Section_OF_Master_Specifications.pdf

Section 01100 1

SECTION 01100

GENERAL CONDITIONS

PART 1 – APPLICABLE NORMS

1.1 The Italian norms for building works and the instructions of materials suppliers shall be strictly observed for the execution of the works. In addition the general safety regulations for construction and the Base regulation for traffic, accidents and fire fighting shall be observed as follows:

a. UNI Norms – Demolition works; masonry works, pavement works, concrete reinforcement bars, structural steels, pipes, painting, plumbing, heating system and electrical system.

b. C.N.R.; ASTM; AASHTO norms – Aggregates, bitumen, bituminous mixtures and road works in general.

c. Legislative Decree No. 494 dated 14 August 1996.

d. Legislative Decree No. 528 dated 19 November 1999.

e. CEI norms in force at tender date.

f. UNEL norms in force at tender date.

g. ENPI norms in force at tender date.

h. NEC norms in force at tender date.

i. AFPM 91-210 Contract Safety.

j. AFI 91-202 Safety Program Management.

The manuals and regulations relative to paragraphs i and j, will be available for review at the Engineering Office, Bldg 407 of Aviano Air Base, during normal working hours, from Monday to Friday, from 0800 to 1700 hrs. Further clarifications regarding the type of materials and the work specified in the Schedule to Work items or indicated in the drawings, will be provided during the site survey scheduled prior to the submittal of proposal.

1.2 CERTIFICATION OF COMPLIANCE WITH ITALIAN LAWS

1.2.1 Static Load Testing

The Contractor shall comply with the pertinent articles of Italian Law

1086 dated 5 November 1971, and all subsequent revisions. The Contractor shall be fully responsible for construction, supervision, static load tests, final testing, and for all costs associated with this procedure.

Article 2 of Law 1086, as amended, requires the static load tests to be performed under the supervision of an engineer or architect registered on the National Professional Rolls of Italy for at least ten years (10).

Prior to performing the tests, submit to the Contracting Officer the names and certified credentials of proposed testing personnel, engineer(s) or architect(s) they propose to perform the static load testing.

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1.2.2 Mechanical and Electrical Work Certifications

As a condition of final acceptance of the work, the Contractor shall submit to the Contracting Officer a certificate of compliance for all contract work certifying that all electrical and mechanical work complies with Law No. 46 dated 5 March 1990, and that the provided work is adequate and safe for the designated use.

1.2.3 Other Certifications

In addition to the certifications listed above, the Contractor shall provide all other certifications and testing required by Italian Law.

Such certifications may include but are not limited to the following:

a. Certificate of compliance for electrical systems in accordance with CEI regulations and with D.P.R. No.547 dated 27 April 1955 on accident prevention.

b. Certificate of compliance for heating systems above 100,000 kcal/hr in accordance with Italian Law No. 373 dated 30 April 1976.

c. Certificate of compliance for fire prevention systems in accordance with Ministerial Decrees dated 16 February 1982 and 8 March 1985.

d. Certificate for elevator systems test in accordance with Italian Law No. 1415 dated 24 October 1942.

PART 2 – MATERIALS

2.1 All materials shown on drawings and listed in the Schedule of Work

Item or anyhow necessary for the accomplishment of project will be furnished and installed by the Contractor except those shown on drawings which will be furnished and installed by the U.S.A. Government and installed by the Contractor.

2.2 DEMOLITION AND INTERVENTION WORK ON EXISTING STRUCTURES

During possible partial demolition or intervention operation of bearing structures the Contractor shall provide for the shoring of existing structures, for the safety of personnel and building, being responsible for any accident and/or damage. Shoring will be performed in a way to assure the integral conservation of structures not to be demolished or modified. Shoring shall be inspected by Contracting Officer’s Technical Representative prior to proceeding with any demolition work of structural elements.

2.3 REMOVED MATERIALS

The materials to be removed, (specified on drawings and/or on the Schedule of Work Items) shall be handled as follows:

2.3.1 Unsalvageable materials

Shall be transported to public dump in accordance with Italian communal norms in force. The Contracting Officer’s Technical Representative shall determine which materials are unusable. Under no circumstances will the Contractor attempt to sell or otherwise use such material unless and until he first obtains, the necessary permits, licenses etc. from the

Section 01100 3

Italian Government Officials and will hold the U.S. Government free and harmless from his failure to do so.

2.3.2 Salvageable materials

Shall be loaded, unloaded and stacked at a warehouse of Aviano Air Base.

The Contracting Officer’s Technical Representative shall determine which material is salvageable and the storage location. Maximum distance will be 15 km.

2.3.3 Materials to be reused in the project

Shall be removed with care and stored by the Contractor on site, after inspection of operating state of such fixtures which will be done jointly with the Contracting Officer’s Technical Representative. The Contractor shall be fully responsible for preservation of such fixtures and before their installation, in the location he shall provide for cleaning and rehabilitation work.

2.4 SELECTION OF EQUIPMENT, MATERIALS AND COLORS

The Contracting Officer’s Technical Representative will select equipment, materials and colors from among the charts and factory samples which will be submitted by the Contractor and approved by the Government in accordance with the indications of the project documents. It will be the Contracting Officer’s Technical Representative’s option to request all samples and catalogues of materials to be incorporated in the project to ensure the satisfactory and proper completion of the work. All samples shall be returned to Contractor.

2.5 SUBMITTALS

This paragraph applies only to those items not subject to the “brand name or equal” provision of the contract and listed in AF Form 3052. Within 15 days from the date of notice to proceed, or in accordance with the prescriptions given by the Contracting Officer, the Contractor shall submit Contracting Officer’s Technical Representative’s approval the data requested by the project documents and listed in the paragraph entitled “Material Approval” in order to ascertain that the material corresponds to the technical characteristics of the project. The submittals consisting of AF Form 3000, and catalog contracts (4 copies), beside the samples, will be in English or Italian with the English translation attached. The list preparation shall be coordinated with the work schedule keeping in mind that the Government needs at least 15 days for the approval. Every disapproved item shall be resubmitted following the same procedure. A copy of the AF Form 3000 and relative attachments will be returned to the Contractor. No work will be started prior to obtaining the approval for the proposed material and equipment. The approval of submittals does not relieve the Contractor of responsibility for proper application and installation of the items, of other evident or hidden defects. Shop drawings, for electric equipment shall include construction drawings, diagrams and schematics for power circuits and control circuits, and component reference list.

2.6 USE OF BRAND NAMES IN SPECIFICATIONS

Unless otherwise specifically provided on this contract, reference to any equipment, material article or patented process by trade name, make or cat number shall be regarded as establishing a standard of quality and

4 Section 01100 shall not be construed as limiting competition, and the Contractor may, at his option use any equipment, material, article, or process which, in the judgment of the Contracting Officer’s Technical Representative, is equal to that named. The Contractor shall furnish to the Contracting Officer’s Technical Representative all required data and samples as may be called for the these technical provisions or which the Contracting Officer’s Technical Representative determines necessary for approval prior to use of the items during work performance.

2.7 “EQUIVALENT” ITEMS PROPOSED BY CONTRACTOR

If the Contractor intends to propose “brand names” different than the ones specified by U.S. Government, he will clearly indicate the “equivalent” proposed item, the manufacturer, type, catalog No., etc. in the List of Equivalent Proposed Items attached to AF Form 3052 which shall be returned to the Government together with the proposal. Each equivalent item listed shall be supported by the relative technical documentation (catalog cuts, certificates, technical descriptions, calculations, etc.) in order to prove the equivalency of the technical characteristics of the product listed in the project document. Such documentation shall also be attached to the proposal.

2.8 INFORMATION DATA

Prior to work completion date and if expressly requested by project documents will submit the following information data in English and Italian:

2.8.1 Manufacturer’s literature

Catalog extracts for all items (materials and equipment) furnished, in accordance with project documents.

2.8.2 Parts List

List of furnished items, in accordance with project documents:

a. Item description

b. Current unit price

c. Reference to manufacturing Firm

2.8.3 Manufacturer’s Address

List of materials and equipment suppliers, in accordance with project documents.

a. Firm Name

b. Complete address and telephone number

c. Reference to parts list

2.8.4 Operation and Maintenance Manuals

At work completion date, the Contractor shall submit three (3) copies of operation and maintenance manuals of all equipment installed.

Section 01100 5

2.8.5 Operation Test Reports

In accordance with project documents, prior to work completion date, the

Contractor shall perform balancing and testing of each system installed and will submit three (3) copies of testing report containing recorded data of readings performed during tests.

PART 3 – SITE CONDITIONS

3.1 WORKING HOURS

Normal working hours authorized on base, are from 0800 to 1700 hrs., Monday through Friday. Any working hours different from the authorized hours must be previously approved by the Contracting Officer.

3.2 UTILITY CUT-OFF

When interruption of existing utilities is deemed necessary for the installation of the lines or equipment, the Contractor shall submit a written request, to the Contracting Officer of his authorized representative for approval ten (10) days prior to his scheduled starting of work. For the electrical cut-off the request shall be submitted (10) ten days prior the scheduled starting of work. Such interruption shall not be started before receipt of the approved request, nor shall interruptions request be submitted at the end of the week (from Friday through Sunday). The request shall state the duration of interruptions and the description of work to be done.

3.3 STORAGE SHED

It will be Contractor’s option to provide one or more storage sheds to store materials and work tools. The available area, for the assembly of such shed, shall be indicated by the designated representative of the Contracting Officer’s Technical Representative. At work completion the shed shall be disassembled and the area shall be restored to its original condition.

3.4 AIRFIELD SAFETY TRAINING

The Contractor shall contact Airfield Management to receive flightline driver and airfield safety training prior to start of any work beginning on the flightline.

3.5 TRANSPORTATION OF PERSONNEL AND MATERIALS

It will be the Contractor’s responsibility to transport the personnel to and from the job site and to load, transport, unload and place all supplies, materials and equipment involved in this contract.

3.6 UTILITIES

Electric power, existing grounding system and water available in the area, will be made available to the Contractor by the U.S. Government.

Connections and disconnections will be at Contractor’s expense and utilities are to be restored to their original condition at no extra cost to the Government. All damages caused, if any, to the existing utilities will be repaired immediately at Contractor’s expenses, also in case that such repairs are made by Government’s personnel and as directed by the

6 Section 01100

Contracting Officer’s Technical Representative. Before starting the works, the Contracting Officer will indicate the point wherefrom water and electric power will be taken. The Contractor will be entitled to provide for himself, if desired, a generating set, and his own expense.

The electrical characteristics of available power will be indicated in project documents.

3.7 TOILET FACILITY

The toilet facilities available in the vicinity of site of work may be used by Contractor’s personnel provided there are no instructions to the contrary in the project documents.

3.8 EXCAVATIONS

The Contractor shall initiate no excavation work prior to receiving an approved AF Form 103. This form will be prepared by U.S. Government personnel.

PART 4 - LABOR

All installation and construction operations, calibrations and tests during service, etc, shall be performed in a workmanlike manner by skilled tradesmen being qualified to perform the most difficult operations pertaining to their respective craft. The use of common labor for operations normally assigned to skilled tradesmen will not be accepted.

PART 5 – DEFINITIONS

As used throughout this master specification set the terminologies used such as: project, drawings, project documents and documents mean the additional specifications. Schedule of Work Items, Drawings and other documents which compose the specific individual project to be performed and for which a proposal is solicited separately.

PART 6 - ORDER OF PRECEDENCE

In case of conflict between this master specification set and the individual project documents, the difference shall be resolved by giving precedence to the individual project documents.

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Section 01101 1

SECTION 01101

PROJECT SIGN

PART 1 - PROJECT SIGN

1.1 Scope

Furnish labor and material required for the construction and painting of a sign as shown on the attached sketch.

PART 2 - GENERAL

The Contractor shall identify the project by means of an appropriate sign mounted in a conspicuous area of the work site, as indicated by the Contracting Officer or his designated representative. The sign shall be erected within 10 days of initiation of work at the job site. The sign shall be 120 cm wide x 80 cm high and shall be constructed of a material suitable to withstand exposure to inclement weather for the duration of the contract, and must not show evidence of warping, cracking, or other defects. The sign shall have a blue background with white lettering, and shall contain the following information in English:

a. Project No.

b. Project description

c. Constructed under Supervision of Base Civil Engineering

d. Contracted by 31st Contracting Squadron

e. Contractor

f. Design Engineer

g. Inspector

h. Contract Management: 31 CONS Construction Flight

i. ERP Coord

Lettering of the sign will be as shown on the following sketch, and may be painted or stenciled directly on sign. The sign will remain the property of the Contractor, and shall be promptly removed upon completion of the project.

2 Section 01101

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.

4 Section 05500

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

6 Section 05500

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.

8 Section 05500

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.

Section 07600 1

SECTION 07600

FLASHING AND SHEET METAL

1.1 APPLICABLE PUBLICATIONS

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

PUBLICATIONS:

UNI EN 13605 (2004) Copper and copper alloys - Copper profiles and profiled wire for electrical purposes.

UNI 4157 (1987) Bitumen for Roofing. Sampling and

Acceptance Limits.

UNI 9001-2 (1987) Wrought primary aluminum and aluminum alloys. Aluminum group. Al 99,5 (1050 a).

UNI 5649-1 (1988) Copper. Wrought coppers. Qualities, requirements and tests.

UNI EN 10142 (2002) Continuously hot-dip zinc coated low carbon steels strip and sheet for cold forming. Technical Delivery Conditions.

UNI EN 10130 (2000) Cold rolled low carbon steel flat products for cold forming. Technical Delivery Conditions.

UNI EN 10051 (2000) Continuously hot-rolled uncoated plate, sheet and strip of non-alloy and alloy steels. Tolerances on dimensions and shape.

UNI EN 10152 (1994) Electrolytically zinc coated cold rolled steel flat products. Technical delivery conditions.

1.2 SUBMITTALS

1.2.1 Samples

Submit the following samples for approval:

a. Sheet Metal Materials: Two pieces 150 x 250 mm, of each type, and color.

1.2.2 Drawings

2 Section 07600

Submit shop drawings for approval, indicating thickness, dimensions, fastenings and anchoring methods, expansion joints, and other provisions necessary to provide for thermal expansion and contraction. Scaled catalogue cuts may be submitted for factory fabricated items. Submit shop drawings for the following items:

a. Metal base, cap (counterflashing) and valley flashing.

b. Flashing at all roof penetrations.

1.3 PRODUCT DELIVERY STORAGE AND HANDLING

Materials shall be adequately packaged and protected during shipment and inspected for damage, dampness, and wet-storage stains upon delivery to the job site. Damaged or permanently stained materials that cannot be restored to like-new condition shall be removed from the site and replaced at no additional cost to the Government. Carefully handle sheet metal items to avoid damage to surfaces, edges and ends. Crated materials shall not be uncrated until ready for use. Store materials in dry, weathertight, ventilated areas until immediately before installation.

PART 2 - PRODUCTS

2.1 GENERAL SHEET METAL

Sheet metal items shall be shop or factory fabricated. Furnish sheet metal items in 2.50 meter to 3.00 meter lengths. Single pieces less than

2.50 meters long may be used to connect to factory inside and outside corners, and at ends of runs. Accessories and other items essential to complete the sheet metal installation shall be provided and shall be of the same materials as the items to which they are applied.

2.2 MATERIALS

2.2.1 Steel Sheet, Zinc Coated (Galvanized)

UNI EN 10142

2.2.2 Stainless Steel

Shall be fully annealed, dead soft temper with slow cold-rolled dull finish. Stainless steel shall be made by the electric-arc process, electric-induction process or other suitable process.

Stainless steel shall have the following chemical compositions:

Carbon 0.15 +0.005 Manganese 2.0 +0.04 Phosphorus 0.045 +0.010 Sulfur 0.030 +0.005 Silicon 0.75 +0.05 Chromium 17.0-19.0 +0.20 Nickel 8.0-10.0 +0.10 Other 0.10 Max.

Stainless steel shall have the following mechanical properties:

Section 07600 3

Tensile Strength 515 mPa minimum Yield Strength 205 mPa minimum Elongation in 50 mm 40.0% minimum Brinell Hardness 201 maximum Rockwell B Hardness 92 maximum

The material shall be of uniform quality consistent with good manufacturing and inspection practices. The steel shall have no imperfections of a nature or degree that will adversely affect the stamping, forming, machining, or fabrication of finished parts. Refer to Table I at the end of this section for required weights and thickness.

2.2.3 Aluminum Alloy Sheet and Plate

UNI 9001-2.

2.2.4 Soldering Flux

Use an approved acid type flux for steel.

2.2.5 Solder

50 percent pig lead and 50 percent pure block tin.

2.2.6 Polyvinyl Chloride Reglet

2 mm minimum thickness.

2.2.7 Bituminous Plastic Cement

Shall be an asphaltic base material compatible with the roofing asphalts and asphalt primer.

2.2.8 Copper

Copper sheet or strip shall be a cold-rolled tempered flat product of the weight listed in Table I at the end of this section. Lengths shall not exceed 3 meters. The quality of the materials shall comply with the following tables.

Mechanical Requirements

Tensile Yield Strength Yield Strength Approximate Strength (mPa) at 5% at 2% Rockwell Extension Extension Hardness Under Load Under Load Min. Max. Min. mPa Min. mPa F Scale Superficial 30T

220 275 135 105 60-82 25-49

The material shall have a minimum copper and silver content of 99.9 percent. The material shall be free from defects of a nature that interfere with normal commercial operations, shall be well cleaned, and shall be free from dirt.

2.2.9 Fasteners

Fasteners shall be the same metal or a metal compatible with the item fastened. Use aluminum fasteners with aluminum; and stainless steel

4 Section 07600 fasteners with stainless steel and to fasten dissimilar materials. Use copper or stainless steel nails with copper.

2.2.10 Optional Materials

Optional materials are listed in Table I. Any of the optional materials specified therein may be selected by the Contractor; however, all exposed sheet metal items shall be of the same material, prefabricated, with a factory baked enamel finish, unless indicated otherwise. Colors will be selected by the Contracting Officer’s Technical Representative. The following items shall be considered as exposed sheet metal: Gutters, including hangers; downspouts and leaders; fascias; copings, roof edges and trim, cap and eave flashing.

2.2.11 Sheet Metal

Provide flashing in the roof valleys and where roof decks abut walls, curbs, ventilators, pipes or other vertical surfaces and wherever indicated and necessary to make the work watertight. All aluminum sheet metal shall be pre-finished unless specified otherwise herein. Tempers of metals shall be suitable for their respective forming conditions.

Fabricate sheet metal items to the gage, thickness or weight shown in Table I and join multiple lengths of items together as shown in Table II.

3.1 GENERAL

Comply with the hereinafter paragraphs as applicable to this project.

Surfaces to receive sheet metal must be plumb and true, clean, even, smooth, dry and free from defects and projections which might affect the application.

3.2 WORKMANSHIP

Install sheet metal work with lines, arises, and angles sharp and true.

Exposed surfaces shall be free from visible wave, warp, and buckle, and tool marks. Exposed edges shall be folded back neatly to form a 15 millimeter hem on the concealed side. Sheet metal exposed to the weather shall be watertight with provisions for expansion and contraction.

3.3 NAILING

Nailing of sheet metal shall be confined generally to sheet metal having a maximum width of 500 mm. Nailing of flashing shall be confined to one edge only. Nails shall be evenly spaced not over 80 mm on centers and approximately 15 millimeters from edge unless otherwise specified or indicated. Face nailing will not be permitted. Where sheet metal is applied to other than wood surfaces, detailed shop drawings shall include locations for sleepers and nailing strips required to properly secure the work. Sleepers and nailing strips are specified in Section 06100, "Rough Carpentry".

3.4 CLEATS

Provide cleats for sheet metal 100 mm and over in width. Space cleats evenly not over 300 mm on centers unless otherwise specified or indicated. Cleats shall be not less than 50 millimeters wide x 75

Section 07600 5 millimeters long and of the same material and thickness as the sheet metal being installed. For cleats used in conjunction with flashing:

One end of the cleat shall be secured with nails and the cleat folded back over the nail-heads. Cleats for soldered seams shall be pre-tinned.

3.5 BOLTS, RIVETS AND SCREWS

Install bolts, rivets and screws where indicated or required. Provide compatible washers where required to protect surface of sheet metal and to provide a watertight connection.

3.6 SEAMS

Straight and uniform in width and height with no solder showing on the face.

3.6.1 Flat-Lock Seams

Finish not less than 20 millimeters wide.

3.6.2 Lap Seams

Finish soldered seams not less than 25 millimeters wide. Overlap seams not soldered, not less than 75 millimeters.

3.6.3 Loose-lock Expansion Seams

Not less than 75 millimeters wide, and shall provide minimum 25 millimeters movement within the joint. Joints shall be completely filled with the specified sealant, applied at not less than 3 millimeters thick bed. Sealants are specified in Section 07920, "Joint Sealants".

3.6.4 Flat Seams

Make seams in the direction of the flow.

3.7 SOLDERING, WELDING, AND MECHANICAL FASTENING

Where soldering is specified herein it shall apply to copper, zinc coated steel and stainless steel items. Welding is specified for aluminum of thickness greater than 1 millimeter. Aluminum 1 millimeter or less in thickness shall be butted with space and backed with formed flashing plate; or lock joined, mechanically fastened, and filled with sealant as recommended by the aluminum manufacturer.

3.7.1 Soldering

Pre-tin edges of sheet metals, except lead coated material, before soldering is begun. Soldering shall be done slowly with well heated soldering irons so as to thoroughly heat the seams and completely sweat the solder through the full width of the seam. Edges of lead-coated material to be soldered shall be scraped or wire-brushed to produce a bright surface, and seams shall have a liberal amount of flux brushed in before soldering is begun. Edges of stainless steel to be pre-tinned shall be treated with soldering acid flux. Upon completion of soldering the acid flux residue shall be thoroughly cleaned from the sheet metal with solution of washing soda in water and rinsed with clean water.

Joints in aluminum sheets 1 millimeter or less in thickness shall be made

6 Section 07600 mechanically and sealed with the sealant specified. Aluminum shall not be soldered.

3.7.2 Welding of Aluminum

Joints in aluminum sheets more than 1 millimeter thick shall be welded.

Welding shall be of the inert gas, shield-arc type. The procedures, the appearance and quality of welds made, and the methods used in correcting welding work shall conform to the aluminum manufacturer's recommendations.

3.7.3 Mechanical Fastening of Aluminum

Aluminum alloy sheet metal screws or other suitable aluminum alloy or stainless steel fasteners shall be driven in holes made with a 4 millimeter diameter drill, shall be used in securing side laps, end laps, and flashing. Maximum spacing for fasteners shall be 300 mm. Where end lap fasteners are required to improve closure, they shall be located not more than 50 mm from the end of the overlapping sheet.

3.8 PROTECTION FROM CONTACT OF DISSIMILAR MATERIALS

3.8.1 Copper or Copper-bearing Alloys

Surfaces in contact with dissimilar metal shall be painted with heavy-bodied bituminous paint, or shall be separated by means of moisture proof building felts.

3.8.2 Aluminum

Surfaces shall not contact other metals except stainless steel, zinc, or zinc coating. Where aluminum contacts another metal, the dissimilar metal shall be painted with a primer followed by two coats of aluminum paint.

3.8.3 All Metal

Surfaces in contact with mortar or concrete materials shall be painted with alkali-resistant coatings such as heavy-bodied bituminous paint.

3.8.4 Wood or Other Absorptive Materials

Surfaces that may become repeatedly wet and in contact with metal shall be painted with two coats of aluminum paint or a coat of heavy-bodied bituminous paint.

3.8.5 Dissimilar Metal

Paint with a non-lead pigmented paint if drainage from it passes over aluminum.

3.9 PROVISION FOR EXPANSION AND CONTRACTION

Section 07600 7

Provide expansion and contractor joints at not more than 10 meter intervals for aluminum and at not more than 12 meter intervals for other metals, except that where the distance between the last expansion joint and the end of the continuous run is more than half the required interval spacing an additional joint shall be provided. Space joints evenly.

Extruded aluminum copings and fascias shall be joined by expansion and contraction joints at not more than 4 meter spacing.

3.10 BASE FLASHING

Where sloped roofs abut chimneys, curbs, walls, or other vertical surfaces, the base flashings shall be laid in with the roof covering.

The flashing shall extend up vertical surfaces under or over roof covering as indicated. Where finish wall coverings form a counterflashing, the vertical leg of the flashing shall extend up behind the applied wall covering not less than 150 mm, otherwise the vertical leg of the flashing shall extend up behind a continuous counterflashing and reglet system. Flashings shall be installed and fitted so as to be completely weathertight. Strips shall be fastened at their upper edge to the deck, with compatible large-head roofing nails. End laps shall be soldered, except that provision shall be made for expansion and contraction. At the up-slope side of vertical surfaces extending through the roof decks, metal flashings shall extend over crickets. At the lower side of vertical surfaces extending through the roof decks, metal flashings shall extend onto the roof covering not less than 10 centimeters. Flashings shall be installed and fitted so as to be completely weathertight.

3.11 VALLEY FLASHING

Where sloped roofs meet, the valley flashings shall be laid in with the roof covering. The flashing shall extend beneath both sides of roof covering and be secured to cleats as indicated and specified. Valley flashing shall be fabricated in longest sections possible to minimize the number of joints. Valley flashing shall overlap a minimum of 200 mm in the direction of flow. The top of each section of valley flashing shall be secured to the roof construction with a minimum of six fasteners; the fasteners shall be compatible with the flashing. The edges of the valley flashing shall be formed with hook edges to be compatible with the cleats.

3.12 COUNTERFLASHING

Except where indicated or specified otherwise, insert counterflashing in reglets located from 200 to 250 mm above roof decks and extend down vertical 100 millimeters minimum over upturned vertical leg of base flashing or continuous hook strip not less than 75 millimeters. Exposed edges of counterflashings shall be folded 15 millimeters. Where stepped counterflashings are required, they may be installed in short lengths or may be of the preformed one-piece type. End laps in counterflashings shall be not less than 75 millimeters and shall be made weathertight with plastic cement. Lengths of metal counterflashings shall not exceed 3 meters. The flashing shall be formed to the required shapes prior to installation. Corners shall be factory formed with joints not less than 300 mm from the angle. Flashing shall be secured in the reglets with lead wedges spaced not to exceed 450 mm apart; on short runs, wedges shall be placed closer together. Calked-type reglets or raked joints that will receive counterflashing shall be filled with calking compound.

Calking is covered in Section 07920, "Joint Sealants". The concealed

8 Section 07600 edge of counterflashings built into concrete walls shall be turned up not less than 50 millimeters into the walls. Counterflashing shall provide a spring action against base flashing.

3.13 METAL REGLETS

3.13.1 Friction-type Reglets

Provide with flashing receiving slots not less than 15 millimeters deep,

2.5 centimeters jointing tongues, and upper and lower anchoring flanges.

The flashing shall be inserted the full depth of the slot and locked therein by indentations made with a dull-pointed tool.

3.13.2 Calked-type Reglets

Provide with rounded edges and metal strap brackets or other approved anchors for securing to the concrete forms. They shall be provided with an approved type core to protect them from injury during the installation. Built-up mitered corner pieces shall be provided for internal and external angles. Flashing shall be wedged in the reglets with lead wedges every 45 centimeters and shall be calked full and solid with an approved compound.

3.14 ROOF EDGE FASCIAS AND TRIM

Fabricate in the shapes and sizes indicated and in lengths not less than

2.50 meters. Extend flanges at least 100 millimeters onto roof deck.

Extend the vertical face at least 50 millimeters beyond the roofing and insulation onto the wall face. Provide prefabricated mitered corners for internal and external corners. Set flange on top of wood rail or in a 3 millimeters thick bed of plastic cement. Nail flange securely to wood nailer with large-head barbed-shank roofing nails 35 millimeters long spaced not more than 75 millimeters on centers. Finish shall be baked enamel, color as approved.

3.14.1 Hook Strips

The lower edge of fascias shall be hooked at least 20 millimeters over a continuous hook strip of the same material bent outward at an angle of 45 degrees to form a drip. Nail hook strip to a wood nailer at 150 mm maximum on centers. Where fastening is made to concrete, screws spaced 300 mm on center shall be used and shall be driven in expansion shields set in the concrete. Where horizontal wood nailers are slotted to provide for insulation venting, install hook strips in such a manner that vent slots are not obstructed. Where necessary, install hook strips over 2 millimeters thick compatible spacer or washers.

3.14.2 Joints

Section ends of gravel stops, copings and fascias shall be left open 6 millimeters and backed with a formed flashing plate, mechanically fastened in place and lapping each section end a minimum of 100 millimeters; set laps in plastic cement. Face nailing will not be permitted. Extruded aluminum gravel stops, copings and fascias shall be installed in accordance with the manufacturer's printed instructions and details.

3.14.3 Metal Drip Edge

Section 07600 9

Provide a metal drip, designed to allow water run-off to drip free of underlying construction as indicated. Apply directly on the wood blocking at the eaves and over the underlay along the rakes, extend back from the edge of the deck not more than 100 mm and secure with compatible nails spaced not more than 250 mm on center along upper edge.

3.15 GUTTERS

The hung type of shape indicated and supported on underside by brackets that permit free thermal movement of the gutter. Provide gutters in sizes indicated complete with mitered corners, end caps, outlets, brackets, and other accessories necessary for installation. The outer edge of gutter shall be beaded or reinforced with a stiffening bar not less than 20 millimeters by 5 millimeters of material compatible with gutter. Gutters shall be fabricated in sections not less than 2.50 meters long. The sections shall be lapped a minimum of 25 millimeters in the direction of flow. Gutters shall be joined by riveted and soldered joints. Expansion type slip joints shall be provided midway between outlets.