DRAFT Cab Glass Fabricator Specification (7-22-2020).pdf

ATCT CAB GLASS FABRICATION SPECIFICATION July 21, 2020

PART 1 GENERAL

1.1 SUMMARY

A. Furnish labor, material, equipment, and services required for the fabrication and delivery of

Airport Traffic Control Tower (ATCT) Cab Glass units to Federal Aviation Administration

(FAA) facility locations indicated in the delivery order. ATCT locations include the continental

US, Alaska, Hawaii, Puerto Rico, and Guam.

1.2 REFERENCES AND STANDARDS

A. American National Standards Institute (ANSI)

1. ANSI Z 97.1 Safety Glazing Materials Used in Buildings - Safety Performance

Specifications and Methods of Test

B. American Society for Testing and Materials (ASTM)

1. ASTM C 162 Standard Terminology of Glass and Glass Products

2. ASTM C 1036 Standard Specification for Flat Glass

3. ASTM C 1087 Standard Test Method for Determining Compatibility of Liquid-Applied

Sealants with Accessories Used in Structural Glazing Systems

4. ASTM C 1172 Standard Specification for Laminated Architectural Flat

5. ASTM C 1376 Standard Specification for Pyrolytic and Vacuum Deposition Coatings on

Flat Glass

6. ASTM E 773 Standard Test Method for Accelerated Weathering of Sealed Insulating

Glass Units

7. ASTM E 774 Standard Specification for Sealed Insulating Glass Units

8. ASTM E 1300 Standard Practice for Determining Load Resistance of Glass in Buildings

9. ASTM E 1886 Standard Test Method for Performance of Exterior Windows, Curtain

Walls, Doors, and Impact Protective Systems Impacted by Missile(s) and Exposed to

Cyclic Pressure Differentials

10. ASTM E 1996 Performance of Exterior Windows, Curtain Walls, Doors, and Impact

Protective Systems Impacted by Windborne Debris in Hurricanes

11. ASTM E 2188 Standard Test Method for Insulating Glass Unit Performance

12. ASTM E 2189 Standard Test Method for Testing Resistance to Fogging in Insulating

Glass Units

13. ASTM E 2190 Standard Specification for Insulating Glass Unit Performance and

Evaluation

14. ASTM E 2461 Standard Practice for Determining the Thickness of Glass in Airport

Traffic Control Tower Cabs

15. ASTM E 2649 Standard Test Method for Determining Argon Concentration in Sealed

Insulating Glass Units Using Spark Emission Spectroscopy

16. ASTM F 1642 / F 1642M Standard Test Method for Glazing and Glazing Systems

Subject to Airblast Loadings

17. ASTM F 2248 Standard Practice for Specifying an Equivalent 3-Second Duration Design

Loading for Blast Resistant Glazing Fabricated with Laminated Glass

18. ASTM F 2912 Standard Specification for Glazing and Glazing Systems Subject to

Airblast Loadings

C. Insulating Glass Manufacturers Alliance (IGMA)

1. IGMA TB-3001 Guidelines for Sloped Glazing

2. IGMA TB-1601-95 Guidelines for Use of Capillary / Breather Tubes

3. IGMA TM-3000 North American Glazing Guidelines for Sealed Insulating Glass Units for Commercial & Residential Use

4. IGMA TM-4000-02 – Insulating Glass Manufacturing Quality Procedures

5. IGMA TM-4100-03 – Preventing Insulating Glass Failures Manual

D. Sealed Insulating Glass Manufacturers Association (SIGMA)

1. A1202 Commercial Insulating Glass Dimensional Tolerances

E. Glass Association of North America (GANA)

1. Laminated Glazing Reference Manual

2. Glazing Manual

3. Sealant Manual

F. Consumer Product Safety Commission (CPSC)

1. CPSC 16 CFR 1201 – Safety Standard for Architectural Glazing Materials

1.3 DEFINITIONS

A. Manufacturer: Where used in this specification to refer to a firm that produces primary glass or fabricated glass as defined in the referenced standards.

B. Fabricator: Where used in this specification to refer to a firm that fabricates glass units as defined in the referenced standards.

C. Deterioration of Glass: Defects developed from normal use and weather conditions that are attributed to the manufacturing or fabricating process and not to causes other than glass breakage and practices for maintaining and cleaning glass contrary to fabricator's directions. Defects include glass found to be out of compliance with ASTM C1036.

D. Deterioration of Coated Glass: Defects developed from normal use that are attributed to the manufacturing or fabricating process and not to causes other than glass breakage and practices for maintaining and cleaning coated glass contrary to manufacturer’s directions. Defects include peeling, cracking, discoloration, and other indications of deterioration in coating.

E. Deterioration of Insulating Glass: Failure includes, but is not limited to, failure of the hermetic seal under normal and weather conditions due to causes other than glass breakage and improper practices for maintaining and cleaning insulating glass. Evidence of failure is the obstruction of vision by dust, moisture, film, or minerals on the surfaces of insulating glass facing the interspace or optical distortions (ghosting / double-images) not due to improper practices for maintaining and cleaning glass not in compliance with manufacturer’s or fabricator’s directions.

F. Deterioration of Laminated Glass: Defects developed from normal use and weather conditions that are attributed to the manufacturing or fabricating process and not to glass breakage and practices for maintaining and cleaning laminated glass contrary to manufacturer’s or fabricator’s directions. Defects include edge separation, delamination materially obstructing vision through glass, and blemishes exceeding those allowed by referenced laminated glass standard. Laminated glass shall be considered defective when dissolved gases come out of solution (forming bubbles, haze or delaminated areas between the glass / interlayer interface) by any cause including elevated temperatures due to weather conditions and sunlight exposure.

G. Glass Thickness: Designated in inches or millimeters according to ASTM C 1036 and E 2461.

H. Interspace or Airspace: Air or inert gas-filled space between lites of an insulating glass unit.

1.4 SUBMITTALS

A. Product Data: Submit manufacturer’s descriptive product data for each glass product and material used for glass unit fabrication including coatings (if specified in the order), spacer, desiccant, primary sealant and secondary sealants for insulating glass units, and the interlayers for laminated units. Submit manufacturer’s handling and storage recommendations, installation instructions, and cleaning instructions from both the manufacturer of the glass lites and the manufacturer of the insulating glass and laminated glass units.

B. Samples: Provide three 12” x 12” (minimum) samples of cab glass units.

C. Compatibility Test Report: Submit compatibility and adhesion test reports from manufacturer of insulating glass edge sealant indicating that glass edge sealants were tested for compatibility with other glazing materials including sealants, glazing tape, gaskets, setting blocks and edge blocks.

Include recommendations for glazing tape and caulking materials that are compatible with sealants and coatings used in assembled units.

D. Product Certificates: Certify final glass product complies with Insulated Glass Certification

Council (IGCC), IGMA, Keystone or other comparable IG certification programs and meet the performance requirements of ASTM E 2190 per test methods E 2188 and E 2189. Provide reports indicating a pass on tests for units matching the product number of units received. If unit(s) is ordered for an application where manufacturer recommends capillary tubes be left permanently open, the test report must indicate the product has a capillary tube left open during testing.

E. User Information: Submit glass product handling and storage recommendations, installation instructions, and cleaning and maintenance instructions.

1.5 QUALITY ASSURANCE

A. Fabricator must be approved and certified by primary glass manufacturer for low-E coated glass and insulating glass units, and must have successfully fabricated Cab Glass for at least five (5)

FAA ATC Towers within the last five (5) years.

B. The government reserves the right to visit on-demand the fabrication facility to inspect the glass, production facility, and quality control program, and to review their Quality Control (QC) inspection process and test reports.

C. Fabricator must maintain IGCC Certification and provide updated documentation whenever changes are made and test reports are received.

1.6 DELIVERY, STORAGE, AND HANDLING

A. Deliver glass products to the destination indicated in the delivery order.

B. All orders shall be processed in accordance with fabricator’s in-house Quality Control / Quality

Assurance (QC/QA) Program. Handle, store, and protect glass and units in accordance with manufacturer’s written instructions.

C. Prior to shipment, test of all newly fabricated cab glass units for visual distortion. Perform test under all levels of light, with unit tilted in its’ final 15° configuration while viewing many types and shapes of objects including moving objects and red and white lights. Visual ghosting or double imaging will not be acceptable.

D. Prepare glass products for shipment in accordance with manufacturer's written instructions using appropriate wood and glass blocking materials to prevent damage while in shipment from condensation, moisture ingress, temperature changes, direct exposure to sun, or other causes.

Allow sealants to cure fully prior to boxing, crating, and shipping.

E. Box, crate, and transport all glass products in the appropriate vertical position exclusively.

F. Provide temporary labels on each glass unit with the following information: date of fabrication, unit size, weight, glass type and thickness, and spacer information if an insulating glass unit

(IGU).

G. Only when necessary, provide capillary tubes in insulating glass units exposed to substantial altitude changes between location of fabrication and destination site, or in transit to site, in accordance with manufacturers’ written instructions to avoid hermetic seal ruptures, or the bowing inward or outward of the glazing lites due to altitude change.

1.7 WARRANTY

A. Insulating Glass Units

1. Provide warranty signed by fabricator agreeing to replace insulating glass units that deteriorate as defined in Section 1.3 of this specification, FOB point of manufacture, freight allowed project site, within 10 years after date of Final Acceptance, or within 5 years for units over 65 square feet or over 96 by 96 inches. Warranty covers only deterioration due to normal conditions of use as defined and not due to handling and installing.

B. Laminated Glass Units

1. Provide warranty signed by fabricator agreeing to replace laminated glass units that deteriorate as defined in Section 1.3 of this specification, FOB point of manufacture, freight allowed project site, within 10-years after date of Final Acceptance. Warranty covers only deterioration due to normal conditions of use as defined and not due to handling and installing.

C. Coated Glass Products

1. Provide warranty signed by fabricator agreeing to replace coated glass units that deteriorate as defined in Section 1.3 of this specification, FOB point of manufacture, freight allowed project site, within 10-years after date of Final Acceptance. Warranty covers only deterioration due to normal conditions of use as defined and not due to handling and installing.

D. Replacement of Failed Units

2. Provide new units for any units failing to comply with the terms of this warranty within

45 calendar days after receipt of notice from the Government.

PART 2 PRODUCTS

2.1 GLASS MANUFACTURERS

A. Subject to compliance with this Section, provide glass products by one of the following:

1. Vitro / PPG

2. Nippon / Pilkington

3. Saint-Gobain

4. Guardian

5. AGC Glass

2.2 GLASS PRODUCTS

A. All glass must meet ASTM C 1036-11 Quality 2 (Q2), along with the following revision to Table

3: Note A does not apply; instead, the largest point blemish in glass 6 mm to 12 mm thick shall be smaller than 1.5 mm. Additionally, etching or permanent labels on glass are not acceptable, neither are scratches on any glass surface.

B. Clear Annealed Float Glass: ASTM C 1036-11, Type I (Transparent Glass, Flat), Class 1 (Clear), C. Low-Iron Annealed Float Glass: ASTM C1036-11, Type I (Transparent Glass, Flat), Class I

(Clear), and Q2 (Quality Q2).

D. Coated Vision Glass: ASTM C1376, coated by vacuum deposition (sputter-coating) process, and subject to compliance with this Section.

2.3 LAMINATED GLASS

A. Laminated Glass: Vertically-assembled units in accordance with ASTM C1172. Use materials that have a proven record of no tendency to bubble, discolor, or lose physical and mechanical properties after fabrication and installation. Maximum allowable edge-overlap of the plies to be 3 mm for butt joints and 5 mm for all other edges. Comply with manufacturer’s written instructions for edge deletion. Unless otherwise approved by FAA, manufacturers shall be:

1. Kuraray / Dupont

2. Kuraray / Trosifol

3. Eastman

4. Vanceva

B. Interlayers: Clear or ultra clear polyvinyl butyral (PVB) sheets in compliance with manufacturer's written instructions. When ordered, provide clear rigid ionomeric interlayer with structural properties to achieve wind load resistance as required.

C. Interlayer Thickness: Not less than 0.060” (1.52 mm), and as needed to comply with requirements.

D. Interlayer Color: Clear / Ultra Clear as indicated in the delivery order.

E. Edgework: Post-lami CNC machine ground flat and polish glass edges and corners, with slight chamfers on each side. For butt-glazed monolithic and laminated glass, flat-grind vertical edges to produce mitered edges with slight chamfers at junctions of edges and faces.

F. Low-E Coating: When ordered, coating material must be submitted for approval and designed for the intended environment. Apply to glass Surface 2 unless indicated otherwise in the order.

Provide edge deletion according to manufacturer’s recommendations to improve spacer adhesion and avoid deterioration of the coating.

G. Tin Surface Orientation: If no coatings are specified or if coating specified for glass surfaces 2 or

4, then tin surfaces to be 1 and 3. If coating specified for surface 1 or 3, then tin surfaces to be 2 and 4. These configurations assume the final product is a laminated unit of two lites and one interlayer. FAA will address other configurations during the submittal process.

2.4 INSULATING GLASS

A. Insulating-Glass Units: Vertical and automatic assembly of units consisting of sealed lites of glass separated by a dehydrated interspace, qualified in accordance with ASTM E2190.

B. Sealing System: Dual seal, with polyisobutylene primary and black silicone secondary sealants in compliance with SIGMA A1202 and TB-3000. When ordered, provide secondary seal with increased depth of up to 1.25-inch from the edge of glass. Both seals must be continuous around spacer and maintain a constant depth to ensure a watertight and airtight seal. Any voids in primary seal will result in rejection of material. Undulations in the edge of the sealing system may be discernible but will be considered minor and not constitute rejection when the reduced depth of the seal is less than 10% reduction in depth.

C. Spacer: Fabricator’s standard spacers shall meet the requirements below:

1. Material: Stainless Steel

2. Location: Space set back up to 1.25” from glass edge to increase secondary seal size

3. Corners: All corners shall be machine bent without cuts and corner keys; must be smooth and contain no out-of-plane bends on the surface which contacts the glass

4. Joints: Bent corners with only one assembly joint permitted, located on the left or right side of the unit at mid-height of the unit

5. Spacers with plugged holes shall not be allowed

6. Cuts & Splices: No burrs or jagged edges allowed

7. Labels: Provide clearly visible label with date stamp

D. Desiccant: Molecular sieve or silica gel, filled on all four sides. Use of desiccant prefill-in foam spacer must be submitted for approval and meet initial submittal documentation requirements with the justification for the substitution.

E. Interspace: The hermetically sealed air space shall be dehydrated air, or when ordered, argon gas at a minimum concentration of 90%.

F. Capillary Tube: When recommended by manufacturer or indicated in the delivery order, provide stainless steel tubes 12” long, 0.25 to 0.5 mm inside diameter, capillary tube located on one side near the top of unit, with the exposed end pointing downward and secured temporarily in this position during shipment in accordance with IGMA TB-1601-95 (14).

G. Edgework: CNC machine ground flat and polish glass edges and corners, and producing slight chamfers on each side.

H. Low-E Coating: When ordered, coating material must be submitted for approval and designed for the intended environment. Apply to glass Surface 2 unless indicated otherwise in the delivery order. Provide edge deletion according to manufacturer’s recommendations to improve spacer adhesion and avoid deterioration of the coating.

I. Tin Surface Orientation: If no coatings are specified or if coating specified for glass surfaces 2 or

4, then tin surfaces to be 1 and 3. If coating specified for surface 1 or 3, then tin surfaces to be 2 and 4. These configurations assume the final product is a laminated unit of two lites and one interlayer. FAA will address other configurations during the submittal process.

LIST of ACRONYMS and ABBREVIATIONS:

ASCE – American Society of Civil Engineering

ASTM – American Society for Testing and Materials

ATC – Airport Traffic Control ATCT – Airport Traffic Control Tower

Cab – An ATCT cabin

CO – Government Contracting Officer

COR – Government Contracting Officer’s Representative

FAA – Federal Aviation Administration

IG – Insulating Glass

IGCC – Insulating Glass Certification Council

IGU – Insulating Glass Unit

Low-E – low emissivity glass mm -- millimeter

PVB – Polyvinyl Butyral

QA – Quality Assurance

QA/QC – Quality Assurance/Quality Control

SOW – Statement of Work