SECTION 05521 - PIPE AND TUBE RAILINGS.pdf

U.S EMBASSY- SKOPJE, MACEDONIA 30 NOV, 2006

ISSUED FOR CONSTRUCTION

PIPE AND TUBE RAILINGS SECTION 05521 - 1

SECTION 05521 - PIPE AND TUBE RAILINGS

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes the following:

1. Steel pipe and tube handrails and railings.

1.2 PERFORMANCE REQUIREMENTS

A. General: In engineering handrails and railings to withstand structural loads indicated, determine allowable design working stresses of handrail and railing materials based on the following:

1. Structural Steel: AISC S335, "Specification for Structural Steel Buildings Allowable

Stress Design and Plastic Design with Commentary."

2. Cold-Formed Structural Steel: AISI SG-673, Part I, "Specification for the Design of

Cold-Formed Steel Structural Members."

B. Structural Performance of Handrails and Railings: Provide handrails and railings complying with requirements of ASTM E 985 for structural performance, based on testing performed according to ASTM E 894 and ASTM E 935.

1. Top Rail of Guards: Capable of withstanding the following loads applied as indicated:

a. Concentrated load of 890 N applied at any point and in any direction.

b. Uniform load of 730 N/m applied horizontally and concurrently with uniform load of 1460 N/m applied vertically downward.

c. Concentrated and uniform loads above need not be assumed to act concurrently.

2. Handrails Not Serving As Top Rails: Capable of withstanding the following loads applied as indicated:

a. Concentrated load of 890 N applied at any point and in any direction.

b. Uniform load of 730 N/m applied in any direction.

c. Concentrated and uniform loads above need not be assumed to act concurrently.

C. Thermal Movements: Provide handrails and railings that allow for thermal movements resulting from the following maximum change (range) in ambient and surface temperatures by preventing buckling, opening of joints, overstressing of components, failure of connections, and other detrimental effects. Base engineering calculation on surface temperatures of materials due to both solar heat gain and nighttime-sky heat loss.

1. Temperature Change (Range): 67 deg C, ambient; 100 deg C, material surfaces.

D. Control of Corrosion: Prevent galvanic action and other forms of corrosion by insulating metals and other materials from direct contact with incompatible materials.

E. Available mechanical finishes.

PIPE AND TUBE RAILINGS SECTION 05521 - 2

1.3 SUBMITTALS

A. Product Data: For the following:

1. Manufacturer's product lines of mechanically connected railings.

2. Grout, anchoring cement, and paint products.

B. Shop Drawings: Include plans, elevations, sections, details, and attachments to other work.

C. Samples for Initial Selection: For products involving selection of color, texture, or design including mechanical finishes on stainless steel.

D. Samples for Verification: For each type of exposed finish required.

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

F. Welding certificates.

1.4 QUALITY ASSURANCE

A. Professional Engineer Qualifications: A professional engineer who is legally qualified to practice in jurisdiction where Project is located and who is experienced in providing engineering services of the kind indicated. Engineering services are defined as those performed for installations of handrails and railings that are similar to those indicated for this Project in material, design, and extent.

B. Testing Agency Qualifications: An independent testing agency with the experience and capability to conduct the testing indicated, as documented according to ASTM E 548 where required for submittal requirements.

C. Source Limitations: Obtain each type of handrail and railing through one source from a single manufacturer.

1.5 PROJECT CONDITIONS

A. Field Measurements: Verify handrail and railing dimensions by field measurements before fabrication and indicate measurements on Shop Drawings. Coordinate fabrication schedule with construction progress to avoid delaying the Work.

1. Established Dimensions: Where field measurements cannot be made without delaying the Work, establish dimensions and proceed with fabricating handrails and railings without field measurements. Coordinate construction to ensure that actual dimensions correspond to established dimensions.

1.6 COORDINATION AND SCHEDULING

A. Coordinate installation of anchorages for railings. Furnish setting drawings, templates, and directions for installing anchorages, including sleeves, concrete inserts, anchor bolts, and items

PIPE AND TUBE RAILINGS SECTION 05521 - 3

with integral anchors, that are to be embedded in concrete or masonry. Deliver such items to Project site in time for installation.

B. Schedule installation so wall attachments are made only to completed walls. Do not support railings temporarily by any means that do not satisfy structural performance requirements.

PART 2 - PRODUCTS

2.1 METALS, GENERAL

A. Metal Surfaces, General: Provide materials with smooth surfaces, without seam marks, roller marks, rolled trade names, stains, discolorations, or blemishes.

B. Brackets, Flanges, and Anchors: Cast or formed metal of same type of material and finish as supported rails, unless otherwise indicated.

2.2 STEEL AND IRON

A. Tubing: ASTM A 500 (cold formed) .

B. Pipe: ASTM A 53/A 53M, Type F or Type S, Grade A, Standard Weight (Schedule 40), unless another grade and weight are required by structural loads.

1. Provide galvanized finish for exterior installations and where indicated.

C. Plates, Shapes, and Bars: ASTM A 36/A 36M.

D. Castings: Either gray or malleable iron, unless otherwise indicated.

1. Gray Iron: ASTM A 48/A 48M, Class 30, unless another class is indicated or required by structural loads.

2. Malleable Iron: ASTM A 47/A 47M.

2.3 FASTENERS

A. General: Provide the following:

1. Steel Railings: Plated steel fasteners complying with ASTM B 633, Class Fe/Zn 25 for electrodeposited zinc coating.

B. Fasteners for Anchoring Railings to Other Construction: Select fasteners of type, grade, and class required to produce connections suitable for anchoring railings to other types of construction indicated and capable of withstanding design loads.

C. Fasteners for Interconnecting Railing Components:

1. Provide concealed fasteners for interconnecting railing components and for attaching them to other work, unless otherwise indicated.

PIPE AND TUBE RAILINGS SECTION 05521 - 4

2. Provide concealed fasteners for interconnecting railing components and for attaching them to other work, unless exposed fasteners are unavoidable or are the standard fastening method for railings indicated.

3. Provide Phillips flat-head machine screws for exposed fasteners, unless otherwise indicated.

D. Anchors: Provide cast-in-place torque-controlled expansion anchors, fabricated from corrosion-resistant materials with capability to sustain, without failure, a load equal to six times the load imposed when installed in unit masonry and equal to four times the load imposed when installed in concrete, as determined by testing per ASTM E 488 conducted by a qualified independent testing agency.

2.4 MISCELLANEOUS MATERIALS

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

1. For aluminum railings, provide type and alloy as recommended by producer of metal to be welded and as required for color match, strength, and compatibility in fabricated items.

B. Shop Primers: Provide primers that comply with Division 9 painting Sections.

C. Universal Shop Primer: Fast-curing, lead- and chromate-free, universal modified-alkyd primer complying with MPI#79.

1. Use primer with a VOC content of 420 g/L (3.5 lb/gal.) or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

2. Use primer containing pigments that make it easily distinguishable from zinc-rich primer.

D. Zinc-Rich Primer: Complying with SSPC-Paint 20 or SSPC-Paint 29 and compatible with topcoat.

1. Use primer with a VOC content of 420 g/L (3.5 lb/gal.) or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

E. Shop Primer for Galvanized Steel: Zinc-dust, zinc-oxide primer formulated for priming zinc-coated steel and for compatibility with finish paint systems indicated, and complying with SSPC-Paint 5.

F. Galvanizing Repair Paint: High-zinc-dust-content paint for regalvanizing welds in steel, complying with SSPC-Paint 20.

G. Bituminous Paint: Cold-applied asphalt emulsion complying with ASTM D 1187.

H. Nonshrink, Nonmetallic Grout: Factory-packaged, nonstaining, noncorrosive, nongaseous grout complying with ASTM C 1107. Provide grout specifically recommended by manufacturer for interior and exterior applications.

I. Anchoring Cement: Factory-packaged, nonshrink, nonstaining, hydraulic-controlled expansion cement formulation for mixing with water at Project site to create pourable anchoring, patching, and grouting compound.

PIPE AND TUBE RAILINGS SECTION 05521 - 5

1. Water-Resistant Product: At exterior locations provide formulation that is resistant to erosion from water exposure without needing protection by a sealer or waterproof coating and that is recommended by manufacturer for exterior use.

2.5 FABRICATION

A. General: Fabricate handrails and railings to comply with requirements indicated for design, dimensions, member sizes and spacing, details, finish, and anchorage, but not less than that required to support structural loads.

B. Assemble handrails and railings in the shop to greatest extent possible to minimize field splicing and assembly. Disassemble units only as necessary for shipping and handling limitations.

Clearly mark units for reassembly and coordinated installation. Use connections that maintain structural value of joined pieces.

C. Form simple and compound curves by bending members in jigs to produce uniform curvature for each repetitive configuration required; maintain cylindrical cross section of member throughout entire bend without buckling, twisting, cracking, or otherwise deforming exposed surfaces of handrail and railing components.

D. Welded Connections: Fabricate handrails and railings for connecting members by welding.

Cope components at perpendicular and skew connections to provide close fit, or use fittings designed for this purpose. Weld connections 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 flux immediately.

4. At exposed connections, finish exposed surfaces smooth and blended so no roughness shows after finishing and welded surface matches contours of adjoining surfaces.

E. Welded Connections for Aluminum Pipe: Fabricate pipe handrails and railings to interconnect members with concealed internal welds that eliminate surface grinding, using manufacturer's standard system of sleeve and socket fittings.

F. Brackets, Flanges, Fittings, and Anchors: Provide wall brackets, flanges, miscellaneous fittings, and anchors to interconnect handrail and railing members to other work, unless otherwise indicated.

G. Provide inserts and other anchorage devices for connecting handrails and railings to concrete or masonry work. Fabricate anchorage devices capable of withstanding loads imposed by handrails and railings. Coordinate anchorage devices with supporting structure.

H. For railing posts set in concrete, provide preset sleeves of steel not less than 150 mm long with inside dimensions not less than 12 mm greater than outside dimensions of post, and steel plate forming bottom closure.

I. Shear and punch metals cleanly and accurately. Remove burrs from exposed cut edges.

J. Ease exposed edges to a radius of approximately 1 mm, unless otherwise indicated. Form bent-metal corners to smallest radius possible without causing grain separation or otherwise impairing the Work.

PIPE AND TUBE RAILINGS SECTION 05521 - 6

K. Cut, reinforce, drill, and tap components, as indicated, to receive finish hardware, screws, and similar items.

L. Provide weep holes or another means to drain entrapped water in hollow sections of handrail and railing members that are exposed to exterior or to moisture from condensation or other sources.

M. Fabricate joints that will be exposed to weather in a watertight manner.

N. Close exposed ends of handrail and railing members with prefabricated end fittings.

O. Provide wall returns at ends of wall-mounted handrails, unless otherwise indicated. Close ends of returns, unless clearance between end of railing and wall is 6 mm or less.

P. Fillers: Provide fillers made from steel plate, or other suitably crush-resistant material, where needed to transfer wall bracket loads through wall finishes to structural supports. Size fillers to suit wall finish thicknesses and to produce adequate bearing area to prevent bracket rotation and overstressing of substrate.

2.6 FINISHES, GENERAL

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

B. Protect mechanical finishes on exposed surfaces from damage by applying a strippable, temporary protective covering before shipping.

C. Provide exposed fasteners with finish matching appearance, including color and texture, of handrails and railings.

2.7 STEEL FINISHES

A. Galvanized Handrails and Railings: Hot-dip galvanize exterior steel and iron handrails and railings to comply with ASTM A 123. Hot-dip galvanize hardware for exterior steel and iron handrails and railings to comply with ASTM A 153/A 153M.

B. Fill vent and drain holes that will be exposed in finished Work, unless indicated to remain as weep holes, by plugging with zinc solder and filing off smooth.

C. For galvanized handrails and railings, provide galvanized fittings, brackets, fasteners, sleeves, and other ferrous components.

D. For nongalvanized steel handrails and railings, provide nongalvanized ferrous-metal fittings, brackets, fasteners, and sleeves, except galvanize anchors to be embedded in exterior concrete or masonry.

E. Preparation for Shop Priming: After galvanizing, thoroughly clean handrails and railings of grease, dirt, oil, flux, and other foreign matter, and treat with metallic-phosphate process.

PIPE AND TUBE RAILINGS SECTION 05521 - 7

F. Preparation for Shop Priming: Prepare uncoated ferrous-metal surfaces to comply with minimum requirements indicated below for SSPC surface-preparation specifications and environmental exposure conditions of installed handrails and railings:

1. Exteriors (SSPC Zone 1B): SSPC-SP 6, "Commercial Blast Cleaning."

2. Interiors (SSPC Zone 1A): SSPC-SP 7, "Brush-off Blast Cleaning."

G. Apply shop primer to prepared surfaces of handrail and railing components, unless otherwise indicated. Comply with requirements in SSPC-PA 1, "Paint Application Specification No. 1," for shop painting. Primer need not be applied to surfaces to be embedded in concrete or masonry.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine gypsum board assemblies, where reinforced to receive anchors, to verify that locations of concealed reinforcements have been clearly marked for Installer. Locate reinforcements and mark locations if not already done.

3.2 INSTALLATION, GENERAL

A. Fit exposed connections together to form tight, hairline joints.

B. Perform cutting, drilling, and fitting required to install handrails and railings. Set handrails and railings accurately in location, alignment, and elevation; measured from established lines and levels and free from rack.

1. Do not weld, cut, or abrade surfaces of handrail and railing components that have been coated or finished after fabrication and that are intended for field connection by mechanical or other means without further cutting or fitting.

2. Set posts plumb within a tolerance of 2 mm in 1 m.

3. Align rails so variations from level for horizontal members and from parallel with rake of steps and ramps for sloping members do not exceed 5 mm in 3 m.

C. Corrosion Protection: Coat concealed surfaces of aluminum that will be in contact with grout, concrete, masonry, wood, or dissimilar metals with a heavy coat of bituminous paint.

D. Adjust handrails and railings before anchoring to ensure matching alignment at abutting joints.

Space posts at interval indicated, but not less than that required by structural loads.

E. Fastening to In-Place Construction: Use anchorage devices and fasteners where necessary for securing handrails and railings and for properly transferring loads to in-place construction.

3.3 RAILING CONNECTIONS

A. Nonwelded Connections: Use mechanical or adhesive joints for permanently connecting railing components. Use wood blocks and padding to prevent damage to railing members and fittings.

PIPE AND TUBE RAILINGS SECTION 05521 - 8

Seal recessed holes of exposed locking screws using plastic cement filler colored to match finish of handrails and railings.

B. Welded Connections: Use fully welded joints for permanently connecting railing components.

Comply with requirements for welded connections in "Fabrication" Article whether welding is performed in the shop or in the field.

C. Expansion Joints: Install expansion joints at locations indicated but not farther apart than required to accommodate thermal movement. Provide slip-joint internal sleeve extending 50 mm beyond joint on either side, fasten internal sleeve securely to one side, and locate joint within 150 mm of post.

3.4 ANCHORING POSTS

A. Use steel pipe sleeves preset and anchored into concrete for installing posts. After posts have been inserted into sleeves, fill annular space between post and sleeve with the following anchoring material, mixed and placed to comply with anchoring material manufacturer's written instructions.

B. Form or core-drill holes not less than 125 mm deep and 20 mm larger than OD of post for installing posts in concrete. Clean holes of loose material, insert posts, and fill annular space between post and concrete with the following anchoring material, mixed and placed to comply with anchoring material manufacturer's written instructions:

1. Nonshrink, nonmetallic grout or anchoring cement.

C. Cover anchorage joint with flange of same metal as post, attached to post as follows:

1. Welded to post after placing anchoring material.

D. Leave anchorage joint exposed; wipe off surplus anchoring material; and leave 3-mm build-up, sloped away from post.

E. Anchor posts to metal surfaces with oval flanges, angle type, or floor type as required by conditions, connected to posts and to metal supporting members as follows:

1. For aluminum pipe railings, attach posts as indicated using fittings designed and engineered for this purpose.

2. For steel pipe railings, weld flanges to post and bolt to metal supporting surfaces.

F. Install removable railing sections, where indicated, in slip-fit metal sockets cast in concrete.

3.5 ANCHORING RAILING ENDS

A. Anchor railing ends into concrete and masonry with round flanges connected to railing ends and anchored into wall construction with postinstalled anchors and bolts.

B. Anchor railing ends to metal surfaces with flanges bolted to metal surfaces.

1. Weld flanges to railing ends.

PIPE AND TUBE RAILINGS SECTION 05521 - 9

3.6 ATTACHING HANDRAILS TO WALLS

A. Attach handrails to wall with wall brackets. Provide bracket with 38-mm clearance from inside face of handrail and finished wall surface.

B. Locate brackets as indicated or, if not indicated, at spacing required to support structural loads.

C. Secure wall brackets to building construction as follows:

1. For concrete and solid masonry anchorage, use drilled-in expansion shields and hanger or lag bolts.

2. For hollow masonry anchorage, use toggle bolts.

3.7 CLEANING

A. Clean aluminum and stainless steel by washing thoroughly with clean water and soap and rinsing with clean water.

B. Touchup Painting: Immediately after erection, clean field welds, bolted connections, and abraded areas of shop paint, and paint exposed areas with same material.

C. Touchup Painting: Cleaning and touchup painting of field welds, bolted connections, and abraded areas of shop paint are specified in Division 9 Section "Painting."

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

3.8 PROTECTION

A. Protect finishes of handrails and railings from damage during construction period with temporary protective coverings approved by railing manufacturer. Remove protective coverings at the time of Substantial Completion.

B. Restore finishes damaged during installation and construction period so no evidence remains of correction work. Return items that cannot be refinished in the field to the shop; make required alterations and refinish entire unit, or provide new units.

END OF SECTION 05521

D. Anchors: Provide cast-in-place torque-controlled expansion anchors, fabricated from corrosion-resistant materials with capability to sustain, without failure, a load equal to six times the load imposed when installed in unit masonry and equal to f...

G. Apply shop primer to prepared surfaces of handrail and railing components, unless otherwise indicated. Comply with requirements in SSPC-PA 1, "Paint Application Specification No. 1," for shop painting. Primer need not be applied to surfaces to be...

F. Install removable railing sections, where indicated, in slip-fit metal sockets cast in concrete.