I. Provide for anchorage of the type indicated. Fabricate and space anchoring devices as indicated and as required to provide adequate support for the intended use of the work. J. Cut, reinforce, drill and tap metal work as may be required to receive finish hardware and similar items of work. K. Use hot-rolled steel bar for work fabricated from bar stock, unless work is indicated or specified to be fabricated from cold-finished or cold-rolled stock. L. Pre-assemble work at shop to the greatest extent possible to minimize field splicing assembly of units at DART - October

20 OVERHEAD CONTACT SYSTEM FABRICATED METAL SUPPORTS M. 2.3 A. F. G. the work site. Disassemble units to the extent required to comply with shipping limitations. Mark all units clearly for reassembly and proper installation. Where indicated as galvanized, complete the shop fabrication prior to application of the coating. Remove mill scale and rust, clean and pickle the units as required for coating. Apply hot-dip zinc coating of 2 ounces in accordance with ASTM A123. GALVANIZING Steel members, fabrication, and assemblies shall be galvanized after fabrication: 1. Method: Hot-dip process in accordance with ASTM A Weight of zinc coating to conform to requirements specified under "Weight of Coating" in ASTM A123, as applicable. Safeguard against steel conformance with ASTM A143. embrittlement Safeguard against warpage or distortion of steel members to conform to ASTM A384. Notify the Authority of potential warpage problems that may require modification in design before proceeding with steel fabrications. Finish and uniformity of zinc coating and adherence of coating shall conform to ASTM A153. Passivating: Galvanizing materials subject to extended periods of storage in open, exterior locations shall be given passivating treatment or light oiling to prevent humid storage stain; treatment, solution and process shall be subject to review and acceptance by the Authority. Preservative Oils: Do not treat freshly galvanized or passivated surfaces with oils, grease, or chemicals that might interfere with adhesions of subsequent paint primers and coatings. Field Inspection: Visually inspect galvanized materials, fabrications, and assemblies for conformity with applicable requirements of AHDGA, Inspection Manual for Hot-Dip Galvanized Products. 1. Steel for timber screw spikes shall be heattreated to a minimum of 150,000 psi tensile strength. 2. Timber screw spike head shall be square headed or match equal drive sockets for installation. in measured from established lines and levels. Temporarily embrace or anchor in formwork where Work is to be built into concrete. B. Fit exposed connections accurately together to form tight, hairline joints. Weld connections that are not to be left as exposed joints, but cannot be shop welded because of shipping size limitations. Grind joints smooth, and touch-up shop paint coat. Do not weld, cut or abrade the surfaces of exterior units which have been hot-dip galvanized after fabrication, and are intended for bolted or screwed field connections. C. Anchor securely as shown or as required for the intended use, using concealed anchors wherever possible. D. Grout with non-shrinking, nonferrous cement grout, or pack with lead wool and caulk where pipe sleeves are used to support metal Work. Provide galvanized steel pipe on pipe sleeves not less than 6 inches long and having an inside diameter not less than 1/2 inch greater than outside diameter of insert. E. Install insulating devices or butyl tapes in between dissimilar metals. 3.2 TOUCH-UP A. Immediately after erection, any areas of paint damaged by field installation, including field welding, shall be thoroughly cleaned to bare metal. B. Paint those areas with the same material as used for shop coating. C. Coat areas of damaged galvanizing with a compound such as Galvalloy by Metalloy Products Co., Hardhat 2185 by Rust-oleum, or ZRC by ZRC Chemical Products, or approved equal. PART 4 - MEASUREMENT AND PAYMENT 4.1 GENERAL A. The Work specified in this Section will not be measured separately for payment. 4.2 PAYMENT A. All costs connected herewith will be considered incidental to the Work specified under Section "Overhead Contact System." END OF SECTION PART 3 - EXECUTION 3.1 INSTALLATION A. Set metalwork accurately in location, alignment and elevation, plumb, level, true and free of rack, DART - October 2005