Attachment 2 - Spec Section 083454 FEBR Door Assemblies Bandar GPE 2 Oct 24.doc

UNITED STATES DEPARTMENT OF STATE

UNCLASSIFIED

OCTOBER 2024

OVERSEAS BUILDINGS OPERATIONS

BANDAR FACILITY MAINTNANCE GPE FEBR DOORS

SECTION 083454 - FORCED ENTRY (FE) / BALLISTIC RESISTANT (BR) DOOR ASSEMBLIES

PART 1 - GENERAL

1.1 SUMMARY

A. The extent of forced-entry resistant (FE) and ballistic resistant (BR) door assemblies required for the Project is indicated on Contract Drawings, and in Door/Frame/Hardware schedules, including construction, profiles, swing, sizes, hardware, accessories, devices, and locations.

B. Install FE/BR door assemblies only into steel substrate in such a manner that allows for future frame adjustment. This may be structural steel wall or other structural steel assembly, steel sub-frame in concrete, or steel sub-frame attached to concrete or masonry.

C. [Definitions and Roles for Projects Utilizing the GPE Program:

1. Government Procured Equipment (GPE) Program: Program of the Overseas Buildings Operations (OBO) in which OBO procures security doors and windows in advance of and for use of upcoming projects. All GPE windows and doors shall be designed and engineered prior to award of the project to the Contractor.

2. Fabricator: This entity is fabricator/manufacturer of GPE items.

3. Manufacturer: This entity is manufacturer/fabricator of GPE items.

4. Contractor: Contractor is responsible for design incorporation, delivery, and installation of GPE products. Contractor is also responsible for design and construction of overall facility, as well as installation of GPE items selected by Contractor in conformance with overall requirements of the project. Contractor is responsible for development of a GPE product list and submission of the list to the Government for approval, with Design Development drawings.] D. Related Sections include the following:

1. Section 055005 “Metal Fabrications” for steel supports.

2. [Division 08 Section “GPE Window and Door Requirements.”]

3. Division 08 Sections for doors not designated for special security performances.

4. Section 087145 "Security Door Hardware" for hardware to be installed as work of this Section.

5. Section 088855 "Security Glazing."

6. Other sections of these specifications for interface of door hardware and device units, with alarm/security/safety/access/monitoring systems; not work of this Section.

1.2 PRE-INSTALLATION MEETINGS

A. Before beginning installation of FE/BR assemblies, Manufacturer's technical representative shall conduct pre-installation conference at the Project site with installation sub-contractor, electrical sub-contractor, the Project Director/COR, and other interested parties to review installation procedures and manuals, schedules, and coordination of FE/BR-assembly installation with other elements of the Work.

1.3 ACTION SUBMITTALS

A. General:

1. Action submittals should be accepted by the PD/COR prior to procurement of associated items by Contractor; premature procurement is at the risk of Contractor.

2. Refer to Division 01 Section on Submittals for general administrative requirements.

B. Product Data:

1. Product data for each element of work, whether purchased from other manufacturers or provided as door Fabricator's standard production to include door hardware, weather-stripping and thresholds. Include data substantiating that products comply with requirements of these specifications.

2. RAL standard color chart.

C. Certificates:

1. Letter from manufacturer indicating the products have been certified by Bureau of Diplomatic Security (DS).

2. Letter from manufacturer indicating that automatic door operators for handicap compliance have been fully designed by and coordinated with hardware supplier for width and weight of each applicable door, that operator controls and equipment are sized adequately given location of control box and its relationship to associated door, and is fully compliant with accessibility and fire protection requirements (for doors that are part of fire egress system) of the OBO Building Code.

D. Shop Drawings:

1. General:

a. Show each dimensioned detail of each door assembly.

b. Indicate performance rating, swing, hardware set, and adjacent construction. Shop drawings must also clearly indicate all modified hardware sets.

c. Provide drawings on B-size (297 mm x 420 mm) sheets. All dimensions shall be indicated in metric. Show typical door exterior elevations at not less than 1:20 scale.

d. Submittals in PDF format: Provide Table of contents and bookmarks organizing by building and floor for each product using contract identification number.

e. After final modifications and corrections have been incorporated into the drawings, submit drawings as AutoCAD files with .DWG extension.

2. Cover sheet: Include manufacturer's name, address, telephone, and facsimile numbers; customer and address; project location; contract or purchase order number; and submittal release record.

3. General Notes and details sheet:

a. Information about insulation in door and thermal properties of door, including weather-stripping.

b. Minimum size of FE/BR door shall conform to smallest clear opening requirement of 813 mm (32 inches) in OBO Building Code for accessibility, and for fire and life safety.

c. Terminal strip size, location and height above bottom of door frame.

d. Door frame socket head cap screw horizontal slotted holes location and sizes.

e. Identify exact location on door and frame of two required ID plates; see Article on IDENTIFICATION SYSTEMS. Identify plate type and size, and type of information included on the plate about door.

f. All FE/BR product bolts, screws and anchors shall be metric products.

g. Abbreviations used.

4. Unit information:

a. Manufacturer's model number.

b. DOS Code number.

c. Mark (door no.).

d. Door/frame finish.

e. Door type.

f. Government or ASTM/UL certification number.

g. Government or ASTM/UL certification number for glazing panel(s), if different from door certification.

h. Government certification number for deal tray, if different from door certification.

i. Blast characteristics (i.e., ASTM 2947-12 or none).

5. Elevation Drawings (Attack side):

a. Rough opening dimensions.

b. Door opening dimensions.

c. Frame opening dimensions.

d. Vision opening dimensions. (per contract drawings)

e. Clear width opening dimension to demonstrate conformance to accessibility requirements in OBO Building Code Chapter 11.

f. Substrate/rough opening material.

g. Finished floor.

h. Sill condition.

i. Undercut for carpet.

j. Weather-stripping. (hardware component keynote)

k. Manufacturer's name and reference numbers for primer and finish paint, including number of coats applied.

l. Door class (fire) rating: rated or non-rated.

m. Separate steel sub-frames (number and list).

n. Detail symbols.

o. Hardware and hardware symbols. Include part numbers.

p. Electrical access, including terminal strips.

q. Thumbturn lock guards,

r. location of conduit entry into both sub-frame and door frame,

6. Plan Drawings:

a. Relate to elevation on drawing.

b. Identify "Attack" and "Protected" sides.

c. Identify door swing (i.e., RH, LH, RHRB, LHRB).

d. Provide key notes on drawings.

e. Indicate room space numbers taken from Contract Drawings.

7. Details: Show section at 1:5 scale of members indicating construction, size, and thickness of components. Details shall be on separate sheets from plan and elevations

a. Frame profile, anchorage

b. Steel sub-frames,

c. Continuous shim plates (where applicable),

d. Threshold configuration,

e. Glazing panel together with connections,

f. Fasteners,

g. Shims,

h. Flashing, sealant, backer rods,

i. Means of separating dissimilar metals.

j. Undercut for carpet.

k. Weather-stripping.

l. Door and frame thickness.

m. Ballistic trim

n. Detail shall include contract drawing information of “products by others” such as flashing and finishes surrounding the product

8. General Product Information: Include notes sheet, miscellaneous materials specifications, abbreviations, finish/paint system, legend, and glazing specifications.

9. Breakdown of Product Line Items:

a. If Manufacturer produces one contract line item as several parts (e.g., door with transom and sidelights), they shall break out items on drawings. Each item shall be a subdivision of that product line item number.

E. Installation Instruction Manual:

1. Manual shall cite all anchorage components, including complete description of anchors, as well as installation criteria such as drilling specifications into concrete or masonry, torque requirements, minimum edge distance, spacing, etc. For sub-frame attachment to concrete, instructions shall include alert to installers to avoid cutting rebar during anchor installation.

2. Manual shall be customized for each type of application.

3. Manual shall include installation steps of contract drawing information of “products by others” such as flashing and finishes surrounding the product.

4. Develop instructions for unique conditions as they are identified.

F. Manufacturer’s Technical Representative shall submit list of unique project specific site conditions that require special manufacturer representative inspection and/or installation training.

G. Samples for Verification: For doors and components required, prepare samples of size indicated below.

1. Door and Frame Corner Fabrication: 300-by-300-mm (12-by-12-inch) long, with one hinge, full-size door corner including full-size sections of extrusions with factory-applied color finish, cladding and removable covers, weather-stripping, hinge, and glazing panel and glazing stops (if applicable).

a. If Manufacturer has previously submitted sample to OBO/CFSM/SM, and there have been not substantial updates and there are not unique finishes, then OBO/CFSM may waive requirement upon request. This request must be done prior to submittal submission. This does not affect glazing on material finish samples in this Section or other Sections of the Specification.

1.4 INFORMATIONAL SUBMITTALS

A. General:

1. Informational submittals shall be submitted at least four weeks prior to installation.

2. Refer to Division 01 Section on Submittals for general administrative requirements.

B. Qualification Data: For Manufacturer and Installer in accordance with Article on QUALITY ASSURANCE.

1.5 CLOSEOUT SUBMITTALS:

A. General:

1. Refer to Division 01 Sections on Submittals and on Closeout for general administrative requirements.

B. Special Warranty: Provide special warranty in accordance with the Article on WARRANTY.

C. Maintenance Data.

1. Data shall include instructions for cleaning and maintenance of Spall Shield glazing layer.

D. Inspection Reports and Certificate of Compliance: See forms at end of this Section.

1. Provide Table of contents and/or bookmarks organizing by building and floor for each product using contract identification number.

2. Provide plan showing location of products (one plan may cover multiple products or whole floor if legible).

3. Provide completed certificates of compliance documenting that all FE/BR door assemblies have been installed in accordance with contract documents. Signed by certified installer.

4. Provide any additional QC documents used by Contractor during the installation.

1.6 QUALITY ASSURANCE

A. Quality Control for Forced-Entry/Ballistic Resistant (FE/BR) Products: Certify compliance of fabricated and assembled FE/BR products specified in this Section with each quality control procedure established by the Government; these procedures are identified in Compliance Form at end of this Section. Other quality control forms are also found at end of this Section.

B. Testing Laboratory Qualifications: For compliance with non-security performance requirements on security door assemblies of this Section, use only those testing laboratories, which have successfully demonstrated to Project Director/COR that they have experience and capabilities needed to satisfactorily conduct required tests.

C. RESERVED:

D. Manufacturer's Technical Representative: For GPE projects Contractor shall hire from manufacturer technical representative. Manufacturer's technical representative shall be an employee of manufacturer, and have the following responsibilities:

1. Pre-Installation Conference: See Part 1 Article on PRE-INSTALLATION MEETINGS.

2. Installation Team Training: Manufacturer's technical representative (at no cost to the U.S. Government) shall provide the crew which is to actually perform installations of FE/BR assemblies with minimum of 16 hours of on-site, hands-on training before installation of first FE/BR door. Manufacturer's technical representative shall also instruct the crew on preventive measures which must be taken to protect installers from injury and protect FE/BR assemblies from damage during construction.

3. Inspection: See Part 3 Article on FIELD QUALITY CONTROL.

4. Additional Assistance: Manufacturer's technical representative (at no cost to the U.S. Government) shall provide General Contractor any additional advice, instruction, training, supervision, or inspection required to enable General Contractor to complete installation certification described below, and to fully train the Embassy staff in proper operation and maintenance of FE/BR assemblies.

1.7 IDENTIFICATION SYSTEMS

A. Identify each assembly to provide the Government with ready reference to original manufacturer to facilitate reorders, replacement parts, service, resolution of complaints, and inventory. Provide two identification labels per door assembly. Labels shall be embossed/printed metal plate or metallic foil with adhesive backing for permanent identification. Locate one label on door frame header so that it is not exposed when door is closed and is clearly visible and not obscured by hardware when door is open. Locate second label on top edge of door leaf. Labels shall be approximately 40 x 75 mm and shall cite:

1. Manufacturer's name/city/state.

2. Contract number.

3. Month/year of manufacture.

4. Mark number.

5. Government or ASTM/UL certification model number.

6. DOS Code number (i.e., 1123, 2123, etc.).

7. SHW Hardware package number.

8. Blast characteristics (i.e., ASTM 2947-12 or none)

B. Provide steel or aluminum stamped ID codes. One ID code shall be located on top edge of door leaf. ID code shall consist of FE/BR manufacturer name abbreviation, a space and unique manufacturer product identifier (example: FDI #####).

1. Manufacturer Name Abbreviations:

a. Maximum Security Products (MSP).

b. Fabrication Designs Inc. (FDI).

c. Norshield Security Products (NSP).

d. Ross Technology (RT).

e. Habersham Metal Products (HMP).

f. Salzer Building Security (SBS).

g. U.S. Bullet Proofing (USBP).

h. R2P Innovations (R2P)

i. PWS (PWS)

1.8 DELIVERY, STORAGE, AND HANDLING

A. Deliver and offload each assembly to project site with fabrication, finishing, and assembly of primary panels, sub-frames, and frames completed and prepared for installation and connection with security systems. Disassemble hardware for shipping only to extent hardware interferes with shipping. Refer to Division 01 Section “Secure Shipment” for additional requirements.

B. Deliver door assemblies with glazing panels as factory glazed unless otherwise directed by the Government.

C. Pack door assemblies and accessories in two crates: One crate for door and frame, and one crate for sub-frame and ballistic trim. Provide at least two wood cross braces on both sides of crates. In each crate, provide a separate compartment for installation hardware. Provide “Tip-N-Tell” indicators on inside of crate to assist in ensuring care was taken in shipment. Secure side of crate to be opened with screws.

D. Provide removable spreader bar between jambs used during fabrication, delivery, and installation and to include mullions of each frame assembly, except where threshold covers the spreader bar. Do not mar finishes of assembly with installation or removal of spreader bars. Removeable with mechanical fasteners without use of grinding.

E. Provide protection of pre-finished units, such as pre-finished with baked enamel or stainless steel, using self-adhesive paper of film.

F. Treat security door assemblies as fragile merchandise packaged and shipped in export wood crates, with width end in upright position and blocked together in a mass. Comply with manufacturer's directions for storage and handling to prevent edge damage or other damage to assembly resulting from effects of moisture, condensation, temperature changes, direct exposure to sun, and contact with chemical solvents. Provide at least two wood cross-braces for door assembly. Clearly mark crates to indicate which side shall be opened first.

G. Clearly mark sub-frames with door mark number and identify head and left and right jambs. Package sub-frames separately, and ship in export wood crates separate from the door assemblies. Protect each sub-frame piece to minimize damage to finished surfaces.

H. Package and ship installation hardware (anchors, bolts, screws, shims, ballistic trim, shop drawings, etc.) for each door in same crate as door assembly.

I. Package and ship shop drawings and installation manual for each door in same crate as door assembly.

J. Manufacturer shall ship sub-frames factory welded together with adequate temporary bracing for installation on site for new concrete wall construction.

1.9 WARRANTY

A. Special Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace doors that fail in materials or workmanship within specified warranty period.

1. Failures include, but are not limited to, the following:

a. Failure to meet performance requirements.

b. Structural failures including excessive deflection, water leakage, air infiltration, or condensation.

c. Deterioration of metals, other materials, and metal finishes beyond normal weathering.

d. Failure of insulating glass.

e. Failure of hardware components.

f. Delamination of glazing layup.

2. Warranty Period:

a. Doors: Manufacturer will warrant the doors for a period of five years.

PART 2 - PRODUCTS

2.1 PERFORMANCE REQUIREMENTS

A. General: Fabricate and install FE/BR door assemblies to achieve indicated levels of resistance. Extend resistance to include anchorages, interfaces with adjoining substrates, and hardware. Provide specific performance ratings, also referred to as Government Code numbers, as indicated below. Refer to Article on MATERIALS, GENERAL for composition portion of Government Code.

1. Fire-rated assemblies: Where indicated for fire resistance, provide flush steel doors-and-frame units; comply with NFPA 80, Standard for Fire Doors and Windows. Provide units that have been tested by recognized testing agency in accordance with NFPA No. 252 and ASTM E 152. Provide rated units where shown or scheduled, as follows:

a. Government Code 1: No fire resistance rating.

b. Government Code 2: 1-1/2 hour, with 30-min. temperature rise limited to 232 C (450 deg F).

c. Government Code 3: 3 hour, with 30-min. temperature rise limited to 232 C (450 deg F).

d. Government Code 4: 3/4 hour, with 30-min temperature rise limited to 232 C (450 deg F).

e. Government Code 5: 20 minutes.

f. Government Code 6: 1 hour.

2. Forced-Entry (FE) resistant assemblies: Where door assembly is shown or scheduled as FE, provide door manufacturer's material and fabrication for panels, inserts, hardware, devices, and framing of units for the following ratings by the Physical Security Division of the Bureau of Diplomatic Security (DS/PSP/PSD):

a. Government Code 1: No FE resistance rating.

b. Government Code 2: Provide resistance of 15 minutes for forced entry, using basic hand tools.

c. Government Code 3: Provide resistance of 60 minutes for forced entry, using basic hand tools.

d. Government Code 4: Provide resistance of five minutes for forced entry, using basic hand tools.

3. Ballistic resistant (BR) assemblies: Where door assembly is shown or scheduled as BR, provide door manufacturer's materials and fabrication for panel, inserts, and framing of unit. Provide the following DS/PSP/PSD ratings:

a. Government Code 1: No BR resistance rating.

b. Government Code 2: Submachine gun, 9mm.

c. Government Code 3: Rifle, 5.56 & 7.62 NATO.

d. Government Code 4: Armor piercing, .30-06.

4. DOS Door Codes: See Table 2.1 “Door Codes” below:

TABLE 2.1 – DOOR CODES

(Class B, Class D at exterior)

(9 mm)

3 hours (Class A)

NATO

45 minutes (Class C)

(.30-06)

2.2 MANUFACTURERS

A. Certified Units: Provide units, including frames and sub-frames which meet the following requirements:

1. Have been certified by Bureau of Diplomatic Security (DS) in accordance with DS/PSP/PSD SD-STD-01.01, Rev G or Rev H.

B. Selection of fabricator/manufacturer for each type of security door assembly, and selection of manufactured elements, which are used in make-up of that assembly, are Contractor's options subject to the following requirements and limitations, and subject to general provisions of Construction Contract:

1. Pre-certified fabricators (by DS) of ballistic-resistant and forced-entry-resistant assemblies are identified in a separate Contract Attachment labeled "Government Certified FE/BR Products and Designs".

2.3 MATERIALS, GENERAL REQUIREMENTS FOR STEEL DOOR

A. Composition: A Government Code number, defined as indicated below, identifies the composition of the door. Refer to Article on PERFORMANCE REQUIREMENTS for other portions of Government Code.

1. Rating 1: Transparent (vision panels).

2. Rating 2: Opaque B. Hot-Rolled Steel Sheets and Strips: ASTM A 569, commercial quality, pickled and oiled, except as otherwise indicated.

C. Cold-Rolled Steel Sheets: ASTM A 366, commercial quality, except as otherwise indicated.

D. Galvanized Steel Sheets: ASTM A 526, with ASTM A 525, G90 zinc coating, mill phosphatized; commercial quality, except as otherwise indicated.

E. Stainless Steel Sheets where required for finish: AISI Type 316, complying with ASTM A 167; commercial quality, No. 4 directional polish.

F. Supports and Anchors: Fabricate to endure required performances, but of not less than 1.5 mm sheet steel. For exterior wall assemblies, hot-dip zinc coat support/anchor units after fabrication in compliance with ASTM A 153, Class B.

G. Inserts, Bolts Fasteners: Standard units of strengths required to endure performances; hot-dip zinc coated where used in exterior wall assemblies in compliance with ASTM A 153, Class C/D.

H. Paint for Shop Application: Rust-inhibitive enamel for baking suitable as base for finish coats, which are specified as work of other sections.

I. Door Core Insulation:

1. Polyisocyanurate: Rigid foam, thermal value: R12.3 (RSI 2.17) (minimum), conforming to ASTM C1289.

2. Ceramic Fiber Wool: ASTM C 892 and ASTM C201.

J. Glazing Panels, General: Fabricate glazing panels of sizes shown and scheduled with same performance capabilities as specified/shown for door assembly where installed. Where applicable, achieve performances and combined performances through lamination of transparent sheets, films, and screens of standard manufactured/tested products. Comply with applicable provisions of Division 08 glazing section and Section 088855 "Security Glazing."

1. Forced-Entry (FE) Resistance: Where assembly is indicated for forced-entry resistance rating (FE), provide glazing panel of size shown or scheduled in accordance with Bureau of Diplomatic Security (DS) certification.

2. Ballistic Resistance (BR): Where assembly is indicated for ballistic-resistance rating (BR), provide glazing panel of size shown or scheduled in accordance with DS certification.

K. Hot-Dip Galvanizing: All doors must be hot-dip galvanized in accordance with ASTM A123M-09; ASTM A123 standards or made of galvanneal material in accordance with ASTM A653/A653M, G90.

L. Sealants: For sealants required within fabricated security doors, provide type recommended by manufacturer for joint size and movement. Sealant shall remain permanently elastic, non-shrinking, and non-migrating.

2.4 MATERIALS, GENERAL REQUIREMENTS FOR ALUMINUM DOORS

A.

Assembled Door Characteristics:

1. Maximum Weight: 265kg (585 lbs) for a 3’x7’ nominal full vision leaf, including frame.

2. Maximum Thickness: 65-mm (2-1/2 inches), excluding door hardware, FEL protector and glazing trim.

3. No ferrous metal to be used in assembly of door except DOS security door hardware.

4. Use non-ferritic stainless-steel sheets and strips where required for interior reinforcements and per tested assembly.

B.

Minimum Aluminum Extrusions: In accordance with tested assembly.

C.

Aluminum Sheet and Plate Cladding and Facing: ÅSTM B 209, one-piece 1.02 mm (0.040-inch) smooth 5005-H14 stretcher-leveled aluminum alloy.

D.

Inserts, Anchors, Bolts, Fasteners: Standard units of strengths required to endure performances; Stainless steel, grade shall match tested/certified condition.

E.

Door Core Insulation:

1.

Liquid (expanding) polyisocyanurate or polyurethane foam (minimum), conforming to ASTM C1289 shall be used to fill any voids, excluding access areas such as anchor, wiring points, etc.

F.

Vision Panels, General: Fabricate vision panels of sizes shown and scheduled with same performance capabilities as specified/shown for door assembly where installed. Where applicable, achieve performances and combined performances through lamination of transparent sheets, films, and screens of standard manufactured/tested products. Comply with applicable provisions of Section 088855, "Security Glazing."

1.

Forced-Entry (FE) Resistance: Where assembly is indicated for forced-entry resistance rating (FE), provide light of size shown or scheduled in accordance with Bureau of Diplomatic Security (DS) certification.

2.

Ballistic Resistance (BR): Where assembly is indicated for ballistic-resistance rating (BR), provide glazing of size shown or schedule in accordance with DS certification.

G.

Sealants: For sealants required within fabricated security doors, provide type recommended by manufacturer for joint size and movement. Sealant shall remain permanently elastic, nonshrinking, and nonmigrating.

2.5 HARDWARE

A. General: Provide special units of door hardware to achieve performances, and as shown and scheduled. Standard units for each security door assembly are specified to be furnished as work of Section 087145 "Security Door Hardware"; see Project "Finish Hardware Schedule" and "Data Sheets," and provisions of this Section, as well as notes on door-and-frame schedule.

B. FE and FE/BR Hinges:

1. For FE and FE/BR doors, provide ANSI/BHMA compliant extra-heavy duty needle bearing type hinges, minimum 910 kg (2000 pound) capacity per hinge, for door leafs weighing 200 kg (450 pounds) or more and minimum 450 kg (1000 pound) capacity per hinge for door leafs weighing 200 kp (450 pounds) or less. Polymer and Teflon bearing hinges are not permitted. Provide cycle tested hinges in accordance with ANSI/BHMA 156.1-2013 on an actual door specimen to a minimum of 1,000,000 cycles. Test shall be performed using hinges installed in accordance with DS forced-entry test in number and in how hinges are attached. Other minimum requirements are as follows:

a. Cycle Testing: 1,000,000 (exceeds ANSI requirements; DOS-specific requirement)

b. Hinge Pin Rise: None Allowed

c. Hinge Play: 0.38 mm (.015 in)

d. Vertical Wear: 0.76 mm (.030 in)

e. Lateral Wear: 1.60 mm (.062 in)

2. For permanently adhered hinges provide ANSI/BHMA compliant extra-heavy duty type hinges, minimum 910 kg (2000 pound) capacity per hinge, for double weight doors. Polymer and Teflon bearing hinges are not permitted. Provide cycle tested hinges per ANSI/BHMA 156.1-2013 on an actual door specimen to a minimum of 1,500,000 cycles. Other minimum requirements are as follows:

a. Cycle Testing: 1,500,000

b. Hinge Pin Rise: None Allowed

c. Hinge Play: 0.38 mm (.015 in)

d. Vertical Wear: 0.76 mm (.030 in)

e. Lateral Wear: 1.60 mm (.062 in)

3. Continuous hinges are normally prohibited; they may be permitted on case-by-case basis by OBO/CFSM/SM FE/BR Coordination Team for certain applications at work on existing buildings.

4. For door leaf over 2.5 square meters, provide minimum of three hinges.

5. Stamp each FE and FE/BR hinge with Manufacturer and model number, visible on installed hinge.

C. All forced entry locks (FEL) shall include an adjustable and removable strike plate that is bolted in place. Strike plates shall be adjustable (in and out) a minimum of 2 mm in each direction.

2.6 FABRICATION AND ASSEMBLY

A. General: Fabricate, test, and pre-assemble security door assemblies with hardware at factory; disassemble hardware only to extent necessary for handling, packaging, shipment, and installation at Project. Fabricate metal work to comply with performance requirements. Fabrications shall be rigid, neat, and free from warp/buckle/similar defects, with eased edges and continuously-welded joints, ground where exposed, to provide smooth, flush, invisible joints. Weld in accordance with AWS D1.1, Structural Welding Code for Steel.

1. Prepare door leafs and frames of each assembly to receive hardware, devices, and accessory units as shown and scheduled. Reinforce work for hardware and devices, and cut work for mortised or concealed units; comply with ANSI A115 series specifications, working from templates supplied by unit manufacturers and suppliers.

a. Locate hardware, devices, and accessories as shown and scheduled (including on approved shop drawings) or, if not otherwise indicated: 1) in accordance with DHI Recommended Locations for Builder's Hardware or, 2) in accordance with security device manufacturer's recommendation for optimum responses, but 3) in any case, as required to achieve required assembly performances. Do not cut or otherwise alter hardware in order to install on door without officially notifying the OBO/SM FE/BR Coordination Team with a detail drawing showing/indicating the modification(s), the FE/BR manufacturer’s part number.

b. Except where assembly is equipped with door-seal stripping at jambs and head, provide neoprene door silencers on stops; three at strike jamb for single door, and four at head for double door.

c. Except as otherwise indicated, pre-fabricate and pre--assemble security door assemblies to include full extent of required conduit-protected electrical/electronic power and control wiring placed and supported to avoid conflicts with other elements and subsequent drilling/cutting-in of work during installation of units. Provide access ports as required to support 25 mm conduit in door frames and sub-frames.

d. Clearances: Not more than 3 mm at jambs and head, except not more than 6 mm between fire-rated pair of doors. Not more than 6 mm at bottom. Undercut for carpets are not permitted where doors are used in corridors.

e. Fabricate frames with horizontally slotted bolt holes to allow for future frame adjustment.

f. Locate terminal block access on hinge side of door frame, between 1.2 meters (47”) and 2 meters (80”) above the finished floor. The terminal block opening shall have removable cover, and provide clear opening of 50 mm (2”) wide by 250 mm (10”) long.

1) All wires from electrical components on the door should terminate on the terminal block using same colored wires as the electrical door component wires.

2) The wires at the terminal block shall be labeled properly with electrical door component.

2. Provide removable glazing stops and similar moldings on interior or "protected" side of assemblies. Glazing panels shall be removable without removing door from frame, through top of door or by removing any surface steel panel. Select and size stops, moldings, and anchors to conform to Bureau of Diplomatic Security (DS) certified design.

3. Shop painting: Provide base-coat, factory-applied painting of ferrous metal elements of assemblies excluding other specified exposed-finish surfaces of stainless steel, aluminum, bronze, and similar metals not intended for painting. Provide touch-up paint with each painted door.

a. Clean steel and zinc-coated steel surfaces of mill scale, rust, oil, grease, dirt, and other substances, immediately before finish application.

b. Apply pretreatment of cold phosphate solution (SSPC--PT2), hot phosphate solution (SSPC-PT4), or basic zinc -chromate/vinyl-butyl solution (SSPC-PT3).

c. Apply paint coat specified for shop application, and bake on within time limits recommended by manufacturer of pretreatment. Apply in a uniform, smooth coat to result in dry film thickness of not less than 0.05 mm.

4. Glazing panels:

a. Glazing panels shall be enclosed and cushioned within core of door for continuous perimeter bite of not less than 20 mm on each side, and with 6 mm cushion clearance to fixed metal stop on glazing edges. Glazing panels shall be factory installed with no raw metal edges evident or in contact with glass in door glazing panel openings. Glazing panel opening edges shall be cushioned and trimmed neatly to provide acceptable appearance.

b. If external frames are used to either side or to both faces of door, frame(s) shall not exceed 40 mm in width and shall be configured internally to cushion all perimeter edges and faces of glazing panel and provide minimum bite of 20 mm and 6 mm cushion clearance to fixed metal stop on glazing panel edges. Frame shall not produce pinch point with hardware. All external bolts to attach frame shall be flush mounted. Alternatively, protruding bolt heads shall be covered with additional trim frame and flush mounted screws.

5. Sub-frames: Provide steel sub-frames for all FE or FE/BR doors for installation at concrete, masonry, and other non-steel rough openings and for structural steel openings where depth is less than door frame depth. For individual openings, sub-frames shall be provided by door supplier. For larger, multi-panel openings, sub-frames may be provided by either door supplier or Contractor; in either case they shall be designed by door supplier and shown with door shop drawings. For larger elevations that require knock-down subframe, provide hot-dipped embeds, but where field welded, provide similar equivalent treatment. Sub-frames shall be minimum 12 mm thickness steel with a minimum depth equal to or greater than door frame depth on side of sub frame that door is bolted. When embed plate is used in concrete, provide adjustable “mud box” to allow for bolt to penetrate plate and be fully unencumbered. Coordinate sub-frame anchor locations with door frame bolt hole locations. Steel sub-frame shall be assembled and braced by manufacturer prior to shipping to avoid out of plane deformation during transportation, installation, or concrete pouring. Steel sub-frame shall be installed plumb and square. All sub-frames without adjustability shall be drilled and tapped in the field. All fasteners for doors or windows shall be metric (Class 8.8) equivalent to ASTM grade 5 or other appropriate high strength bolt as identified in the blast report, and complying with standard OBO specifications for FE/BR and Blast resistant products. All door sub-frames shall be pre-punched for the technical security conduit. Subframe bracing for shipping or construction methods should be installed and removed without impacting galvanization (i.e., bracing shall not be welded to subframe)

a. For New Concrete: Attach steel sub-frame per the blast report or with minimum 12 mm x 150 mm steel studs, spaced 150 mm on center. Subframe may be minimum 12 mm thick embed plate or 12mm thick tube. All embed plates shall be factory drilled and tapped with anchor design to allow minimum 10-mm (3/8”) adjustment 360 degrees from centerline of center of drilled and tapped hole. Drilled and tapped adjustable plate shall also be 12mm thick. Final sub-frame design; construction and features shall be approved by OBO/SEB prior to fabrication and shipment.

1) Exterior sub-frames shall be constructed of A36 mild steel 12 mm (1/2 inch) thick steel or greater as required to comply with engineer's report for blast resistance, if applicable, and shall be hot dip galvanized for corrosion resistance or made of galvanneal material in accordance with ASTM A653/A653M, G90.

2) Interior sub-frames shall be A36 mild steel 12 mm (1/2 inch) minimum thickness and shall be prime painted with a high-grade metal primer.

6. Doors, windows and glazed panels in multi-unit elevations shall be designed and fabricated to separate head and jambs of each door frame from other door and/or window frames. Separation shall be minimum 50 mm x 150 mm x 12 mm steel tubes, or as required by blast loading (but must be minimum either 12mm wall steel tube or minimum 25mm steel plate).

B. Flashing: Provide rigid through-wall flashing at all head locations of exterior doors. Provide counter flashing at locations where building finish materials interface with door systems. Provide flashing at door jambs and sills. Provide drip edges at all exterior door heads. Flashing materials must be protected from interaction with dissimilar materials.

2.7 DOOR COMPONENTS

A. Glazing Panel: Comply with requirements in Section 088855 "Security Glazing" for performance indicated.

B. Anchors, Clips, and Door Accessories: Stainless steel; hot-dip, zinc-coated steel or iron, complying with ASTM B 633; provide sufficient strength to withstand design pressure indicated.

C. Protect bottom forced entry lock thumbturn with "U" shaped metal guard, with opening at bottom or toward door jamb side that has been officially approved by the OBO/SM FE/BR Program. Attach guard to door surface with counter-sunk screws on inside of "U." Finish of guard shall match finish of door.

2.8 CLADDING

A. Materials: Door cladding and glazing trims shall be fabricated from commercial grade, tension leveled stainless steel to ASTM A167-92b, Type 316, XL Blend S (brushed) or XL Buff (mirror) Finish as indicated by project specific requirements.

B. Adhesives: Heat resistant, single component, polyurethane reactive (water) hot melt, thermoset adhesive, UL/ULC/WH approved or equivalent.

C. Inter-locking Edge Seams: Resin reinforced polychloroprene (RRPC), fire resistant, high viscosity, sealant/adhesive or UL approved equivalent.

D. Construction: All exposed surfaces of door and frame shall be clad with 1.2 mm (18 gage) commercial grade, tension leveled stainless steel to ASTM A167-92b, Type 316.

1. Door faces shall be fabricated without visible seams, free of scale, pitting, coil brakes, buckles and waves.

2. Direction of grain on faces and bevels shall be vertical.

3. Formed edges shall be true and straight with minimum radius for thickness of steel used.

4. Longitudinal edges of base doors clad in stainless steel shall be mechanically inter-locked, adhesive assisted. Edge seams shall be visible.

5. Cladding shall be securely attached to front, back and edges with visible hair-line butted joints at door edges.

6. Lock and hinge edges shall be beveled 3mm in 50 mm (1/8” in 2") unless hardware or door swing dictates otherwise.

7. Cladding installed around electromagnetic lock that is installed on door frame shall allow for lock position to be adjusted 3 mm in both directions.

8. Cladding installed around panic exit device strike plate shall allow for strike plate position to be adjusted 3 mm in both directions E. Finished Sizes Tolerances of Cladded Doors:

1. Widths of door openings shall be measured from inside of frame jamb rabbets with tolerance of +1.6 mm, -0.8 mm (+ .063", -.031").

2. Heights of door openings shall be measured from the finished floor (exclusive of floor coverings) to head rabbet of frame with tolerance of 1.2 mm (± .047").

3. Unless hardware requirements dictate otherwise, finished cladded doors shall be sized so as to fit above openings and allow 3 mm (.125") clearance at jambs and head. Provide clearance of 19 mm (.75") between bottom of door and finished floor (exclusive of floor coverings). Tolerances on door sizes shall be 1.2 mm (± .047").

F. Removable Covers: Fabricate perimeter removable/snap in place covers from 2.78 mm (0.109-inch) nominal-thickness commercial grade, tension leveled stainless steel to ASTM A167-92b, Type 316 sheet or extruded aluminum. If permanent covers are used provide access holes to all bolts, screws and hardware items. Provide covers for access holes with materials that match the covers/cladding. If covers are attached with screws, provide flush flat hex socket cap screw to match cover. For snap-in-place cover, provide any special tool required to release.

G. Glazing Panel: Where glazing panel is specified, doors shall receive 1.0 mm (20 gage) stainless steel trim and screw fixed glazing stops. Glazing panel trim and stops shall be accurately fitted, butted at corners, with removable stops located on the “push” side of door.

H. Finish Cladded Product Installation Tolerances:

1. Plumbness tolerance, measured through a line from intersecting corner of vertical members and head to floor, shall be +/- 1.6 mm (.063").

2. Squareness tolerance, measured through a line 90° from one jamb at the upper corner of product, to opposite jamb, shall be +/- 1.6 mm (.063").

3. Alignment tolerance, measured on jambs, through a horizontal line parallel to plane of wall, shall be +/- 1.6 mm (.063").

4. Twist tolerance, measured at face corners of jambs, on parallel lines perpendicular to plane of wall, shall be +/- 1.6 mm (.063").

2.9 ALUMINUM FINISHES

A. Finish designations prefixed by AA comply with system established by the Aluminum Association for designating aluminum finishes.

B. Class I, Clear Anodic Finish: AA-M12C22A41 (Mechanical Finish: non-specular as fabricated; Chemical Finish: etched, medium matte; Anodic Coating: Architectural Class I, clear coating 0.018 mm or thicker) complying with AAMA 611.

C. Class I, Color Anodic Finish: AA-M12C22A42/A44 (Mechanical Finish: non-specular as fabricated; Chemical Finish: etched, medium matte; Anodic Coating: Architectural Class I, integrally colored or electrolytically deposited color coating 0.018 mm or thicker) complying with AAMA 611.

1. Color: As selected by Project Director/COR.

D. High-Performance Organic Finish (3-Coat Fluoropolymer): AA-C12C40R1x (Chemical Finish: cleaned with inhibited chemicals; Chemical Finish: conversion coatings; Organic Coating: manufacturer's standard 3-coat, thermocured system consisting of specially formulated inhibitive primer, fluoropolymer color coat, and clear fluoropolymer topcoat, with both color coat and clear topcoat containing not less than 70 percent polyvinylidene fluoride resin by weight). Prepare, pretreat, and apply coating to exposed metal surfaces to comply with AAMA 2605 and with coating and resin manufacturers' written instructions.

1. Color and Gloss: As selected by Project Director/COR.

E. Factory-Glazed Fabrication: Glaze aluminum windows in the factory. Comply with requirements in Section 088855 "Security Glazing" and with AAMA/WDMA 101/I.S.2/NAFS.

F. Glazing Stops: Provide snap-on glazing stops coordinated with Section 088855 "Glazing" and glazing system indicated.

2.10 METALLIC-COATED STEEL FINISHES

A. Surface Preparation: Clean surfaces with nonpetroleum solvent so surfaces are free of oil and other contaminants. After cleaning, apply a conversion coating suited to the organic coating to be applied over it. Clean welds, mechanical connections, and abraded areas and apply galvanizing repair paint, complying with SSPC-Paint 20, to comply with ASTM A 780.

B. Factory Prime Finish: Apply an air-dried primer, complying with SSPC-Paint 5, immediately after cleaning and pretreating.

C. Baked-Enamel or Powder-Coat Finish: Immediately after cleaning and pretreating, apply manufacturer's standard two-coat, baked-on finish consisting of prime coat and thermosetting topcoat, with a minimum dry film thickness of 0.025 mm (1 mil) for topcoat. Comply with coating manufacturer's written instructions for applying and baking to achieve minimum dry film thickness of 0.05 mm (2 mils).

1. Color and Gloss: As selected by the Project Director/COR.

2.11 STAINLESS-STEEL FINISHES

A. Surface Preparation: Remove tool and die marks and stretch lines, or blend into finish.

B. Polished Finishes: Grind and polish surfaces to produce uniform finish, free of cross scratches.

1. Run grain of directional finishes with long dimension of each piece.

2. When polishing is completed, passivate and rinse surfaces. Remove embedded foreign matter and leave surfaces chemically clean.

PART 3 - RESERVED

END OF SECTION 083185

Certificate of Compliance Manufacturers and Contract Specifications for FE/BR Products FE/BR Door Assemblies

Door Number__________

(Per Construction Documents)

Each of these items indicated below must be inspected by the contractor prior to acceptance of the FE/BR products by DoS. A completed Certificate of Compliance is required for each individual product.

Date

Date

Doors shall be mounted maximum 6mm proud of the subframe on the attack side.

Door frame socket head cap screw horizontal slotted holes shall be 19 mm x 35 mm (3/4” x 1-1/4”) round access holes. Washers shall be 27 mm diameter

[Existing Door Replacement:

Slotted holes may match existing]

Existing door replacement only: 6 mm (¼”) gap between back of ballistic trim bar and door frame has been maintained.