Specification Steel Works

Petroleum Coke Calcination Plant

Dar Al-Jazera Consultants III-2/05120-1 Structural Steel

SECTION 05120

STRUCTURAL STEEL

PART 1 GENERAL

1.01 DESCRIPTION

A. Drawings and general provisions of the Contract, including General and Particular conditions and Division 1 Specifications, apply to this Section.

B. The work covered by this Section comprises furnishing all plant, labour, equipment, appliances and materials and performing all operations in connection with Structural Steel Work.

C. Related Sections:

i. Division 3 - Concrete ii. Section 05500 - Metal Fabrications iii. Section 05580 - Sheet Metal Fabrications

1.02 REFERENCE STANDARDS

All structural steel except as otherwise shown shall comply with the applicable provisions and recommendations of the following codes, Specifications and Standards:

A. American Institute of Steel Construction:

1. AISC S303 - Code of Standard Practice for Steel Buildings and Bridges.

B. ASTM International:

1. ASTM A53/A53M - Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-

Coated, Welded and Seamless. 2. ASTM A123/A123M - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on

Iron and Steel Products. 3. ASTM A153/A153M - Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel

Hardware. 4. ASTM A242/A242M - Standard Specification for High-Strength Low-Alloy Structural Steel.

5. ASTM A307 - Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile

Strength.

6. ASTM A325M - Standard Specification for High-Strength Bolts for Structural Steel Joints.

7. ASTM A449 - Standard Specification for Quenched and Tempered Steel Bolts and Studs.

8. ASTM A490M - Standard Specification for High-Strength Steel Bolts, Classes 10.9 and 10.9.3, for Structural Steel Joints.



9. ASTM A500 - Standard Specification for Cold-Formed Welded and Seamless Carbon Steel

Structural Tubing in Rounds and Shapes.

10. ASTM A501 - Standard Specification for Hot-Formed Welded and Seamless Carbon Steel Structural Tubing.

11. ASTM A514/A514M - Standard Specification for High-Yield-Strength, Quenched and

Tempered Alloy Steel Plate, Suitable for Welding.

12. ASTM A529/A529M - Standard Specification for High-Strength Carbon-Manganese Steel of Structural Quality.

13. ASTM A563M - Standard Specification for Carbon and Alloy Steel Nuts.

14. ASTM A568/A568M - Standard Specification for Steel, Sheet, Carbon, and High-Strength,

Low-Alloy, Hot-Rolled and Cold-Rolled, General Requirements for.

15. ASTM A572/A572M - Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel.

16. ASTM A615/A615M Standard Specification for Deformed and Plain Billet-Steel Bars for

Concrete Reinforcement

C. American Welding Society: 1. AWS A2.4 - Standard Symbols for Welding, Brazing, and Nondestructive Examination. 2. AWS D1.1 - Structural Welding Code - Steel.

D. Research Council on Structural Connections: 1. RCSC - Specification for Structural Joints Using ASTM A325 or A490 Bolts.

E. SSPC: The Society for Protective Coatings: 1. SSPC - Steel Structures Painting Manual.

F. Underwriters Laboratories Inc.: 1. UL - Fire Resistance Directory.

G. Intertek Testing Services (Warnock Hersey Listed): 1. WH - Certification Listings.

a. Systems and Specifications.

H. Copies of all the above codes and standards shall be submitted to the Engineer.



1.03 QUALIFICATIONS

A. Structural steel work shall be executed by an approved specialist Sub-Contractor unless the contractor can satisfy the Engineer that he (the contractor) has sufficient experience and expertise in this field to execute this work himself in which case his tradesmen and their supervisory personnel engaged in such work must have successful experience with work comparable to that shown and specified including organized quality control and testing procedures.

1.04 SUBMITTALS

A. Shop Drawings: Submit to the Engineer for approval shop drawings including structural calculations for all connection all in accordance with the requirements of the Contract Documents showing the following: 1. Shop fabrication drawings which show type of material, size and weight of members and

other information necessary for the fabrication of each member and for shop assembly of members of the structure. The drawings shall include the type, size, location and extent of all welds and bolts. The drawings shall clearly distinguish between shop and field, bolts and welds.

2. Field assembly and erection drawings which show all field assembly prior to erection and

after erection. The drawings shall indicate all details, schedules, procedures and diagrams showing field assembly and sequence of erection. The information shall indicate locations of shorings and how shoring is stabilized and controlled. The drawings shall indicate elevations of shored points and splice locations. The procedures shall indicate step by step erection sequences including intermediate surveys and allowances for temperature. Diagrams shall indicate erection equipment size and weight and additional elements which may be required to support or stabilize elements during erection.

3. The contractor shall prepare and submit to the Engineer written procedures for fabrication

of the steel work. The procedure shall describe the complete welding process including machine, current, voltage, preheat, filler metal, welding system (manual, semi-automatic or automatic), positions of welding, etc. These procedures shall indicate the Contractor’s quality control measures, monitoring and repair procedures.

4. The contractor shall be responsible for the arrangement of all joints and their load carrying

capacities. The connection may or may not be shown on the contract drawings. Submit all details along with calculations to Engineer prior to fabrication for approval.

B. Manufacturer’s Literature

1. Submit to the Engineer manufacturer’s specifications and installation instruction for the

following products, including laboratory test reports and such other data to show compliance with these Specifications (including specified standards):

a. Structural steel, (each type) including certified copies of mill reports covering the

chemical and physical properties, country and rolling mill of origin, and including a statement indicating that the steel is new billet steel and that testing has been performed in accordance with ASTM or equivalent standards.



b. High strength bolts (each type) including nuts and washers.

c. Welding electrodes (each type)

d. Shop coat primer paint, field touch-up paint.

e. Coal tar epoxy paint.

f. Bearing materials or assemblies

C. Testing Reports

1. The following reports shall be submitted in triplicate directly to the Engineer by the Testing

Laboratory, with copy to the Contractor.

a. Shop Welders Certification b. Field Welders Certification c. Magnetic Particle Tests, Shop Welds and Field Welds d. Ultra-sonic tests, shop welds and field welds. e. High strength bolted connection tests, shop and field.

1.05 TESTING

A. The contractor shall engage, at his own expense, an independent certified Testing Laboratory approved by the Engineer to inspect high strength bolted connections and welds, and to perform all tests and submit test reports to the Engineer as herein specified.

B. The contractor shall submit evidence regarding qualification of the proposed Testing Laboratory.

C. The Contractor shall provide the Testing Laboratory with the following:-

1. A complete set of shop fabrication and erection drawings. 2. Cutting lists, order sheets, material bills, shipping bills and mill test reports. Provide

certified copies of mill test reports of bolts, nuts and washers, including names and locations of mills and shops and analysis of chemical and physical properties.

3. Information as to time and place of all rollings and shipment of material to shops.

4. Representative sample pieces requested for testing.

5. Full and ample means and assistance for testing all material.

6. Proper facilities, including scaffolding, temporary work platforms, hoisting facilities, etc., for

inspection of the work in the mills, shop and field.



D. Bolted connections shall be inspected by the Testing Laboratory in accordance with AISC

Specifications for “Structural Joints Using ASTM A 325-83C, ASTM 325M-83 and ASTM 490-83A or ASTM 490-82.

E. Welding shall be inspected and tested by a Testing Laboratory approved by the Engineer during fabrication and erection of structural steel as follows: 1. Certify all welders in accordance with AWS and make inspections and tests as required.

Record types and locations of all defects found in the work, and measures required and performed to correct such defects.

2. In addition to visual inspection of all welds, magnetic particle and ultra-sonic inspection

shall be made of all welds indicated on the drawings. Magnetic particle inspection shall be made on the root pass and finished weld.

3. The method of magnetic particle inspection shall be in accordance with ASTM E109. Any

type of crack or zone of incomplete fusion or penetration will not be acceptable.

4. Ultra-sonic inspection for structural welding shall be performed in accordance with AWS D1.1.

F. Each bolting crew and welder shall be assigned an identifying symbol or mark and all shop and

field connections shall be so identified so that the inspector can refer back to the crew or person making the connection.

G. The Testing Laboratory shall be responsible for conducting and interpreting the tests, shall

state in each report whether or not the test specimens conform to all requirements of the contract Documents, and shall specifically not any deviations there from.

H. Access to places where material for this Contract is being fabricated or produced shall be provided to the Engineer and the Testing Laboratory for the purpose of inspection and testing.

I. The Engineer and the Testing Laboratory may inspect structural steel at the plant before shipment, however, the Engineer reserves the right to reject any material, at any time before final acceptance, which does not conform to all of the requirements of the drawings and specifications.

J. The Testing Laboratory shall perform specified tests and submit reports to the Engineer. Corrective measures, including additional and more complete testing, which may result from these tests shall be the Contractor’s responsibility; all costs of which shall be paid for by the contractor.

K. The contractor shall coordinate and allow for necessary time for the Testing Laboratory complete all testing and inspections prior to shop painting.

L. The Testing Laboratory shall prepare test specimen from steel samples cut from delivered material and shall conduct tension tests in accordance with ASTM. The Contractor shall mill order 1.0 metre extra length for the members noted on the drawings to provide the steel for testing.



1.06 SUBSTITUTIONS

A. The contractor shall fabricate and erect the structural steel work as shown on the drawing and specifications.

B. Substitutions of the structural system shown or member sizes of similar steel strengths will be permitted providing the architecture is not changed and the structural strength and deflection are maintained. No reduction in member sizes shall be permitted if steel strength exceeds that specified.

1.07 DELIVERY, STORAGE AND HANDLING

A. Do not handle structural steel until paint has thoroughly dried. Care shall be exercised to avoid abrasions and other damage.

B. Stack material above ground out of mud and dirt and provide for proper drainage. Protect from damage or soiling by adjacent construction operations.

C. Do not deliver material to the project site until the proposed method and sequence of erection has been reviewed by the Engineer. Method and sequence shall be planned so as to avoid delay or damage to the work of other trades.

D. Storage of fabricated steel at the job site shall be the responsibility of the Contractor. Material stored at the job site shall not exceed design loads on existing or newly constructed structures so that members will not be distorted or otherwise damaged, and shall be protected against corrosion or deterioration.

PART 2 PRODUCTS 2.01 STRUCTURAL STEEL

A. All structural steel shall conform to ASTM A615 Grade 50 (minimum yield strength 50,000 psi or 3500 kg/sq.cm) unless otherwise noted on drawings.

2.02 BOLTS

A. All bolts, nuts and washers shall conform to the requirements of ASTM A490 and A325. All bolts shall be cold forged with rolled threads.

B. Anchor Bolts: ASTM A307.

2.03 WELDING ELECTRODES

A. All welding electrodes shall be E70XX and shall comply with the provisions of AWS Specifications A5.1, A5.5, A5.17, A5.18, 15.20.

B. All welds not specified shall be continuous fillet welds using not less than the minimum size

based on thickness of the thicker part jointed.



1. Thickness to 12mm -min. size 4mm 2. Over 12mm to 20mm -min. size 6mm 3. Over 20mm to 40mm -min. size 8mm 4. Over 40mm to 50mm -min. size 10mm

2.04 GROUT:

Non-shrink type, pre-mixed compound consisting of non-metallic aggregate, cement, water reducing and plasticizing additives, capable of developing minimum compressive strength of 48MPa

at 28 days.

2.05 PAINT

A. Primers: Steel surfaces which are not embedded in concrete to be painted with anti-corrosive primer (KPID), complying with B.S.5493, minimum dry film thickness 50 microns for all members that will receive finishing coat. All other members/surfaces will receive 3 coats of total thickness 150 microns.

B. Finishing Coat: All steel members exposed to view or covered with cladding system (refer architectural drawing) shall have special structural approved paint system to be used to protect structure (built up section and metal deck) against corrosive. Submit colour chart for Engineer selection.

C. Use spray application for painting. The minimum thickness shall be maintained on all corners, edges and ends of pieces. The surface to be painted shall be dry and above 2deg C; the temperature of the air shall be over 5deg C. Do not paint outdoors in rainy and dusty weather. Allow paint at least 24 hours drying time in good weather before re-coating.

D. Fire Protection “Spray applied system” of approved product Mandolite P20 or Vermiculite or Perlite including binder shall be applied to all steel members and metal deck to the exposed structure in enclosed room areas as shown in architectural drawing.

2.06 SOURCE QUALITY CONTROL

A. Testing and inspection of structural steel will be performed by an independent structural steel testing agency engaged by the contractor, at his own expense and approved by the Engineer. Provide the testing agency with the following:

1. A complete set of accepted documents required under paragraph “Submittals”.

2. Cutting lists, order sheets, materials bills and shipping bills.

3. Information as to time and place of all rollings and shipments of materials to shops.

4. Representative sample pieces as requested by the testing agency.

5. Full and ample means and assistance for testing all material.

6. Proper facilities, including scaffolding, temporary work platforms, etc. for inspection of the

work in the mills, shop and field.



B. The inspector will perform his duties in such a way that fabrication and erection are not

unnecessarily delayed or impeded, and as follows:

1. The inspector will make all tests and inspection as required by “Structural Welding Code”.

2. The edges of material to be welded will be ultrasonically examined for evidence of laminations, inclusions or other discontinuities. The extent to which such defects will be permitted and the extend of repair permitted shall be determined by the inspector and made in accordance with ASTM A6, Paragraph 9. Repairs made by welding shall be done in compliance with the requirements of AWS D1.1 and the accepted welding procedures.

3. The root layer of all multiple pass welds and the backside of groove welds made from both

sides, after back gouging or chipping, will be examined by magnetic particle inspection for dye penetration if magnetic particle inspection is not feasible).

4. All shop and field welds shall be listed as stated on Drawings.

5. The technique of radiographic inspection shall be in accordance with the requirements of

AWS D1.1. A double film technique will bused. One copy of each film will be sent to the Engineer, the other will be retained by the inspector.

6. Where inspection reveals defects, the extent of inspection will be increased as much as

necessary to ensure that the full extent of the defects in a joint has been found and to ensure that the same defects are not present in welds made on similar parts of under similar circumstances.

7. Work that is not acceptable will be designated by “Repair” or “Reject”, as applicable.

8. Shop welds will be inspected in the shop before the work painted or approved for shipment.

9. The inspector will maintain a daily record of the work he has inspected and its disposition.

Reports of tests will be made in form prescribed in AWS D1.1. One copy of each of the reports will be submitted to the Engineer on a weekly basis.

10. The inspector will make all tests and inspections of high strength bolt connections as

required by AISC S314. PART 3 EXECUTION 3.01 BENCH MARKS

A. The contractor shall employ the services of a registered professional Engineer, in accordance with the requirements of the Contract Document, who shall establish permanent bench marks, field check all elevations of concrete on which structural steel is to be placed and locations of anchor bolts, reporting any discrepancies to the Engineer and obtaining the Engineer’s approval before the work proceeds.



3.02 ERECTION

A. The contractor shall be responsible for the accurate setting and levelling of all bearing plates or setting plates. Bearing plates or setting plates shall be levelled on steel wedges or shims or as otherwise detailed. Bearing and setting plates shall be grouted as specified.

B. Furnish templates for accurate setting of all anchor bolts. Furnish shim plates or development fills where required to obtain proper fit and alignment.

C. Oxygen cutting of structural steel in excess of 3mm for “fitting-up” purposes shall not be done except with the prior approval of the Engineer.

D. The use of an oxygen cutting torch for correcting fabrication errors will be permitted only when the member is not under load, and only after prior written approval of the Engineer to the procedures to be followed in the event corrective work is necessary.

3.03 ERECTION TOLERANCE

A. The contractor alone shall be responsible for the correct fitting of all structural members and for the elevation and alignment of the finished structure. Any adjustments necessary in the steel work because of discrepancies in elevations and alignment shall be the responsibility of the contractor.

B. Unless otherwise noted , the structure shall be levelled and plumbed to an accuracy of 1 to 1000, but not to exceed 12mm. The actual centrelines of truss chords shall not vary from theoretical centrelines by more than 12mm at any point. The different between offsets to the actual centrelines of truss chords at adjacent panel points shall not exceed 3mm. All levelling and plumbing shall be done based on the mean operating temperature of the structure. Allowances shall be made for the difference in temperature at time of erection and the mean temperature at which the structure will be when completed and in service.

C. All measurements relating to the above shall be on the theoretical centrelines of the members. 3.04 CONNECTIONS

A. No welding or bolting shall be done until as much of the structure as will be stiffened by the welding or bolting has been properly aligned.

B. Drift pins shall not be used to enlarge unfair holes in main material. Holes that must be enlarged to admit bolts shall be reamed. Burning and drifting may be used to align unfair holes in secondary bracing members only, when acceptable to the Engineer.

C. When high strength bolts or high strength bearing bolts are used, the AISC specifications shall apply including values as noted therein, and installation by either “turn of nut tightening” or with torque wrenches. In using manual torque wrenches, the required torque can be read from the wrench dial. Care should be taken that the wrench is properly calibrated. Nuts shall be in motion when torque is measured. In using power wrenches, the recommendations of the wrench manufacturer shall be followed. Use hardened washer under bolt head or nut whichever is turned in tightening, unless the specified standards required hardened washer under both head and nut.



All bolts shall be kept in dry storage until needed for installation. A325 bolts 1-1/8inch (28mm) and 1.1/4 inch (32mm) diameter and A490 bolts 1 inch (25mm) diameter and over shall first have Johnson’s Stick Wax No. 140 applied to their threads before being assembled in the work. If bolts have been left out and have become rusty before use, they shall be rejected and shall not be used until they have been cleaned and waxed with Johnson’s Stick Wax No. 140.

D. Bolted connections shall be tested in accordance with the requirements of Para. TESTING and as indicated on the drawings.

E. Welded connections shall be tested in accordance with the requirements of Para. TESTING and as indicated on the drawings.

3.05 SURVEY

A. Make an accurate survey of actual locations of steel members immediately upon the completion of erection of steel but before removal of shoring and promptly submit same to the Engineer. Should locations very beyond the allowable tolerances, take necessary corrective measures and modify details and/or procedure as required.

B. Survey the final erected structural steel after release of shoring but prior to removal of shoring elements and prior to the application of any other work, reporting any discrepancies from contract requirements to the Engineer.

END OF SECTION


Dar Al-Jazera Consultants III-2/05500-1 Metal Fabrications

SECTION 05500

METAL FABRICATIONS

PART 1 GENERAL 1.01 DESCRIPTION


B. Provide labor, materials, equipment and services, and perform operations required for installation of miscellaneous metal and related work as indicated on the drawings and specified herein.

C. Work Included: The work of this section shall include, but not be limited to, the following:

1. Loose bearing and leveling plates.

2. Shelf angles.

3. Metal Covers for Trenches

4. Stair nosing, preassembled stairs, Cat ladders, Catwalks and fire escapes.

5. Miscellaneous steel framing and supports for elevator guide rails, interior and exterior stone supports, architectural woodwork.

6. Miscellaneous steel including posts, bracing, columns, beams, girders, plates, angles,

channels, brackets and closures and other miscellaneous metal items required to support work of this section and the work of other sections.

7. Cutting, fitting, drilling and tapping work of this section to accommodate work of other

sections and of concrete, masonry or other materials as required for attaching and installing work of this section.

1.02 REFERENCES

A. Aluminum Association: 1. AA DAF-45 - Designation System for Aluminum Finishes.

B. American Architectural Manufacturers Association:

1. AAMA 611 - Voluntary Specification for Anodized Architectural Aluminum.

2. AAMA 2603 - Voluntary Specification, Performance Requirements and Test Procedures for Pigmented Organic Coatings on Aluminum Extrusions and Panels.

3. AAMA 2604 - Voluntary specification, Performance Requirements and Test Procedures for

High Performance Organic Coatings on Aluminum Extrusions and Panels.



4. AAMA 2605 - Voluntary Specification, Performance Requirements and Test Procedures for

Superior Performing Organic Coatings on Aluminum Extrusions and Panels.

C. ASTM International: 1. ASTM A36/A36M - Standard Specification for Carbon Structural Steel.

2. ASTM A53/A53M - Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-

Coated, Welded and Seamless.

3. ASTM A123/A123M - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products.

4. ASTM A153/A153M - Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel

Hardware.

5. ASTM A167 - Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip.

6. ASTM A276 - Standard Specification for Stainless Steel Bars and Shapes.

7. ASTM A297/A297M - Standard Specification for Steel Castings, Iron-Chromium and Iron-

Chromium-Nickel, Heat Resistant, for General Application.

8. ASTM A283/283M - Standard Specification for Low and Intermediate Tensile Strength Carbon Steel Plates.

9. ASTM A307 - Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile

Strength.

10. ASTM A312/A312M - Standard Specification for Seamless and Welded Austenitic Stainless Steel Pipes.

11. ASTM A325M - Standard Specification for High-Strength Bolts for Structural Steel Joints

(Metric). 12. ASTM A354 - Standard Specification for Quenched and Tempered Alloy Steel Bolts, Studs,

and Other Externally Threaded Fasteners.

13. ASTM A479/A479M - Standard Specification for Stainless Steel Bars and Shapes for Use in Boilers and Other Pressure Vessels.

14. ASTM A500 - Standard Specification for Cold-Formed Welded and Seamless Carbon Steel

Structural Tubing in Rounds and Shapes.

15. ASTM A501 - Standard Specification for Hot-Formed Welded and Seamless Carbon Steel Structural Tubing.

16. ASTM A554 - Standard Specification for Welded Stainless Steel Mechanical Tubing.



17. ASTM B26/B26M - Standard Specification for Aluminum-Alloy Sand Castings.

18. ASTM B85 - Standard Specification for Aluminum-Alloy Die Castings.

19. ASTM B177 - Standard Guide for Chromium Electroplating on Steel for Engineering Use.

20. ASTM B209M - Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate (Metric).

21. ASTM B210M - Standard Specification for Aluminum and Aluminum-Alloy Drawn Seamless

Tubes (Metric).

22. ASTM B211M - Standard Specification for Aluminum and Aluminum-Alloy Bar, Rod, and Wire (Metric).

23. ASTM B221M - Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars,

Rods, Wire, Profiles, and Tubes (Metric).

D. American Welding Society: 1. AWS A2.4 - Standard Symbols for Welding, Brazing, and Nondestructive Examination. 2. AWS D1.1 - Structural Welding Code - Steel. 3. AWS D1.6 - Structural Welding Code - Stainless Steel.

E. National Ornamental & Miscellaneous Metals Association:

1. NOMMA Guideline 1 - Joint Finishes.

F. SSPC: The Society for Protective Coatings: 1. SSPC - Steel Structures Painting Manual.

2. SSPC SP 1 - Solvent Cleaning.

3. SSPC SP 10 - Near-White Blast Cleaning.

4. SSPC Paint 15 - Steel Joist Shop Paint.

5. SSPC Paint 20 - Zinc-Rich Primers (Type I - Inorganic and Type II - Organic).

1.03 QUALITY ASSURANCE

A. Materials and work shall conform to the latest edition of referenced standards specified herein and to applicable codes and requirements of local authorities having jurisdiction, including the following: 1. The National Association of Architectural Metal Manufacturer’s (NAAMM) following

standards:



a. Metal Finishes Manual.

b. Metal Products Outline Manual.

c. Pipe Railing Manual.

B. Qualify welding processes and welding operators in accordance with AWS D1.1 "Structural Welding Code - Steel," D1.3 "Structural Welding Code - Sheet Steel", and D1.2 "Structural Welding Code - Aluminum." 1. Certify that each welder has satisfactorily passed AWS qualification tests for welding

processes involved and, if pertinent, has undergone recertification.

C. Structural Performance: Design, engineer, fabricate and install the following metal fabrications to withstand structural loads without exceeding the allowable design working stress of the materials involved, including anchors and connections. Apply each load to produce the maximum stress in each respective component of each metal fabrication.

D. Conflicting Requirements: In the event of conflict between pertinent codes and regulations and the requirements of the referenced standards or these specifications, the provisions of the more stringent shall govern.

E. Qualifications

1. Fabricator’s Qualifications: Firm experienced in successfully producing metal fabrications

similar to that indicated for this Project, with sufficient production capacity to produce required units without causing delay in the Work.

2. Installer’s Qualifications: Arrange for installation of metal fabrications specified in this

section by same firm that fabricated them. 1.04 SUBMITTALS

A. Product Data: Submit copies of manufacturer's latest published literature for materials specified herein for approval, and obtain approval before materials are fabricated and delivered to the site.

B. Shop Drawings: Submit shop drawings for work specified herein for approval and obtain approval prior to fabrication and shipment of materials to the job site. 1. Shop drawings shall show locations of work in the Project, elevations and profiles. Indicate

materials, sizes, shapes, thicknesses, sizes and locations of structural subframes and reinforcing, location and installation requirements for fasteners and anchors and joints and connection to other work.

2. Where installed metal fabrications are indicated to comply with specified design loadings,

submit with shop drawings calculations in reference to structural properties of members, assemblies and connections prior to fabrication of any parts of the work and provide additional structural members or increase gauge and weight of finished metals required for the proper erection and structural stability of the work.



3. Welding shall be indicated on shop drawings using AWS symbols and showing length, size and spacing (if not continuous). Auxiliary views shall be shown to clarify welding. Notes such as 6.4 mm (1/4 inch) weld, weld and tack weld are not acceptable.

C. Samples: Samples of materials specified herein shall be submitted for approval, and approval

obtained before materials are delivered to the site. 1.05 DELIVERY, STORAGE AND HANDLING

A. Exercise proper care in the handling of work so as not to injure the finished surfaces, and take proper precautions to protect the work from damage after it is in place.

B. Deliver materials to the job site ready for use, and fabricated in as large sections and assemblies as practical. Assemblies shall be identical to submitted and reviewed shop drawings, samples and certificates.

C. Store materials under cover in a dry and clean location off the ground. Take every precaution not to damage or mar prime coats or galvanizing. Remove materials which are damaged or otherwise not suitable for installation from the job site and replace with acceptable materials at no additional cost to the Engineer.

1.06 PROJECT CONDITIONS

A. Check actual locations of walls and other construction to which metal fabrication must fit, by accurate field measurements before fabrication. Show recorded measurements on final shop drawings and coordinate fabrication schedule with construction progress to avoid delay of Work.

PART 2 PRODUCTS 2.01 MATERIALS

A. Structural Steel Shapes: ASTM A36.

B. Steel Plates: ASTM A36.

C. Rolled Steel Floor Plates: ASTM A786.

D. Steel Tubing 1. Cold-Formed Steel Tubing: ASTM A500, Grade A, unless otherwise indicated or required

for design loading.

2. Hot-Formed Steel Tubing: ASTM A501.

3. For exterior installations and where indicated, provide hot-dip galvanized coating per ASTM A53.

E. Steel Pipe: ASTM A53, Schedule 40.



F. Gray Iron Castings: ASTM A48, Class 30.

G. Malleable Iron Castings: ASTM A47, Grade 32510.

H. Brackets, Flanges and Anchors: Cast or formed metal of the same type material and finish as supported rails, unless otherwise indicated.

I. Fastening and Anchorage Devices 1. Provide zinc-coated fasteners for exterior use or where built into exterior walls. Select

fasteners for the type, grade and class required.

2. Concrete Inserts: Threaded or wedge type, galvanized ferrous castings, either malleable iron ASTM A47 or cast steel ASTM A27. Provide bolts, washers and shims as required, hot-dipped galvanized, ASTM A153.

3. Drilled-In Expansion Anchors: Expansion anchors complying with FS FF-S-325, Group VIII

(anchors, expansion, [nondrilling]), Type I (internally threaded tubular expansion anchor); and machine bolts complying with FS FF-B-575, Grade 5.

4. Toggle Bolts: FS FF-B-588, tumble-wing type, class and style as required.

5. Machine Screws: FS FF-S-92.

6. Nuts and Bolts: ASTM A307.

7. Lag Bolts: FS FF-B-561, square head type.

8. Lock Washers: FS FF-S-84, helical spring type carbon steel.

9. Wood Screws: FS FF-S-111, flat head carbon steel.

10. Plain Washers: FS FF-W-92, round, carbon steel.

J. Stainless Steel

1. Bars and Shapes: ASTM A276, type 316.

2. Plate , Sheet and Strip: ASTM A167, type 316.

3. Fasteners: ASTM F593, type 316.

4. Tubing: ASTM A269, Type 316.

5. Pipe: A312M, seamless 316.

6. Bolts, Nuts, and Washers: ASTM A354.

7. Welding Materials: AWS D1.6; type required for materials being welded.

K. Aluminum: Of approved manufacture, composed of suitable alloy for forming the aluminum;



bending or rolling and temper for structural requirements and to receive the specified finish.

1. Extruded Bars and Shapes: ASTM B221, alloys as follows:

a. 6061-T6 or 6063-T6.

2. Cast Aluminum: ASTM B85.

3. Fasteners for Aluminum: Use fasteners made of same basic metal as fastened metal except use galvanized fasteners complying with ASTM A153 for exterior aluminum units unless otherwise indicated. Do not use metals that are corrosive or incompatible with metals joined.

L. Paint

1. Paint for the rust-inhibitive treatment of miscellaneous steel shall be catalyzed epoxy primer

"Chembuild Series 135" by Tnemec Co., Inc. or Carbomastic 90 by Carboline Co., or approved equal by Ameron Inc. or duPont.

2. Paint for aluminum work in contact with concrete, masonry, mortar and dissimilar metal

shall be bituminous mastic type complying with SSPC-Paint 12 except with no asbestos fibers as manufactured by Kop-Coat Inc. or approved equal.

3. Touch-up paint for galvanized surfaces shall be epoxy zinc rich primer; "90-97 Tneme-Zinc"

by Tnemec Co., Inc., Carbomastic 96 by Carboline Co., or approved equal by Ameron Inc. or duPont.

4. Paint for exterior steel pipe railings and toeguards shall be one of the following types.

Verify Engineer's final color selections to insure total coverage of primer. Prime paint for cold weather applications and where final finish color matches primer color shall be Rust-Inhibitive Urethane Primer; Series 50-330 Poly-Ura-Prime by Tnemec Co. Inc., Carbomastic 242 by Carboline Co. or approved equal by Ameron Inc. or duPont.

M. Grout and Anchoring Cement

1. Non-shrink, Non-metallic Grout: Premixed, factory-packaged, non-staining, non-corrosive,

non-gaseous grout complying with CE CRD-C 621. Provide grout specifically recommended by manufacturer for interior and exterior applications of type specified in this section.

2. Grout shall be one of the following:

a. "Bonsal Construction Grout", W.R. Bonsal Co.

b. "Euco N-S Grout"; Euclid Chemical Co.

c. "Crystex", L&M Construction Chemicals, Inc.

d. "Masterflow 713", Master Builders, Inc.

e. "Sealtight 588 Grout", W.R. Meadows, Inc.



f. "Sonogrout"; Sonneborn Building Products Div.

g. "Five Star Grout", U.S. Grout Corp.

h. Or approved equal.

N. Galvanizing: Provide materials required for galvanizing as specified herein.

O. Welding Rods and Bare Electrodes: Select in accordance with AWS specifications for the

metal alloy to be welded. 2.02 FABRICATION

A. Miscellaneous metal work shall be of the design, gauge, dimensions and location indicated on the drawings, sections and details. Miscellaneous metal work and finishes shall be first class in every aspect and in accordance with trade practice. Insofar as practicable, fabrication, assembly and fitting of the work shall be executed in the shop with the various parts or assemblies ready for erection at the building. Work that cannot be shop-assembled shall be given a trial fit at the shop to insure a proper and expeditious field assembly.

B. In the event that shop-fabricated miscellaneous metal items do not fit the field condition, the item shall be returned to the shop for correction, including regalvanizing or priming where required.

C. Removable members shall be carefully machined and fitted and shall be secured by screws or bolts of proper size and approved spacing. Structural supports, hangers and built-in reinforcement wholly concealed within the finished assemblies shall be as indicated or required.

D. Shear saw and punch metal accurately, cleanly, sharply and free of burrs, without deforming adjacent surfaces or metals. Flame cutting will be permitted only if cut edges are ground back to clean, smooth edges.

E. Drill or cleanly punch holes; do not burn.

F. Form exposed work true to line and level with accurate angles and surfaces and straight sharp edges.

G. Allow for thermal movement resulting from temperature change (range) of 55OC (100°F) in the

design, fabrication and installation of installed metal assemblies to prevent buckling, opening up of joints and overstressing of welds and fasteners. Base design calculations on actual surface temperatures of metals due to both solar heat gain and nighttime sky heat loss.

H. Fabricate joints that will be exposed to weather in a manner to exclude water or provide weep holes where water may accumulate.

I. Ease exposed edges to a radius of approximately 0.8 mm (1/32 inch), unless otherwise indicated. Form bent-metal corners to smallest radius possible without causing grain separation or otherwise impairing work.

J. Remove sharp or rough areas on exposed traffic surfaces.



K. Weld corners and seams continuously to comply with AWS recommendation and the following:

1. Use materials and methods that minimize distortion and develop strength and corrosion

resistance of base metals.

2. Obtain fusion without undercut or overlap.

3. Remove welding flux immediately.

4. At exposed connections, finish exposed welds and surfaces smooth and blend so that no roughness shows after finishing and contour of welded surface matches those adjacent.

L. Form exposed connections with hairline joints, flush and smooth, using concealed fasteners wherever possible. Use exposed fasteners of type indicated or, if not indicated, Phillips flat-head (countersunk) screws or bolts. Locate joints where least conspicuous.

M. Provide for anchorage of type indicated; coordinate with supporting structure. Fabricate and space anchoring devices to provide adequate support for intended use.

N. Rough Hardware 1. Furnish bent or otherwise custom fabricated bolts, plates, anchors, hangers, dowels and

other miscellaneous steel and iron shapes as required for framing and supporting woodwork, and for anchoring or securing woodwork to concrete or other structures.

2. Fabricate items to sizes, shapes and dimensions required. Furnish malleable-iron washers

for heads and nuts which bear on wood structural connections; elsewhere, furnish steel washers.

O. Coordination: Accurately cut, fit, drill and tap work of this section to accommodate and fit work

of other trades. Furnish or obtain, as applicable, templates and drawings to or from applicable trades for proper coordination of this work.

P. Castings: Carefully made, straight, true to mold, with smooth surfaces, clean-cut sharp arrises, with intersections well defined, free from blowholes, shrinkage defects, cracks or other injurious defects.

Q. Shop Painting

1. Painting shall be done in dry weather or under cover, and steel or iron surfaces shall be free from moisture or frost. No materials shall be delivered until the shop coat has dried.

2. Paint shall be delivered in the original containers of the approved manufacturer.

3. Ferrous Metal

a. Remove loose rust, mill scale and existing paint by power tool cleaning, including

power sanders, wire brushes chipping hammers, abrasive grinding wheels and needle guns, in accordance with Steel Structures Painting Manual Volume 2, SSPC-SP3 - Power Tool Cleaning.



b. Ferrous metal surfaces (except galvanized steel) shall be given a shop coat of modified

alkyd primer specified herein.

c. Each coat applied shall produce a dry film thickness of 2.0 to 2.5 mils.

d. Surfaces, which will be concealed in the finished construction or will not be accessible to finish painting, shall receive an additional shop coat of the specified paint to which a small amount of tinting has been added for color differentiation. Touch-up marred and abraded surfaces with the specified paint after erection in the field.

4. Exterior Railings

a. Remove loose rust, mill scale and existing paint by power tool cleaning, including power sanders, wire brushes chipping hammers, abrasive grinding wheels, and needle guns, in accordance with Steel Structures Painting Manual Volume 2, SSPC-SP3 - Power Tool Cleaning.

b. Surfaces, which will be concealed in the finished construction or will not be accessible

to finish painting, shall receive an additional shop coat of the specified paint to which a small amount of tinting has been added for color differentiation.

c. Apply a prime coat of rust-inhibited primer specified herein at minimum 2.0-3.5 dry film

thickness.

5. Aluminum and Other Non-ferrous Metals: Clean and apply one shop coat of zinc-chromate primer or bituminous paint on surfaces which will come in contact with masonry, concrete, or plaster or will be fastened to a dissimilar metal other than stainless steel.

6. Repaint areas if shop coat damaged during handling or installation with paint similar to that

applied in the shop.

R. Shop Finishes; Exposed aluminum (saddles) shall be provided with manufacturer's standard non-slip finish.

S. Shop Galvanizing: Galvanize exterior ferrous metals unless specified otherwise. 1. Hot-dipped Galvanizing shall conform to ASTM A123, Table 1.

2. Electro-Galvanizing, where specified or required, shall conform to the requirements for type

GS (0.0010 inch minimum thickness) of ASTM B633.

3. Hot-dipped Galvanized Steel Sheet: ASTM A446, 1 ¼ ounce per Sq. ft.

4. Galvanized Coating on Iron and Steel Hardware: ASTM A153, Table 1.

5. Galvanized Coating on Assembled Steel Products: ASTM A383, Table 1.

6. Galvanize after fabrication.



2.03 FABRICATION - SPECIFIC ITEMS

A. Shelf Angles 1. Fabricate shelf angles from steel angles of sizes indicated. Provide slotted holes to receive

19 mm (3/4 inch) bolts, spaced not more than 150 mm (6 inches) from ends and not more than 24 inches on center, unless otherwise indicated.

2. Galvanize shelf angles supporting exterior work.

3. Furnish wedge-type concrete inserts, including fasteners, for attachment of shelf angles to

cast-in-place concrete.

B. Sleeves and Slots 1. Sleeves shall be of Schedule 40 steel pipe with inner diameter 50.8 mm (2 inches) larger

than outer diameter of pipe (including insulation, if any) to be accommodated. Sleeves shall project 12.7 mm (1/2 inch) on each side of finished wall, unless otherwise indicated. Provide rectangular 6.4 mm (1/4 inch) steel plate collar at center, continuously welded to the perimeter of the sleeve and 150 mm (6 inches) wider than the outer diameter.

2. Slots in slabs shall be 12 gauge steel sheet, galvanized of dimensions indicated, with strap

anchors welded in place not more than 300 mm (12 inches) on centers.

C. Loose Bearing and Leveling Plates: Provide loose bearing and leveling plates for steel items bearing on masonry or concrete construction, made flat, free from warps or twists, and of required thickness and bearing area. Drill plates to receive anchor bolts and for grouting as required. Galvanize after fabrication.

D. Miscellaneous Steel, Built up Sections & Decking 1. Miscellaneous steel shall include required support steel for the work of this section, and for

the work of other sections.

2. Miscellaneous Steel members shall be of such shapes and sizes indicated on drawings and details or as required to suit the condition and shall be provided with necessary supports and reinforcing such as hangers, braces, struts, clip angles, anchors, bolts, nuts, welds, etc., as required to properly support and rigidly fasten and anchor same in place and to steel, concrete, masonry and other connecting and adjoining work.

3. Equip units with integrally welded anchors for casting into concrete or building into

masonry. Furnish inserts if units must be installed after concrete is placed. Space anchors 300 mm (12 inches) on center and provide minimum anchor units of 31.6 mm by 6.4 mm by 200 mm (1 ¼ inch by ¼ inch by 8 inches) steel straps.

4. Included under this heading of miscellaneous steel are:

a. Steel angles for framed opening in floors.

b. Steel angles and plates for pipe and duct protection.



c. Elevator tie down and machine beams.

d. Steel supports for elevator guide rails, sculptures, chandeliers and shelves.

e. Steel supports for interior and exterior stonework.

PART 3 EXECUTION 3.01 EXAMINATION

A. Examine conditions at the job site where work of this section is to be performed to insure proper arrangement and fit of the work. Start of work implies acceptance of job site conditions.

3.02 PREPARATION

A. Examine the Contract Drawings and specifications in order to insure the completeness of the work required under this Section.

B. Verify measurements and dimensions at the job site and cooperate in the coordination and scheduling of the work of this Section with the work of related trades, with particular attention given to the installation of items embedded in concrete and masonry so as not to delay job progress.

C. Provide templates as required to related trade for location of support and anchorage items.

D. Dissimilar Materials: Isolate aluminum from masonry, concrete, wood and dissimilar metals by coating with heavy-bodied bituminous paint or by using a non-absorbent gasket. Fasteners shall be selected to prevent galvanic action.

3.03 INSTALLATION

A. Install work of this section square, plumb, straight, true to line or radius, accurately fitted and located, with flush tight hairline joints (except as indicated otherwise or to allow for thermal movement). Provide attachment devices as required for secure and rigid installation.

B. Exposed joints shall be close fitting, and bolts and screws, where exposed, shall be cut off flush with nuts or other adjacent metal. Cutting, drilling, punching and tapping required for the installation and attachment of other work to miscellaneous metal work, except where specified in connection with work under other sections, shall be performed as required.

C. Metal work built-in with concrete or masonry shall be formed for anchorage, or be provided with suitable anchors, expansion shields or other anchoring devices indicated on drawings or required. Such metal work shall be furnished in ample time for setting and securing in place.

D. Where indicated, install miscellaneous metal items in sleeves (furnished under this section) embedded in concrete with setting grout specified herein.

E. Unless otherwise indicated, joints shall be as strong and rigid as adjoining sections. Welding shall be continuous along entire line of contact, except where spot welding is indicated or



permitted. Where exposed, welds shall be ground smooth. Where bolted or riveted connections are indicated, such connections may be welded at the Contractor's option.

F. Where welding is required, it shall conform to requirements for shielded metal arc welding of the Standard Code for Arc and Gas Welding of the American Welding Society. Exposed welds shall be flush and ground smooth.

G. Threaded connections shall be made up tight so that threads are entirely concealed. Abutting bars shall be so shouldered and headed, doweled and pinned. Small bars shall pass through larger bars and be pinned. Rivet, bolts and screw heads shall be flat and countersunk in exposed work and elsewhere as required. Removable members shall be carefully machined and fitted and secured, by means of screws or bolts of proper size and approved spacing.

H. Bolts, brackets, sleeves and other items embedded in concrete shall be galvanized.

I. Except where otherwise indicated, miscellaneous metal work shall be fastened to concrete with expansion bolts and to hollow block with toggle bolts. Fastening to wood plugs in concrete or masonry will not be permitted. Holes for plugs or bolts shall be drilled to the exact diameter of the plug or bolt, using a percussion drill for concrete and a rotary drill for masonry. Screws shall be threaded full length to the head of the screw.

J. Provide for adjustments of miscellaneous metal items, with particular attention given to miscellaneous steel supporting the work of other sections, as required during the construction process.

K. Setting Loose Plates 1. Clean concrete and masonry bearing surfaces of any bond-reducing materials, and

roughen to improve bond to surfaces. Clean bottom surface of bearing plates.

2. Set loose leveling and bearing plates on wedges, or other adjustable devices. After the bearing members have been positioned and plumbed, tighten the anchor bolts. Do not remove wedges or shims, but if protruding, cut off flush with the edge of the bearing plate before packing with grout.

3. Pack grout solidly between bearing surfaces and plates to ensure that no voids remain.

L. Installation of Cast Treads and Thresholds: Install cast treads and thresholds with anchorage system indicated to comply with manufacturer's recommendations.

END OF SECTION


Dar Al-Jazera Consultants III-2/05580-1 Sheet Metal Fabrications

SECTION 05580

SHEET METAL FABRICATIONS PART 1 GENERAL 1.01 DESCRIPTION


B. Provide materials and services, and perform operations required for installation of sheet metal fabrications and related work as indicated on the drawings or specified herein.

C. Work Included: The work of this section shall include works in relation, but not limited to, enclosures for Mechanical Work

1.02 REFERENCES

A. Aluminum Association:

1. AA DAF-45 - Designation System for Aluminum Finishes.

B. ASTM International:

1. ASTM A167 - Standard Specification for Stainless and Heat-Resisting Chromium-Nickel

Steel Plate, Sheet, and Strip.

2. ASTM B209M - Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate (Metric).


A. Materials and work shall conform to the latest edition of referenced standards listed below and specified herein and to applicable codes and requirements of local authorities having jurisdiction, whichever is more stringent.

1. The National Association of Architectural Metal Manufacturer’s (NAAMM) following

standards:

a. Metal Finishes Manual. b. Metal Bar Grating Manual. c. Metal Products Outline Manual.

2. Applicable provisions of the Architectural Sheet Metal Manual (SMACNA).

3. Applicable provisions of the Aluminum Association, Inc.

B. Welding shall conform to requirements for shielded metal arc welding of the Standard Code for

Arc and Gas Welding of the American Welding Society.



C. Qualifications: Work shall be done by a firm/company regularly engaged in the fabrication and erection of work specified herein. Workmen shall be skilled in fabrication and erection of high grade work.

1.04 SUBMITTALS

A. Product Data: Submit copies of manufacturer's latest published literature for materials specified herein for approval, and obtain approval prior to start of fabrication. Product data shall include paint materials and finishes specified herein.

B. Shop Drawings: Submit shop drawings for work specified herein for approval and obtain

approval prior to start of fabrication. 1. Shop drawings shall show locations of work in the Project, elevations and profiles. Indicate

materials, sizes, shapes, thicknesses; sizes and locations of structural subframes and reinforcing; location and installation requirements for fasteners and anchors; joints and connection to other work and finishes.

C. Job Site Mock-ups

1. Provide a full scale mock-up of each type of enclosure, installed at a building location as

selected by the Engineer for acceptance before manufacture of the units has begun. Mock-ups shall include typical and corner conditions. Each mock-up shall be a minimum length of 2 typical sections.

2. Mock-up shall show final finish specified herein.

3. Rework mock-up until accepted by Engineer. Installed work shall match accepted mock-

ups.

4. Accepted mock-ups may remain as part of the finished building construction.


A. Exercise proper care in the handling of work so as not to injure the finished surfaces, and take proper precautions to protect the work from damage after it is in place.

B. In the event of damage, immediately make repairs and replacements necessary to the

satisfaction of the Engineer and at no additional cost to the Engineer. PART 2 PRODUCTS 2.01 MATERIALS

A. Provide materials which have been selected for their surface flatness, smoothness and free from surface blemishes where exposed to view in the finished unit. Exposed to view surfaces which exhibit pitting, seam marks, roller marks, "oil canning", stains, discolorations or other imperfections on the finished units are not acceptable.

B. Steel sheets shall be commercial quality, cold-rolled, carbon steel sheets, full pickled,



annealed, stretcher or roller-leveled, bonderized, free from scale, waves or other defects and conforming to ASTM A366, matte finish. For gauges of steel sheet refer to United States Standard Gauge.

C. Structural steel shapes including welded construction shall conform to ASTM A36.

D. Steel plates shall conform to ASTM A283.

E. Aluminum extrusions for channels, tubes and fittings shall conform to ASTM B209 and B221

and shall be approved manufacturer composed of extruded aluminum 6063 T5 or T6 alloy and temper, uniform in quality and free from defects.

1. Channels and tubes shall be of sizes indicated on the drawings and specified herein.

F. Aluminum sheets shall conform to ASTM B209 and B221 and shall be composed of 5005 H34

alloy and temper, uniform in quality and free from defects in thickness specified herein.

G. Fastening Devices 1. Concrete Anchors shall conform to Federal Specifications FF-S-325, and shall be die cast

zinc alloy, "Split Shield and Wedge" type machine bolt expansion shields of rated holding power four times required working load, tested in accordance with ASTM E488.

2. Masonry Anchors shall be zinc plated steel "Gravity Action" toggle bolts conforming to

Federal Specifications FF-B-588, or machine bolt expansion shields, UL approved for use in hollow masonry; of rated holding power four times required working load, tested in accordance with ASTM E488.

3. Machine Screws shall be hot-dipped galvanized conforming to Federal Specification

FF-S-92.

4. Nuts and Bolts shall be hot-dipped galvanized conforming to ASTM A307.

H. Paint 1. Paint shall be standard baked-on rust-resistant primer type as approved.

2. Paint for aluminum work in contact with concrete masonry or dissimilar metals shall be

bituminous mastic type as manufactured by Kop-Coat Inc. or approved equal.

2.02 FABRICATION

A. Fabricate items to comply with requirements indicated, including those for quality, thickness and finish of material as well as those indicating dimensions and details. Use heavier metal gauges, stiffeners or metal backing as required to produce surface flatness, free of "oil canning" and to impart sufficient strength for use indicated.

B. Form sheet metal items in maximum lengths and keep joints to a minimum. Do not expose cut

edges of sheet metal except as shown. Fold back exposed ends of unsupported sheet metal to form a 1/2 inch (13 mm) wide hem on the concealed side, or ease exposed edges with backing to a radius of approximately 1/32 inch. Form items with flat, flush surfaces, true to line and



level, and without cracking and grain separation at bends.

C. Continuously weld joints and seams except where other methods of joining are indicated. Grind welds smooth and flush on exposed surfaces. Comply with AWS and other metal authorities.

D. Provide straps, plates and brackets as required for support and anchorage of fabricated items

to adjoining work.

E. Hollow Metal Partition Closures shall be fabricated of No. 14 gauge sheet steel and shall be constructed as indicated on drawings and specified herein. Provide supporting and attachment metal work, fasteners and accessories as required for installation.

1. Partition closures shall be completely filled with high density, glass or mineral fiber

insulation.

F. Sheet Metal Blind Pockets: Sheet metal [venetian] [vertical] blind pockets shall be constructed as indicated on the drawings and specified herein, of not less than No. 16 gauge sheet steel as specified above. Pockets shall be adequately supported as indicated or required, installed level and true, carefully fitted to adjoining construction and fastened rigidly in place. Provide supporting and attachment metal work, fasteners and accessories as required for installation.

G. Shop Finishing

1. Comply with NAAMM "Metal Finishes Manual" for finish designations and application

recommendations, except as otherwise indicated.

2. Ferrous Metal

a. Surface Preparation: Solvent-clean surfaces in compliance with SSPC-SP 1 to remove dirt, oil, grease and other contaminants that could impair paint bond. Remove mill scale and rust, if present, from uncoated steel in compliance with SSPC-SP 5 (white metal blast cleaning).

b. Chemical Pretreatment: Apply hot phosphate surface treatment to uncoated steel

sheet to comply with SSPC-PT 4.

c. Factory-Primed Finish: For uncoated steel sheet indicated to be painted after installation, apply metal primer paint immediately following surface preparation and pretreatment.

PART 3 EXECUTION 3.01 EXAMINATION

A. Examine conditions at the job site where work of this section is to be performed to insure proper arrangement and fit of the work. Start of work implies acceptance of job site conditions.



3.02 PREPARATION

A. Examine the Contract Drawings and specifications in order to insure the completeness of the work required under this Section.

B. Verify measurements and dimensions at the job site and cooperate in the coordination and

scheduling of the work of this Section with the work of related trades, so as not to delay job progress.

3.03 INSTALLATION

A. Work shall be installed in a thorough and workmanlike manner by skilled workmen to the satisfaction of the Engineer.

B. Work shall be installed rigid, plumb, level and true, free of rattles, with proper alignment and

proper relationship to adjoining work.

C. Exposed surfaces shall be free of any tool marks or blemishes. Materials not conforming to the specification requirements shall be removed and replaced with acceptable materials at no additional cost to the Engineer.

END OF SECTION


Dar Al-Jazera Consultants III-2/05700-1 Ornamental Metal

SECTION 05700

ORNAMENTAL METAL PART 1 - GENERAL 1.01 DESCRIPTION

A. Provide labor, materials, equipment and services, and perform operations required for

installation of Ornamental Metal as. 1. Steel fabrications. 2. Stainless steel fabrications. 3. Aluminum fabrications.

1.02 PROJECT CONDITIONS

A. Take field measurements prior to preparation of shop drawings and fabrication, where possible, to ensure proper fitting of Ornamental metalwork. Do not delay job progress; allow for adjustment and fitting where taking of field measurements before fabrication might delay Work.

PART 2 – PRODUCTS 2.01 PRODUCTS

A. Furnishing anchors to be set into concrete as may be required to properly erect, align and secure the work of this section.

2.02 MATERIALS

A. Steel Materials:

1. Steel Plate 2. Hollow structural sections 3. Galvanized sheet 4. Pipe 5. Bolts, nuts and washers 6. Welding Materials

B. Stainless Steel Materials: 1. Bars and shapes 2. Tubing 3. Pipe 4. Plate, sheet and strip 5. Bolts, Nuts, and washers 6. Welding Materials


Dar Al-Jazera Consultants III-2/05700-2 Ornamental Metal

C. Aluminium Materials: 1. Aluminium extrusions 2. Sheet and plate 3. Tubing: seamless 4. Bars, Rod 5. Sand castings 6. Die castings 7. Bolts, Nuts, and washers: stainless steel. 8. Welding materials

2.03 FABRICATION

A. Take field measurements prior to preparation of shop drawings and fabrication to insure proper fitting of the work. Allow for adjustments and fitting wherever the taking of field measurements before fabrication might delay the work.

PART 3 - EXECUTION 3.01 INSTALLATION

A. Perform cutting, drilling, and fitting required for the installation of the Ornamental metal items. Set the work accurately in location, alignment and elevation, plumb, level and true, measured from established lines and levels.

END OF SECTION


Dar Al-Jazera Consultants III-2/08110-1 Metal Doors & Frames

SECTION 08110

METAL DOORS AND FRAMES

PART 1 GENERAL 1.01 DESCRIPTION


B. Provide labor, materials, equipment and services, and perform operations required for

furnishing hollow metal work as indicated on the drawings and specified herein. C. Work Included: The work of this Section shall include, but not be limited to, the following:

1. Flush and seamless hollow metal doors. 2. One piece hollow metal frames. 3. Steel doors and frames. 4. Prefinished Interior Steel Frames. 5. Fire rated doors for substations, transformer, Electrical and machinery rooms with rating as

stated on the Door schedule. D. Related Sections:

1. Section 08210 - Wood Doors 2. Section 08410 - Aluminum Framed Doors 3. Section 08520 - Aluminum Windows 4. Section 08710 - Finish Hardware 5. Section 09900 - Painting

1.02 REFERENCES

A. American Architectural Manufacturers Association:

1. AAMA 1503 - Voluntary Test Method for Thermal Transmittance and Condensation Resistance of Windows, Doors and Glazed Wall Sections.

B. American National Standards Institute:

1. ANSI Z97.1 - Safety Glazing Materials Used in Buildings Safety.



2. ANSI A250.8 - Recommended Specifications for Standard Steel Doors and Frames.

C. American Society for Testing and Materials:

1. ASTM A653/A653M - Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process.

2. ASTM C236 - Standard Test Method for Steady-State Thermal Performance of Building

Assemblies by Means of a Guarded Hot Box. 3. ASTM E283 - Standard Test Method for Determining the Rate of Air Leakage Through

Exterior Windows, Curtain Walls, and Doors Under Specified Pressure Differences Across the Specimen.

4. ASTM E330 - Standard Test Method for Structural Performance of Exterior Windows,

Curtain Walls, and Doors By Uniform Static Air Pressure Difference. 5. ASTM E331 - Standard Test Method for Water Penetration of Exterior Windows, Curtain

Walls, and Doors By Uniform Static Air Pressure Difference. 6. ASTM E547 - Standard Test Method for Water Penetration of Exterior Windows, Curtain

Walls, and Doors by Cyclic Static Air Pressure Differential. 7. ASTM C1036 - Standard Specification for Flat Glass. 8. ASTM A591/A591M - Standard Specification for Steel Sheet, Electrolytic Zinc-Coated, for

Light Coating Mass Applications. 9. ASTM E413 - Standard Classification for Rating Sound Insulation.

D. Hollow Metal Manufacturers Association:

1. HMMA 802 - Manufacturing of Hollow Metal Doors and Frames. 2. HMMA 810 - Hollow Metal Doors. 3. HMMA 830 - Hardware Preparation and Locations for Hollow Metal Doors and Frames. 4. HMMA 840 - Installation and Storage of Hollow Metal Doors and Frames. 5. HMMA 850 - Fire Rated Hollow Metal Doors & Frames. 6. HMMA 890 - Technical Summary of Hollow Metal by HMMA.

E. Consumer Product Safety Commission:

1. CPSC 16 CFR 1201; Safety Standard for Architectural Glazing.



F. Glass Association of North America:

1. GANA - Glazing Manual. G. National Fire Protection Association:

1. NFPA 80 - Standard for Fire Doors, Fire Windows. 2. NFPA 252 - Standard Methods of Fire Tests of Door Assemblies.

H. National Fenestration Rating Council Incorporated:

1. NFRC 100 - Procedures for Determining Fenestration Product U-Factors. I. Underwriters Laboratories Inc.:

1. UL 10B - Fire Tests of Door Assemblies. J. Uniform Building Code:

1. UBC Standard 7-2 - Fire Tests of Door Assemblies.

K. Kuwait Fire Brigade:

1. All doors shall be rated according to the KFB requirements


A. Materials and work shall conform to the latest edition of referenced standards listed below, specified herein and to applicable codes and requirements of local authorities having jurisdiction, whichever are more stringent.

B. Standards: Except as modified by governing codes “Kuwait Fire Brigade” and “Kuwait

Municipality” and stated on Contract Drawings, comply with the applicable provisions and recommendations of ANSI 250.8

C. Label each fire rated door in accordance with Underwriters Laboratories Labeling system. D. Welding of steel shall conform to the requirements of the Standard Code for Arc & Gas Welding

of the American Welding Society. E. Steel Doors shown on drawings and in door schedule, interfacing with fire alarm system shall

open automatically to the outside when Fire alarm triggers. F. Maintain one copy of all documents on site.

1.04 SUBMITTALS

A. Product Data: Submit copies of manufacturer's latest published literature for materials specified herein.



B. Shop Drawings

1. Submit shop drawings for metal work. Include for each opening and location details of frame, elevation of door design type, conditions at opening, details of construction, details of joints and connections, description of anchorage and accessory items, locations of reinforcement, master key, sub-master key system and installation requirements for finish hardware.

2. Submit schedule of doors and frames utilizing reference numbers for details and openings

as shown. 3. Shop drawings shall indicate in detail the design, dimension, gauges, finishes, methods of

construction, installation and attachment of work, and other pertinent data and information. Shop drawing details for steel doors and frames shall be at a minimum scale of one-half full size.

C. Samples: Submit two samples of door face metal, 300 x 300 mm

in size illustrating factory finished door colors and surface texture.

1.05 MOCK-UP

A. Section 01400 – Contractor’s Quality Control: Mock-up requirements. B. Construct mock-up of one door panel indicating typical metal door and frame construction

including all materials and conditions. C. Locate where directed by Engineer. Incorporate accepted mockup as part of Work.


A. Materials shall be delivered to the site clearly indicating manufacturer's name, brand name and other identifying information. Provide temporary steel spreaders at the bottom of each frame.

B. Protect units during construction so that they will be free from deterioration or damage at time

of substantial completion. Clean exposed primed metal surfaces as recommended by manufacturer and leave ready for final painting.

C. Place Doors and frames on wood platform and cover them in a manner to prevent rust.

1.07 WARRANTY:

A. Section 01700 – Contract Closeout: Requirements for warranties. B. Furnish five year manufacturer’s warranty on workmanship and materials. C. Furnish five year manufacturer’s warranty for insulated glass units from seal failure, interpane

dusting or misting, including replacement.



PART 2 PRODUCTS 2.01 MANUFACTURERS

A. Amweld Building Products, Inc. 1500 Amweld Drive Garrettsville, OH 44231, USA Tel: 330-527-4385 Fax: 330-527-5122 E-mail: [email protected] Web site: www.amweld.com

B. CURRIES Company

1502 12th Street NW Mason City, IA 50401, USA Tel: (641) 423-1334 Fax: (641) 424-8305 E-mail: [email protected] Web site: http://www.curries.com

C. Fleming

An ASSA ABLOY Group company 20 Barr Road, Ajax On, L1S 3X9 Canada Tel: (905) 683-3667 Fax: (905) 427-1668 E-mail: [email protected]

D. Substitutions Under Provisions of Section 01630

2.02 MATERIALS

A. Sheet Steel: Commercial quality, cold rolled, pickled, annealed and stretcher leveled, entirely free from scale, pitting, wave or other defects. Gauges indicated on drawings and specified herein for sheet steel refer to the United States Standard Gauge for Sheet Iron and Steel.

1. Sheet Steel for Frames: ASTM A569 and ASTM A568, hot rolled prime quality carbon

steel. 2. Sheet Steel for Doors: ASTM A366 and ASTM A568, cold rolled stretcher level sheet

steel. B. Galvanized Steel Sheet (Doors and Frames): ASTM A526, and galvanized in accordance with

ASTM A525, Coating designation G-90, phosphatized, stretcher leveled sheet for doors.

1. Galvanized miscellaneous ferrous metal components in accordance with ASTM A153. C. Steel Shapes: Provide steel for supporting, reinforcing and attachment of work.

1. Structural Steel: ASTM A36.

2. Plates: ASTM A283, Grade C.



D. Sound-Deadening and Heat Retarding Filler: Mineral wool or other inorganic insulating non-

combustible, non-settling material, verminproof and complying with labeling requirements. E. Fire Rating: provide Assembly of fire rated door, frame and hardware, where each element

performs according to the NFPA 80 standards. F. Accessories: Provide manufacturer's standard or custom units for supports, anchors, inserts

and fasteners. Hot-dipped galvanized units shall comply with ASTM A153, Class B. G. Shop Primer : Baked-on shop primer compatible with respective specified finish paint and

complying with ANSI A224. H. Fasteners: Galvanized or cadmium plated steel.

1. Bolts and Nuts: ASTM A307, Grade A 2. Expansion Bolts: FS FF-S-325, Group III, expansion shield (self drilling tubular expansion

shell bolt anchors), Type 1 or 2. 3. Machine Screws: FS SS-S-92, carbon steel, Type III cross-recessed, design I or II recess,

style 2C flat head. I. Types of Doors:

1. Hollow Steel Doors.

2. Hollow Steel Doors of Acoustic Insulation of STC 45 and NIC of 35 for doors, frames,

hinges, retainers and covers on any of the Offices floors.

3. STC (60) and NIC of 50 for the car park doors frames, hinges, retainers and covers.

4. Fire rated Hollow Steel Doors with 2 hrs rating

5. Fire rated Hollow Steel Doors with 4 hrs rating

2.03 FABRICATION, GENERAL

A. Hollow metal work shall be of the design and dimensions indicated on the drawings. Sections and details shall be fabricated by skilled workmen in accordance with industry standards. Work shall be strong and rigid, neat in appearance and free from defects. Where coordination with adjoining work is necessary, field measurements shall be taken.

B. Form exposed surfaces free from warp, wave and buckle, with corners square unless otherwise

indicated. Members shall be set in proper alignment and relationship to adjoining work, with surfaces straight and in true plane. Mitered joints shall be well formed and in true alignment. Arises shall be straight and true.

C. Galvanizing: Provide galvanized hollow metal assemblies at the following locations:

1. Exterior openings.



2. Interior locations of high humidity or water exposure.

3. Interior rooms with floor drains or troughs.

D. Joints, corners and miters shall be accurately machined and fitted. Metal in contact shall have

hairline joints unless otherwise indicated on drawings. Joints shall be continuously welded to their full lengths and ground flush smooth and invisible on exposed surfaces.

E. Use of metallic fillers is prohibited. F. Fasteners shall be concealed where possible. Where indicated on the drawings or required,

exposed screws shall be flat head, countersunk, Phillips or Jackson head type. G. Welding of steel shall conform to the requirements of the Standard Code for Arc and Gas

Welding of the American Welding Society. Welding shall be of adequate strength and durability with joints tight, flush, smooth and clean where exposed.

H. Fire Rating: Where assemblies of doors and frames occur in openings scheduled to be labeled

or fire rated. provide Assembly of fire rated door, frame and hardware, where each element performs according to the NFPA 80 standards. labeled doors and frames shall be provided for those openings. Such doors and frames shall be constructed as tested and approved by Underwriters' Laboratories. Labels shall be left in place on doors and frames. If any door or frame specified to be fire-rated cannot qualify for appropriate labeling because of any reason, the Engineer shall be so advised before fabricating work on that item is started.

I. Finish Hardware: Prepare metal work to receive finish hardware including cutouts, reinforcing,

drilling and tapping in accordance with final Finish Hardware Schedule and templates provided by hardware supplier for the Project. Comply with applicable requirements of ANSI A115 "Specifications for Door and Frame Preparation for Hardware." Provide hardware with properties complying with the door performance.

2.04 HOLLOW METAL FRAMES

A. Hollow metal frames shall be of one piece fully welded construction of profiles, types, and sizes

as indicated. Provide frames constructed from the following gauges.

1. Interior Door Frames: 1.5 mm (16 gauge).

2. Interior Frames For Pairs Of Doors: 1.9 mm (14 gauge).

3. Exterior Door Frames: 1.9 mm (14 gauge).

4. Interior Frame 4 Feet Wide and Over: 1.9 mm (14 gauge). B. Floor anchors shall be 2.6 mm (12 gauge) steel welded inside each jamb with 2 anchor holes;

for 9.5 mm (3/8 inch) diameter fasteners. C. Jamb Anchors

1. For Masonry Construction: Welded adjustable, 1.5 mm (16 gauge) steel jamb anchors,



corrugated, with leg not less than 50.8 mm (2 inches) wide by 254 mm (10 inches) long. Furnish at least 3 anchors per jamb up to 2250 mm (7 ½ feet) height; 4 anchors up to 2400 mm (8 feet) jamb height; one additional anchor for each 600 mm (24 inches) or fraction thereof over 2400 mm (8 feet) height.

2. For Metal Stud Partitions: Furnish 1.5 mm (16 gauge) hat section anchors welded to back

of frames. Furnish at least 3 anchors per jamb up to 2250 mm (7 ½ feet) height, 4 anchors up to 2400 mm (8 feet) jamb height, one additional anchor for each 600 mm (24 inches) or fraction thereof, over 2400 mm (8 feet) height.

3. For Existing Concrete or Masonry: Anchor frame jambs with minimum 9.5 mm (3/8 inch)

concealed bolts into expansion shields or inserts at 150 mm (6 inches) from top and bottom and 660 mm (26 inches) on center. Reinforce frames at anchor locations with 1.5 mm (16 gauge) sheet steel stiffeners welded to frame at each hole.

D. Head Anchors and Reinforcing

1. For frames in steel stud walls, provide a minimum of 2 anchors at head of frames. 2. For frames over 1200 mm (4 feet) wide in masonry walls, provide continuous steel channel

or angle stiffener, not less than 2.6 mm (12 gauge) thickness, for full width of openings welded to back of frame at head. Reinforcing is not to act as lintel or load carrying members.

E. Provide removable spreader bar across bottom of frames, tack welded to jambs and mullions.

Remove spreaders after frames are enclosed and built into adjacent work. F. Drill stop to receive silencers on door frames. Install plugs to keep holes clear during

construction. G. Provide 0.60 mm (24 gauge) steel plaster guards or dustcover boxes, welded to frame, at back

of finish hardware cutouts where mortar or other materials might obstruct hardware installation. H. Borrowed light and or observation window frames shall meet specifications for door frames;

loose glazing stops shall be 0.85 mm (20 gauge) steel prepunched to receive countersunk zinc coated or cadmium plated Jackson head machine screws no greater than 227 mm (9 inches) on center. Corners of stops shall be mitered. Loose glazing stops to be installed after frame has been shop primed.

2.05 HOLLOW METAL DOORS AND PANELS

A. Fabricate doors in accordance with HMMA, AAMA and ANSI standards and specifications for

hollow metal doors and frames fabrication. B. Hollow metal doors and panels shall be seamless flush construction of profiles, types, and sizes

as indicated. Provide doors and panels constructed from the following gauges (thicknesses) prior to painting or galvanizing:

1. Interior Doors and Panels To 7 feet in Height: 1.2 mm (18 gauge).

2. Interior Doors and Panels Above 7 feet in Height: 1.5 mm (16 gauge).



3. Exterior Door s and Panels: 1.5 mm (16 gauge).

4. Interior Frame 4 Feet Wide and Over: 1.9 mm (16 gauge).

C. All doors shall have edges welded and finished flush. Do not expose seams or joints on door

faces or edges. Hollow Metal Doors shall be flush seamless and continuously welded. Tops of doors shall be flush construction.

D. Provide doors and panels 44.5 mm (1 ¾ inch) thick. E. Reinforce face sheets with 20 gage interlocking vertical C or Z shaped reinforcing members

spaced not over 150 mm (6 inches) apart and spot welded to face sheets not more than 150 mm (6 inches) on center. Provide flush inverted 1.5 mm (16 gage) steel channels welded to face sheets at top and bottom of door. Place filler between reinforcing members for full height of door. Provide removable moldings of 1.2 mm (18 gage) steel for glazed openings in doors applied with countersunk screws spaced not more than 300 mm (12 inches) on center.

F. Sound deadening and heat retarding materials shall be placed between the stiffeners and outer

sheets, and shall extend to the full extent of doors and panels. G. Vision Panels: Provide removable frames for glazing within hollow metal work. Frames shall

be of welded one piece construction, formed of not less than 1.2 mm (18 gauge) steel. Frames shall be removable from the room side (secure side) only.

H. Door Edges: Join door face sheets at vertical edges of door with continuous weld to full height

of door; grind, fill and dress welds smooth to provide invisible seam and smooth, flush surface. Reinforce door corners to prevent sagging or twisting of door. Close top and bottom edges of doors with continuous recessed steel channels, 1.5 mm (16 gauge) minimum, extending to full width of door and spot welded to both faces.

1. Provide concealed, sheltered, openings in bottom closure of exterior doors to permit

escape of entrapped moisture. 2. Provide additional flush closing channels continuously welded at top and bottom edges of

exterior doors, and interior doors which are indicated to be verminproof. I. Profile of Edges of Doors

1. Single Acting Swing Doors: Bevel both vertical edges 3.2 mm in 50.8 mm (1/8

inch in 2 inches).

2. Pairs of Single-Acting Swing Doors: Bevel hinge edge 3.2 mm in 50.8 mm (1/8

inch in 2 inches). Form integral center rabbet or edge rabbet, as approved by Engineer, at vertical meeting edges or surface mounted astragals as indicated on drawings.

3. Double-Acting Swing Doors: Round both vertical edges on 54 mm (2 1/8

inches) radius.

4. Special Profiles: As detailed on drawings. J. Door Clearances



1. Between doors and frame at jambs: 2.4 mm (3/32 inch) max. 2. Between doors and frame at head: 3.2 mm (1/8 inch). 3. At door sills where no threshold is used: 9.5 mm (3/8 inch) max. 4. Where threshold or carpeting is used: 6.4 mm (1/4 inch) maximum between bottom of door

and threshold or carpet. 5. Between meeting edges of pair of doors: 3.2 mm (1/8 inch) max.

K. Flatness: Doors shall maintain a flatness tolerance of 1.6 mm (1/16 inch) max. in any direction, including in a diagonal direction.

L. Door Louvers: Provide louvers with a minimum free area of 45 percent.

1. Fixed Louvers: Fixed door louvers of size and location indicated on the drawings shall be formed of 1.5 mm (16 gauge) steel 38.1 mm (1 ½ inch) thick and shall be completed with removable metal moldings on both sides. Frames shall be flush channel type with mitered and welded corners, ground smooth. Louver blades shall be inverted "V" type or lightproof where indicated and shall be straight, level, parallel and welded to frames, integral with and welded to door.

2.06 STEEL DOOR FRAMES AND PANELS

A. Fabricate steel door frames from structural shapes and bars of size and to dimensions indicated, fully welded together, with 15.9 mm by 38 mm (5/8 inch by 1 ½ inch) steel bar stops, unless otherwise indicated. Plug weld built-up members and continuously weld exposed joints. Secure removable stops to frame with countersunk machine screws, uniformly spaced at not more than 250 mm (10 inches) on centers. Reinforce frames and drill and tap as required to accept finish hardware.

B. Provide steel strap anchors for securing door frames into adjoining concrete or masonry, using

3.2 mm by 50 mm (1/8 inch by 2 inch) straps of the length required for minimum 200 mm (8 inch) embedment, unless otherwise indicated. Weld anchors to frame jambs no more than 300 mm (12 inches) from both bottom and head of frame and space anchors not more than 750 mm (30 inches) apart.

C. Extend bottom of frames to floor elevation indicated with steel angle clips welded to frames for

anchoring frame to floor with expansion shields and bolts. D. Galvanize exterior frames and anchors. E. Fire Doors; Fabricate all frames, leaves and panels including the required fire-rating, all

hardware, master key system etc. complete in all respects to the requirement and approval of the Engineer.

2.07 REINFORCEMENT FOR HARDWARE

A. Mortise, reinforce, drill and tap hollow metal work for hardware devices at the factory from fully



templated hardware, in accordance with approved hardware schedule including electric hardware devices wherever shown. Where surface mounted hardware is to be applied, hollow metal work shall have reinforcing only; drilling and tapping shall be done in the field by trade installing doors and finish hardware. Provide cutouts and reinforcing as required for security hardware and electrical work, including providing of related coverplates. Reinforcements shall be concealed.

B. Minimum thickness for hardware reinforcing shall be as follows:

1. For butts and pivot hinges: 4.8 mm (3/16 inch) steel plate, 31.8 mm by 254 mm (1 ¼ inch by 10 inches) minimum size.

2. For closers, overhead: 4.8 mm (3/16 inch) steel plate, on holders and stops both sides of

frame so closers, holders or stops can be applied to either side of frame. 3. For strikes: 2.6 mm (12 gauge) sheet steel. 4. For lock face, latch face and flush bolts: 2.6 mm (12 gauge) sheet steel (interior doors) 11

gauge sheet steel (exterior doors) Lock and latch reinforcement at least 38.1 mm by 75 mm (1 ½ inches by 3 inches).

5. Dust cover boxes, mortar guards and electric devices (at hardware mortises on frames to

be set in masonry or plaster): 0.60 mm (24 gauge) sheet steel. 6. For other surface-mounted hardware: 2.6 mm (12 gauge) sheet steel.

2.08 TRANSOMS, SIDELIGHTS AND GLAZED FRAMES

A. Form transoms, sidelights and glazed frames to the profiles shown. Provide anchors at jambs same as for door frames. Provide closed mullion sections same as for door frames. Fabricate from 1.6 mm (16 gage) steel for interior work and 1.9 mm (14 gage) galvanized steel for exterior work, unless otherwise required.

B. Miter, fit and weld corners of panel moldings for glass panels in sidelights and borrowed lights

to form continuous frame around panels. Provide non-removable panel moldings on the exterior. Secure removable moldings with not less than No. 6 x 32 Phillips oval-head countersunk machine screws at 300 mm (12 inches) on center.

C. Provide continuous felt strips cemented in place, on all bed and stop surfaces for interior light

frames to be glazed so that at no time does metal touch glass.

3.01 SHOP PAINTING

A. Metal surfaces shall be cleaned thoroughly of loose scale, shavings, filings, dirt, dust or other foreign materials by use of wire brushes or other effective means. Remove grease, oil and other deleterious materials which will impair the performance of the paint coating.

B. Bonderize metalwork exposed to view in finished work prior to shop painting. C. Hollow Metal Doors



1. Prior to fabrication, all concealed surfaces of hollow metalwork shall receive a shop painting with a rust inhibitive baked-on primer.

2. After fabrication, all exposed surfaces of hollow metal work shall receive shop application

treatment and paint as follows:

a. Primer: Baked.

b. Factory Finish: Thermosetting epoxy of color as selected. 3. The concealed surfaces of frames to be set in masonry walls shall additionally receive a

shop coating of bituminous paint. D. Touch-up marred and abraded surfaces of shop priming with paint as furnished by the hollow

metal work manufacturer, compatible with shop paint and subsequent finishing by others.

1. Touch-up galvanized finishes with zinc rich primer.

PART 3 EXECUTION 3.01 INSTALLATION

A. Set hollow metal frames at locations shown, in perfect alignment and elevation, plumb, level, straight, true and free from rack. Brace frames to prevent displacement.

B. Extend frame anchorages below fills and finishes, except over membrane waterproofed areas.

Anchor bottom of frames to floors with anchor bolts or with power driven fasteners. Coordinate the installation of built-in anchors for wall and partition construction as required with other work.

C. After wall construction has been completed, remove temporary braces. Leave surfaces smooth

and undamaged. D. Install labeled fire doors and frames to meet requirements of the Insurance Inspection and

Rating Bureaus having jurisdiction at the Project site so as to avoid any rate penalty. Correct any installation which would subject the Engineer to a rate penalty.

E. Apply hardware in accordance with hardware manufacturer's instructions and Section 08710

"Finish Hardware" of these Specifications. Drill and tap for machine screws as required. Do not use self-tapping sheet metal screws.

F. Anchor panels in place with concealed fasteners. Adjust door installation to provide an uniform

clearance at head and jambs, and to contact stops uniformly. Remove and replace doors which are found to be warped, bowed or otherwise damaged and cannot be properly fitted in frames.

3.02 INSTALLATION OF METAL FRAMES

A. Installation of Frames

1. Install frames in accordance with approved shop drawings, manufacturer's recommendations and as specified herein.



2. Steel frames shall be set in the correct locations in perfect alignment, plumb, straight and

true. Frames shall be substantially braced to prevent displacement until adjacent construction has been completed and anchors installed. Removable spreaders in frames shall not be removed until frame has been permanently anchored to floor and at jambs.

3. Setting Masonry Anchorage Devices

a. Provide masonry anchorage devices where required for securing hollow metal frames to cast-in-place concrete or masonry construction.

b. Set anchorage devices opposite each anchor location, in accordance with details on

final shop drawings and anchorage device manufacturer's instructions. Leave drilled holes rough, not reamed, and free from dust and debris.

c. At cast-in-place concrete or masonry construction, set frames and secure in place with

machine screws and masonry anchorage devices.

4. Place frames at fire-rated openings in accordance with NFPA Standard No. 80. 5. Make field splices in frames as detailed on final shop drawings, welded and finished to

match factory work.

3.03 DOORS AND HARDWARE

A. Installation of Doors and Hardware

1. Doors shall be fitted with the specified hardware, hung, and immediately before final completion of work, additional adjustments shall be made so that doors operate in perfect order.

2. Location of hardware on doors and frames shall be in accordance with applicable standard

of the National Association of Architectural Metal Manufacturers (NAAMM) and the Door Hardware Institute (DHI).

3. Doors shall be installed with the following clearances unless otherwise indicated on the

drawings:

a. Jambs 3.2 mm each side; 6.4 mm total (1/8 inch each side; 1/4 inch total). b. Head: 3.2 mm (1/8 inch). c. Meeting edges, pairs of doors: 3.2 mm each leaf; 6.4 mm total (1/8 inch each leaf; 1/4

inch total). d. Bottom: 9.5 mm (3/8 inch), where no threshold or carpet occurs. e. Bottom: At threshold or carpet, 3.2 mm (1/8 inch) above carpet or threshold. f. Place fire-rated doors with clearances as specified in NFPA Standard No. 80.



4. Install finishing hardware in accordance with manufacturer's written instructions. 5. Do not use shims without Engineer's approval. 6. Wrapping or other factory-applied protection furnished with finish hardware shall be left on

such hardware until final acceptance of the building by the Engineer. 7. Exposed surfaces shall be free of any tool marks, rust, or blemishes, and any damage to

exposed surfaces shall be repaired or replaced at the Contractor's expense and to the satisfaction of the Engineer and Engineer’s Representative.

8. Fasteners furnished with the hardware shall be used to secure the hardware in place for each type of substrate. Hardware shall be properly adjusted and checked out to ensure the hinges, locks, latches, bolts, holders and closers are in proper operational condition. Any errors in cutting and fitting, keying or any damage to adjoining work shall be repaired at no extra cost to the Owner.

9. Cut and fit threshold and floor covers to profile of door frames, with mitered corners and

hairline joints. Join units with concealed welds or concealed mechanical joints. Cut smooth openings for spindles, bolts and similar items, if any.

10. Keys used shall be construction keys which are to be tagged with fiber discs as approved,

clearly labeled with identifying inscriptions and then neatly arranged in a temporary cabinet. Construction keys shall be returned to the Engineer.

11. Adjusting and Cleaning: Adjust and check each operating item of hardware and each door,

to ensure proper operation or function of every unit. Lubricate moving parts with type lubrication recommended by manufacturer. Replace units which cannot be adjusted and lubricated to operate freely and smoothly as intended for the application made. Final adjustment of hardware is to be done after heating and ventilating has been balanced.

3.04 FIELD QUALITY CONTROL

A. Rejection: Hollow metal work which in the opinion of the Engineer is defective, shall be removed and replaced with new at no additional cost to the Owner. Rejection will additionally be considered for items including; hardware cutouts of improper size or location or which prevent proper installation of doors, hardware or work of other trades.

END OF DOCUMENT


Dar Al-Jazera Consultants III-2/08461 - 1 Automatic Sliding Door

SECTION 08461

AUTOMATIC SLIDING DOORS PART 1 - GENERAL

1.01 DESCRIPTION

A. This Section includes the following:

1. Aluminum Automatic Sliding doors, side entrance doors, frames including hood. 2. Complete operating system including electrical connections, motors, gears, limit switches,

chains, controls, remote sensors, etc. complete as per the recommendation of the Door manufacturer and to meet with the approval of the Engineer.

3. Adjacent sidelight and transom framing.

B. Related Sections: The following Sections contain requirements that relate to this Section: 1. Section 05500: Metal Fabrications. 2. Section 08710: Finish hardware 3. Section 08800: Glazing. 4. Section 16720: Fire Alarm System

1.02 RELATED DOCUMENTS A. Drawings and general provisions of Contract, including General and Supplementary Conditions

and Division 1 Specification Sections, apply to this Section.

1.03 DEFINITIONS A. Aluminum sliding doors consist of complete units fabricated, assembled, and tested for proper

operation at the factory. Each unit includes door wings, enclosure, hardware, weather-stripping, collapsing mechanism, speed control, and other components to manufacturer’s standard.

B. REFERENCES

1. Aluminum Association:

i. AA DAF-45 - Designation System for Aluminum Finishes.

2. American Architectural Manufacturers Association: i. AAMA 611 - Voluntary Specification for Anodized Architectural Aluminum. ii. AAMA 2603 - Voluntary Specification, Performance Requirements and Test

Procedures for Pigmented Organic Coatings on Aluminum Extrusions and Panels.



iii. AAMA 2604 - Voluntary specification, Performance Requirements and Test Procedures for High Performance Organic Coatings on Aluminum Extrusions and Panels.

iv. AAMA 2605 - Voluntary Specification, Performance Requirements and Test Procedures for Superior Performing Organic Coatings on Aluminum Extrusions and Panels.

3. American National Standards Institute:

i. ANSI A156.10 - Power Operated Pedestrian Doors. ii. ANSI A156.19 - Power Assist and Low Energy Power Operated Doors.

4. ASTM International: i. ASTM A36/A36M - Standard Specification for Carbon Structural Steel. ii. ASTM A123/A123M - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings

on Iron and Steel Products. iii. ASTM A924/A924M - Standard Specification for General Requirements for Steel

Sheet, Metallic-Coated by the Hot-Dip Process. iv. ASTM B209M - Standard Specification for Aluminum and Aluminum-Alloy Sheet and

Plate (Metric). v. ASTM B221M - Standard Specification for Aluminum and Aluminum-Alloy Extruded

Bars, Rods, Wire, Profiles, and Tubes (Metric).

C. National Electrical Manufacturers Association: i. NEMA MG 1 – Motors and Generators.

D. SSPC: The Society for Protective Coatings: i. SSPC Paint 20 - Zinc-Rich Primers (Type I - Inorganic and Type II - Organic). ii. SSPC Paint 25 - Red Iron Oxide, Zinc Oxide, Raw Linseed Oil, and Alkyd Primer.

E. Underwriters Laboratories Inc.: i. UL 325 - Door, Drapery, Gate, Louver, and Window Operators and Systems.

1.04 SYSTEM PERFORMANCE REQUIREMENTS

A. General: Provide automatic Sliding entrance Aluminum door assemblies that comply with

performance requirements specified, as demonstrated by testing the manufacturer's assemblies according to test methods indicated. 1. Air Infiltration: Sliding door assemblies shall limit air leakage to a rate not to exceed 6.4

litres per second per square metre of door area when tested in accordance with requirements of ASTM E 283 .

1.05 SUBMITTALS

A. General: Submit the following in accordance with Conditions of the Contract and Division 1

Specification Sections. B. Product data for each different Sliding door assembly, is required, including:

1. Manufacturer's standard details and fabrication methods.



2. Data on finishing, hardware, and accessories. 3. Recommendations for maintenance and cleaning of exterior surfaces.

C. Shop Drawings: Submit shop drawings for fabrication and installation of Sliding doors and associated components. Indicate enclosures, speed control units, and other components not included in manufacturer's product data. Include the following: 1. Layout and installation details, including relationship to adjacent work. 2. Elevations at 1/4 inch = 1 foot (1:50) scale. 3. Hardware, indicating mounting heights. 4. Detail sections of typical composite members. 5. Provisions for expansion and contraction. 6. Anchors and reinforcements. 7. Glazing details.

D. Samples for Initial Color Selection: Submit pairs of samples of each specified color and finish on 300 mm long sections of extrusions or formed shapes

E. Samples for Verification Purposes: The Engineer reserves the right to require additional

samples that show fabrication techniques and workmanship, and design of hardware and accessories.

F. Maintenance Instructions: Submit manufacturer's maintenance and service instructions for

adjustment, operation, and maintenance including name, address, and telephone number of the nearest service representative. Include instructions for maintenance of metal finishes.

G. Test Reports: Provide certified test reports from a qualified independent testing laboratory

showing that the Sliding door assembly has been tested in accordance with specified test procedures and complies with performance characteristics indicated.


A. Installer’s Qualifications: For installation of the automatic sliding entrance door assemblies,

engage an experienced Installer who is an authorized representative of the manufacturer for the installation and maintenance of the type of units required for this Project. 1. Maintenance Proximity: The Installer shall maintain offices and repair or service facilities

not more than 2 hours normal travel time from the Project site.

B. Manufacturer's Qualifications: Provide automatic sliding entrance door assemblies produced by a firm experienced in manufacturing systems that are similar to those indicated for this Project and that have a record of successful in-service performance.



C. Safety Glazing Standard: Where safety glass is indicated or required by authorities having

jurisdiction, provide the type of products indicated that comply with ANSI Z97.1 and testing requirements of 16 CFR Part 1201 for category II materials. 1. Subject to compliance with requirements, provide safety glass permanently marked with a

certification label of the Safety Glazing Certification Council (SGCC) or other certification agency acceptable to authorities having jurisdiction.

D. Design Concept: The drawings shall indicate the size, profile and dimensional requirements of

the sliding door assemblies required and are based on the specific types and models indicated. Door assemblies by other manufacturers may be considered provided deviations in dimensions and profiles are minor and do not change the design concept as judged by the Engineer. The burden of proof of equality is on the Contractor.

E. Emergency Exits: Automatic sliding doors serving as a required means of egress shall comply

with requirements of authorities having jurisdiction. Provide manufacturer's certification that doors comply with these requirements.

F. Control: Electric control unit of modular design. Opening & closing speeds independently

adjustable between 20 & 60 cm per second per leaf. Self-diagnosis test routines for microprocessor control, locking & emergency opening models.

G. Safety System: Self controlling & self monitoring of door leaf movements of cling force. On

power failure, the door opens automatically unless locked. H. Activators : In entry / exit direction, special radar movements detector shall be installed.

1.07 DELIVERY, STORAGE, AND HANDLING A. Deliver Automatic sliding doors and related components to the Project in manufacturer's

original, unopened protective packaging. Use padded blankets or other approved protective wrapping for glass, decorative metal work, and other exposed elements. 1. Do not deliver door units until Work is ready for their installation. 2. Inspect components for damage upon delivery. Unless minor defects can be repaired to

the Engineer's satisfaction, remove and replace damaged components at no additional cost to the Owner.

B. Storage: If temporary storage is necessary, store doors and related components inside the

building in a dry protected area apart from construction traffic in their original shipping containers with protective wrapping or packaging securely in place.

C. Protect finish surfaces from damage during handling and installation.

1.08 PROJECT CONDITIONS A. Field Measurements: Check openings by accurate field measurement before fabrication.

Show recorded measurements on shop drawings. Coordinate fabrication schedule with



construction progress to avoid delay of the Work. 1. Where necessary, proceed with fabrication without field measurements, and coordinate

fabrication tolerances to ensure proper fit.

PART 2 - PRODUCTS 2.01 MANUFACTURERS

A. Automatic Sliding doors manufactured by one of the following:

1. Dorma Automatics, Inc. 375 Prince George’s Boulevard Upper Marlboro, MD 20774 Tel: 301 390 3600 Fax: 301 390 5515

2. NABCO Entrances, Inc. S82 W 18717 Gimini Drive Muskego, WI 53150

3. KM Systems Inc. P.O.Box 3099, 4910 Starerest Drive (28110) Monroe, NC 28111-3099

4. Substitutions under provisions of Section 01630

2.02 MATERIALS A. Extruded Aluminum ASTM B221M; 6063 alloy, T5 temper typical, 6061 alloy, T6 temper for

extruded structural members. B. Sheet Aluminum: ASTM B209M, 5005 alloy, H15 or H34 temper. C. Glass and Glazing Materials: Glass and glazing materials shall comply with requirements of

the Section 08800: “Glazing” of these specifications. 1. Tempered Glass: Provide tempered glass in thicknesses as per Section 08800-Glazing

indicated in drawings. Comply with requirements of ASTM C 1048 , kind FT (fully tempered), condition A (uncoated surfaces), Type I (transparent), class and thickness, as indicated.

a. Wings and side entrance doors: Provide the same thickness of

the main door panels.

D. Weather-stripping: Provide heavy duty, single-piece rubber and rubber-felt combinations.

2.03 EQUIPMENT A. Speed Control: Provide mechanical speed regulator allowing free rotation of wings up to a



predetermined rate of speed not exceeding 12 rpm. 1. Location: Provide overhead speed control unit.

B. Threshold Sensor Microprocessor: 1. Completely electro mechanical safety beams, threshold sensor microprocessor control box

C. Hardware: Provide manufacturer's UL listed mortised locks to receive cylinders, finished to match doors. Provide mortised locks in bottom rails of wings with deadbolts to dustproof floor strikes. Include the lock cylinders and keys in the master key system.

D. Ceiling Lights: Provide manufacturer's standard ceiling lights consisting of 2 recessed light

fixtures within the sliding door enclosure ceiling, complete with lamps and translucent lens. E. Adjustable safety reversing system: Provide UL listed swing out hinged cover, adjust the door

to swing open automatically when fire alarm triggers.

2.04 FABRICATION A. Fabricate sliding door units to sizes and configurations indicated. Carefully cut and fit all

components. 1. Weld reinforcing firmly in place. Weld corners. Grind and polish welds to produce an

invisible joint. Mechanically finish exposed surfaces after fabrication to eliminate surface blemishes caused by welding, rolling, bending, and forming.

2. Joints shall be tightly bolted together to produce hairline joints. Finish material prior to

fabrication. Take care in assembly to prevent welds or adhesives from blemishing finished surfaces. Glass stops shall be snap-in type where possible.

a. Screws, and other fastenings, when required, shall be equally spaced, countersunk, and

finished to match the adjacent work. 3. Provide reinforcement for hardware and operating mechanism necessary to meet

performance requirements and to withstand operating stresses without metal or glass failure.

4. Install weather-stripping in stiles, head and sill rails to be adjustable and replaceable

without dismantling wings.

B. Dissimilar Metals: Separate dissimilar metals with bituminous paint or other separator that will prevent corrosion.

C. Fasteners: Conceal fasteners wherever possible. Countersink heads of exposed fasteners.

2.05 METAL FINISHES

A. General: Comply with NAAMM "Metal Finishes Manual" for recommendations relative to

application and designations of finishes.



B. Finish designations prefixed by "AA" conform to the system established by the Aluminum

Association for designating aluminum finishes. C. High-Performance Organic Coating for Aluminum: AA-C12C42R1x (Chemical Finish: cleaned

with inhibited chemicals; Chemical Finish: chemical conversion coating, acid chromate-fluoride-phosphate pretreatment; Organic Coating: as specified below). Prepare, pretreat, and apply coating to exposed metal surfaces to comply with coating and resin manufacturer's instructions. 1. Fluorocarbon Three-Coat Coating System: Manufacturer's standard three-coat, thermo-

cured system composed of specially formulated inhibitive primer, fluorocarbon color coat, and clear fluorocarbon topcoat with both color coat and clear topcoat containing not less than 70 percent polyvinylidene fluoride resin by weight; comply with AAMA 605.2.

2. Color and Gloss: Match sample.

D. Stainless Steel Accessories: Provide hair line finish unless otherwise indicated in drawings.

PART 3 - EXECUTION 3.01 PREPARATION

A. Templates and Diagrams: Furnish installation templates, diagrams, and other data to

fabricators and installers of related work as necessary for coordination of the installation.

3.02 INSTALLATION A. Install automatic sliding doors in accordance with manufacturer's printed instructions and

recommendations. B. Cut and trim framing during installation only with approval of the manufacturer and in

accordance with manufacturer's recommendations. 1. Restore finish and remove and replace members as directed where cutting and trimming

has impaired strength or appearance. 2. Do not install members that are warped, bowed, deformed, or otherwise damaged or

defaced to such extent as to impair strength or appearance. Remove and replace members as directed that have been damaged during installation at no additional cost to the Owner.

C. Set units level, plumb, and true to line with uniform hairline joints. Support on metal shim and

secure in place by bolting to clip angles and supports anchored to supporting structure. D. Paint concealed contact surfaces of dissimilar materials, including metal in contact with

masonry or concrete work, with a heavy coating of bituminous paint, or provide other separation as recommended by manufacturer.



3.03 ADJUSTING A. Adjust doors to provide a tight fit at contact points and weather-stripping for smooth operation

and weathertight closure and to operate smoothly with hardware and operators functioning properly. 1. Lubricate hardware and other moving parts.

3.04 CLEANING A. Clean metal surfaces promptly after installation, exercising care to avoid damage to coatings. B. Clean glass surfaces after installation complying with requirements contained in the "Glazing"

Section 08800 for cleaning and maintenance. Remove excess glazing and sealant compounds, dirt, and other substances. 1. Follow the recommendations of the automatic sliding door manufacturer in selection of

cleaning agents. Do not use cleaning agents containing ammonia or other compounds that might damage finished metal surfaces.

3.05 PROTECTION

A. Institute protective measures required throughout the remainder of the construction period to

ensure that automatic sliding door units will be without damage or deterioration, other than normal weathering, at time of substantial completion and handing over of the work.

END OF SECTION


Dar Al-Jazera Consultants III-2/08331 - 1 Overhead Coiling Doors

SECTION 08331

OVERHEAD COILING DOORS PART 1 - GENERAL 1.01 DESCRIPTION

A. Drawings and general provisions of the Contract, including General and Particular conditions

and Division 1 Specifications, apply to this Section. B. The work included in the section comprises furnishing all plant, labour, equipment, appliances

and materials and performing all operations in connection with Overhead coiling Door work in accordance with the requirements of the Contract Documents.

C. Provide Insulated Overhead Coiling Doors at the park exit in accordance with the requirements

of the Drawings, Bills of Quantities and to the Engineers approval. D. Work Included: The work of this section shall include, but not be limited to, the following:

1. Overhead coiling doors including controls, equipment, jamb guides, hood, operating

hardware and accessories. 2. Brackets, fasteners, inserts and accessories required to install panel support the work of

this section.

1.02 QUALITY ASSURANCE A. Materials and labor shall conform to the latest edition of referenced standards specified herein

and to applicable codes and requirements of local authorities having jurisdiction, whichever are more stringent.

B. Provide coiling doors as a complete unit produced by one manufacturer, including hardware,

accessories, mounting and installation components.

1.03 SUBMITTALS A. Product Data: Submit manufacturer's latest printed literature. Include roughing-in diagrams,

installation instructions, wiring diagrams installation and operating instructions, maintenance information and electrical equipment data. Furnish Underwriters Laboratories Inc. (UL) approvals for all electrical devices.

B. Shop Drawings: Submit Shop Drawings indicating details of all conditions, sizes, arrangement

of parts, adjacent construction, materials and all other pertinent data. C. Samples: Submit samples of exposed materials (including guide rails and curtain) showing

finishes for approval and obtain approval prior to delivery of materials.




A. Adequately protect and crate components against damage, dirt, disfigurement and weather. Deliver doors with installation instructions.

B. Store materials and equipment where designated. Contractor shall assume responsibility and

security for materials and equipment. Protect during storage from detrimental conditions. C. Protect the materials of this section after installation and protect installed work and materials of

other trades. D. Replacements: In the event of damage, immediately make repairs and replacements

necessary to the approval of the Engineer at no additional cost to the Engineer.

1.05 WARRANTY: A. Section 01700 – Contract Closeout Requirements for warranties.

B. Furnish five year manufacturer’s warranty on materials, Specification, performance and

workmanship.

C. Furnish five year manufacturer’s warranty for insulated glass units from seal failure, interpane dusting or misting, including replacement.

1.06 PERFORMANCE CRITERIA

A. Design, fabricate and install exterior overhead coiling door assemblies to withstand the inward

and outward wind pressure of 146 kg/m2

(30 psf) normal to the plane of the door.

B. Design, fabricate and install curtains, hoods and related sheet metal components to withstand the specified loads with a maximum deflection of Span/120, without permanent deflection or deformation.

C. Provide wind locks on all exterior doors. D. Provide safety automatic reversing edge guards on all door bottoms.

PART 2 - PRODUCTS 2.01 MANUFACTURERS

A. Provide doors manufactured by a single manufacturer for the entire Project. The Following are

the acceptable manufacturers for the work specified in this section:

1. Wayne Dalton Corporation, USA P.O.Box 67 Mt. Hope, OH 44660 Phone: + 1 (216) 674-7015

2. Bostwick Doors U.K. Ltd. Stockport, Cheshire, SK4 3ED, England



Tel: 061 442 7227 Fax: 061 431 6406

3. Substitutions under provisions of Section 01630

2.02 MATERIALS, GENERAL A. Steel Sheet Metal: Commercial grade conforming to ASTM A446 with galvanized zinc coating

to ASTM A525 designation G90, unpassivated or phosphate treated before fabrication. B. Miscellaneous Steel Shapes: Commercial grade to ASTM A386 or A123, G90 class coating. C. Weather-stripping: Manufacturer's standard neoprene, vinyl or natural rubber designated for

conditions. D. Paint for priming and touchup of galvanized surfaces shall be a epoxy zinc-rich primer No.

90-97 Tneme-Zinc by Tnemec Co., Inc. or approved equal. E. Inserts and Anchorages: Furnish inserts and anchoring devices for setting in concrete or

building into masonry for the installation of the units.

2.03 FABRICATION, GENERAL A. Work shall be of the design, gauge, dimensions and location indicated on the Drawings. Work

and finishes shall be first class in every particular and in accordance with trade practice. B. Members shall be carefully ma8+chined and fitted and shall be assembled by means of spot or

arc welding. Structural supports, hangers and built-in reinforcement wholly concealed within the finished assemblies shall be as indicated or required.

C. Fabricate the work true to dimensions and square. Accurately fit joints and intersecting

members with screws or bolts of proper size and approved spacing. D. Fabricate finished work free from distortion and defects detrimental to appearance and

performance. E. File or grind exposed welds smooth and flush. Do not leave grinding marks. F. Shop Painting

1. Shop clean and prime ferrous metal and galvanized surfaces, exposed and unexposed,

except lubricated surfaces, with door manufacturer's standard rust-inhibitive primer drying to a flat sheen.

2. Painting shall be done in dry weather or under cover, and steel or iron surfaces shall be

free from moisture or frost. No materials shall be delivered until the shop coat has dried. 3. Ferrous Metal: Prepare surfaces in accordance with Steel Structures Painting Manual

Volume 2, SSPC-SP2 - Hand Tool Cleaning and SSPC-SP3 - Power Tool Cleaning as recommended by approved door manufacturer.



4. Galvanized Metal: Prepare surfaces in accordance with Steel Structures Painting Manual,

Volume 2, SSPC-SP1 Solvent Cleaning. 5. Metal surfaces, except galvanized steel, shall be given a shop coat of manufacturer's

recommended paint. 6. Surfaces which will be concealed in the finished construction or will not be accessible to

finish painting shall receive an additional shop coat of the specified paint to which a small amount of tinting has been added for color differentiation. Touch-up marred and abraded surfaces with the specified paint after erection in the field.

7. Repaint areas of shop coat damaged during handling or installation with paint similar to

that applied in the shop.

2.04 INSULATED OVERHEAD DOORS A. Door Curtains: Fabricate rolling door curtain of flat faced interlocking slats of continuous length

for the width of the door without splices. Unless otherwise indicated, provide slats of the material gauge recommended by the door manufacturer for the opening size and performance criteria indicated.: 1. Galvanized Steel Door Curtain Slats: Structural quality, 0.85 mm (20 gauge) cold-rolled

galvanized steel sheets complying with ASTM A446, Grade A with G90 zinc coating complying with ASTM A525, and treated before fabrication. a. Formed of insulated interlocking flat slats, "No. 6 Insulated" design, galvanized sheet

steel. b. Provide each slat with malleable iron end locks and wind locks designed to engage the

guide safety internal angle and so as to withstand specified minimum wind pressure. c. Provide pressure foamed-in-place urethane insulation between exterior and interior

slats to provide curtain with a "U" factor of 0.16 and an "R" value of 6.2 d. Equip each curtain with bottom bar of two galvanized steel angles not less than 38 mm

by 38 mm by 3.2 mm (1 ½ inches by 1 ½ inches by P

1P/R8R inch), securely fastened to the

bottom of the curtain for reinforcement and an approved continuous safety bottom edge.

e. Endlocks: Provide malleable iron castings galvanized after fabrication, secured to

curtain slats with galvanized rivets. Provide locks on alternate curtain slats for curtain alignment and resistance against lateral movement

B. Curtain Jamb Guides

1. Fabricate curtain jamb guides of galvanized steel angles, or channels and angles with

sufficient depth and strength to retain the curtain loading. Build up units with minimum 4.8 mm (3/16 inch) thick steel sections, galvanized after fabrication. Slot bolt holes for track adjustment.



2. Secure continuous wall angle to wall framing by 4.8 mm (3/16 inch) minimum bolts at not

more than 762 mm (30 inches) on center, unless increased anchorage is required to sustain loads. Extend wall angles above door opening head to support coil brackets, unless otherwise shown. Place anchor bolts on wall guides so that they are concealed when door is in closed position. Provide removable stops on guides to prevent over-travel of curtain.

3. Provide weather stripping full length of curtain jamb guides.

C. Counterbalancing Mechanism: Counterbalance doors by means of an adjustable steel helical torsion spring, mounted around a steel shaft and mounted in a spring barrel and connected to the door curtain with the required barrel rings. Use grease-sealed bearings or self-lubricating graphite bearings for rotating members. 1. Counterbalance Barrel: Fabricate spring barrel of hot-formed structural quality carbon

steel, welded or seamless pipe, of sufficient diameter and wall thickness to support the rollup of curtain without distortion of slats and limit barrel deflection to not more than 0.76 mm per 300 mm (0.03 inch per foot) of span under full load.

2. Provide spring balance of one or more oil-tempered, heat-treated steel helical torsion

springs. Size springs to counterbalance the weight of the curtain, with an uniform adjustment accessible from outside barrel. Provide cast steel barrel plugs to secure ends of springs to the barrel and the shaft.

3. Fabricate torsion rod for counterbalance shaft of case-hardened steel, of required size to

hold the fixed spring ends and carry the torsional load.

D. Brackets: Provide mounting brackets of manufacturer's standard design, either cast iron or cold-rolled steel plate with bell mouth guide groove for curtain.

E. Hoods: Enclosed coiled curtain and operating mechanism at opening head shall act as a

weather seal. Contour to suit end brackets to which hood is attached. Roll and reinforce top and bottom edges for stiffness. Provide closed ends for surface-mounted hoods and any portion of between-jamb mounting projecting beyond wall face. Provide intermediate support brackets as required to prevent sag. 1. Provide hoods of the same material and finish as curtains.

F. Operation 1. Furnish electric door operator assembly of the size and capacity recommended and

provided by the door manufacturer; including electric motor and factory-prewired motor controls, starter, gear reductions unit, solenoid operated brake, clutch, remote control stations control devices, conduit and wiring from controls to motor and central stations, and accessories required for proper operation. Starter shall be combination unfused disconnect and reversing starter with fused control transformer for operation of controls at not more than 120 volts and NEMA 1 enclosure.

a. Provide a hand-operated disconnect or a mechanism for automatically engaging a



sprocket and chain operator and releasing brake for emergency manual operation. Mount disconnect and operator so that they are accessible from floor level. Include an interlock device to automatically prevent the motor from operating when emergency operator is engaged.

b. Design operator so that motor may be removed without disturbing the limit-switch

adjustment and without affecting the emergency auxiliary operator.

2. Door Operator Type: Provide wall or bracket-mounted door operator units as required consisting of an electric motor, a worm gear drive from motor to reduction box to a gear wheel mounted on the counterbalance shaft, and a quick-clutch disconnect-release for manual operation. Provide motor, clutch and drive assembly of horsepower and design as determined by the door manufacturer for the size of door required and as herein specified.

3. Electric Motors: Provide high-starting torque, reversible, constant duty, Class A insulated

electric motors with overload protection, sized to move door in either direction, from any position, at not less than 200 mm (2/3 foot) nor more than 300 mm (1 foot) per second. Motor shall be not less than 1/2 hp (horse-power) and shall be rated 460 volts, three phase, 60 Hz (hertz). Furnish open-dripproof type (NEMA Type 1), unless otherwise indicated.

4. Remote Control Station: Unless otherwise shown, provide momentary- contact, 3-button

control station with push button controls labeled "open", "close" and "stop". "Open" and "close" buttons shall require sustained pressure for operation. Provide interior units, full-guarded type, surface-mounted, heavy duty, with dustproof enclosure unless otherwise indicated.

5. Automatic Reversing Control: Furnish each door with an automatic safety switch,

extending full width of door bottom and located within a U-shaped neoprene or rubber astragal mounted to the bottom door rail. Contact with switch before fully closing will immediately stop the downward travel and reverse direction to the fully opened position. Connect to the control circuit through a retracting safety cord and reel.

PART 3 - EXECUTION 3.01 EXAMINATION

A. Examine conditions at the job site where work of this section is to be performed to insure

proper arrangement and fit of the work. Start of work implies acceptance of job site conditions.

3.02 PREPARATION A. Examine the Contract Drawings and Specifications in order to insure the completeness of the

work required under this Section. B. Verify measurements and dimensions at the job site and cooperate in the coordination and

scheduling of the work of this Section with the work of related trades, with particular attention given to the installation of items embedded in concrete or built into masonry so as not to delay job progress.



3.03 INSTALLATION

A. Install door and operating equipment including necessary hardware, jamb and head mold

strips, anchors, inserts, hangers and equipment supports in accordance with final shop drawings, manufacturer's instructions and as specified herein.

B. Metal work built-in with concrete or masonry shall be formed for anchorage, or be provided with

suitable anchors, expansion shields or anchoring device indicated on drawings. Such metal work shall be furnished in ample time for setting and securing in place.

C. Upon complete installation, lubricate, test and adjust doors to operate easily, free from warp,

twist or distortion. Doors shall fit weathertight for the entire perimeter.

3.04 ADJUST AND CLEAN A. Upon completion, clean exposed surfaces and leave them in a condition entirely satisfactory to

the Engineer’s Representative and the Engineer. B. Demonstrate operation of overhead doors to the Engineer’s designated staff and perform

required adjustments. Review maintenance items and service procedures. END OF SECTION