SECTION 16100

BASIC MATERIALS & METHODS

PART 1 - GENERAL

1.1	SCOPE

A.	Furnish and install material and equipment as indicated on drawings and as specified.

1.2	MATERIALS AND EQUIPMENT

A.	Shall be new and of the best quality used for the purpose in good commercial practice.

1.3	UL APPROVAL

A.	All material and equipment within the scope of the UL reexamination service shall be approved by the Underwriters Laboratories for the purpose for which they are used and shall bear their label.

1.4	STORAGE

A.	All material and equipment shall be stored in a manner to prevent damage or corrosion. Equipment with components which can be damaged by moisture shall be placed in special heated storage facilities.

1.5	DRAWINGS

A.	Drawings for all equipment are intended to be diagrammatic only. Any location not actually dimensioned is not to be considered as necessarily final or accurate. Exact locations must be determined in the field from the requirements of the equipment that is to be installed.

1.6	COORDINATION

A.	Before rough-in of any utility lines, services, and feeders, or of any equipment, this Contractor must coordinate his work with that of other crafts and trades so that these services shall be installed in their proper locations and without interference to the equipment or building structure. This will require cooperation among all crafts and trades, the Inspector, and General Contractor, along with study of shop drawings and the building plans.

1.7	ELECTRICAL WORK EXPOSED TO WEATHER

A.	All electrical devices and equipment installed in exposed locations shall be protected by suitable NEMA type 3R enclosures, cast steel boxes with gasketed covers, or other Engineer approved methods.

B.	All ferrous metal portions of electrical work exposed to weather including conduits, clamps, supports, etc. shall be hot-dipped galvanized.

PART 2 - PRODUCTS

2.1	CONDUIT MATERIALS AND COMPONENTS

A.	Threaded Metal; Rigid galvanized steel

1.	All locations as follows excepting those specifically indicated for EMT and PVC. All exterior locations above grade, in concrete walls and slabs, or elsewhere shown on plans. Runs within, passing through, or above hazardous areas shall be rigid. Rigid conduit shall be new galvanized threaded, conforming to UL 6. All couplings and connectors shall be threaded.

B.	Pre-coated threaded steel: Rigid

1.	All locations in process areas not designated as stainless steel on plans, details, or specifications. All exposed steel will be PVC coated(color grey) with 40 mil thickness, will be "Robroy" plasti-bond red. Use appropriate tools and installation procedures. Any conduit or fittings with nicks, etc. will be replaced. Use PVC "Robroy" plasti-bond red covered fittings and clamps.

C.	Thin Wall E.M.T

1.	Interior dry locations above ground, exposed only above 60" above floor in non-finished areas where not subject to physical abuse or damage, and exterior walls and underside of eaves above 96" above grade. E.M.T. shall be new galvanized, conforming to UL 797, furnished in 10 foot lengths. In all locations E.M.T. shall be coupled with compression type couplings requiring the tightening of a nut in all locations. Crimp type or die cast connectors are not acceptable. Connectors to have nylon insulated throats.

D.	Flexible Metallic Conduit

1.	Connections from junction boxes to lay-in fluorescent fixtures in accessible ceilings, 6' maximum. Flexible conduit shall be flexible interlocking single strip zinc coated steel with an insulated copper ground wire, pulled with the conductors, conforming to UL 1. Aluminum flexible conduit shall not be used. Minimum size ½". Fittings shall be clamp type utilizing two (2) screws, galvanized steel with nylon insulated throat type.

E.	Flexible Liquid Tight Metallic Conduit

1.	Connections to machinery. Conduit shall be flexible interlocking single strip steel conduit with liquid tight exterior cover, with all connections made with galvanized steel liquid tight with "O" ring gaskets, and with copper ground wire (maximum length 30"), American Brass Sealtight or equivalent, conforming to UL 1. Nylon insulated throat. In process areas use Robroy plastibond red or equal with appropriate nylon connectors and fittings.

F.	Plastic PVC

1.	Underground locations and below vapor barrier of slabs. No plastic conduit shall be installed in slab floors or in exposed locations. PVC conduit shall be Type 40 heavy thickwall polyvinyl chloride conduit, Underwriters' Laboratories tested, furnished in 10 or 20 foot lengths, conforming to UL 651-77. All conduit entrances in bottom of floor mounted switchgear or manholes/pullboxes will be belled ends.

G.	Surface Metal Raceway

1.	Type and locations as noted on the drawings. Provide concealed connections. Paint to match adjacent surface unless noted otherwise.

2.2	OUTLET AND SWITCH BOXES

A.	Boxes shall be one piece die formed galvanized steel of shape and with fittings necessary to suit location and use. Boxes shall be of sufficient size to contain all wires, devices, and connection fittings required without crowding, minimum 2 gang for receptacles. Ceiling and surface mounted boxes shall be minimum 4" square by 1½" or octagonal. Plaster rings shall be provided where required. Boxes shall be used wherever possible. Where voltages are mixed in the same box (120V/277V), install welded partition barriers to separate the systems.

B.	Exposed boxes shall be provided with gasketed weatherproof covers and utilize only cast steel threaded hub type fittings.

2.3	WIRING DEVICES

A.	Wall Switches:

1.	120/277 Volt Switches

a.	Quiet slow make, slow break design, toggle handle, with totally enclosed case, rated 20 ampere, heavy duty specification grade conforming to Federal Specification WS896. Provide matching two pole, 3-way, 4-way, and key switches as required. Hubbell or ArrowHart 1221 series.

2.	Switch and Pilot Light

a.	Push action type with red handle, integral long-life neon pilot light, rated at 20 ampere, 120 volts.

3.	Color

a.	Normal Lighting Circuits; provide grey colored switches or as directed by Architect.

4.	Thermal switches where designated on plans or in specifications shall be equivalent to Square D, Type "F", Class 2510. Thermal switch heater elements shall be rated for overload protection of loads controlled. Switches for special purposes, such as exhaust fans, etc., shall be engraved with 1/8" high letters on plates. Adhesive labels are not acceptable.

B.	Receptacles:

1.	Duplex Receptacles

a.	Full gang size, polarized duplex, parallel blade, U-grounding slot, specification grade conforming to Federal Specification WC596, rated at 20 amperes, 125 volts, designed for split feed service. Hubbell or ArrowHart 5352 series.

2.	Duplex Receptacle - Ground Fault Interrupting

a.	Hubbell or ArrowHart #GF-5362 series, specification grade. Ground fault interrupting receptacles shall be required within six (6) feet of all sinks and in exterior locations.

3.	Nameplates

a.	Provide engraved or embossed plastic for receptacles other than standard duplex receptacles, indicating voltage, phase and amperes.

4.	Color

a.	Provide grey colored receptacles or as directed by Architect.

2.4	WALL PLATES

A.	Provide plate for each wiring device.

B.	Interior Flush

1.	All locations unless noted otherwise; stainless steel (0.35") satin finish, Sierra "S" series.

C.	Weatherproof Plates

1.	Cast steel, gasketed; for receptacles, provide spring loaded gasketed doors. Provide at all weatherproof locations.

D.	Where two gang boxes are required for single gang devices, provide special plates with device opening in one gang and second gang blank.

E.	Receptacle Plates, other than 120 volt single phase.

1.	Each receptacle plate shall be identified with the panel number and the circuit number; this identification shall be with engraved phenolic labels applied to plate with permanent contact cement. Labels shall be 5/16" high, gray phenolic plastic, with 1/8" high white engraved lettering. Special receptacles shall also indicate voltage, phase, and amps.

F.	Multi-Gang Switch Plates

1.	Where three or more switches occur at a common location, provide engraved labeling, ¼" high (black), on the switch plate(s) indicating areas or fixtures served by each switch. Submit schedule to Engineer for approval.

2.5	FLOOR BOXES

A.	Floor Boxes

1.	Concrete tight fully adjustable type with round brass faceplate, deep fill type. Walker 886 series, Hubbell or Steel City equivalent.

B.	Receptacle Floor Fitting

1.	Brass, duplex flap Walker 895 series or equivalent.

C.	Telephone Floor Fitting

1.	Brass round opening, combination 2¼" x 1", Walker 866 CK-1 series or equivalent.

2.6	WIRE

A.	Low Voltage - (Under 600 Volt):

1.	Feeder and Branch Circuit Wire

a.	Copper type THWN/THHN, 600 volt, from new fresh stock, bearing UL label, delivered to site in unbroken packages; minimum size 12 AWG. All 20/1 home runs over 180 feet from panel for 277 volt circuits, and 100 feet from panel for 120 volt shall be increased to next larger size. All conductors shall be stranded copper. All control, fire alarm, signal, and communication wires shall be stranded.

2.	High Temperature Wire

a.	NEMA type AF or SFF-2 stranded, for fixture wires and circuit runs within fixtures.

PART 3 - EXECUTION

3.1	INSTALLATION OF CONDUIT RACEWAYS

A.	General

1.	Install conduits in a neat manner, concealed except as noted. Mount conduits directly to building structure with clamps or two hole straps where possible. Secure straps with cadmium plated wood screws into wood, and machine screws into metal or inserts preset in concrete. Where impractical to secure directly to structure, suspended on conduit hangers. Wherever possible, group and rack multiple conduit runs.

2.	Conduit Size

1.	All branch circuit homeruns, and conduit runs containing more than two (2) circuits shall be a minimum of ¾" diameter.

B.	Installation and Cleaning

1.	Install free from dents, kinks and bruises. Plug ends at time of installation to prevent entry of dirt or moisture. Thoroughly clean out conduits before installing conductors. Thoroughly clean all exposed conduit exteriors.

C.	Provide tagged pullwire in all empty conduits. Pullwire shall be 1/4" Kevlar high strength measuring tape #39243 with a minimum breaking strength of 1250 pounds. Leave 36" free coiled each end. Tagging all runs shall include the source and destination locations.

D.	Plastic conduit shall be installed in accordance with manufacturer's recommendations and accepted trade practice. Where plastic conduit runs rise above ground in exposed locations, and for all conduit runs, 1" diameter and larger, the riser bend and riser shall be of 40 Mil PVC coated galvanized rigid metal or aluminum conduit installed according to rigid metal or aluminum portion of this specification section.

1.	All horizontal PVC elbows and sweeps sized 2" and larger shall be concrete encased to thickness of 3" all around.

E.	All feeder and receptacle branch conduits shall carry a grounding bond wire with the size as shown, or where not shown, as determined by applicable codes for the ampacity of the circuit being carried.

F.	Protective Coating

1.	All metallic conduits installed in contact with earth, or in concrete in contact with earth, shall be coated with a minimum 40 Mil PVC coating on all conduit lengths and fittings. The coating shall correspond to ATSM D638-68, D1706, D140-64, and D746-64T specifications and Federal Test Standard 141, Method 615z. Coating shall be continuous without flaws showing exposed metal. Coating shall extend to the device conduit is terminated to in exposed locations and 12" above grade in unexposed locations.

G.	Conduits which stub-up from or through floor slabs shall be installed so that none of the curved portion of the elbow is exposed. Conduits stubbed up shall be rigid type with coupling installed flush floor to permit future conduit removal. Seal unused conduit with a flush threaded pipe plug.

H.	Conduit Routing

1.	Route exposed conduits parallel or perpendicular to walls or floors. Install conduits in masonry walls at time of wall construction. No conduits shall be run under heavy equipment, footing or other structural elements. Where runs must cross footings, install in sleeves per structural details.

I.	Conduit Runs in Ceiling Areas

1.	Conduits running above accessible ceiling shall be routed parallel or perpendicular to ceiling system and structural members. All conduit runs shall be coordinated to avoid conflicts with mechanical and structural systems, lighting fixtures and ceiling support system. Conduits shall be installed as close to the structure above as possible to avoid conflict with removal of ceiling panels. It is specifically not permitted to attach or support conduit from ceiling system suspension wire. Exposed cables shall be strapped to the structure above the accessible ceiling.

J.	Conduits Penetrating Membranes

1.	Where conduits penetrate wall or slab membrane moisture barriers, penetration shall be sealed in accordance with the requirements of applicable sections of these Specifications for "Thermal and Moisture Protection."

K.	Conduits Penetrating Roof

1.	Provide flashing and counter flashing making watertight joints where conduits pass through roof or waterproofing membranes.

L.	Escutcheons

1.	Conduits penetrating wall, floors, or ceiling in exposed locations shall be installed with appropriate escutcheon plates.

M.	Separations

1.	Coordinate with all other crafts to allow minimum of 12" running and 6" crossing clearance at flues, hot water pipes, steam pipes, and heat sources. Keep electrical conduits free from contact with all other piping runs of other systems or of dissimilar metals.

N.	Conduits Crossing Building Joints

1.	Conduits shall not be run in concrete slab or wall construction where passing through an earthquake or expansion joint. At such condition, conduit shall be run exposed or in furred ceiling space with 24" length of flexible conduit crossing joints.

O.	Conduits Penetrating Floors and Walls

1.	Provide grouting around raceways where penetrating floor slabs, concrete or masonry walls. At fire separation walls or floors, use Engineer and CSFM approved expanding type intumescent foam, to maintain the fire rating of the surface penetrated.

P.	Conduit Support

1.	Support of conduit and tubing in steel stud walls shall be by #18 gauge steel wire, secured to steel bars or straps attached to steel studs. Conduits rising vertically between wall studs shall be tied to a horizontal cross support attached tightly to eliminate any movement.

Q.	Conduits Installed Below Floor Slabs

1.	Conduits 1" diameter and smaller may be installed below concrete slab vapor barriers or sand fill by shallow scraping and recovering with earth as required to bury just below surface. Install to minimize disruption to engineered fill. Conduits larger than 1" shall be trenched to a minimum depth of 12" below slab and backfilled and compacted in accordance with Section 16110.

R.	Conduits Installed in Area of Footings

1.	Conduits installed in the area of footings shall be installed per the applicable structural details and the electrical details for installing conduits in the vicinity of footings.

S.	Conduit Hangers:

1.	Conduit hangers spaced at 8'-0" on center maximum with one hanger adjacent to each outlet box, or down turn shall be installed.. Hangers shall be secured to wood structures with steel brackets and wood screws; to steel structures with appropriate clamps complete with positive attachment restraining strap or hook rod to prevent slippage; and to concrete structures with preset imbedded inserts or machine screws with expansion shields. Preset inserts are preferred to provide a secure anchorage with greatest location flexibility. Power or velocity driven type attachments will not be allowed. Complete hanger installation shall provide a safety factor of five (5) based upon maximum NEC allowed conduit fill. No conduits will be installed and clamped directly to walls or ceiling panels.

2.	Hangers for conduits and smaller in concealed spaces shall be galvanized perforated type strap wrapped around raceway and bolted; then fastened to structure as described above.

3.	Hangers for exposed conduit and tubing suspended below roofing members shall be stainless steel rods ¼" size for up to 2" and 3/8" for larger size conduits, with "Z" type stainless steel channels and clamps of stainless steel u-bolts and nuts.

4.	Trapeze type supports shall be used where conduits are run grouped together. Such hangers shall consist of 3/8" minimum stainless steel rods, "Z" type stainless steel channels, and clamps of stainless steel u-bolts and nuts.

5.	Conduits exposed up/down or horizontally along walls will be secured to stainless steel "Z" type channels clamped with stainless steel u-bolts and nuts.

6.	Electrical Contractor shall furnish concrete inserts to General Contractor, and coordinate location.

3.2	INSTALLATION OF JUNCTION BOXES AND INTERIOR PULL BOXES

A.	Locate pull boxes and junction boxes above removable ceilings or in electrical rooms, utility rooms, or storage areas. No junction box shall be installed in an inaccessible area. Exposed boxes shall be cast steel with gasketed weatherproof covers.

3.3	INSTALLATION OF OUTLET AND SWITCH BOXES

A.	Mounting

1.	Mount outlet boxes flush in finished areas other than mechanical rooms, electrical rooms, and above removable ceilings. Boxes shall be set true and flush with all necessary and correct adapters and/or plaster rings. All boxes set deeper than code allowable shall be corrected by use of factory made extension rings such as Raco #976 or equivalent.

B.	Device Locations

1.	Locations of devices on plans are approximate only. Contractor shall study the architectural and structural plans and locate the outlets so that his work is coordinated with the work of others and the fixtures and devices present a pleasing and symmetrical appearance when installed. The location of outlets centered on any architectural feature shall be exact. Outlet locations may be moved a maximum of ten (10) feet from the location shown on the plans before roughing-in without cost to Owner. Switches in relation to door swings and cabinets must be coordinated with architectural drawings.

C.	Device Height

1.	The following dimensions for locating wall outlets represent the distance from the finished floor to the center of the outlet, unless noted otherwise.

OUTLET	INCHES

Telephone	15 or 54"

Convenience receptacle	15 Office-30

Lighting switch	48

Wall mount telephone	54

Adjust outlet mounting height to agree with required location for equipment served.

D.	Boxes Located in Stud Walls

1.	Securely mount with screws to studs or blocking so that box face is straight and true with finish wall alignment. Install backing to align box where studs are twisted or crooked, and as required to meet dimensioned or detailed device spacings. Blocking material shall be same as wall studs and shall be attached to two adjacent studs.

E.	Boxes in Counterbacks or Casework

1.	Install in accordance with architectural details. Where not indicated in details, the Architect or Engineer shall be consulted prior to installation.

F.	Boxes Above Accessible Suspended Ceilings

1.	Mount to horizontal trapeze hangers, secured to rod attached to structure above. It is specifically not permitted to attach or support boxes from ceiling system suspension wire. Conduit and boxes shall be located a minimum of 12" above ceiling where suspended depth permits. Conduit and boxes shall not be installed prior to ceiling unless system is attached or braced to structure as to prevent horizontal movement of conduit.

G.	Boxes Located In Masonry Walls

1.	Coordinate cutting of masonry walls to achieve neat openings for boxes. Use rotary cutting equipment to cut masonry work for installation. Where furring occurs, install extension rings to bring box flush to furred surface. Where masonry is the finished surface, locate boxes uniformly for each height at either the top or bottom of a block course and install so that device plate will fit tight to block wall without extending over mortar joints.

H.	Outlets in Acoustical Tile Ceilings

1.	Locate either centered on the joint between tiles, or in the center of a tile. All such outlet locations shall be carefully planned and verified with the Architect or Engineer.

I.	Exterior Wall Outlets

1.	Conduits shall enter boxes or exterior wall mounted devices at the sides or top only. No conduit shall enter the bottom of such boxes.

J.	Common Boxes and Alignment

1.	Devices shown adjacent to each other at the same mounting location shall be gang under a common plate, except for outlets of different voltages such as telephone and duplex receptacles. Outlets mounted one over the other, or side by side, shall be in exact alignment, centered on one another.

K.	Sound Control

1.	Boxes and conduit shall be installed in a manner which minimizes sound transmission between rooms. Boxes mounted in a common wall shall be off-set horizontally a minimum of 12" and mounted in different stud spaces wherever possible. No boxes shall be mounted back to back. No through boxes shall be used. Off-set boxes shall be connected with flexible conduit not to exceed 18" length.

L.	Sealing

1.	All unused holes or openings in boxes shall be slugged or sealed by an acceptable means.

M.	Boxes in 1-Hour Rated Walls

1.	Back to back boxes in all walls shall be horizontally separated by a minimum of 24".

3.4	INSTALLATION OF WIRING DEVICES

A.	Devices shall be securely fastened to outlet box with face flush with plate.

B.	Mount receptacles vertically in appropriate boxes with grounding pin towards floor, except where noted for horizontal installation.

3.5	INSTALLATION OF WALL PLATES

A.	Install coverplates on wiring devices. Plates shall be set plumb and flush with finish wall surface. Plates located adjacent to one another shall be exactly the same height.

3.7	INSTALLATION OF WIRE

A.	Scope

1.	Provide all wiring for complete electrical work, installed in code conforming raceway. Branch circuit wiring shall be #12 AWG minimum, unless noted otherwise.

B.	Home Runs

1.	Branch circuit conductors shall home run topanelboards or motor control centers in groupings shown on the drawings. Combining branch circuit home run conductors in single conduits other than that shown shall not be permitted.

C.	Color Coding shall be strictly adhered to and shall be as indicated in Section 16210 ELECTRICAL IDENTIFICATION:

1.	Color coding utilized shall be noted on electrical "as constructed" drawings and shop drawings.

2.	The color coding for control circuit wires will be as noted on the plans or as agreed upon with the Architect or Electrical Engineer and will be of a color other than that designated for the phase wires. Where control wires are installed and various colors are used, they shall be noted on them "as constructed" drawings and shop drawings turned in at the completion of the job.

D.	Pulling

1.	Use approved wire pulling lubricant for pulling #4 AWG and larger wire. Oil or grease is prohibited as a conductor pulling lubricant. All conductors #8 and smaller shall only be pulled by hand. Pulling lubricant for conductors over 600 volt shall be approved by the conductor manufacturer and the Architect or Electrical Engineer.

E.	Splices

1.	Join the conductors securely, both mechanically and electrically using crimp, compression, or pressure type connectors, except that screw-on type connectors shall not be used for wires larger than #10 AWG. The splice area shall be taped to provide equal or greater insulation than the original. Tape run-back over the original insulation shall extend 3 to 5 overall diameters of the insulated wire.

2.	No splices in feeders over #6 AWG permitted.

F.	Splice only in accessible junction or outlet boxes.

G.	Wiring in panel boards, switchboards, and cabinets shall be neatly installed. Wiring shall be grouped, laced or clipped, and fanned out to wiring terminals.

H.	Identification and Markings

1.	Provide identification and markings as indicated in Section 16080 ELECTRICAL IDENTIFICATION.

I.	Cable Testing:

1.	All wires under 600 volt potential, #6 or larger shall be tested as follows:

a.	Continuity test to insure proper cable connection.

b.	Insulation resistance test on each conductor with respect to ground and adjacent conductors. Applied potential shall be 1000 Volts dc for 1 minute.

c.	Readings shall be recorded and handed in with the record drawings at the completion of the project.

2.	Test Values

a.	Minimum insulation resistance values shall be not less than 5 megohms.

3.7	INSTALLATION OF TERMINAL CABINETS

A.	Install cabinets flush, straight and true, with top aligned with any adjacent panelboards.

B.	Terminate conduits in cabinet with lock nut and bushing or lock nut and grounding bushing. Conduits shall be located in front of plywood backboard; minimum 1" from rear of terminal cabinet (measured from edge of conduit).

C.	Unless noted otherwise, install 2" conduit from each terminal cabinet to nearest signal equipment room or backboard location.

D.	Install a minimum of two (2) ¾" and two (2) 1" conduits from each cabinet stubbed to accessible ceiling space for future connections.

E.	Terminate wiring on terminal blocks or strips. All wiring shall be neatly cabled or fanned. Label conductors and cables, including spares with plastic Panduit MP series labels, and corresponding location on terminal or punch block with permanent black marker.

F.	Identify all conduits terminating in terminal cabinets, new and existing, with waterproof permanent black marker on conduit surfaces close to terminal cabinet; or inside terminal cabinet adjacent to conduits. Contractor shall furnish a supplemental diagrammatic layout of conduits inside each terminal cabinet at Project Closeout.

END OF SECTION