05_50_11.pdf

SECTION 05 50 11 METAL FABRICATIONS FOR FEBRUARY 2015

FALL PROTECTION SYSTEMS

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SECTION 05 50 11 - METAL FABRICATIONS FOR FALL PROTECTION SYSTEMS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and other Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. Section Includes

1. Structural steel support to horizontal lifeline and track-mounted fall protection systems.

B. Related Sections:

1. Division 11 Section "Rigid-rail Fall Protection Systems”

2. Division 11 Section "Bolt D-Rings”

1.3 SUBMITTALS

A. Shop Drawings: Show fabrication and installation details for metal fabrications.

1. Include plans, elevations, sections, and details of metal fabrications and their connections. Show anchorage and accessory items.

B. Qualification Data: For qualified professional engineer.

C. Mill Certificates: Signed by manufacturers of stainless-steel certifying that products furnished comply with requirements.

D. Welding certificates.

E. Independent testing agencies: Qualifications of firm(s) to be subcontracted to perform testing required by the drawings and specifications.

F. Test reports: As defined in Article 3.5 "Testing".

G. Submit at closeout, documentation to include:

1. As-built drawings of the installed Work.

2. Warranty paperwork.

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1.4 QUALITY ASSURANCE

A. Welding Qualifications: Qualify procedures and personnel according to AWS D1.1/D1.1M, "Structural Welding Code - Steel."

B. Welding Qualifications: Qualify procedures and personnel according to the following:

1. AWS D1.1/D1.1M, "Structural Welding Code - Steel."

2. AWS D1.6, "Structural Welding Code - Stainless Steel."

1.5 PROJECT CONDITIONS

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

1.6 WARRANTY

A. Provide a minimum one-year material and labor warranty.

PART 2 - PRODUCTS

2.1 METALS, GENERAL

A. Metal Surfaces, General: Provide materials with smooth, flat surfaces without blemishes.

2.2 FERROUS METALS

A. W-Shapes: ASTM A 992/A 992M

B. Channels and Angles-Shapes: ASTM A 36/A 36M

C. Plate and Bar: ASTM A 36/A 36M

D. Cold-Formed Hollow Structural Sections: ASTM A 500 Grade B, cold-formed steel tubing

E. Steel Pipe: ASTM A 53/A 53M, Type E or S, Grade B

2.3 AUSTENITIC METALS

A. Bars and Shapes-Rounds, Squares, Angles, Tees, and Channels: ASTM A 276, Type 304/304L.

With a minimum yield stress (Fy) = 30,000 PSI.

B. Plate, Sheet, and Strip: ASTM A 240, Type 304/304L. With a minimum yield stress (Fy) =

30,000 PSI.

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C. Hollow Structural Sections-Round, Square, Rectangular, and Special: ASTM A 554, Type 304/304L. With a minimum yield stress (Fy) = 30,000 PSI.

D. Pipe: ASTM A 312, Grade TP 304/304L. With a minimum yield stress (Fy) = 30,000 PSI.

E. Castings: ASTM A 743, Grade CF 8

2.4 ALUMINUM

A. Aluminum, General: Provide alloy and temper recommended by aluminum producer and finisher for type of use and finish indicated, and with not less than the strength and durability properties of alloy and temper designated below for each aluminum form required.

B. Extruded Bars and Tubing: ASTM B 221 (ASTM B 221M), Alloy 6063-T5/T52.

C. Extruded Structural Pipe and Round Tubing: ASTM B 429/B 429M, Alloy 6063-T6.

D. Drawn Seamless Tubing: ASTM B 210 (ASTM B 210M), Alloy 6063-T832.

E. Plate and Sheet: ASTM B 209 (ASTM B 209M), Alloy 6061-T6.

F. Die and Hand Forgings: ASTM B 247 (ASTM B 247M), Alloy 6061-T6.

G. Castings: ASTM B 26/B 26M, Alloy A356.0-T6.

2.5 MISCELLANEOUS MATERIALS

A. Welding Rods and Bare Electrodes: Select according to AWS specifications for metal alloy welded.

1. E70XX: Carbon Steel to Carbon Steel

2. E308: Stainless Steel Type 304 to Stainless Steel Type 304

3. E309: Stainless Steel Type 304 to Carbon Steel

B. Galvanizing Repair Paint: High-zinc-dust-content paint complying with SSPC-Paint 20 and compatible with paints specified to be used over it.

2.6 FASTENERS

A. Steel Bolts and Nuts: Regular hexagon-head bolts, ASTM A 325, Type 3; with hex nuts, ASTM A 563, Grade C3; and, where indicated, flat washers.

B. Stainless-Steel Bolts and Nuts: Regular hexagon-head annealed stainless-steel bolts, ASTM F 593; with hex nuts, ASTM F 594; and, where indicated, flat washers; Alloy Group 2.

C. Plain Washers: Round, ASME B18.22.1.

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D. Lock Washers: Helical, spring type, ASME B18.21.1.

E. Post-Installed Anchors: Torque-controlled expansion anchors or adhesive anchors.

1. Material for exterior locations or where stainless steel is indicated: Alloy Group 2 (A4) stainless-steel bolts, ASTM F 593 (ASTM F 738M); and nuts, ASTM F 594 (ASTM F 836M).

2. Material for interior locations: ASTM F 1554, Grade 36; and nuts, ASTM A 563; and, where indicated, flat washers. Hot-dipped galvanize where item being fastened is indicated to be galvanized.

F. High Strength Fastening System for One-Sided Blind Fastening.

1. Fastener for hollow steel sections or to steelwork where access is available from one side only.

2. Material for exterior locations or where stainless steel is indicated: ASTM F 593.

3. Material for interior locations: ASTM A 325. Hot-dipped galvanize where item being fastened is indicated to be galvanized.

4. Fasteners shall meet or exceed the following load capacities:

Bolt Dia.

Clamping Range Hole Dia.

Thickness of material being connected to

Safe Working Load* (lbs)

Min Max Tensile Shear 5/16 1/8 1 5/8 3/16 607 1,574 5/16 1/2 1 13/16 5/8 1/4 or 5/16 1,012 1,574 5/16 1 2 5/8 5/8 3/8 or 1/2 1,349 1,574 3/8 1/8 7/8 3/4 3/16 1,012 2,922 3/8 5/8 1 11/16 3/4 1/4 or 5/16 1,888 2,922 3/8 1 3/16 2 1/2 3/4 5/16, 3/8 or 1/2 2,585 2,922 1/2 1/8 1 13/16 3/16 1,012 3,372 1/2 3/4 2 13/16 1/4 1,753 3,372 1/2 1 7/16 2 3/4 13/16 5/16 2,945 3,372

3/8 or 1/2 3,468 3,372 5/8 1/8 1 3/8 1 1/8 3/16 1,439 7,868 5/8 1 2 3/8 1 1/8 1/4 1,843 7,868 5/8 1 7/8 3 1/8 1 1/8 5/16 3,125 7,868

3/8 5,328 7,868 1/2 6,969 7,868

3/4 1 5/8 1 5/8 1 3/8 1/4 1,798 8,992 3/4 2 13/16 2 13/16 1 3/8 5/16 3,439 8,992 3/4 2 3/8 4 1 3/8 3/8 6,984 8,992

1/2 9,824 8,992

* = Safe Working Load (5:1 Factor of Safety)

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G. Self-Drilling or Self-Piercing Tapping Screws Mechanical Fasteners: ASTM C 1513, corrosion-resistant-coated, self-drilling, self-tapping steel drill screws.

1. Fasteners shall be self-drilling or self-piercing tapping screws complying with ASTM C 1513. Tapping screws shall comply with SAE J78 or ANSI/ASME B18.6.4, whichever is more restrictive, when the screw size is not covered under ASTM C 1513.

2. Tapping screws shall have a corrosion-resistant treatment specified in ASTM F 1941 and shall be tested in accordance with ASTM B 117 for a minimum 12-hour test period.

Coated screws shall not show products of corrosion from either the coating (white corrosion) or the base metal (red rust) at the end of the test period.

2.7 INJECTION ADHESIVE FOR POST-INSTALLED ANCHORS INTO CONCRETE

A. Injection adhesive for post-installed adhesive anchors into concrete shall be a two-part epoxy.

Resin and hardener components shall be suitable for injection nozzle mixing directly into drilled hole.

B. Cured epoxy properties shall conform to:

1. Bond strength ASTM C882-911

a. 2-day cure 1,800psi

b. 7-day cure 1,800 psi

2. Compressive strength ASTM D-695-96 12,000 psi

3. Compressive modulus ASTM D-695-96 0.22 x 106 psi

4. Tensile strength 7-day ASTM D-638-97 6,310 psi

5. Elongation at break ASTM D-638-97 2.0 %

6. Heat deflection temperature ASTM D-649-95 146° F

7. Absorption ASTM D-570-95 0.06 %

8. Linear coefficient of shrinkage on cure ASTM D-2566-86 0.004

9. Electrical resistance DIN IEC 93 (12.93) 1.7 x 1012 Ω/in

C. Injection adhesive shall be mixed and installed in accordance with manufacturer’s requirements.

2.8 INJECTION ADHESIVE FOR POST-INSTALLED ANCHORS INTO MASONRY

CONTAINING VOIDS

A. Anchoring system shall be suitable for fastening into materials containing voids and holes, such as hollow block, brick with holes and multi-wythe brick walls and clay tile. Anchoring system shall consist of a threaded anchor rod, nut and washer; a cylindrical mesh screen tube, and an injectable adhesive.

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B. Injection adhesive for post-installed adhesive anchors into masonry shall be a two-part adhesive. Components shall be suitable for injection nozzle mixing directly into the mesh screen tube.

C. Cured adhesive properties shall conform to:

1. Compressive strength ASTM D-695 7,410 psi

2. Modulus of elasticity (compression test) ASTM D 790 0.33 x 106 psi

3. Water absorption ASTM D 570 2.5 %

4. Electrical resistance VDE 7.9 x 1010 Ω/in

D. Injection adhesive shall be mixed and installed in accordance with manufacturer’s requirements.

E. Mesh screen tube shall be formed into a cylindrical shape. One end shall be closed to prevent extrusion of adhesive. Mesh shall be fabricated from low carbon steel.

2.9 FABRICATION, GENERAL

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

B. Cut, drill, and punch metals cleanly and accurately. Remove burrs and ease edges to a radius of approximately 1/32 inch unless otherwise indicated. Remove sharp or rough areas on exposed surfaces.

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

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

E. Weld corners and seams continuously to comply with the following:

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

2. Obtain fusion without undercut or overlap.

3. Remove welding flux immediately.

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

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

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

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

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

2.10 MISCELLANEOUS FRAMING AND SUPPORTS

A. General: Provide steel framing and supports not specified in other Sections as needed to complete the Work.

B. Fabricate units for supporting horizontal lifeline and track-mounted fall protection systems from steel shapes, plates, and bars of welded construction unless otherwise indicated. Fabricate to sizes, shapes, and profiles indicated and as necessary to receive adjacent construction.

2.11 FINISHES, GENERAL

A. Comply with NAAMM's "Metal Finishes Manual for Architectural and Metal Products" for recommendations for applying and designating finishes.

B. Finish metal fabrications after assembly.

2.12 STEEL FINISHES

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

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

2. Fill vent and drain holes that will be exposed in the finished Work unless they will function as weep holes, by plugging with zinc solder and filing off smooth.

2.13 STAINLESS-STEEL FINISHES

A. Surface Preparation: Remove tool and die marks and stretch lines, or blend into finish.

B. NAAMM #4 brushed (satin) finish.

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PART 3 - EXECUTION

3.1 INSTALLATION, GENERAL

A. Cutting, Fitting, and Placement: Perform cutting, drilling, and fitting required for installing metal fabrications. Set metal fabrications accurately in location, alignment, and elevation; with edges and surfaces level, plumb, true, and free of rack; and measured from established lines and levels.

B. Fit exposed connections accurately together to form hairline joints. Weld connections that are not to be left as exposed joints but cannot be shop welded because of shipping size limitations.

Do not weld, cut, or abrade surfaces of exterior units that have been hot-dip galvanized after fabrication and are for bolted or screwed field connections.

3.2 ONE-SIDED BLIND FASTENERS

A. All contact surfaces shall be free of dirt, grease, burs or other foreign material that may affect the proper mating of materials and expansion of fastener clamping mechanism.

B. Installation of the fasteners shall comply with manufacturers installation instructions.

C. Fasteners shall be torqued in accordance with manufacturer’s specifications.

D. Bolt toque test fasteners in accordance with the manufacturer’s specifications.

3.3 INSTALLING MISCELLANEOUS FRAMING AND SUPPORTS

A. General: Install framing and supports to comply with requirements of items being supported, including manufacturers' written instructions and requirements indicated on Shop Drawings.

3.4 EXISTING REINFORCEMENT

A. Where holes are to be drilled into existing reinforced concrete of masonry walls:

1. Identify location and bar diameter of reinforcing steel in the vicinity of the required hole locations prior to drilling. Use equipment utilizing eddy currents, magnetic inductance or other appropriate means to locate the reinforcement. Calibrate the equipment prior to use. Drill pilot holes to confirm location and bar diameter of reinforcing steel.

2. The Contractor shall be solely responsible for the cost and execution of work necessary for the repair of damaged reinforcing steel and surrounding concrete.

3.5 TESTING

A. All testing specified within this section, including the cost of engaging independent testing agencies, shall be the responsibility of the Contractor.

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B. The Contractor shall produce a written record of test results to be delivered to the Architect upon completion of the test.

C. Anchors to existing concrete structure relying upon chemical adhesive and/or torque-controlled mechanical expansion shall be inspected and axial load tested in accordance with product-specific International Code Council Evaluation Service inspection requirements.

1. 100% of the anchors shall be inspected and tested.

2. Load testing shall be performed in accordance with the anchor manufacturer’s required methods. If no manufacturer-required methods are provided, the anchors shall be axial load tested to the loads shown on the drawings. If no loads are provided on the drawings, the anchors shall be axial load tested to 200% of the anchor manufacturer-provided tensile working load capacity. If any signs of slippage, detachment or fracture are detected, the anchor shall be rejected and replaced.

3. Testing shall be conducted by an independent qualified testing agency. Submit test reports prepared by the testing agency, on the agency's standard form, indicating and interpreting results of field tests performed.

4. Contractor shall submit inspection reports specifically indicating compliance with product-specific International Code Council Evaluation Service requirements.

D. Anchors to existing steel structure relying upon torque-controlled mechanical expansion shall be subjected to a torque check to the anchor manufacturer’s required values.

E. All anchors not meeting the requirements of this section shall be replaced.

F. The Contractor shall be solely responsible for the cost and execution of work necessary for concrete repair and replacement of rejected anchors.

3.6 ADJUSTING AND CLEANING

A. Galvanized Surfaces: Clean field welds, bolted connections, and abraded areas and repair galvanizing to comply with ASTM A 780.

END OF SECTION 05 50 11