Technical_Specifications_10-0006P1.pdf

REPAIR AIR HANDLERS & CONTROLS

BUILDING 3

PHASE 1

'CHILLER PLANT ALTERATIONS AND

REPAIR (NLC)'

TECHNICAL SPECIFICATIONS

For

AIR FORCE RESEARCH LABORATORY

ROME RESEARCH SITE

ROME, NEW YORK

PROJECT NR: ULDF 10-0006P1

Prepared By

TOWNE ENGINEERING

CONSULTING ENGINEERS

18 South Street Utica, New York

315.733.9000

October 24, 2012

DIVISIONS 2-14 – GENERAL CONSTRUCTION

SECTION 02000 – 14999

TABLE OF CONTENTS

SECTION TITLE PAGES

GENERAL CONSTRUCTION TOC - 1

03300 11

05120 5

05210 3

05310 4

05400 5

07210 3

07400 4

07530 4

07600 2

07901 4

08110 4

08310 2

08710 5

09900

Cast-In-Place Concrete Structural

Steel

Steel Joists

Steel Deck

Cold-Formed Metal Framing

Building Insulation

Metal Siding and Accessories

Single-Ply Membrane Roofing

Flashing and Sheet Metal

Joint Sealers

Steel Doors and Frames

Roof Hatch

Finish Hardware

Painting 6

01010 General Scope 2

AFRL, Repair Air Handlers, Bldg 3 GENERAL SCOPE

SECTION 01010-1

SECTION 01010

GENERAL SCOPE

1.01 SCOPE

A. The work covered under this Contract consists of furnishing all labor, equipment, devices, and materials and performing all work required to accomplish the first phase of the AE design to ‘Repair Air Handlers & Controls, Electronics Research Facility, Building 3’, ULDF 10-0006.

1.02 ITEMS OF WORK

A. Remove the B/C Bay entrance door and in fill the opening to match the existing. Install entrance door, as indicated on the drawings, in the stepped out section of the wall to the east of the original location. Relocate ¾” conduit running along floor to around top of the relocated door. See Drawings 13 & 14 of 19.

B. Remove condenser water pump CWP-1, and associated accessories and store for reinstallation. Remove concrete pad and indicated sections of the 6” CHWS and CHWR.

Remove pumps concrete pad, if necessary for equipment rigging. See Drawing 13 of 19.

C. Install 500 ton chiller (B/C-2), York model YK or approved equal; cooling tower (B/C-2), Baltimore Aircoil PT2 Series or approved equal; indoor sump and all associated piping and accessories, rerouted 6” CHWS and CWHR piping, controls and structural members. See Drawing 14 of 19.

D. Reinstall condenser water pump CWP-1 and updated piping for the existing 250 ton chiller and tower. See Drawing 14 of 19.

E. Install a condenser water chemical feed system for the new chiller/tower. Equipment should be installed next to and match the existing. Three Pulsatron Model LE02SA-PTCJ-xxx, 6GPD pumps controlled by a Pulsatrol Series 9000 controller and sensors to measure conductivity and OPR. See Drawing 3 of 19.

F. The remaining drawings contain details, schematics and schedules referenced for this work and contain additional information for this phase, as well as other phases of the full AE design.

2 SUBMITTALS

A. Request four (4) copies of engineering catalog cuts for the chiller, tower, sump, pumps, valves, pipe, sensors and insulation.

3 SAFETY REQUIREMENTS

AFRL, Repair Air Handlers, Bldg 3 GENERAL SCOPE

SECTION 01010-2

A. Comply with all safety and health requirements necessary for the protection of personnel, facilities and equipment including, but not limited to, the Occupational Safety and Health Administration (OSHA) standards, while performing this contract at the Air Force Research Laboratory (AFRL), Rome Research Site (RRS), Rome NY. It is the contractor’s sole responsibility to make certain that all safety requirements are met.

B. Maintain a written safety program for compliance with the applicable OSHA standards, and make said program available for review by the Government upon request by the Contracting Officer.

C. In the event of a mishap, or a “near miss”, during the performance of this contract at

AFRL RRS, notify the Contracting Officer or the DET 4 Safety Office in an expeditious manner. Written notification shall be provided to the Contracting Officer (who will forward a copy to the DET 4 Safety Office) within 72 hours and shall include the following information (AF Form 978 Supervisor Mishap Report may be used):

a. Contract, Contract number, Name and Title of Person(s) Reporting

b. Date, Time and exact location of accident/incident

c. Brief Narrative of accident/incident (events leading to accident/incident)

d. Cause of accident/incident (if known)

e. Type of injuries resulting from the accident/incident and estimated cost of accident/incident (material and labor to replace/repair)

f. Nomenclature of equipment involved in accident/incident

g. Personnel involved in accident/incident

h. Corrective Actions (taken or proposed)

i. Other pertinent information

AFRL, Repair Air Handlers, Bldg 3 CAST-IN-PLACE CONCRETE TE Project #3364 SECTION 03300- 1

SECTION 03300

CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.01 RELATED DOCUMENTS

A. Drawings and general provisions of Contract, including General and Supplementary

Conditions and Division 1 Specification Sections, apply to this Section.

1.02 SUMMARY

A. This Section specifies cast-in place concrete, including reinforcing, mix design, formwork, placement procedures and finishes.

1.03 SUBMITTALS

A. General: Submit the following in accordance with Conditions of Contract and Division 1 Specification Sections.

B. Product data for proprietary materials and items, including reinforcement, admixtures, patching compounds, waterstops, joint systems, curing compounds, and others as requested by Engineer.

C. Shop drawings for reinforcement, prepared for fabrication, bending, and placement of concrete reinforcement. Comply with ACI SP-66 (88), "ACI Detailing Manual," showing bar schedules, stirrup spacing, diagrams of bent bars, and arrangement of concrete reinforcement. Include special reinforcement required for openings through concrete structures.

D. Laboratory test reports for concrete materials and mix design test.

1.04 QUALITY ASSURANCE

A. Codes and Standards: Comply with provisions of following codes, specifications, and standards, except where more stringent requirements are shown or specified:

1. ACI 318, "Building Code Requirements for Reinforced Concrete."

2. Concrete Reinforcing Steel Institute (CRSI), "Manual of Standard Practice."

B. Concrete Testing Service: Engage a testing laboratory acceptable to Engineer to perform material evaluation tests and to design concrete mixes.

C. Materials and installed work may require testing and retesting at any time during progress of work. Tests, including retesting of rejected materials for installed work, shall be done at Contractor's expense.

D. Owner will engage an independent testing laboratory to perform “Special Inspections” in accordance with the New York State Building Code and the statement of Special Inspections.

PART 2 - PRODUCTS

TE Project #3364 SECTION 03300- 2

2.01 FORM MATERIALS

A. Forms for exposed finished concrete: Plywood, metal, metal-framed plywood faced, or other acceptable panel-type materials, to provide continuous, straight, smooth, exposed surfaces. Furnish in largest practicable sizes to minimize number of joints.

B. Use plywood complying with U.S. Product Standard PS-1 “B-B (Concrete Form)

Plywood”, Class I, Exterior Grade or better, mill-oiled and edge-sealed, with each piece bearing legible inspection trademark.

C. Forms for unexposed finish concrete: Plywood, lumber, metal or other acceptable material. Provide lumber dressed on at least 2 edges and one side for tight fit.

D. Form coatings: Provide commercial formulation form-coating compounds that will not bond with, stain, or adversely affect concrete surfaces, and will not impair subsequent treatments of concrete surfaces.

E. Form ties: Factory-fabricated, adjustable length, removable or snap-off metal form ties, designed to prevent form deflection and to prevent spalling concrete upon removal. Provide units which will leave no metal closer than 1 ½” to surface.

Provide ties which, when removed, will leave holes not larger than 1” diameter in concrete surface.

2.02 REINFORCING MATERIALS

A. Deformed Bars: ASTM A 615, Grade 60.

B. Steel Wire: ASTM A 82, plain, cold-drawn steel.

C. Welded Wire Fabric: ASTM A 185, welded steel wire fabric.

D. Supports for Reinforcement: Bolsters, chairs, spacers, and other devices for spacing, supporting, and fastening reinforcing bars and welded wire fabric in place. Use wire-bar-type supports complying with CRSI specifications.

2.03 CONCRETE MATERIALS

A. Portland Cement: ASTM C 150, Type I or Type II.

1. Use one brand of cement throughout project.

B. Normal Weight Aggregates: ASTM C 33 and as herein specified. Provide aggregates from a single source for exposed concrete.

1. For exterior exposed surfaces, do not use fine or coarse aggregates containing spalling-causing deleterious substances.

C. Water: Drinkable.

D. Admixtures, General: Provide admixtures for concrete that contain not more than

0.1 percent chloride ions.

E. Air-Entraining Admixture: ASTM C 260, certified by manufacturer to be compatible with other required admixtures.

TE Project #3364 SECTION 03300- 3

1. Available Products: Subject to compliance with requirements, products that may be incorporated in the work include, but are not limited to, the following:

"Air-Tite," Cormix.

"Air-Mix" or "Perma-Air," Euclid Chemical Co.

"Darex AEA" or "Daravair," W.R. Grace & Co.

"MB-VR" or "Micro-Air," Master Builders, Inc.

"Sealtight AEA," W.R. Meadows, Inc.

"Sika AER," Sika Corp.

2.04 RELATED MATERIALS

A. Liquid Membrane-Forming Curing Compound: Liquid-type membrane-forming curing compound complying with ASTM C 309, Type I, Class A. Moisture loss not more than

0.055 gr./sq. cm. when applied at 200 sq. ft./gal.

B. Underlayment Compound: Free-flowing, self-leveling, pumpable, cement-based compound for applications from one inch thick to feathered edges.

C. Bonding Compound: Polyvinyl acetate or acrylic base.

D. Epoxy Adhesive: ASTM C 881, two-component material suitable for use on dry or damp surfaces. Provide material "Type," "Grade," and "Class" to suit project requirements.

2.05 PROPORTIONING AND DESIGN OF MIXES

A. Prepare design mixes for each type and strength of concrete by laboratory trial batch method as specified in ACI 301. Use an independent testing facility acceptable to Engineer for preparing and reporting proposed mix designs. The testing facility shall not be the same as used for field quality control testing.

B. Submit written reports to Engineer of each proposed mix for each class of concrete at least 15 days prior to start of work. Do not begin concrete production until proposed mix designs have been reviewed by Engineer.

C. Design mixes to provide normal weight concrete with the following properties, as indicated on drawings and schedules:

Piers - 4000-psi 28-day compressive strength.

Supported Slabs - 3500-psi 28-day compressive strength.

Footings – 3000-psi 28-day compressive strength.

D. Adjustment to Concrete Mixes: Mix design adjustments be requested by Contractor when characteristics of materials, job conditions, weather, test results, or other circumstances warrant, as accepted by Engineer. Laboratory test data for revised mix design and strength results must be submitted to and accepted by Engineer before using in work.

2.06 ADMIXTURES

A. Use air-entraining admixture in all concrete except interior slabs. Add air-entraining

TE Project #3364 SECTION 03300- 4 admixture at manufacturer's prescribed rate to result in concrete at point of placement having total air content with a tolerance of plus or minus 1-1/2 percent within following limits:

5.5 percent.

B. Water-Cement Ratio: Provide concrete for following conditions with maximum water-cement (W/C) ratios as follows:

1. Air-entrained, 4000 psi; W/C 0.35

2. Non-Air-entrained, 3500 psi; W/C 0.51

3. Air-entrained, 3000 psi; W/C 0.46

C. Slump Limits: Proportion and design mixes to result in concrete slump at point of placement as follows:

1. Slabs: Not more than 3 inches.

2. Other concrete: Not more than 4 inches.

2.07 CONCRETE MIXING

A. Ready-Mix Concrete: Comply with requirements of ASTM C 94, and as specified.

1. When air temperature is between 85 deg F (30 deg C) and 90 deg F (32 deg C), reduce mixing and delivery time from 1-1/2 hours to 75 minutes, and when air temperature is above 90 deg F (32 deg C), reduce mixing and delivery time to 60 minutes.

PART 3 - EXECUTION

3.01 GENERAL

A. Coordinate the installation of joint with placement of forms and reinforcing steel.

3.02 FORMS

A. General: Design, erect, support, brace and maintain formwork to support vertical, lateral, static and dynamic loads that might be applied until concrete structure can support such loads. Construct formwork so concrete members and structures are of correct size, shape, alignment, elevation, and position. Maintain formwork construction tolerances complying with ACI 347.

B. Construct forms to sizes, shapes, lines, and dimensions shown and to obtain accurate alignment, location, grades, level, and plumb work in finished structures. Provide for openings, offsets, sinkages, keyways, recesses, moldings, rustications, reglets, chamfers, blocking, screeds, bulkheads, anchorages and inserts, and other features required in work. Use selected materials to obtain required finishes. Solidly butt joints and provide backup at joints to prevent leakage of cement paste.

C. Fabricate forms for easy removal without hammering or prying against concrete

TE Project #3364 SECTION 03300- 5 surfaces. Provide crush plates or wrecking plates where stripping may damage cast concrete surfaces. Provide top forms for inclined surfaces where slope is too steep to place concrete with bottom forms only. Kerf wood inserts for forming keyways, reglets, recesses, and the like, for easy removal.

D. Provide temporary openings where interior area of formwork is inaccessible for cleanout, for inspection before concrete placement, and for placement of concrete.

Securely brace temporary openings and set tightly to forms to prevent loss of concrete mortar. Locate temporary openings in forms at inconspicuous locations.

E. Chamfer exposed corners and edges as indicated, using wood, metal, PVC, or rubber chamfer strips fabricated to produce uniform smooth lines and tight edge joints.

F. Provisions for Other Trades: Provide openings in concrete formwork to accommodate work of other trades. Determine size and location of openings, recesses, and chases from trades providing such items. Accurately place and securely support items built into forms.

G. Cleaning and Tightening: Thoroughly clean forms and adjacent surfaces to receive concrete. Remove chips, wood, sawdust, dirt, or other debris just before concrete is placed. Retighten forms and bracing before concrete placement as required to prevent mortar leaks and maintain proper alignment.

3.03 PLACING REINFORCEMENT

A. General: Comply with Concrete Reinforcing Steel Institute's recommended practice for "Placing Reinforcing Bars," for details and methods of reinforcement placement and supports and as herein specified.

B. Clean reinforcement of loose rust and mill scale, earth, ice, and other materials that reduce or destroy bond with concrete.

C. Accurately position, support, and secure reinforcement against displacement. Locate and support reinforcing by metal chairs, runners, bolsters, spacers, and hangers, as approved by Engineer.

D. Place reinforcement to obtain at least minimum coverages for concrete protection.

Arrange, space, and securely tie bars and bar supports to hold reinforcement in position during concrete placement operations. Set wire ties so ends are directed into concrete, not toward exposed concrete surfaces.

E. Install welded wire fabric in as long lengths as practicable. Lap adjoining pieces at least one full mesh and lace splices with wire. Offset laps of adjoining widths to prevent continuous laps in either direction. Provide flat sheets only.

3.04 JOINTS

A. Construction Joints: Locate and install construction joints as indicated or, if not indicated, locate so as not to impair strength and appearance of the structure, as acceptable to Engineer. Space joints no farther than 30'-0" apart. Line-up with expansion joints in brick as applicable.

B. Provide keyways at least 1 ½” deep in construction joints in walls, slabs and between walls and footings.

TE Project #3364 SECTION 03300- 6

C. Place construction joints perpendicular to main reinforcement. Continue reinforcement across construction joints, except as otherwise indicated.

D. Isolation Joints in slabs on grade: Construction isolation joints in slabs on grade at points of contact between slabs on grade and vertical surfaces, such as column pedestals, foundation walls, grade beams, and elsewhere as indicated.

E. Contraction Joints in slabs on grade: Construct contraction joints in slabs on grade to form panels of patterns as shown. If joint pattern is not shown, provide joints not exceeding 15’ in either direction and locate to conform to bay spacing.

3.05 INSTALLATION OF EMBEDDED ITEMS

A. General: Set and build into work anchorage devices and other embedded items required for other work that is attached to or supported by cast-in-place concrete.

Use setting drawings, diagrams, instructions, and directions provided by suppliers of items to be attached thereto.

3.06 PREPARATION OF FORMED SURFACES

A. Clean re-used forms of concrete matrix residue, repair and patch as required to return forms to acceptable surface condition.

B. Coat contact surfaces of forms with an approved, nonresidual, low-VOC, form-coating compound before reinforcement is placed.

C. Do not allow excess form-coating material to accumulate in forms or to come into contact with in-place concrete surfaces against which fresh concrete will be placed.

Apply in compliance with manufacturer's instructions.

D. Coat steel forms with a nonstaining, rust-preventative material. Rust-stained steel formwork is not acceptable.

3.07 CONCRETE PLACEMENT

A. Inspection: Before placing concrete, inspect and complete formwork installation, reinforcing steel, and items to be embedded or cast in. Notify other crafts to permit installation of their work; cooperate with other trades in setting such work.

B. General: Comply with ACI 304, "Recommended Practice for Measuring, Mixing, Transporting, and Placing Concrete," and as herein specified.

1. Deposit concrete continuously or in layers of such thickness that no concrete will be placed on concrete that has hardened sufficiently to cause the formation of seams or planes of weakness. If a section cannot be placed continuously, provide construction joints as herein specified. Deposit concrete to avoid segregation at its final location.

C. Placing Concrete Mat Footing: Deposit and consolidate concrete for mat footing in a continuous operation, within limits of construction joints, until the placing of a panel or section is completed.

1. Consolidate concrete during placing operations so that concrete is thoroughly

TE Project #3364 SECTION 03300- 7 worked around reinforcement and other embedded items and into corners.

2. Bring top surfaces to correct level with straightedge and strike off. Use bull floats or darbies to smooth surface, free of humps or hollows. Do not disturb surfaces prior to beginning finishing operations.

3. Maintain reinforcing in proper position during concrete placement.

D. Cold-Weather Placing: Comply with provisions of ACI 306 and as follows. Protect concrete work from physical damage or reduced strength that could be caused by frost, freezing actions, or low temperatures.

1. When air temperature has fallen to or is expected to fall below 40 deg F (4 deg

C), uniformly heat water and aggregates before mixing to obtain a concrete mixture temperature of not less than 50 deg F (10 deg C) and not more than 80 deg F (27 deg C) at point of placement.

2. Do not use frozen materials or materials containing ice or snow. Do not place concrete on frozen subgrade or on subgrade containing frozen materials.

3. Do not use calcium chloride, salt, and other materials containing antifreeze agents or chemical accelerators unless otherwise accepted in mix designs.

E. Hot-Weather Placing: When hot weather conditions exist that would seriously impair quality and strength of concrete, place concrete in compliance with ACI 305 and as herein specified.

1. Cool ingredients before mixing to maintain concrete temperature at time of placement below 90 deg F (32 deg C). Mixing water may be chilled, or chopped ice may be used to control temperature provided water equivalent of ice is calculated to total amount of mixing water. Use of liquid nitrogen to cool concrete is Contractor's option.

2. Cover reinforcing steel with water-soaked burlap if it becomes too hot, so that steel temperature will not exceed the ambient air temperature immediately before embedment in concrete.

3. Fog spray forms, reinforcing steel, and subgrade just before concrete is placed.

3.08 FINISH OF FORMED SURFACES

A. Rough Form Surfaces: For formed concrete surfaces not exposed to view in the finish work or by other construction, unless otherwise indicated. Patch tie holes and defective areas, rub down or chip off fins and other projections exceeding ¼” in height.

B. Smooth Form Finish: For formed concrete surfaces exposed to view or to be covered with a coating material applied directly to concrete, or a covering material applied directly to concrete, such as waterproofing, dampproofing, veneer plaster, painting, or other similar system. This is an as-cast concrete surface obtained with selected form-facing material, arranged in an orderly and symmetrical manner with a minimum of seams. Repair and patch defective areas with fins and other projections completely removed and smoothed. The final finish shall be as directed by the Architect.

TE Project #3364 SECTION 03300- 8

C. Related Unformed Surfaces: At tops of walls, horizontal offsets, and similar unformed surfaces occurring adjacent to formed surfaces, strike-off smooth and finish with a texture matching adjacent formed surfaces. Continue final surface treatment of formed surfaces uniformly across adjacent unformed surfaces unless otherwise indicated.

3.09 MONOLITHIC SLAB FINISHES

A. Float Finish: Apply float finish to monolithic slab surfaces to receive trowel finish.

1. After screeding, consolidating, and leveling concrete slabs, do not work surface until ready for floating. Begin floating, using float blades or float shoes only, when surface water has disappeared, when concrete has stiffened sufficiently to permit operation of power-driven floats, or both. Consolidate surface with power-driven floats or by hand-floating if area is small or inaccessible to power units. Check and level surface plane to tolerances of Fl 18 - Fl 15. Cut down high spots and fill low spots. Uniformly slope surfaces to drains. Immediately after leveling, refloat surface to a uniform, smooth, granular texture.

B. Trowel Finish: Apply trowel finish to all monolithic slab surfaces.

1. After floating, begin first trowel finish operation using a power-driven trowel.

Begin final troweling when surface produces a ringing sound as trowel is moved over surface. Consolidate concrete surface by final hand-troweling operation, free of trowel marks, uniform in texture and appearance, and with surface leveled to tolerances of Fl 20 - Fl 17.

3.10 CONCRETE CURING AND PROTECTION

A. General: Protect freshly placed concrete from premature drying and excessive cold or hot temperatures. In hot, dry, and windy weather, protect concrete from rapid moisture loss before and during finishing operations with an evaporation-control material. Apply in accordance with manufacturer's instructions after screeding and bull floating, but before power floating and troweling.

1. Start initial curing as soon as free water has disappeared from concrete surface after placing and finishing. Weather permitting, keep continuously moist for not less than 7 days.

B. Curing Methods: Perform curing of concrete by curing and sealing compound or by moist curing as herein specified.

C. Provide moisture curing by following methods.

1. Keep concrete surface continuously wet by covering with water.

2. Use continuous water-fog spray.

D. Provide curing and sealing compound to exposed interior slabs as follows:

1. Apply specified curing and sealing compound to concrete slabs as soon as final finishing operations are complete (within 2 hours and after surface water sheen has disappeared). Apply uniformly in continuous operation by power spray or

TE Project #3364 SECTION 03300- 9 roller in accordance with manufacturer's directions. Recoat areas subjected to heavy rainfall within 3 hours after initial application.

Maintain continuity of coating and repair damage during curing period.

2. Use membrane curing compounds that will not affect surfaces to be covered with finish materials applied directly to concrete.

3.11 REMOVAL OF FORMS

A. General: Formwork not supporting weight of concrete, such as sides of walls, and similar parts of the work, may be removed after cumulatively curing at not less than 50 deg F (10 deg C) for 36 hours after placing concrete, provided concrete is sufficiently hard to not be damaged by form-removal operations, and provided curing and protection operations are maintained.

3.12 CONCRETE SURFACE REPAIRS

A. Repair of Unformed Surfaces: Test unformed surfaces, such as monolithic slabs, for smoothness and verify surface plane to tolerances specified for each surface and finish. Correct low and high areas as herein specified. Test unformed surfaces sloped to drain for trueness of slope and smoothness by using a template having required slope.

1. Repair finished unformed surfaces that contain defects that affect durability of concrete. Surface defects, as such, include crazing and cracks in excess of 0.01 inch wide or that penetrate to reinforcement or completely through nonreinforced sections regardless of width, spalling, popouts, honeycomb, rock pockets, and other objectionable conditions.

2. Correct high areas in unformed surfaces by grinding after concrete has cured at least 14 days.

3. Correct low areas in unformed surfaces during or immediately after completion of surface finishing operations by cutting out low areas and replacing with patching compound. Finish repaired areas to blend into adjacent concrete.

Underlayment compounds may be used when acceptable to Engineer.

4. Repair defective areas, except random cracks and single holes not exceeding 1 inch in diameter, by cutting out and replacing with fresh concrete. Remove defective areas to sound concrete with clean, square cuts and expose reinforcing steel with at least 3/4-inch clearance all around. Dampen concrete surfaces in contact with patching concrete and apply bonding compound. Mix patching concrete of same materials to provide concrete of same type or class as original concrete. Place, compact, and finish to blend with adjacent finished concrete. Cure in same manner as adjacent concrete.

B. Perform structural repairs with prior approval of Engineer for method and procedure, using specified epoxy adhesive and mortar.

3.13 QUALITY CONTROL TESTING DURING CONSTRUCTION

A. General: The Owner will employ a testing laboratory to perform tests and to submit test reports.

1. Sampling and testing for quality control during placement of concrete may

TE Project #3364 SECTION 03300- 10 include the following, as directed by Engineer.

B. Sampling Fresh Concrete: ASTM C 172, except modified for slump to comply with

ASTM C 94.

1. Slump: ASTM C 143; one test at point of discharge for each day's pour of each type of concrete; additional tests when concrete consistency seems to have changed.

2. Air Content: ASTM C 173, volumetric method for normal weight concrete;

ASTM C 231 pressure method for normal weight concrete; one for each day's pour of each type of air-entrained concrete.

3. Concrete Temperature: Test hourly when air temperature is 40 deg F (4 deg C) and below, when 80 deg F (27 deg C) and above, and each time a set of compression test specimens is made.

4. Compression Test Specimen: ASTM C 31; one set of 4 standard cylinders for each compressive strength test, unless otherwise directed. Mold and store cylinders for laboratory-cured test specimens except when field-cure test specimens are required.

5. Compressive Strength Tests: ASTM C 39; one set for each day's pour of each concrete class placed in any one day; one specimen tested at 7 days, two specimens tested at 28 days, and one specimen retained in reserve for later testing if required.

a. When frequency of testing will provide fewer than 5 strength tests for a given class of concrete, conduct testing from at least 5 randomly selected batches or from each batch if fewer than 5 are used.

b. When strength of field-cured cylinders is less than 85 percent of companion laboratory-cured cylinders, evaluate current operations and provide corrective procedures for protecting and curing the in-place concrete.

c. Strength level of concrete will be considered satisfactory if averages of sets of three consecutive strength test results equal or exceed specified compressive strength, and no individual strength test result falls below specified compressive strength by more than 500 psi.

C. Test results will be reported in writing to Engineer, Structural Engineer, Ready-Mix

Producer, and Contractor within 24 hours after tests. Reports of compressive strength tests shall contain the project identification name and number, date of concrete placement, name of concrete testing service, concrete type and class, location of concrete batch in structure, design compressive strength at 28 days, concrete mix proportions and materials, compressive breaking strength, and type of break for both 7-day tests and 28-day tests.

D. Nondestructive Testing: Impact hammer, sonoscope, or other nondestructive device may be permitted but shall not be used as the sole basis for acceptance or rejection.

E. Additional Tests: The testing service will make additional tests of in-place concrete when test results indicate specified concrete strengths and other characteristics have not been attained in the structure, as directed by Engineer. Testing service may

TE Project #3364 SECTION 03300- 11 conduct tests to determine adequacy of concrete by cored cylinders complying with ASTM C 42, or by other methods as directed. Contractor shall pay for such tests when unacceptable concrete is verified.

END OF SECTION

AFRL, Repair Air Handlers, Bldg 3 STRUCTURAL STEEL TE Project #3364 SECTION 05120- 1

SECTION 05120

STRUCTURAL STEEL

A. This Section includes fabrication and erection of structural steel work, as shown on drawings including schedules, notes, and details showing size and location of members, typical connections, and types of steel required.

1. Structural steel is that work defined in American Institute of Steel Construction

(AISC) "Code of Standard Practice" and as otherwise shown on drawings.

2. Miscellaneous Metal Fabrications are specified elsewhere in Division 5.

B. Shop drawings including complete details and schedules for fabrication and assembly of structural steel members, procedures, and diagrams.

1. Include details of cuts, connections, camber, holes, and other pertinent data.

Indicate welds by standard AWS symbols and show size, length, and type of each weld.

2. Provide setting drawings, templates, and directions for installation of anchor bolts and other anchorages to be installed as work of other sections.

A. Codes and Standards: Comply with provisions of following, except as otherwise indicated:

1. American Institute of Steel Construction (AISC) "Code of Standard Practice for

Steel Buildings and Bridges."

a. Paragraph 4.2.1 of the above code is hereby modified by deletion of the following sentence:

i. "This approval constitutes the owner's acceptance of all responsibility for the design adequacy of any detail configuration of connections developed by the fabricator as a part of his preparation of these shop drawings."

2. AISC "Specifications for Structural Steel Buildings," including "Commentary."

TE Project #3364 SECTION 05120- 2

3. "Specifications for Structural Joints using ASTM A 325 or A 490 Bolts" approved by the Research Council on Structural Connections.

4. American Welding Society (AWS) D1.1 "Structural Welding Code - Steel."

5. ASTM A 6 "General Requirements for Delivery of Rolled Steel Plates, Shapes, Sheet Piling and Bars for Structural Use."

B. Qualifications for Welding Work: Qualify welding procedures and welding operators in accordance with AWS "Qualification" requirements.

1. Provide certification that welders to be employed in work have satisfactorily passed AWS qualification tests.

2. If recertification of welders is required, retesting will be Contractor's responsibility.

1.05 DELIVERY, STORAGE, AND HANDLING

A. Deliver materials to site at such intervals to ensure uninterrupted progress of work.

B. Deliver anchor bolts and anchorage devices, which are to be embedded in cast-in-place concrete or masonry, in ample time to not to delay work.

C. Store materials to permit easy access for inspection and identification. Keep steel members off ground by using pallets, platforms, or other supports. Protect steel members and packaged materials from erosion and deterioration. If bolts and nuts become dry or rusty, clean and relubricate before use.

1. Do not store materials on structure in a manner that might cause distortion or damage to members or supporting structures. Repair or replace damaged materials or structures as directed.

2.01 MATERIALS

A. Metal Surfaces, General: For fabrication of work that will be exposed to view, use only materials that are smooth and free of surface blemishes including pitting, rust and scale, seam marks, roller marks, rolled trade names, and roughness. Remove such blemishes by grinding, or by welding and grinding, prior to cleaning, treating, and applying surface finishes.

B. Structural Steel Wide Flange Shapes: ASTM 992 Gr. 50.

C. Structural Steel Channels, Angles, Plates and Bars: ASTM A 36.

D. Structural Steel Tubes: ASTM A 500, Grade “B”, 46 KSI.

E. Steel Pipe: ASTM A 53, Type “E”, Grade “B”.

F. Epoxy Bolts: ASTM C 882 Epoxy, ASTM A 193, Grade B7 high strength threaded rod.

TE Project #3364 SECTION 05120- 3

G. High-Strength Threaded Fasteners: Heavy hexagon structural bolts, heavy hexagon nuts, and hardened washers, as follows:

1. Quenched and tempered medium-carbon steel bolts, nuts, and washers, complying with ASTM A 325.

2. Direct Tension Indicators: ASTM F 959, type as required.

3. Use at Contractor’s option.

H. Electrodes for Welding: Comply with AWS Code. E 70 XX.

2.02 FABRICATION

A. Shop Fabrication and Assembly: Fabricate and assemble structural assemblies in shop to greatest extent possible. Fabricate items of structural steel in accordance with AISC Specifications and as indicated on final shop drawings. Provide camber in structural members where indicated.

1. Properly mark and match-mark materials for field assembly. Fabricate for delivery sequence that will expedite erection and minimize field handling of materials.

2. Where finishing is required, complete assembly, including welding of units, before start of finishing operations. Provide finish surfaces of members exposed in final structure free of markings, burrs, and other defects.

B. Connections: Weld or bolt shop connections, as indicated.

1. Bolt field connections, except where welded connections or other connections are indicated.

a. Provide high-strength threaded fasteners for all bolted connections.

b. All connections shall be properly designed for the moments or shears shown on the drawings, or for 1/2 of the maximum allowable uniform load for the span as tabulated by AISC if reactions are not given.

c. Provide for unusual end loads where necessary.

C. Welded Construction: Comply with AWS Code for procedures, appearance and quality of welds, and methods used in correcting welding work.

1. Assemble and weld built-up sections by methods that will produce true alignment of axes without warp.

2.03 SHOP PAINTING

A. General: Shop paint structural steel. See General Notes on drawings for Surface Preparation and Painting requirements.

B. Surface Preparation: After inspection and before shipping, clean steelwork to be painted. Remove loose rust, loose mill scale, and spatter, slag, or flux deposits.

Clean steel as indicated in General Notes on drawings.

TE Project #3364 SECTION 05120- 4

C. Painting: Immediately after surface preparation, apply structural steel primer paint in accordance with manufacturer’s instructions and at a rate to provide dry film thickness as indicated in General Notes on drawigns. Use painting methods that will result in full coverage of joints, corners, edges and exposed surfaces.

2.04 SOURCE QUALITY CONTROL

A. General: Materials and fabrication procedures are subject to inspection and tests in mill, shop, and field, conducted by a qualified inspection agency. Such inspections and tests will not relieve Contractor of responsibility for providing materials and fabrication procedures in compliance with specified requirements.

1. Promptly remove and replace materials or fabricated components that do not comply.

B. Design of Members and Connections: Details shown are typical; similar details apply to similar conditions, unless otherwise indicated. Verify dimensions at site whenever possible without causing delay in the work.

1. Promptly notify Engineer whenever design of members and connections for any portion of structure are not clearly indicated.

3.01 ERECTION

A. Setting Bases and Bearing Plates: Clean concrete and masonry bearing surfaces of bond-reducing materials and roughen to improve bond to surfaces. Clean bottom surface of base and bearing plates.

1. Set loose and attached base plates and bearing plates for structural members on wedges or other adjusting devices.

2. Tighten anchor bolts after supported members have been positioned and plumbed. Do not remove wedges or shims, but if protruding, cut off flush with edge of base or bearing plate prior to packing with grout.

3. Pack grout solidly between bearing surfaces and bases or plates to ensure that no voids remain. Finish exposed surfaces, protect installed materials, and allow to cure.

B. Field Assembly: Set structural frames accurately to lines and elevations indicated.

Align and adjust various members forming part of complete frame or structure before permanently fastening. Clean bearing surfaces and other surfaces that will be in permanent contact before assembly. Perform necessary adjustments to compensate for discrepancies in elevations and alignment.

1. Level and plumb individual members of structure within specified AISC tolerances.

2. Splice members only where indicated and accepted on shop drawings.

TE Project #3364 SECTION 05120- 5

C. Erection Bolts: On exposed welded construction, remove erection bolts, fill holes with plug welds, and grind smooth at exposed surfaces.

1. Comply with AISC Specifications for bearing, adequacy of temporary connections, alignment, and removal of paint on surfaces adjacent to field welds.

2. Do not enlarge unfair holes in members by burning or by using drift pins, except in secondary bracing members. Ream holes that must be enlarged to admit bolts.

D. Gas Cutting: Do not use gas cutting torches in field for correcting fabrication errors in structural framing.

E. Touch-Up: Immediately after erection, clean field welds, bolted connections, and abraded areas of shop paint. Apply paint to exposed areas using same material as used for shop painting.

1. Apply by brush or spray to provide minimum dry film thickness of 3.0 mils.

AFRL, Repair Air Handlers, Bldg 3 STEEL JOISTS TE Project #3364 SECTION 05210- 1

SECTION 05210

STEEL JOISTS

A. Extent of steel joists is shown on drawings, including basic layout and type of joists required.

A. Product Data: Submit manufacturer’s specifications and installation for each type of joist and accessories. Include manufacturers certification that each joist complies with SJI “Specifications”.

B. Shop Drawings: Submit detailed drawings showing layout of joist units, special connections, joining and accessories. Include mark, number, type, location and spacing of joists and bridging.

1. Provide templates or location drawings for installation of anchor bolts and metal bearing plates.

A. Provide joists fabricated in compliance with the following, and as herein specified.

1. Steel Joist Institute (SJI) “Standard Specifications, Load Tables and Weight Tables” for:

a. K-Series Open Web Steel Joists.

2. Qualification of Field Welding: Qualify welding processes and welding operators in accordance with American Welding Society “Structural Welding Code,” AWS D1.1.

3. Inspection: Inspect joists and girders in accordance with SJI specifications.

4. Performance Test: If required, conduct performance tests in accordance with procedures described in “Recommended Code of Standard Practice.”

A. Deliver, store and handle steel joists as recommended in SJI “Specifications”. Handle and store joists in a manner to avoid deforming members and to avoid excessive stresses.

TE Project #3364 SECTION 05210- 2

2.01 MATERIALS

A. Steel: Comply with SJI “Specifications”.

B. Unfinished Threaded Fasteners: ASTM A 307, Grade A, regular hexagon type, low carbon steel.

C. High-Strength Threaded Fasteners: ASTM A 325 or A 490 heavy hexagon structural bolts with nuts and hardened washers.

D. Steel Prime Paint: Comply with SJI “Specifications”.

2.02 FABRICATION

A. General: Fabricate steel joists in accordance with SJI “Specifications”.

B. Holes in Chord Members: Provide holes in chord members where shown for securing other work to steel joists; however, deduct area of holes from the area of chord when calculating strength of member.

C. Extended Ends: Provide extended ends on joist where shown, complying with manufacturer’s standards and requirements of applicable SJI “Specifications” and load tables.

D. Ceiling Extensions: Provide ceiling extensions in the areas having ceilings attached directly to joist bottom chord. Provide either an extended bottom chord element or a separate unit, to suit manufacturer’s standards, of sufficient strength to support ceiling construction. Extend ends to within ½” of finished wall surface unless otherwise indicated.

E. Bridging: Provide horizontal or diagonal type bridging for joists complying with SJI

“Specifications”.

1. Provide bridging anchors for ends of bridging lines terminating at walls or beams.

F. End Anchorage: Provide end anchorages including bearing plates, to secure joists to adjacent construction, complying with SJI “Specifications”, unless otherwise

G. Shop Painting: Remove loose scale, heavy rust, and other foreign materials from fabricated joists and accessories before application of shop paint.

1. Apply one shop coat of steel prime paint to joists and accessories, by spray, dipping, or other method to provide a continuous dry paint film thickness of not less than 0.5 mil.

3.01 ERECTION

A. Place and secure steel joists in accordance with SJI “Specifications”, final shop

TE Project #3364 SECTION 05210- 3 drawings, and as herein specified.

B. Placing Joists: Do not start placement of steel joists until supporting work is in place and secured. Place joists on supporting work, adjust and align in accurate locations and spacing before permanently fastening.

1. Provide temporary bridging, connections, and anchors to ensure lateral stability during construction.

a. Where “open web” joists lengths are 40 feet or longer, install a center row of bolted bridging to provide lateral stability before slackening of hoisting lines.

C. Bridging: Install bridging simultaneously with joist erection, before construction loads are applied. Anchor ends of bridging lines at top and bottom chords where terminating at walls or beams

3.02 FASTENING JOISTS

A. Field weld joists to supporting steel bearing plates in accordance with SJI “Specifications” for type of joists used. Coordinate welding sequence and procedure with placing of joists.

B. Touch-Up Painting: After joist installation, paint field bolt heads and nuts, and welded areas, abraded or rusty surfaces on joists and steel supporting members.

Wire brush surfaces and clean with solvent before painting. Use same type of paint as used for shop painting.

AFRL, Repair Air Handlers, Bldg 3 STEEL DECK TE Project #3364 SECTION 05310- 1

SECTION 05310

STEEL DECK

Conditions and Division 1 Specifications, apply to this section.

A. This section includes steel deck units for floor and roof applications.

1. Product data including manufacturer's specifications and installation instructions for each type of decking and accessories.

a. Provide test data for mechanical fasteners used in lieu of welding for fastening deck to supporting structures.

2. Shop drawings showing layout and types of deck units, anchorage details, and conditions requiring closure strips, supplementary framing, sump pans, cant strips, cut openings, special jointing, and other accessories.

A. Codes and Standards: Comply with provisions of the following codes and standards, except as otherwise indicated:

1. American Iron and Steel Institute (AISI), "Specifications for the Design of Cold-

Formed Steel Structural Members."

2. American Welding Society (AWS), D1.3 "Structural Welding Code - Sheet

Steel."

3. Steel Deck Institute (SDI), "Design Manual for Composite Decks, Form Decks and Roof Decks."

B. Qualification of field welding: Use qualified welding processes and welding operators in accordance with "Welder Qualification" procedures of AWS.

C. FM Listing: Provide steel roof deck units that have been evaluated by Factory Mutual

System and are listed in "Factory Mutual Approval Guide" for "Class I" fire-rated construction.

TE Project #3364 SECTION 05310- 2

2.01 MANUFACTURERS:

A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated in the work include but are not limited to the following:

Bowman Metal Deck Div., Cyclops Corp.

Consolidated Systems, Inc.

Epic Metals Corp.

H. H. Robertson Co.

Roll Form Products, Inc.

Roof Deck, Inc.

United Steel Deck, Inc.

Vulcraft Div., Nucor Corp.

Wheeling Corrugating Co.

2.02 MATERIALS

A. Steel for Painted Metal Deck Units: ASTM A 611, grade as required to comply with SDI specifications.

B. Steel for Galvanized Metal Deck Units: ASTM A 446, grade as required to comply with SDI specifications.

C. Miscellaneous Steel Shapes: ASTM A 36.

D. Sheet Metal Accessories: ASTM A 526, commercial quality, galvanized.

E. Galvanizing: ASTM A 525, G60.

F. Galvanizing Repair: Where galvanized surfaces are damaged, prepare surfaces and repair in accordance with procedures specified in ASTM A 780.

G. Paint: Manufacturer's baked-on, rust-inhibative paint, for application to metal surfaces that have been chemically cleaned and phosphate chemical treated.

H. Flexible Closure Strips: Manufacturer's standard vulcanized, closed-cell, synthetic rubber.

2.03 FABRICATION

A. General: Form deck units in lengths to span three or more supports, with flush, telescoped, or nested 2-inch laps at ends and interlocking or nested side laps, of metal thickness, depth, and width as indicated.

B. Roof Deck and Floor Deck Units: Provide deck configurations that comply with SDI

“Specifications and Commentary for UFS Deck.”

C. Composite Steel Form Deck: Provided fluted sections of metal deck as permanent forms for reinforced concrete slabs.

TE Project #3364 SECTION 05310- 3

D. Metal Cover Plates: Fabricate metal cover plates for end abutting floor deck units of not less than the same thickness as the decking. Form to match contour of deck units and approximately 6 inches wide.

E. Metal Closure Strips: Fabricate metal closure strips for raceways and openings between decking and other construction, of not less than 0.045 inch (18 gage) sheet steel. Form to provide tight fitting closures at open ends of cells or flutes and sides of decking.

2.04 DECK SCHEDULE

A. Roof Deck: 1 ½” Type “B”, 22 gage galvanized deck.

B. Floor Form Deck: 1 ½”, 20 gage galvanized composite form deck.

3.01 INSTALLATION

A. General: Install deck units and accessories in accordance with manufacturer's recommendations, shop drawings, and as specified herein.

1. Place deck units on supporting steel framework and adjust to final position with ends accurately aligned and bearing on supporting members before being permanently fastened. Do not stretch or contract side lap interlocks.

2. Align deck units for entire length of run of cells and with close alignment between cells at ends of abutting units.

3. Place deck units flat and square, secured to adjacent framing without warp or deflection.

4. Coordinate and cooperate with structural steel erector in locating decking bundles to prevent overloading of structural members.

5. Do not use floor deck units for storage or working platforms until permanently secured.

3.02 FASTENING DECK UNITS

A. Fasten roof deck units to steel supporting members by not less than 5/8 inch puddle welds or elongated welds of equal strength, spaced not more than 8 inches o.c. at every support, and at closer spacing where indicated. In addition, secure deck to each supporting member in ribs where side laps occur.

B. Fasten floor deck units to steel supporting members by not less than 5/8 inch puddlewelds or elongated welds of equal strength, spaced not more than 12 inches o.c. at every support, and at closer spacing where indicated. In addition, secure deck to each supporting member in ribs where side laps occur.

C. Comply with AWS requirements and procedures for manual shielded metal arc welding, appearance and quality of welds, and methods used in correcting welding work.

TE Project #3364 SECTION 05310- 4

1. Use welding washers where recommended by deck manufacturer.

D. Mechanically fasten side laps of adjacent roof deck units between supports, at intervals not exceeding 36 inches o.c., using self-tapping No. 8 or larger machine screws.

E. Mechanically fasten side laps of adjacent floor deck units between supports, at intervals not exceeding 36 inches o.c., using 5/8 inch puddle welds.

F. Uplift Loading: Install and anchor roof deck units to resist gross uplifts loading of 45 lbs. psf at eave overhang and 30 lbs. psf for other roof areas.

G. Cutting and Fitting: Cut and neatly fit deck units and accessories around other work projecting through or adjacent to the decking, as shown.

H.…