Attachment 6 - Spec Section 055005 Metal_Fabrications Bandar GPE Doors-Windows 2 Oct 24.docx

UNITED STATES DEPARTMENT OF STATE UNCLASSIFIED OCTOBER 2024

OVERSEAS BUILDING OPERATIONS

BANDAR MAINTENANCE FACILITIES – GPE DOORS-WINDOWS

SECTION 055005 - METAL FABRICATIONS

GENERAL

SUMMARY

Section Includes:

Miscellaneous steels plates and related framing for FE (Forced Entry) and BR (Ballistic resistance) security assemblies Miscellaneous steel trim.

Loose bearing and leveling plates for applications where they are not specified in other Sections.

Products furnished, but not installed, under this Section include the following:

Loose steel lintels.

Anchor bolts, steel pipe sleeves, slotted-channel inserts, and wedge-type inserts indicated to be cast into concrete or built into unit masonry.

Steel weld plates and angles for casting into concrete for applications where they are not specified in other Sections.

Related Requirements:

Section 033000 "Cast-in-Place Concrete" for installing anchor bolts, steel pipe sleeves, slotted-channel inserts, wedge-type inserts, and other items cast into concrete.

Division 08 Sections for steel embeds related to security doors, windows, and louvers.

Division 09 Sections on general painting.

Section 099605 “High-Performance Coatings.”

Section 323120 “Decorative Metal Fences” for perimeter security fences and general control fences.

Section 323305 “Site Furnishings” for metal site furnishings.

Division 32 Sections for perimeter security gates and associated fencing, rising bollard barricades, and other perimeter security assemblies.

COORDINATION

Coordinate selection of shop primers with topcoats to be applied over them. Comply with paint and coating manufacturers' written recommendations to ensure that shop primers and topcoats are compatible with one another.

Coordinate installation of metal fabrications that are anchored to or that receive other work. Furnish setting drawings, templates, and directions for installing anchorages, including sleeves, concrete inserts, anchor bolts, and items with integral anchors, that are to be embedded in concrete or masonry. Deliver such items to Project site in time for installation.

ACTION SUBMITTALS

Professional Certification: Provide Shop Drawings and engineering calculations prepared and sealed by Registered Professional Engineer, licensed in accordance with requirements of the OBO Building Code, for fabrications required to comply with structural requirements.

Product Data: Manufacturer’s specifications and installation instructions for products used in miscellaneous metal fabrications, including paint products and grout.

Shop Drawings: Show fabrication and installation details for all fabrications. Include plans, elevations, sections, and details of metal fabrications and their connections. Show anchorage and accessory items.

Delegated-Design Submittal: Include analysis data signed and sealed by the qualified professional engineer responsible for their preparation.

INFORMATIONAL SUBMITTALS

Calculations: Submit for information only, engineering calculations for fabrications required to comply with structural requirements.

Design Modifications: Submit for review proposed variations in details or substitutions in material required to meet specified performance to coordinate Work.

Qualification Data: For professional engineer.

Certificates:

Submit certification that materials receiving polyurethane coating system have received compatible surface preparation and priming.

Submit certification that steel to be galvanized contains elements within ranges listed below:

Carbon: Less than 0.25 percent.

Phosphorus: Less than 0.05 percent.

Manganese: Less than 1.35 percent.

Silicon: Within range of 0 to 0.04 percent or 0.15 to 0.25 percent.

Welding certificates.

<CONSIDER RETAINING "PAINT COMPATIBILITY CERTIFICATES" PARAGRAPH BELOW IF PRIMERS ARE FULLY SPECIFIED IN THIS SECTION RATHER THAN IN PAINTING SECTIONS.> [Paint Compatibility Certificates: From manufacturers of topcoats applied over shop primers, certifying that shop primers are compatible with topcoats.] Research/Evaluation Reports: For post-installed anchors, from ICC-ES.

QUALITY ASSURANCE

Designer/Engineer Qualifications: Design elements required to meet structural requirements under direct supervision of a Registered Professional Engineer, licensed in accordance with requirements of the OBO Building Code.

Fabricator and Installer Qualifications: Not less than 5 years documented, successful experience with work comparable to Work of this Project.

Welding Standards:

Comply with applicable provisions of AWS D1.1 “Structural Welding Code--Steel,” AWS D1.2 “Structural Welding Code--Aluminum,” and AWS D1.3 “Structural Welding Code--Sheet Steel.”

Welder qualifications: AWS certified for type of welding required.

Finish joints in accordance with National Ornamental & Miscellaneous Metals Association (NOMMA) Guideline 1:

Finish 1: No evidence of a welded joint.

Finish 2: Completely sanded joint, some undercutting and pinholes acceptable.

Finish 3: Partially dressed weld with splatter removed.

Finish 4: Good quality, uniform undressed weld with minimal spatter.

Galvanizing:

Coating Applicator: Company specializing in hot dip galvanizing after fabrication approved by manufacturer or fabricator.

Hot-Dip Galvanizing Fabrication Practices: Conform to requirements of ASTM A123, A143, A384 and A385 unless otherwise specified.

FIELD CONDITIONS

Field Measurements: Verify actual locations of walls and other construction contiguous with metal fabrications by field measurements before fabrication.

PRODUCTS

PERFORMANCE REQUIREMENTS

Delegated Design: Engage a qualified professional engineer to design metal fabrications.

Design Requirement:

Use materials of size and thickness indicated or, if not indicated, as required to produce strength and durability in finished product for use intended.

Design and fabricate components to support loads indicated or required to comply with requirements of authorities having jurisdiction over Project.

Design modifications:

May be proposed by manufacturer to satisfy performance requirements.

Must conform to design and specified durability and strength.

Must maintain profiles and alignments indicated.

Structural Performance:

Treads, Platforms, and Gratings: Capable of withstanding uniform load of 490 kg/m2 , or concentrated load of 1340 N applied at any point, whichever produces the greater stresses.

Ladders, including landings, shall withstand the effects of loads and stresses within limits and under conditions specified in ANSI A14.3.

Visual Requirements: For metal fabrications exposed to view, use materials which are smooth and free of surface blemishes, including pitting, seam marks, roller marks, rolled trade names, and roughness.

Interface with Other Systems:

Coordinate and furnish anchorages, setting drawings, diagrams, templates, instructions and directions for installation of anchors, including concrete inserts, sleeves, anchor bolts and miscellaneous items having integral anchors, which will be embedded in concrete or masonry construction.

Coordinate delivery of such items to Project site.

Thermal Movements: Allow for thermal movements from ambient and surface temperature changes acting on exterior metal fabrications by preventing buckling, opening of joints, overstressing of components, failure of connections, and other detrimental effects.

Temperature Change: 67 deg C, ambient; 100 deg C, material surfaces.

METALS

Metal Surfaces, General: Provide materials with smooth, flat surfaces unless otherwise indicated. For metal fabrications exposed to view in the completed Work, provide materials without seam marks, roller marks, rolled trade names, or blemishes.

[Recycled Content of Steel Products: Postconsumer recycled content plus one-half of preconsumer recycled content not less than [25] <Insert value> percent.] Steel Plates, Shapes, and Bars: ASTM A 36/A 36M.

Steel Sheet:

Uncoated, Cold-Rolled Steel Sheet: ASTM A1008 either commercial steel, Type B, or structural steel, Grade 25, unless another grade is required by design loads; exposed.

Uncoated, Hot-Rolled Steel Sheet: ASTM A1011 either commercial steel, Type B, or structural steel, Grade 30, unless another grade is required by design loads.

Galvanized Steel Sheet: ASTM A653, G90 coating, either commercial steel, Type B, or structural steel, Grade 33, unless another grade is required by design loads.

<USE STAINLESS STEEL AT LOCATIONS WITH MODERATE OR EXTREME CORROSION RISKS FOR COMPONENTS OR ASSEMBLIES FOR WHICH STAINLESS STEEL IS AN OPTION. USUALLY RETAIN TYPE 304 IN "STAINLESS-STEEL SHEET, STRIP, AND PLATE" AND "STAINLESS-STEEL BARS AND SHAPES" PARAGRAPHS BELOW; TYPE 316L IS FOR EXTREME CORROSION RISK ENVIRONMENTS.> Stainless-Steel Sheet, Strip, and Plate: ASTM A 240/A 240M or ASTM A 666, [Type 304] [Type 316L].

Stainless-Steel Bars and Shapes: ASTM A 276, [Type 304] [Type 316L].

Rolled-Steel Floor Plate: ASTM A 786/A 786M, rolled from plate complying with ASTM A 36/A 36M or ASTM A 283/A 283M, Grade C or D, minimum 0.0747 inch thick.

Rolled-Stainless-Steel Floor Plate: ASTM A 793.

Steel Tubing: ASTM A 500/A 500M, cold-formed steel tubing.

Steel Pipe: ASTM A 53/A 53M, Standard Weight (Schedule 40) unless otherwise indicated.

Slotted Channel Framing: Cold-formed metal box channels (struts) complying with MFMA-4.

Size of Channels: [41 by 41 mm] [As indicated] <Insert size>.

Material: Galvanized steel, ASTM A 653/A 653M, [commercial steel, Type B] [structural steel, Grade 230], with Z275 coating; [2.8-mm (12 gauge)] [2-mm (14 gauge)] [1.6-mm (16 gauge)] nominal thickness.

Material: Cold-rolled steel, ASTM A 1008/A 1008M, [commercial steel, Type B] [structural steel, Grade 230]; [2.5-mm (12 gauge)] [1.7-mm (114 gauge)] [1.35-mm (16 gauge)] minimum thickness; [unfinished] [coated with rust-inhibitive, baked-on, acrylic enamel] [hot-dip galvanized after fabrication].

Aluminum Plate and Sheet: ASTM B 209M, Alloy 6061-T6.

Aluminum Extrusions: ASTM B 221M, Alloy 6063-T6.

Aluminum Castings: ASTM B 26/B 26M, Alloy 443.0-F.

FASTENERS

<SEE NOTE ON STAINLESS STEEL IN ARTICLE ON “METAL”.>

General: Unless otherwise indicated, provide [Type 304] [Type 316] stainless-steel fasteners for exterior use and zinc-plated fasteners with coating complying with ASTM B 633 or ASTM F 1941M, Class Fe/Zn 5, at exterior walls. Select fasteners for type, grade, and class required.

Provide stainless-steel fasteners for fastening aluminum.

Steel Bolts and Nuts: Regular hexagon-head bolts, ASTM F 568M, Property Class 4.6; with hex nuts, ASTM A 563M; and, where indicated, flat washers.

Steel Bolts and Nuts: Regular hexagon-head bolts, ASTM A 325M, Type 3; with hex nuts, ASTM A 563M, Class 8S3; and, where indicated, flat washers.

Stainless-Steel Bolts and Nuts: Regular hexagon-head annealed stainless-steel bolts, ASTM F 738M; with hex nuts, ASTM F 836M; and, where indicated, flat washers; Alloy [Group A1 with Type 304] [Group A4 with Type 316L].

Anchor Bolts: ASTM F 1554, Grade 36, of dimensions indicated; with nuts, ASTM A 563M; and, where indicated, flat washers.

Hot-dip galvanize or provide mechanically deposited, zinc coating where item being fastened is indicated to be galvanized.

<If retaining "Anchors, General" Paragraph below, indicate loads on Drawings and verify safety factors with Project's structural engineer.> [Anchors, General: Anchors capable of sustaining, without failure, a load equal to six times the load imposed when installed in unit masonry and four times the load imposed when installed in concrete, as determined by testing according to ASTM E 488/E 488M, conducted by a qualified independent testing agency.] Cast-in-Place Anchors in Concrete: Either threaded type or wedge type unless otherwise indicated; galvanized ferrous castings, either ASTM A 47/A 47M malleable iron or ASTM A 27/A 27M cast steel. Provide bolts, washers, and shims as needed, all hot-dip galvanized per ASTM F 2329.

Post-Installed Anchors: [Torque-controlled expansion anchors] [or] [chemical anchors].

Material for Interior Locations: Carbon-steel components zinc plated to comply with ASTM B 633 or ASTM F 1941M, Class Fe/Zn 5, unless otherwise indicated.

Material for Exterior Locations and Where Stainless Steel Is Indicated: Alloy [Group A1 for Type 304] [Group A4 for Type 316L] stainless-steel bolts, ASTM F 738M, and nuts, ASTM F 836M.

Slotted-Channel Inserts: Cold-formed, hot-dip galvanized-steel box channels (struts) complying with MFMA-4, 41 by 22 mm by length indicated with anchor straps or studs not less than 75 mm long at not more than 200 mm o.c. Provide with temporary filler and tee-head bolts, complete with washers and nuts, all zinc-plated to comply with ASTM B 633, Class Fe/Zn 5, as needed for fastening to inserts.

MISCELLANEOUS MATERIALS

Shop Primers: Provide primers that comply with Division 09 Sections on painting and on high performance coatings.

Ferrous metal - typical painting systems: Universal shop primer; fast-curing, lead- and chromate-free, universal modified-alkyd primer complying with MPI#79.

<BELOW APPLIES TO LEED V4>

[Use primer with a VOC content of 420 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).] Ferrous metal - polyurethane coating system: Moisture-cure organic zinc-rich primer complying with SSPC-Paint 20 or SSPC-Paint 29 and compatible with topcoat.

<BELOW APPLIES TO LEED V4>

[Use primer with VOC content of 420 g/L or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).] Galvanizing Repair Paint: High-zinc-dust-content paint complying with SSPC-Paint 20 and compatible with paints specified to be used over it.

Bituminous Paint: Cold-applied asphalt emulsion complying with ASTM D 1187/D 1187M.

Nonshrink, Nonmetallic Grout: Factory-packaged, nonstaining, noncorrosive, nongaseous grout complying with ASTM C 1107/C 1107M. Provide grout specifically recommended by manufacturer for interior and exterior applications.

FABRICATION, GENERAL

Shop Assembly: Preassemble items in the shop to greatest extent possible. Disassemble units only as necessary for shipping and handling limitations. Use connections that maintain structural value of joined pieces. Clearly mark units for reassembly and coordinated installation.

Cut, drill, and punch metals cleanly and accurately. Remove burrs and ease edges to a radius of approximately 1 mm unless otherwise indicated. Remove sharp or rough areas on exposed surfaces.

Form bent-metal corners to smallest radius possible without causing grain separation or otherwise impairing work.

Form exposed work with accurate angles and surfaces and straight edges.

Weld corners and seams continuously to comply with AWS recommendations and the following:

Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals.

Obtain fusion without undercut or overlap.

Remove welding flux immediately.

At exposed connections, finish exposed welds and surfaces smooth and blended so no roughness shows after finishing[ and contour of welded surface matches that of adjacent surface].

Form exposed connections with hairline joints, flush and smooth, using concealed fasteners or welds where possible. Where exposed fasteners are required, use Phillips flat-head (countersunk) fasteners unless otherwise indicated. Locate joints where least conspicuous.

Fabricate seams and other connections that are exposed to weather in a manner to exclude water. Provide weep holes where water may accumulate.

Cut, reinforce, drill, and tap metal fabrications as indicated to receive finish hardware, screws, and similar items.

Provide for anchorage of type indicated; coordinate with supporting structure. Space anchoring devices to secure metal fabrications rigidly in place and to support indicated loads.

Where units are indicated to be cast into concrete or built into masonry, equip with integrally welded steel strap anchors, 3.2 by 38 mm, with a minimum 150-mm embedment and 50-mm hook, not less than 200 mm from ends and corners of units and 600 mm o.c., unless otherwise indicated.

Galvanized Steel:

Fabricate items in accordance with Class [I] [II] [III] guidelines as described in AGA's Recommended Details for Galvanized Structures.

Use fabrication practices for products in accordance with applicable portions of ASTM A143, A384 and A385, except as specified herein. Avoid fabrication techniques which could cause distortion or embrittlement of steel.

Consult Project Director/COR regarding potential warpage problems or potential handling problems during the galvanizing process which may require modification of design before fabrication proceeds.

Remove welding slag and burrs prior to delivery for galvanizing.

Provide vent and drain holes and/or lifting lugs to facilitate handling during the galvanizing process that are suitable to Project Director/COR and fabricator.

Locate holes so they will not be visible on exposed surfaces. If this is not possible, plug holes with zinc solder after galvanizing and file smooth. Do not fill holes indicated to remain as weep holes.

Remove lifting lugs after galvanizing.

After galvanizing, fill holes that were required for the galvanizing process.

Remove, by blast cleaning or other methods, surface contaminants and coatings which would not be removable by normal chemical cleaning process in galvanizing operation.

FORCED-ENTRY (FE) AND BALLISTIC-RESISTANCE (BR) PENETRATION SECURITY ASSEMBLIES

Fabricate assemblies in accordance with DS approved security details in the “DS Security Detail Handbook (Red Book),” and in accordance with Construction Drawings.

Refer to the Articles on FABRICATION, GENERAL and on FASTENERS for general fabrication requirements.

Finish:

All interior steel assemblies shall be prime coated or galvanized, unless noted as stainless steel on the Construction Drawings.

All Exterior steel assemblies shall be [galvanized] .

MISCELLANEOUS STEEL TRIM

Unless otherwise indicated, fabricate units from steel shapes, plates, and bars of profiles shown with continuously welded joints and smooth exposed edges. Miter corners and use concealed field splices where possible.

Provide cutouts, fittings, and anchorages as needed to coordinate assembly and installation with other work.

Provide with integrally welded steel strap anchors for embedding in concrete or masonry construction.

<PRIME AT LOCATIONS WITH MODERATE OR EXTREME CORROSION RISKS.>

Galvanize [and prime] exterior miscellaneous steel trim.

Prime interior miscellaneous steel trim.

LOOSE BEARING AND LEVELING PLATES

Provide loose bearing and leveling plates for steel items bearing on masonry or concrete construction. Drill plates to receive anchor bolts and for grouting.

Galvanize plates.

<AT LOCATIONS WITH EXTREME RISK, REFER TO SPEC SECTION 099605 FOR PRIMER.>

Prime plates with [zinc-rich primer.] [primer specified in Section 099600 "High-Performance Coatings."]

LOOSE STEEL LINTELS

Fabricate loose steel lintels from steel angles and shapes of size indicated for openings and recesses in masonry walls and partitions at locations indicated. Fabricate in single lengths for each opening unless otherwise indicated. Weld adjoining members together to form a single unit where indicated.

Size loose lintels to provide bearing length at each side of openings equal to 1/12 of clear span, but not less than 200 mm unless otherwise indicated.

<PRIME AT LOCATIONS WITH MODERATE OR EXTREME CORROSION RISKS.>

Galvanize [and prime] loose steel lintels located in exterior walls.

STEEL WELD PLATES AND ANGLES

Provide steel weld plates and angles not specified in other Sections, for items supported from concrete construction as needed to complete the Work. Provide each unit with no fewer than two integrally welded steel strap anchors for embedding in concrete.

FINISHES, GENERAL

Finish metal fabrications after assembly.

Finish exposed surfaces to remove tool and die marks and stretch lines, and to blend into surrounding surface.

STEEL AND IRON FINISHES

Galvanizing: Hot-dip galvanize items as indicated to comply with ASTM A 153/A 153M for steel and iron hardware and with ASTM A 123/A 123M for other steel and iron products.

Do not quench or apply post galvanizing treatments that might interfere with paint adhesion.

Shop Preparation for Galvanized Metal: Clean galvanized metal surfaces designated to be field painted in accordance with SSPC-SP1, “Solvent Cleaning”, followed by SSPC-SP2, “Hand Tool Cleaning” or SSPC-SP3, “Power Tool Cleaning”.

Shop prime iron and steel items not indicated to be galvanized unless they are to be embedded in concrete, sprayed-on fireproofing, or masonry, or unless otherwise indicated.

Preparation for Shop Priming: Prepare surfaces to comply with [SSPC-SP 6/NACE No. 3, "Commercial Blast Cleaning."] [SSPC-SP 3, "Power Tool Cleaning."] [requirements indicated below:] <Retain or revise any of four subparagraphs below to suit Project service conditions of installed work. Insert other exposures and preparation requirements where applicable. See SSPC's painting manual.> [Exterior Items: SSPC-SP 6/NACE No. 3, "Commercial Blast Cleaning."

Items Indicated to Receive Zinc-Rich Primer: SSPC-SP 6/NACE No. 3, "Commercial Blast Cleaning."

Items Indicated to Receive Primers Specified in Division 09 Section "High-Performance Coatings": SSPC-SP 6/NACE No. 3, "Commercial Blast Cleaning."

Other Items: SSPC-SP 3, "Power Tool Cleaning."] Shop Priming: Apply shop primer to comply with SSPC-PA 1, "Paint Application Specification No. 1: Shop, Field, and Maintenance Painting of Steel," for shop painting.

Stripe paint corners, crevices, bolts, welds, and sharp edges.

RESERVED

END OF SECTION 055005

METAL FABRICATIONS UNCLASSIFIED 055005 - 1

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