055000-Metal_Fabrication.pdf

Batavia VAMC Contract #36C24219C0228

Improve Ground Water, Building 30 Project #528A4-18-203

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SECTION 05 50 00

METAL FABRICATIONS

PART 1 - GENERAL

1.1 DESCRIPTION

A. This section specifies items and assemblies fabricated from structural steel shapes and other materials as shown and specified.

B. Items specified.

1. Covers and Frames

2. Ladders

1.2 RELATED WORK (NOT USED)

1.3 SUBMITTALS

A. Submit in accordance with Section 01 33 23, SHOP DRAWINGS, PRODUCT

DATA, AND SAMPLES.

B. Manufacturer's Literature and Data:

Grating, each type Floor plate

Manhole Covers Ladder Steps

C. Shop Drawings:

1. Each item specified, showing complete detail, location in the project, material and size of components, method of joining various components and assemblies, finish, and location, size and type of anchors.

2. Mark items requiring field assembly for erection identification and furnish erection drawings and instructions.

3. Provide templates and rough-in measurements as required.

D. Manufacturer's Certificates:

1. Anodized finish as specified.

2. Live load designs as specified.

E. Design Calculations for specified live loads including dead loads.

F. Furnish setting drawings and instructions for installation of anchors to be preset into concrete and masonry work, and for the positioning of items having anchors to be built into concrete or masonry construction.

1.4 QUALITY ASSURANCE

A. Each manufactured product shall meet, as a minimum, the requirements specified, and shall be a standard commercial product of a manufacturer regularly presently manufacturing items of type specified.

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B. Each product type shall be the same and be made by the same manufacturer.

C. Assembled product to the greatest extent possible before delivery to the site.

D. Include additional features, which are not specifically prohibited by this specification, but which are a part of the manufacturer's standard commercial product.

1.5 APPLICABLE PUBLICATIONS

A. The publications listed below form a part of this specification to the extent referenced. The publications are referenced in the text by the basic designation only.

B. American Society of Mechanical Engineers (ASME):

B18.6.1-97..............Wood Screws

B18.2.2-87(R2010).......Square and Hex Nuts

C. American Society for Testing and Materials (ASTM):

A36/A36M-14.............Structural Steel

A47-99(R2014)...........Malleable Iron Castings

A48-03(R2012)...........Gray Iron Castings

A53-12..................Pipe, Steel, Black and Hot-Dipped, Zinc-Coated

Welded and Seamless

A123-15.................Zinc (Hot-Dip Galvanized) Coatings on Iron and

Steel Products

A240/A240M-15...........Standard Specification for Chromium and

Chromium-Nickel Stainless Steel Plate, Sheet and Strip for Pressure Vessels and for General

Applications.

A269-15.................Seamless and Welded Austenitic Stainless Steel

Tubing for General Service

A307-14.................Carbon Steel Bolts and Studs, 60,000 PSI

Tensile Strength

A391/A391M-07(R2015)....Grade 80 Alloy Steel Chain

A786/A786M-15...........Rolled Steel Floor Plate

B221-14.................Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Shapes, and Tubes

B456-11.................Electrodeposited Coatings of Copper Plus Nickel

Plus Chromium and Nickel Plus Chromium

B632-08.................Aluminum-Alloy Rolled Tread Plate

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C1107-13................Packaged Dry, Hydraulic-Cement Grout

(Nonshrink)

D3656-13................Insect Screening and Louver Cloth Woven from

Vinyl-Coated Glass Yarns

F436-16.................Hardened Steel Washers

F468-06(R2015)..........Nonferrous Bolts, Hex Cap Screws, Socket Head

Cap Screws and Studs for General Use

F593-13.................Stainless Steel Bolts, Hex Cap Screws, and

Studs

F1667-15................Driven Fasteners: Nails, Spikes and Staples

D. American Welding Society (AWS):

D1.1-15.................Structural Welding Code Steel

D1.2-14.................Structural Welding Code Aluminum

D1.3-18.................Structural Welding Code Sheet Steel

E. National Association of Architectural Metal Manufacturers (NAAMM)

AMP 521-01(R2012).......Pipe Railing Manual

AMP 500-06..............Metal Finishes Manual

MBG 531-09(R2017).......Metal Bar Grating Manual

MBG 532-09..............Heavy Duty Metal Bar Grating Manual

F. Structural Steel Painting Council (SSPC)/Society of Protective

Coatings:

SP 1-15.................No. 1, Solvent Cleaning

SP 2-04.................No. 2, Hand Tool Cleaning

SP 3-04.................No. 3, Power Tool Cleaning

G. Federal Specifications (Fed. Spec):

RR-T-650E...............Treads, Metallic and Nonmetallic, Nonskid

PART 2 - PRODUCTS

2.1 DESIGN CRITERIA

A. In addition to the dead loads, design fabrications to support the following live loads unless otherwise specified.

B. Ladders and Rungs: 120 kg (250 pounds) at any point.

C. Manhole Covers: 1200 kg/m2 (250 pounds per square foot).

2.2 MATERIALS

A. Structural Steel: ASTM A36.

B. Stainless Steel: ASTM A240, Type 302 or 304.

C. Aluminum, Extruded: ASTM B221, Alloy 6063-T5 unless otherwise specified. For structural shapes use alloy 6061-T6 and alloy 6061-

T4511.

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D. Floor Plate:

1. Steel ASTM A786.

2. Aluminum: ASTM B632.

E. Cast-Iron: ASTM A48, Class 30, commercial pattern.

F. Malleable Iron Castings: A47.

G. Grout: ASTM C1107, pourable type.

H. Insect Screening: ASTM D3656.

2.3 HARDWARE

A. Rough Hardware:

1. Furnish rough hardware with a standard plating, applied after punching, forming and assembly of parts; galvanized, cadmium plated, or zinc-coated by electro-galvanizing process. Galvanized G-90 where specified.

2. Use G90 galvanized coating on ferrous metal for exterior work unless non-ferrous metal or stainless is used.

B. Fasteners:

1. Bolts with Nuts:

a. ASME B18.2.2.

b. ASTM A307 for 415 MPa (60,000 psi) tensile strength bolts.

c. ASTM F468 for nonferrous bolts.

d. ASTM F593 for stainless steel.

2. Screws: ASME B18.6.1.

3. Washers: ASTM F436, type to suit material and anchorage.

4. Nails: ASTM F1667, Type I, style 6 or 14 for finish work.

2.4 FABRICATION GENERAL

A. Material

1. Use material as specified. Use material of commercial quality and suitable for intended purpose for material that is not named or its standard of quality not specified.

2. Use material free of defects which could affect the appearance or service ability of the finished product.

B. Size:

1. Size and thickness of members as shown.

2. When size and thickness is not specified or shown for an individual part, use size and thickness not less than that used for the same component on similar standard commercial items or in accordance with established shop methods.

C. Connections:

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1. Except as otherwise specified, connections may be made by welding, riveting or bolting.

2. Field riveting will not be approved.

3. Design size, number and placement of fasteners, to develop a joint strength of not less than the design value.

4. Holes, for rivets and bolts: Accurately punched or drilled and burrs removed.

5. Size and shape welds to develop the full design strength of the parts connected by welds and to transmit imposed stresses without permanent deformation or failure when subject to service loadings.

6. Use Rivets and bolts of material selected to prevent corrosion

(electrolysis) at bimetallic contacts. Plated or coated material will not be approved.

7. Use stainless steel connectors for removable members machine screws or bolts.

D. Fasteners and Anchors:

1. Use methods for fastening or anchoring metal fabrications to building construction as shown or specified.

2. Where fasteners and anchors are not shown, design the type, size, location and spacing to resist the loads imposed without deformation of the members or causing failure of the anchor or fastener, and suit the sequence of installation.

3. Use material and finish of the fasteners compatible with the kinds of materials which are fastened together and their location in the finished work.

4. Fasteners for securing metal fabrications to new construction only, may be by use of threaded or wedge type inserts or by anchors for welding to the metal fabrication for installation before the concrete is placed or as masonry is laid.

5. Fasteners for securing metal fabrication to existing construction or new construction may be expansion bolts, toggle bolts, power actuated drive pins, welding, self drilling and tapping screws or bolts.

E. Workmanship

1. General:

a. Fabricate items to design shown.

b. Furnish members in longest lengths commercially available within the limits shown and specified.

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c. Fabricate straight, true, free from warp and twist, and where applicable square and in same plane.

d. Provide holes, sinkages and reinforcement shown and required for fasteners and anchorage items.

e. Provide openings, cut-outs, and tapped holes for attachment and clearances required for work of other trades.

f. Prepare members for the installation and fitting of hardware.

g. Cut openings in gratings and floor plates for the passage of ducts, sumps, pipes, conduits and similar items. Provide reinforcement to support cut edges.

h. Fabricate surfaces and edges free from sharp edges, burrs and projections which may cause injury.

2. Welding:

a. Weld in accordance with AWS.

b. Welds shall show good fusion, be free from cracks and porosity and accomplish secure and rigid joints in proper alignment.

c. Where exposed in the finished work, continuous weld for the full length of the members joined and have depressed areas filled and protruding welds finished smooth and flush with adjacent surfaces.

d. Finish welded joints to match finish of adjacent surface.

3. Joining:

a. Miter or butt members at corners.

b. Where frames members are butted at corners, cut leg of frame member perpendicular to surface, as required for clearance.

4. Anchors:

a. Where metal fabrications are shown to be preset in concrete, weld

32 x 3 mm (1-1/4 by 1/8 inch) steel strap anchors, 150 mm (6 inches) long with 25 mm (one inch) hooked end, to back of member at 600 mm (2 feet) on center, unless otherwise shown.

b. Where metal fabrications are shown to be built into masonry use

32 x 3 mm (1-1/4 by 1/8 inch) steel strap anchors, 250 mm (10 inches) long with 50 mm (2 inch) hooked end, welded to back of member at 600 mm (2 feet) on center, unless otherwise shown.

5. Cutting and Fitting:

a. Accurately cut, machine and fit joints, corners, copes, and miters.

b. Fit removable members to be easily removed.

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c. Design and construct field connections in the most practical place for appearance and ease of installation.

d. Fit pieces together as required.

e. Fabricate connections for ease of assembly and disassembly without use of special tools.

f. Joints firm when assembled.

g. Conceal joining, fitting and welding on exposed work as far as practical.

h. Do not show rivets and screws prominently on the exposed face.

i. The fit of components and the alignment of holes shall eliminate the need to modify component or to use exceptional force in the assembly of item and eliminate the need to use other than common tools.

F. Finish:

1. Finish exposed surfaces in accordance with NAAMM AMP 500 Metal

Finishes Manual.

2. Aluminum: NAAMM AMP 501.

a. Mill finish, AA-M10, as fabricated, use unless specified otherwise.

b. Clear anodic coating, AA-C22A41, chemically etched medium matte, with Architectural Class 1, 0.7 mils or thicker.

c. Colored anodic coating, AA-C22A42, chemically etched medium matte with Architectural Class 1, 0.7 mils or thicker.

d. Painted: AA-C22R10.

3. Steel and Iron: NAAMM AMP 504.

a. Zinc coated (Galvanized): ASTM A123, G90 unless noted otherwise.

b. Surfaces exposed in the finished work:

1) Finish smooth rough surfaces and remove projections.

2) Fill holes, dents and similar voids and depressions with epoxy type patching compound.

c. Shop Prime Painting:

1) Surfaces of Ferrous metal:

a) Items not specified to have other coatings.

b) Galvanized surfaces specified to have prime paint.

c) Remove all loose mill scale, rust, and paint, by hand or power tool cleaning as defined in SSPC-SP2 and SP3.

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d) Clean of oil, grease, soil and other detrimental matter by use of solvents or cleaning compounds as defined in SSPC-

SP1.

e) After cleaning and finishing apply one coat of primer as specified in Section 09 91 00, PAINTING.

2) Non ferrous metals: Comply with MAAMM-500 series.

4. Stainless Steel: NAAMM AMP-504 Finish No. 4.

G. Protection:

1. Insulate aluminum surfaces that will come in contact with concrete, masonry, plaster, or metals other than stainless steel, zinc or white bronze by giving a coat of heavy-bodied alkali resisting bituminous paint or other approved paint in shop.

2. Spot prime all abraded and damaged areas of zinc coating which expose the bare metal, using zinc rich paint on hot-dip zinc coat items and zinc dust primer on all other zinc coated items.

2.5 SUPPORTS

A. General:

1. Fabricate ASTM A36 structural steel shapes as shown.

2. Use clip angles or make provisions for welding hangers and braces to overhead construction.

3. Field connections may be welded or bolted.

2.6 FRAMES (NOT USED)

2.7 GUARDS (NOT USED)

2.8 COVERS AND FRAMES FOR PITS AND TRENCHES

A. Fabricate covers to support live loads specified.

B. Galvanized steel members after fabrication in accordance with ASTM

A123, G-90 coating.

C. Steel Covers:

1. Use 6 mm (1/4 inch) thick floor plate for covers unless otherwise shown. Use gratings where shown as specified in paragraph GRATINGS.

Use smooth floor plate unless noted otherwise.

2. Provide clearance at all sides to permit easy removal of covers.

3. Make cutouts within 6 mm (1/4 inch) of penetration for passage of pipes and ducts.

4. Drill covers for flat head countersunk screws.

5. Make cover sections not to exceed 2.3 m2 (25 square feet) in area and

90 kg (200 pounds) in weight.

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6. Fabricate trench cover sections not be over 900 mm (3 feet) long and if width of trench is more than 900 mm (3 feet)or over, equip one end of each section with an angle or "T" bar stiffener to support adjoining plate.

7. Use two, 13 mm (1/2 inch) diameter steel bar flush drop handles for each cover section.

D. Cast Iron Covers

1. Fabricate covers to support live loads specified.

2. Fabricate from ASTM A48, cast-iron, 13 mm (1/2 inch) minimum metal thickness, cast with stiffeners as required.

3. Fabricate as flush type with frame, reasonably watertight and be equipped with flush type lifting rings. Provide seals where watertight covers noted.

4. Make covers in sections not over 90 kg (200 pounds) except round covers.

F. Cast Iron Frames:

1. Fabricate from ASTM A48 cast iron to shape shown.

2. Provide anchors for embedding in concrete, spaced near ends and not over 600 mm (24 inches) apart.

2.9 GRATINGS

A. Fabricate gratings to support live loads specified and a concentrated load as specified.

B. Provide clearance at all sides to permit easy removal of grating.

C. Make cutouts in gratings with 6 mm (1/4 inch) minimum to 25 mm (one inch) maximum clearance for penetrations or passage of pipes and ducts.

Edge band cutouts.

D. Fabricate in sections not to exceed 2.3 m2 (25 square feet) in area and

90 kg (200 pounds) in weight.

E. Fabricate sections of grating with end-banding bars.

F. Fabricate angle frames and supports, including anchorage as shown.

1. Fabricate intermediate supporting members from "T's" or angles.

2. Locate intermediate supports to support grating section edges.

3. Fabricate frame to finish flush with top of grating.

4. Locate anchors at ends and not over 600 mm (24 inches) o.c.

5. Butt or miter, and weld angle frame at corners.

G. Steel Bar Gratings:

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1. Fabricate grating using steel bars, frames, supports and other members shown in accordance with Metal Bar Grating Manual.

2. Galvanize steel members after fabrication in accordance with ASTM

A123, G-90 for exterior gratings, gratings in concrete floors, and interior grating where specified.

3. Interior gratings: Prime paint unless specified galvanized.

H. Cast Iron Gratings:

1. Fabricate gratings to support a live load of 23940 Pa (500 pounds per square foot).

2. Fabricate gratings and frames for gutter type drains from cast-iron conforming to ASTM A48.

3. Fabricate gratings in section not longer than 1200 mm (4 feet) or over 90 kg (200 pounds) and fit so as to be readily removable.

2.10 LOOSE LINTELS (NOT USED)

2.11 SHELF ANGLES (NOT USED)

2.12 PLATE DOOR SILL (NOT USED)

2.13 SAFETY NOSINGS (NOT USED)

2.14 LADDERS

A. Ladder Rungs:

1. Fabricate from 25 mm (one inch) diameter steel bars.

2. Fabricate so that rungs will extend at least 100 mm (4 inches) into wall with ends turned 50 mm (2 inches), project out from wall 175 mm

(7 inches), be 400 mm (16 inches) wide and be designed so that foot cannot slide off end.

3. Galvanized after fabrication, ASTM A123, G-90 rungs for exterior use and for access to pits.

2.15 RAILINGS (NOT USED)

2.16 CATWALKS

2.17 TRAP DOOR AND FRAMES WITH CEILING HATCH (NOT USED)

2.18 SIDEWALK DOOR (NOT USED)

2.19 SCREENED ACCESS DOORS AND FRAMES (NOT USED)

2.20 STEEL COUNTER OR BENCH TOP FRAME AND LEGS (NOT USED)

2.21 STEEL PIPE BOLLARD (NOT USED)

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PART 3 - EXECUTION

3.1 INSTALLATION, GENERAL

A. Set work accurately, in alignment and where shown, plumb, level, free of rack and twist, and set parallel or perpendicular as required to line and plane of surface.

B. Items set into concrete or masonry.

1. Provide temporary bracing for such items until concrete or masonry is set.

2. Place in accordance with setting drawings and instructions.

3. Build strap anchors, into masonry as work progresses.

C. Set frames of gratings, covers, corner guards, trap doors and similar items flush with finish floor or wall surface and, where applicable, flush with side of opening.

D. Field weld in accordance with AWS.

1. Design and finish as specified for shop welding.

2. Use continuous weld unless specified otherwise.

E. Install anchoring devices and fasteners as shown and as necessary for securing metal fabrications to building construction as specified.

Power actuated drive pins may be used except for removable items and where members would be deformed or substrate damaged by their use.

F. Spot prime all abraded and damaged areas of zinc coating as specified and all abraded and damaged areas of shop prime coat with same kind of paint used for shop priming.

G. Isolate aluminum from dissimilar metals and from contact with concrete and masonry materials as required to prevent electrolysis and corrosion.

H. Secure escutcheon plate with set screw.

3.2 INSTALLATION OF SUPPORTS

A. Anchorage to structure.

1. Secure angles or channels and clips to overhead structural steel by continuous welding unless bolting is shown.

2. Secure supports to concrete inserts by bolting or continuous welding as shown.

3. Secure supports to mid height of concrete beams when inserts do not exist with expansion bolts and to slabs, with expansion bolts.

unless shown otherwise.

4. Secure steel plate or hat channels to studs as detailed.

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3.3 COVERS AND FRAMES FOR PITS AND TRENCHES

A. Set frame and cover flush with finish floor.

B. Secure plates to frame with flat head countersunk screws.

C. Set gratings loose in drainage trenches or over pits unless shown anchored.

3.4 FRAMES FOR LEAD LINED DOORS (NOT USED)

3.5 DOOR FRAMES (NOT USED)

3.6 OTHER FRAMES (NOT USED)

3.7 GUARDS (NOT USED)

3.8 GRATINGS

A. Set grating flush with finish floor; top of curb, or areaway wall. Set frame so that horizontal leg of angle frame is flush with face of wall except when frame is installed on face of wall.

B. Set frame in formwork before concrete is placed.

C. Where grating terminates at a wall bolt frame to concrete or masonry with expansion bolts unless shown otherwise.

D. Secure removable supporting members in place with stainless steel bolts.

E. Bolt gratings to supports.

3.9 STEEL LINTELS (NOT USED)

3.10 SHELF ANGLES (NOT USED)

3.11 PLATE DOOR SILL (NOT USED)

3.12 SAFETY NOSINGS (NOT USED)

3.13 LADDERS

A. Ladder Rungs:

1. Set ladder rungs into formwork before concrete is placed. // Build ladder rungs into masonry as the work progresses. //

2. Set step portion of rung 150 mm (6 inches) from wall.

3. Space rungs approximately 300 mm (12 inches) on centers.

4. Where only one rung is required, locate it 400 mm (16 inches) above the floor.

3.14 RAILINGS (NOT USED)

3.15 CATWALK AND PLATFORMS (NOT USED)

3.16 SIDEWALK DOOR, TRAP DOORS, AND FRAMES (NOT USED)

3.17 SCREENED ACCESS DOOR (NOT USED)

3.18 STEEL COMPONENTS FOR MILLWORK ITEMS

Coordinate and deliver to Millwork fabricator for assembly where millwork items are secured to metal fabrications.

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3.19 INSTALLATION OF STEEL PIPE BOLLARD (NOT USED)

3.20 CLEAN AND ADJUSTING

A. Adjust movable parts including hardware to operate as designed without binding or deformation of the members centered in the opening or frame and, where applicable, contact surfaces fit tight and even without forcing or warping the components.

B. Clean after installation exposed prefinished and plated items and items fabricated from stainless steel, aluminum and copper alloys, as recommended by the metal manufacture and protected from damage until completion of the project.

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