master_spec_05500_en.pdf

Section 05500 1

SECTION 05500

METAL FABRICATIONS

PART 1 - GENERAL

1.1 APPLICABLE PUBLICATIONS

The following publications of the issues listed below, but referred to thereafter by basic designation only, form a part of this specification to the extent indicated by the references thereto:

ITALIAN NATIONAL INSTITUTE FOR THE UNIFICATION OF STANDARDS (UNI)

PUBLICATIONS:

UNI 4630 (1982) Hot rolled finished flat steel products. Buckle plates. Dimensions and tolerances.

UNI 4634 (1960) Classification and qualification of electric welders. Welders of mild or low alloy steel sheet of medium or thick gage.

UNI 3740 –1-9-10-11 (1999-1982) Steel Fasteners. Technical

Specifications.

UNI EN 10056-1 (2000) Structural steel equal and unequal leg angles – Dimensions.

UNI EN 10056-2 (1995) Structural steel equal and unequal leg angles. Tolerances on shape and dimensions.

UNI EN 10025 (1995) Hot rolled products of non - alloys structural steel. Technical delivery conditions.

UNI EN 10002-1 (1992) Metallic materials. Tensile testing. Method of test (at ambient temperature).

UNI 564 (1960) Metal Materials Mechanical Tests.

Bend Test.

NATIONAL COUNCIL FOR SCIENTIFIC RESEARCH (C.N.R.) PUBLICATIONS:

CNR 10011/85 Steel Constructions - Calculation, Execution and Maintenance Instructions.

CNR 10016/85 Steel and Concrete Compound Truss -

Calculation and Execution Instructions.

CNR 10022/85 Cold Sections - Instruction for the Use in

Constructions.

CNR 10029/85 High Resistance Steel Constructions.

Calculation, Execution, Test and Maintenance Instructions.

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EUROPEAN WROUGHT ALUMINUM ASSOCIATION (EWWA-EURAS):

Type 46020 Aluminum Alloy (Cast).

Type 5005 Aluminum Alloy (sheet).

Type 6063 Aluminum Alloy (Extruded).

ITALIAN LAW

Law 1086 (5 November 1971) Norms for the

Regulation of Normal, Prestressed and Metal Structure Cement Conglomerate Works.

Ministerial Decree 9 Jan.1996 Technical Norms for the Calculation, Execution, and Testing of Normal and Prestressed Reinforced Concrete Structures, and Metal Structures.

1.2 DESCRIPTION

Fabrications shall be well-constructed products conforming to the types, materials and details indicated on drawings or specified herein. Basic forms of metal components from which assemblies are fabricated shall be of wrought or cast metal as shown or specified and physical properties, including tempers, of the metals shall be suitable for their intended use. All metals shall be free of defects that will affect their strength or durability and where exposed to view in the finished work, edges, and surfaces shall be without burrs, gouges, scratches, or other blemishes that mark their appearance. Exposed welds and brazed or soldered joints shall be ground smooth; polished or other surfaces with applied finishes shall be protected against damage or defacement of any kind. Assemblies shall be of the manufacturer's standard construction except where indicated or specified otherwise. Permanent connections for components subject to impact or other live loads shall be effected by welding, riveting or other approved methods. Welding shall conform to UNI 4634 and shall be accomplished so as to prevent permanent distortion of the connected parts. Bolts, screws and similar suitable fastenings shall be used for anchoring or securing miscellaneous metal work to supporting construction unless indicated otherwise. The Contractor shall verify all measurements and shall take field measurements before fabrication.

Material and parts to complete each item shall be included, even though such work is not definitely shown or specified. Miscellaneous bolts and anchors, supports, braces and connections for installation and completion of the miscellaneous metalwork shall be provided.

1.3 SUBMITTALS

1.3.1 Data

Data shall be sufficient to show conformance to specified requirements;

submit complete descriptive data on the following materials:

a. Canopy

b. Panels for air handling unit casing

c. Support plates, expansion fasteners, anchors, bolts and miscellaneous fastening devices

d. Fire extinguisher cabinet

Section 05500 3

e. Handrails

f. Steel louvers

1.3.2 Drawings

Submit templates and erection and installation details indicating thickness, type, grade, class of metal and dimensions. Show construction details, reinforcement, anchorage and installation in relation to the building construction:

a. Canopy

b. Panels for air handling unit casing

c. Support plates, expansion fasteners, anchors, bolts and miscellaneous fastening devices

d. Fire extinguisher cabinet

e. Handrails

f. Steel louvers

1.3.3 Shop drawings, descriptive data and samples shall be approved before items are delivered to the job site. The drawings shall show materials, connections, finish and all pertinent details.

1.4 DELIVERY, STORAGE AND HANDLING

Protect from corrosion, deformation, and other types of damage. Store items in an enclosed area free from contact with soil and weather. The Contractor shall replace all damaged items.

1.5 QUALIFICATION OF WELDERS

Qualify welders in accordance with UNI 4630-60 using procedures, materials, and equipment of the type required for the work.

PART 2 - PRODUCTS AND EXECUTION

2.1 MATERIALS

The thickness indicated or specified are minimum. Unless specified otherwise, materials shall be in accordance with the following specifications and standards as applicable. Material not otherwise specified herein shall conform to the requirements of Law 1086.

2.1.1 Structural Steel

UNI 3740

2.1.2 Aluminum Alloy (Extruded)

European Wrought Aluminum Association (EWAA-EURAS) Type 6063.

2.1.3 Steel

Italian Norm Quality 1.

2.1.4 Aluminum Alloy Cast

EWAA-EURAS Type 46020.

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2.1.5 Aluminum Alloy Sheet

EWAA-EURAS Type 5005.

2.1.6 Fittings for Steel Pipe

Standard malleable iron fittings.

2.1.7 Hardware

Provide as an integral part of miscellaneous metal items.

2.1.8 Anchors and Fasteners

Where exposed, shall be of the same material, color and finish as the metal to which applied.

2.1.8.1 Expansion Shields

Provide of group, type, class and style best suited for the purpose.

Provide shields recessed not less than 60 millimeters into concrete or masonry unless indicated otherwise.

2.1.8.2 Lag and Screws or Bolts

Type and grade best suited for the purpose.

2.1.9 Hot Dip Galvanizing

All items indicated or specified to be galvanized shall be hot dipped.

2.2 DISSIMILAR MATERIALS

Where dissimilar metals are in contact or where aluminum is in contact with concrete, mortar, masonry, wood or absorptive materials subject to wetting, protect the surfaces with a coat of bituminous paint or a coat of zinc chromate primer to prevent galvanic or corrosive action.

2.3 FABRICATION

By mechanics skilled in the trade and in accordance with the manufacturer's directions. Metal work shall be well formed to shape and size, with sharp lines and angles and true curves. All work fabricated to allow for expansion and contraction of materials. Provide welding and bracing of adequate strength and durability with tight, flush joints dressed smooth and clean.

2.3.1 Measurements

Before fabrication, take necessary field measurements and verify all related conditions and measurements.

2.3.2 Metal Surfaces

Shall be clean and free from mill scale, rust flakes and rust pitting;

well formed and finished to shape and size, with sharp lines and angles and smooth surfaces. Shearing and punching shall leave clean true lines and surfaces. Weld or rivet permanent connections. Welds and flush rivets shall be used and finished flush and smooth on surfaces that will

Section 05500 5 be exposed after installation. Do not use screws or bolts where they can be avoided; when used, heads shall be countersunk, screwed up tight and threads nicked to prevent loosening.

2.3.3 Construction

Thickness of metal and details of assembly and supports shall give ample strength and stiffness for the minimum loads specified or indicated.

Joints exposed to weather shall be formed to exclude water.

2.3.4 Fastening

Provide the necessary rebates, lugs and brackets so that the work can be assembled in a neat, substantial manner. Holes for bolts and screws shall be drilled. Built-up parts shall be out of wind. Joints exposed to the weather shall be formed to exclude water. Conceal fastenings where possible.

2.3.5 Shop Fabrication

Fabrication and assembly shall be done in the shop to the greatest extent possible.

2.3.6 Drilling and Punching

Shall produce clean, true lines and surfaces.

2.3.7 Welding and Riveting

Welding shall be continuous along the entire area of contact, except where tack welding is permitted. Exposed connections of work in place shall not be tack welded. Exposed welds shall be ground smooth with the adjacent surfaces. Exposed surfaces of work in place shall have a smooth finish, and exposed riveting and screw heads shall be flush.

2.3.8 Joints

Where tight fits are required, mill joints to a close fit. Corner joints shall be coped or mitered, well formed, and in true alignment.

2.3.9 WORKMANSHIP

Fabricate metalwork in accordance with approved drawings, cuts, details and samples. Work shall be accurately set to established lines and elevations and securely fastened in place.

PART 3 - EXECUTION

3.1 INSTALLATION

Install items at locations indicated according to manufacturer's instructions. Items listed below require additional procedures.

3.2 ANCHORAGE, FASTENINGS, AND CONNECTIONS

3.2.1 Anchorage

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Provide anchorage for fastening work securely in place. Set anchors in concrete as the work progresses and space not more than 600 mm on center unless indicated otherwise. Sizes, kinds, and spacings of anchors not indicated or specified shall be necessary for the purpose, as approved.

Anchorage not otherwise specified or indicated includes slotted inserts, expansion shields, and powder-driven fasteners, when approved for concrete; toggle bolts and through bolts for masonry; machine and carriage bolts for steel; through bolts, lag bolts and screws for wood.

Provide inserts of suitable and approved types where required for support or anchorage of equipment and finish construction. Inserts shall be gray or malleable iron castings or galvanized steel unless indicated or specified otherwise. Slotted inserts shall be types required to engage with anchors. Except where specified otherwise, all anchors and anchor bolts in exterior wall shall be zinc-coated and all other anchors and anchor bolts shall be heavily coated with bituminous paint.

3.2.1.1 Fastenings

Do not use wood plugs in any material, except as specified differently.

Use non-ferrous attachments for non-ferrous metal. Make exposed fastenings of compatible materials, generally matching in color and finish, and harmonizing with the material to which fastenings are applied. Conceal fastenings where practicable. Drill and punch to provide clean true lines and surfaces. Countersink metal work to receive hardware.

3.2.1.2 Threaded Connections

Connections shall conform to the minimum standard connections as indicated in Italian Law 1086. Make threaded connections up tight so that threading is entirely concealed. Make bolted work up tight and nick the threads or bush the stem to prevent loosening. Rivet, bolt, and screw heads shall be flat and countersunk in exposed work and elsewhere as required.

3.2.1.3 Anchors and Connecting Members

Provide in concrete or masonry as the work progresses, to avoid unnecessary cutting and drilling. Cut, fit and drill as necessary so all materials are properly set in place and to permit engaging work to be properly installed.

3.2.2 Built-In-Work

All metal work built-in with concrete or masonry shall be formed for anchorage, or be provided with suitable anchoring devices as shown or as required. Furnish metal work in ample time for securing in place as the work progresses.

3.3 WELDING

Weld in a manner to prevent permanent distortion to the connected parts.

Weld continuously along the entire area of contact except where tack welding is permitted. Do no tack weld exposed connections. Grind smooth all welds that will be visible in the finished installation. In addition, see welder's qualifications above.

3.4 FINISHES

Section 05500 7

3.4.1 Galvanizing

Hot-dip galvanize items specified to be zinc-coated, after fabrication where practicable. Galvanize anchor bolts, grating fasteners, washers and parts or devices necessary for proper installation unless indicated otherwise.

3.4.1.1 Repair of Zinc-Coated Surfaces

Repair surfaces damaged by welding or other means with galvanizing repair paint or by the application of stick or thick paste material specifically designed for repair of galvanizing, as approved. Clean areas to be repainted and remove the slag from the welds. Surfaces to which stick or paste material is applied, shall be heated with a torch to a temperature sufficient to melt the metallics in stick or paste; spread the molten material uniformly over surfaces to be coated and wipe the excess material off.

3.4.2 Shop Cleaning and Painting

After surface preparation, apply pretreatment and primer as specified.

Do not coat surfaces of items to be embedded in concrete. Recoat damaged surfaces using surface preparation, treatment, primer and paint that were applied to the adjacent surfaces upon completion of work. Do no apply bituminous protective coatings to items to be finish painted.

3.4.2.1 Environmental Conditions

Do not clean or paint surface when they are damp or exposed to foggy or rainy weather or when the surface temperature is below 7 degrees Centigrade or over 35 degrees Centigrade unless approved by the Contracting Officer’s Technical Representative.

3.4.2.2 Surface Preparation

Unless otherwise specified herein, wash cleaned surfaces which become contaminated with rust, dirt, oil, grease or other contaminants with solvents until thoroughly clean. Insure that steel to be embedded in concrete is free of dirt and grease. Do not paint or galvanize bearing surfaces, including contact surfaces within friction-type joints, but coat them with an approved rust preventative, applied in the shop.

Remove such coating just prior to field erection using a remover approved by the rust preventative manufacturer. Insure that the surfaces, when assembled, are free from rust, grease, dirt and other foreign matter.

Clean steel and iron work by power wire brushing or other approved manual or mechanical means, for removal of rust, loose paint, scale and deleterious substances. Wash cleaned surfaces which become contaminated with rust, dirt, oil, grease or other foreign matter, with solvents until thoroughly clean. The cleaning of steel to be embedded in concrete is not required.

3.4.2.3 Pretreatment, Priming and Painting

Apply pretreatment, primer and paint in accordance with the manufacturer's standard practice. On surfaces that will be concealed in the finished construction or that will not be accessible for finish painting, apply an additional prime coat to a minimum dry film thickness of 3 microns. Tint the additional prime coat with a small amount of tinting pigment.

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3.4.3 Nonferrous Metal Surfaces

Protect by plating, anodic, organic, or other coatings as specified.

3.4.4 Aluminum Surfaces

3.4.4.1 Surface Condition

Before finishes are applied, exposed aluminum sheets, plates, and extrusions shall be free of roll marks, scratches, rolled-in scratches, kinks, stains, pits, orange peel, die marks, structural streaks, and any other defects which will affect uniform appearance of finished surfaces.

3.4.4.2 Aluminum

Unexposed sheet, plate and extrusions may have mill finish as fabricated.

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