Final 05 50 00 Metal Fabrications.pdf

OFFUTT AIR FORCE BASE

(092036) 05 50 00-1 (Repair AHU O-Club, B462)

2010 by FEI

SECTION 05 50 00

METAL FABRICATIONS

PART 1 - GENERAL

1.1 SCOPE

A. The work required under this Section consists of all metal fabrications and related items necessary to complete the work indicated on drawings and / or described in specifications.

B. Metal fabrications includes items made from iron and steel shapes, plates, bars, strips, tubes, pipes and castings which are not a part of structural steel or other metal systems specified elsewhere.

C. Although such work is not specifically shown or specified, all supplementary or miscellaneous items, appurtenances and devices incidental to or necessary for a sound, secure and complete installation shall be furnished and installed as part of this work.

D. Types of Items Included. Without restricting the volume or generality of the above, the work to be performed under this Section shall include but is not limited to the following:

1. Bolts and Anchorage Accessories.

2. Expansion Anchors.

3. Cast - in and Drilled in Anchors for Concrete.

4. Support Assemblies.

5. Structural Framing Members.

6. Steel Gratings/Checker Plate.

7. Other Miscellaneous Steel Assemblies and Pieces Shown on Drawings.

1.2 RELATED WORK

A. Painting of Metal Items is specified elsewhere in Division 09.

1.3 DISCREPANCIES

A. In the event of discrepancy, immediately notify the Contracting Officer’s Representative.

B. Do not proceed with fabrication or installation in areas of discrepancy until all such discrepancies have been fully resolved.

1.4 CODES, SPECIFICATIONS AND STANDARDS

A. Publications listed below form a part of this specification to extent referenced. Publications are referenced in the text by basic designation only. Any material or operation specified by reference to the published specifications of a manufacturer or other referenced specification or standard shall comply with the requirements of the latest edition. In case of a conflict between a referenced specification or standard and these project specifications the more stringent requirement shall govern.

B. Comply with the applicable provisions of the following codes, specifications and standards to the extent indicated by reference thereto.

1. American Institute of Steel Construction - "Specification for the Design, Fabrication, and Erection of Structural Steel for Buildings".

2. American National Standards Institute - ANSI A 14.3.

(092036) 05 50 00-2 (Repair AHU O-Club, B462)

3. American Society of Testing and Materials - ASTM A 36 "Standard Specification for Carbon Structural Steel".

4. American Society of Testing and Materials - ASTM A 53 "Standard Specification for Pipe, Steel, Black and Hot - Dipped, Zinc - Coated, Welded and Seamless".

5. American Society of Testing and Materials - ASTM A108 "Standard Specification for Steel Bar, Carbon and Alloy, Cold - Finished".

6. American Society of Testing and Materials - ASTM A153 "Standard Specification for Zinc Coating (Hot - Dip) on Iron and Steel Hardware".

7. American Society of Testing and Materials - ASTM A193 "Standard Specification for Alloy - Steel and Stainless Steel Bolting Materials for High Temperature or High Pressure Service and Other Special Purpose Applications".

8. American Society of Testing and Materials - ASTM A 307 “Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength”.

9. American Society of Testing and Materials - ASTM A 449 "Specification for Hex Cap Screws, Bolts, and Studs, Steel, Heat Treated, 120/105/90 ksi Minimum Tensile Strength, General Use".

10. American Society of Testing and Materials - ASTM A 510 "Standard Specification for General Requirements for Wire Rods and Coarse Round Wire, Carbon Steel".

11. American Society of Testing and Materials - ASTM A 563 "Standard Specification for Carbon and Alloy Steel Nuts".

12. American Society of Testing and Materials - ASTM A 575 “Standard Specification for Steel Bars, Carbon, Merchant Quality, M - Grades”.

13. American Society of Testing and Materials - ASTM A 576 “Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special Quality”.

14. American Society of Testing and Materials - ASTM A 615 "Standard Specification for Deformed and Plain Carbon - Steel Bars for Concrete Reinforcement".

15. American Society of Testing and Materials - ASTM A 635 “Standard Specification for Steel, Sheet and Strip, Heavy - Thickness Coils, Hot - Rolled, Carbon, Structural, High - Strength Low - Alloy, and High - Strength Low - Alloy with Improved Formability, General Requirements for”.

16. American Society of Testing and Materials - ASTM A 653 “Standard Specification for Steel Sheet, Zinc - Coated (Galvanized) or Zinc - Iron Alloy - Coated (Galvannealed) by the Hot - Dip Process

17. American Society of Testing and Materials - ASTM A 1011 “Standard Specification for Steel, Sheet and Strip, Hot - Rolled, Carbon, Structural, High - Strength Low - Alloy and High - Strength Low - Alloy with Improved Formability”.

18. American Society of Testing and Materials - ASTM B 633 “Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel”.

19. American Society of Testing and Materials - ASTM F 436 "Standard Specification for

(092036) 05 50 00-3 (Repair AHU O-Club, B462)

Hardened Steel Washers".

20. American Society of Testing and Materials - ASTM F 593 "Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs".

21. American Society of Testing and Materials - ASTM F 594 "Standard Specification for Stainless Steel Nuts".

22. American Welding Society - AWS "Code of Welding in Building Construction”.

23. Federal Specifications - FF - S - 92 “Screw, Machine, Slotted, Cross Recessed or Hexagon Head”.

24. Federal Specifications - FF - W - 84 “Washers, Lock (Spring)”.

25. Federal Specifications - FF - W - 92 “Washer, Flat (Plain)”.

26. OSHA Regulations 29 CFR 1926.502 and 29 CFR 1910.23.

27. U.S. Army Corps of Engineers - CRD C 621 “Corps of Engineers Specification for Non -shrink Grout”.

1.5 QUALITY ASSURANCE

A. Qualifications of Welders: Use only certified welders and the shielded arc process for all welding performed in connection with the work of this Section.

B. Installer Qualifications for Anchor Systems: Drilled - in anchors shall be installed by a contractor or installer with at least three years of experience performing similar installations.

C. Certifications for Anchor Systems: Unless otherwise authorized by the Engineer, anchors shall have the following certifications: ICC ES Evaluation Report indicating conformance with current applicable ICC ES Acceptance Criteria.

D. Field Measurements: Take field measurements prior to preparation of shop drawings and fabrication, where possible. Do not delay job progress; allow for trimming and fitting where taking field measurements before fabrication might delay work.

E. Shop Assembly: Preassemble items in shop to greatest extent possible to minimize field splicing and assembly. Disassemble units only as necessary for shipping and handling limitations. Clearly mark units for reassembly and coordinated installation.

1.6 SUBMITTALS

A. Product Data: Submit manufacturer's specifications, anchor details and installation instructions for products used in miscellaneous metal fabrications, including paint products and grout.

B. Shop Drawings: Submit shop drawings for fabrication and erection of miscellaneous metal fabrications. Include plans, elevations and details of sections and connections. Show anchorage and accessory items. Provide templates for anchor and bolt installation by others.

C. Anchor Systems:

1. Submit product specifications with recommended design values and physical characteristics for epoxy dowels, expansion and undercut anchors. Provide certified test reports showing

(092036) 05 50 00-4 (Repair AHU O-Club, B462) compliance with specified performance characteristics and physical properties and Certificates in compliance with ICC ES Evaluation Reports.

2. Provide manufacturer’s installation instructions for anchor systems.

3. Submit installer qualifications showing compliance with requirements of Quality Assurance.

4. Submit a letter of procedure stating method of drilling, the product proposed for use, the complete installation procedure, manufacturer training date, and a list of the personnel to be trained on anchor installation.

D. Where materials or fabrications are indicated to comply with certain requirements for design loadings, include structural computations, material properties and other information needed for structural analysis.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Metals:

1. Metal Surfaces, General: For fabrication of miscellaneous metal work which will be exposed to view, use only materials which are smooth and free of surface blemishes including pitting, seam marks, roller marks, rolled trade names and roughness.

2. All Steel S - Shapes, M - Shapes, Channels, Angles, Bars, and Steel Plates: Comply with ASTM A 36 standards.

3. All Steel W and WT shapes (Fy = 50 KSI): Comply with ASTM A 992 standards.

4. Steel Plates, Shapes and Bars: ASTM A 36 standards.

5. Steel Bar Grating: ASTM A 569 or ASTM A 36 standards.

6. Steel Tubing: Cold formed, ASTM A 500; or hot - rolled, ASTM A 501 standards.

7. Structural Steel Sheet: Hot - rolled, ASTM A 570; or cold - rolled ASTM A 611, Class 1; of grade required for design loading.

8. Galvanized Structural Steel Sheet: ASTM A 653, of grade required for design loading.

Coating designation as indicated, or if not indicated, G90.

9. Steel Pipe: ASTM A 53; Type and grade (if applicable) as selected by fabricator and as required for design loading; black finish unless galvanizing is indicated; standard weight (schedule 40), unless otherwise indicated.

10. Concrete Inserts: Threaded or wedge type; galvanized ferrous castings, either malleable iron, ASTM A 47, or cast steel, ASTM A 27. Provide bolts, washers and shims as required hot-dip galvanized, ASTM A 153.

11. Steel Bar Grating: Comply with the applicable provisions and recommendations of the NAAMM "Metal Bar Grating Manual" ANSI / NAAMM MBG 531. Steel used in bearing bars, cross bars and connecting bars of rectangular section shall conform to ASTM A 1011 / A 1011M Commercial Steel (Type 2) for hot rolled carbon steel sheet and strip. Cross bars made of wire rod shall conform to ASTM A 510 (A510M) for carbon steel wire rods and coarse

(092036) 05 50 00-5 (Repair AHU O-Club, B462) round wire, except that permissible tolerance on diameter of coarse round wire shall be

0.005 inches. Combinations of these steels are permitted to be welded together.

B. Non - shrink grout shall be non - catalyzed, multi - purpose construction grout containing mineral aggregate that complies with Army Corps of Engineers CRD C 621 and ASTM C 1107, Grade C at flowable or plastic consistency. The minimum compressive strength of non - shrink grout shall be 5,000 pounds per square inch in 3 days as tested in accordance with 2 inch cube per ASTM C 109.

1. Acceptable manufacturers subject to compliance with the specifications shall be one of the following:

a. Master Builders - Construction Grout

b. Euclid Chemical Company - NS Grout

c. Or Approved Equal.

C. Fasteners: Provide zinc - coated fasteners for exterior use or where built into exterior walls. Select fasteners for the type, grade and class required.

1. Bolts and Studs: ASTM A 307

2. Bolts and Studs: ASTM A 449 where “high strength” is indicated on the Drawings.

3. Carbon and Alloy Steel Nuts: ASTM A 563.

4. Carbon Steel Washers: ASTM F 436.

5. Carbon Steel Threaded Rod: ASTM A 36; or ASTM A 193 Grade B7; or ISO 898 Class 5.8.

6. Wedge Anchors: ASTM A 510; or ASTM A 108.

7. Stainless Steel Bolts, Hex Cap Screws, and Studs: ASTM F 593.

8. Stainless Steel Nuts: ASTM F 594.

9. Zinc Plating: ASTM B 633.

10. Hot - Dip Galvanizing: ASTM A 153.

11. Reinforcing Dowels: ASTM A 615

D. Cast - In - Place Bolts: Anchors, Bolts, Nuts, and Washers: Bolts and studs, nuts, and washers shall conform to ASTM A 307, Grade A, and ASTM A 449, ASTM A 563, and ASTM F 436, as applicable.

Hot - dip galvanized bolts and studs including associated nuts and washers in accordance with ASTM A 153.

E. Drilled - In Anchors: Wedge type anchors, torque - controlled, with impact section to prevent thread damage complete with required nuts and washers. Provide anchors with length identification markings conforming to ICC ES AC01 or ICC ES AC193.

1. Interior Use: Unless otherwise indicated on the Drawings, provide carbon steel anchors with zinc plating in accordance with ASTM B 633, Type III Fe / Zn 5 (SC1).

2. Where anchor manufacturer is not indicated, subject to compliance with requirements and acceptance by the Engineer, provide the following:

(092036) 05 50 00-6 (Repair AHU O-Club, B462)

a. Hilti Kwik Bolt 3, ICC ESR - 1385.

b. Hilti Kwik Bolt TZ, ICC ESR - 1917 (carbon steel and AISI Type 304 Stainless Steel).

F. Heavy Duty Metric Sleeve Anchors: Torque - controlled, exhibiting follow - up expansion under load, with provision for rotation prevention during installation.

1. Interior Use: Unless otherwise indicated on the Drawings, provide carbon steel anchors manufactured from materials conforming to ISO 898 Part 1, with zinc plating equivalent to ASTM B 633, Type III Fe / Zn 5 (5µm min.).

2. Where anchor manufacturer is not indicated, subject to compliance with requirements and acceptance by the Engineer, provide the following:

a. Hilti HSL, HSLG, or HSLB, ICBO ER - 3987.

b. Hilti HSL - 3, HSL - 3 - G, or HSL - 3 - B, ICC ESR - 1545 (carbon steel).

G. Cartridge Injection Adhesive Anchors: Threaded steel rod, inserts or reinforcing dowels, complete with nuts, washers, polymer or hybrid mortar adhesive injection system, and manufacturer’s installation instructions.

1. Interior Use: Unless otherwise indicated on the Drawings, provide carbon steel threaded rods conforming to ASTM A 36, ASTM A 193 Type B7 or ISO 898 Class 5.8 with zinc plating in accordance with ASTM B 633, Type III Fe / Zn 5 (SC1) [or carbon steel HIT TZ rods conforming to ASTM A 510 with chemical composition of AISI 1038].

2. Reinforcing dowels shall be A615 Grade 60.

3. Where anchor manufacturer is not indicated, subject to compliance with requirements and acceptance by the Architect, provide the following:

a. Hilti HAS threaded rods or HIT - TZ rods with HIT HY - 150 / HIT ICE Adhesive Anchorage System for anchorage to concrete or grouted masonry, ICC ER - 5193, ICC ESR - 1562.

b. Hilti HAS threaded rods with RE 500 Injection Adhesive Anchoring System for anchorage to concrete, ICC ESR - 1682.

H. Capsule Anchors: Threaded steel rod, inserts and reinforcing dowels with 45 degree chisel point, complete with nuts, washers, glass or foil capsule anchor system containing polyvinyl or urethane methacrylate - based resin and accelerator, and manufacturer’s installation instructions.

1. Interior Use: Unless otherwise indicated on the Drawings, provide chisel - pointed carbon steel rods conforming to ASTM A 36, ASTM A 193 Type B7 or ISO 898 Class 5.8 with zinc plating in accordance with ASTM B 633, Type III Fe / Zn 5 (SC1).

2. Reinforcing dowels shall be A615 Grade 60, with 45 degree chisel points at embedded end.

3. Where anchor manufacturer is not indicated, subject to compliance with requirements and acceptance by the Architect, provide the following:

a. Hilti HVA Adhesive System with HVU capsules, ICC ER - 5369.

2.2 PRIMER PAINT

(092036) 05 50 00-7 (Repair AHU O-Club, B462)

A. Primer selected must be compatible with finish coats of paint where finish coats are specified.

Coordinate election of metal primer with finish paint requirements specified elsewhere in Division 09.

B. Metal Primer Paint: Rust - inhibitive, fast curing, low gloss, two component, Polyamide Epoxy with a minimum of 58 percent solids by volume and a minimum 4 mil dry film thickness. Acceptable manufacturer of paint shall be Tneme - Fascure, Series 161 by Tnemec or approved equal.

2.3 FABRICATION, GENERAL

A. Workmanship:

1. Use materials of size and thickness indicated or, if not indicated, as required to produce strength and durability in finished product for use intended. Work to dimensions shown or accepted on shop drawings, using proven details of fabrication and support. Use type of materials shown or specified for various components of work.

2. Form exposed work true to line and level with accurate angles and surfaces and straight sharp edges. Ease exposed edges to a radius of approximately 1/32 inch unless otherwise shown. Form bent - metal corners to smallest radius possible without causing grain separation or otherwise impairing work.

3. Weld corners and seams continuously, complying with AWS recommendations. At exposed connections and surfaces, grind exposed welds smooth and flush to match and blend with adjoining surfaces. Pits, voids, recessed streaks and raised areas are not acceptable at exposed welds and shall be redone until the seams and corners are made smooth and flush.

Bonding filler material shall not be used and is not acceptable as a method to correct the imperfections.

4. Form exposed connections with hairline joints, flush and smooth, using concealed fasteners wherever possible. Use exposed fasteners of type shown or, if not shown, Phillips flat-head (countersunk) screws or bolts.

5. Provide for anchorage of type shown or if not shown of appropriate type as approved, coordinated with supporting structure. Fabricate and space anchoring devices to provide adequate support for intended use.

6. Cut, reinforce, drill and tap miscellaneous metal work as indicated to receive finish hardware and similar items.

B. Shop Painting:

1. Shop paint miscellaneous metal work, except members or portions of members to be embedded in concrete or masonry, surfaces and edges to be field welded, and galvanized surfaces, unless otherwise indicated.

2. Prepare all exterior metals and all interior metals located in “wet areas” by remove scale, rust and other deleterious materials before applying shop coat. Clean in accordance with Steel Structures Painting Council (SSPC) SP - 6 “Commercial Blast Cleaning” or SP - 10 “Near - White Blast Cleaning”.

3. Prepare all interior metals with the exception of structural steel, steel decking and steel located in “wet areas” by removing oil, grease and similar contaminants in accordance with Steel Structures Painting Council (SSPC) SSPC - SP2 “Hand Tool Cleaning” or SSPC - SP3 “Power Tool Cleaning”.

(092036) 05 50 00-8 (Repair AHU O-Club, B462)

4. Immediately after surface preparation, brush or spray on primer in accordance with manufacturer's instructions, and at a rate to provide uniform minimum dry film thickness specified. Use painting methods which will result in full coverage of joints, corners, edges and exposed surfaces. Brush all welds, joints, seams and hard to reach areas to insure proper coverage.

5. Apply one shop coat to fabricated metal items, except apply 2 coats of paint to surfaces inaccessible after assembly or erection. Change color of second coat to distinguish it from the first.

2.4 MISCELLANEOUS METAL FABRICATIONS

A. Rough Hardware: Furnish bent or otherwise custom fabricated bolts, plates, anchors, hangers, dowels and other miscellaneous steel and iron shapes as required for framing and supporting woodwork, and for anchoring or securing woodwork to concrete or other structures. Straight bolts and other stock rough hardware items are specified in Division 6 sections.

1. Fabricate items to sizes, shapes and dimensions required. Furnish malleable iron washers for heads and nuts which bear on wood structural connections; elsewhere, furnish steel washers.

PART 3 - EXECUTION

3.1 PREPARATION

A. Coordinate and furnish anchorages, setting drawings, diagrams, templates, instructions, and directions for installation of anchorages, such as concrete inserts, sleeves, anchor bolts and miscellaneous items having integral anchors, which are to be embedded in concrete or masonry construction. Coordinate delivery of such items to project site.

3.2 INSTALLATION - GENERAL

A. Fastening to In - Place Construction: Provide anchorage devices and fasteners where necessary for securing miscellaneous metal fabrications to in - place construction; including, threaded fasteners for concrete and masonry inserts through - bolts, and other connectors as required.

B. Cutting, Fitting and Placement: Perform cutting, drilling and fitting required for installation of miscellaneous metal fabrications. Set work accurately in location, alignment and elevation, plumb, level, true and free of rack, measured from established lines and levels. Provide temporary bracing or anchors in formwork for items which are to be built into concrete, masonry or similar construction.

C. Fit exposed connections accurately together to form tight hairline joints. Weld connections which are not to be left as exposed joints, but cannot be shop welded because of shipping size limitations. Grind exposed joints smooth and touch - up shop paint coat. Do not weld, cut or abrade the surfaces of exterior units which have been hot - dip galvanized after fabrication, and are intended for bolted or screwed field connections.

D. Weld corners and seams continuously, complying with AWS recommendations for all field and factory welds. At exposed connections and surfaces, grind exposed welds smooth and flush to match and blend with adjoining surfaces. Pits, voids, recessed streaks and raised areas are not acceptable at exposed welds and shall be redone until the seams and corners are made smooth and flush. Bonding filler material shall not be used and is not acceptable as a method to correct the imperfections.

E. Field Welding: Comply with AWS Code for procedures of manual shielded metal - arc welding, appearance and quality of welds made, and methods used in correcting welding work.

(092036) 05 50 00-9 (Repair AHU O-Club, B462)

3.3 ANCHOR INSTALLATION

A. Perform anchor installation in accordance with manufacturer instructions.

B. Cast - In - Place Bolts: Use templates to locate bolts accurately and securely in formwork.

C. Drilled - In Anchors:

1. Drill holes with rotary impact hammer drills using carbide - tipped bits and / or core drills using diamond core bits. Drill bits shall be of diameters as specified by the anchor manufacturer.

Unless otherwise shown on the Drawings, all holes shall be drilled perpendicular to the concrete surface.

a. Cored Holes: Where anchors are to be installed in cored holes, use core bits with matched tolerances as specified by the manufacturer. HIT HY - 150 and HIT ICE shall not be installed in core drilled holes.

b. Embedded Items: Identify position of reinforcing steel and other embedded items prior to drilling holes for anchors. Exercise care in coring or drilling to avoid damaging existing reinforcing or embedded items. Notify the Engineer if reinforcing steel or other embedded items are encountered during drilling. Take precautions as necessary to avoid damaging prestressing tendons, electrical and telecommunications conduit, and gas lines.

c. Base Material Strength: Unless otherwise specified, do not drill holes in concrete or masonry until concrete, mortar, or grout has achieved full design strength.

D. Wedge Anchors, Heavy - Duty Sleeve Anchors, and Undercut Anchors: Protect threads from damage during anchor installation. Heavy - duty sleeve anchors shall be installed with sleeve fully engaged in part to be fastened. Set anchors to manufacturer’s recommended torque, using a torque wrench.

Following attainment of 10 percent of the specified torque, 100 percent of the specified torque shall be reached within 7 or fewer complete turns of the nut. If the specified torque is not achieved within the required number of turns, the anchor shall be removed and replaced unless otherwise directed by the Contracting Officer’s Representative.

E. Cartridge Injection Adhesive Anchors: Clean all holes per manufacturer instructions to remove loose material and drilling dust prior to installation of adhesive. Holes do not need to be cleaned for HIT - TZ Rods with HY - 150 in accordance with ICC ESR - 1562. Holes may be dry, damp or wet. Inject adhesive into holes proceeding from the bottom of the hole and progressing toward the surface in such a manner as to avoid introduction of air pockets in the adhesive. Follow manufacturer recommendations to ensure proper mixing of adhesive components. Sufficient adhesive shall be injected in the hole to ensure that the annular gap is filled to the surface. Remove excess adhesive from the surface. Shim anchors with suitable device to center the anchor in the hole. Do not disturb or load anchors before manufacturer specified cure time has elapsed. Observe manufacturer recommendations with respect to installation temperatures for cartridge injection adhesive anchors.

F. Capsule Anchors: Perform drilling and setting operations in accordance with manufacturer instructions. Clean all holes to remove loose material and drilling dust prior to installation of adhesive.

Remove water from drilled holes in such a manner as to achieve a surface dry condition. Capsule anchors shall be installed with equipment conforming to manufacturer recommendations. Do not disturb or load anchors before manufacturer specified cure time has elapsed. Observe manufacturer recommendations with respect to installation temperatures for capsule anchors.

(092036) 05 50 00-10 (Repair AHU O-Club, B462)

3.4 TOUCH - UP PAINTING

A. Cleaning and touch - up painting of field welds, bolted connections and abraded areas of the shop paint on miscellaneous metal is specified in Division 09 of these specifications.

END OF SECTION