SECTION_08_45_13_for_24-026_SQRC_Upper_Yard_Phase-2.pdf

CDCR San Quentin Rehabilitation Center 24-026 SQRC Upper Yard Phase 2

TRANSLUCENT CORRUGATED POLYCARBONATE PANELS

CDCR-SDD 20250220 08 45 13 – 1 Feb. 26, 2025

SECTION 08 45 13

TRANSLUCENT CORRUGATED POLYCARBONATE PANELS

PART 1 GENERAL

1.1 RELATED DOCUMENTS

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

1.2 SUMMARY

A. Section includes translucent corrugated-polycarbonate panels as follows:

1. Roof assemblies.

1.3 MANUFACTURERS

A. Palram Americas 9735 Commerce Circle Kutztown, PA, 19530 610-285-9918 www.palram.com/us

B. Duralight Plastics 1300 Enterprise Drive De Pere, WI, 54115 765-560-3872 www.duralightplastics.com

C. Or comparable approved product by an acceptable manufacturer.

1.4 PREINSTALLATION MEETINGS

A. Preinstallation Conference: Conduct conference at Project site

1.5 ACTION SUBMITTALS

A. Product Data: For each type of product.

1. Include construction details, material descriptions, dimensions of individual components and profiles, and finishes for translucent corrugated polycarbonate panels.

B. Shop Drawings: For panel assemblies.

1. Include plans, elevations, sections, details, and attachments to other work.

2. Include details of provisions for assembly expansion and contraction and for draining moisture within the assembly to the exterior.

C. Samples: In manufacturer's standard size.

1. For each type of translucent corrugated-polycarbonate panel components and ventilator type.

http://www.palram.com/us/ https://www.duralightplastics.com/

CDCR-SDD 20250220 08 45 13 – 2 Feb. 26, 2025

D. Fabrication Samples: Of each framing system intersection and adjacent panels, made from 12-inch lengths attached to existing framing members and showing details of the following:

1. Joinery.

2. Anchorage.

3. Expansion provisions.

4. Translucent corrugated-polycarbonate panels.

5. Flashing and drainage (ridge cap and ventilators).

E. Delegated-Design Submittal: For panel assemblies indicated to comply with performance requirements and design criteria, including analysis data signed and sealed by the qualified professional engineer responsible for their preparation.

1.6 INFORMATIONAL SUBMITTALS

A. Qualification Data: For qualified Installer and testing agency.

B. Product Test Reports: For each translucent corrugated-polycarbonate-panel assembly, for tests performed by a qualified testing agency.

C. Evaluation Reports: For translucent corrugated-polycarbonate-panel assemblies from ICC-ES.

D. Field quality-control reports.

E. Sample Warranties: For special warranties.

1.7 CLOSEOUT SUBMITTALS

A. Maintenance Data: For panel assemblies to include in maintenance manuals.

1.8 QUALITY ASSURANCE

A. Installer Qualifications: An authorized representative who is trained and approved by manufacturer.

B. Mockups: Build mockups to verify selections made under Sample submittals and to demonstrate aesthetic effects and set quality standards for fabrication and installation.

1. Build mockup of typical panel assemblies as shown on Drawings.

2. Approval of mockups does not constitute approval of deviations from the Contract

Documents contained in mockups unless Architect specifically approves such deviations in writing.

3. Subject to compliance with requirements, approved mockups may become part of the completed Work if undisturbed at time of Substantial Completion.

C. Installer Qualifications: An employer of workers trained and approved by panel manufacturer.

1. Minimum of ten (10) panel installations withing the last three (3) years, similar in type and size to the work of this section.

D. Assign experienced mechanics from previous installations including lead mechanic. These personnel are to be on site when work of this section is being performed.

1.9 WARRANTY

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A. Manufacturer's Warranty: Manufacturer agrees to repair or replace components of panel assemblies that fail in materials or workmanship within specified warranty period.

1. Failures include, but are not limited to, the following:

a. Structural failures including, but not limited to, excessive deflection.

b. Deterioration of panels metal finishes, flashing and other materials beyond normal weathering.

c. Water leakage.

2. Warranty Period: Ten years for panels from date of Substantial Completion.

B. Manufacturer's Special Warranty: Manufacturer agrees to repair or replace translucent corrugated-polycarbonate panels that exhibit defects in materials or workmanship within specified warranty period.

1. Defects include, but are not limited to, the following:

a. Delamination.

b. Color changes exceeding requirements.

c. Losses in light transmission beyond 6 percent from original when measured according to ASTM D1003.

2. Warranty Period: 10 years from date of Substantial Completion.

1.10 TRANSPORTATION, HANDLING AND STORAGE

A. Transport and store panels horizontally on flat, sturdy pallets equal to or longer than the longest panels.

B. Store panels in a cool and shaded place out of direct sunlight. Avoid covering the stack of panels with dark or heat absorbing materials or objects to prevent solar heat buildup.

C. When necessary to store panels outdoors, cover the stack with a white opaque polyethylene sheet of another material that does not absorb or conduct heat. Be sure that the entire stack is covered.

D. Do not drive over the panel or fold the panel when handling and installing.

E. Avoid dragging the panel on the ground, scraping it against the structural elements or any other sharp or rough objects to prevent the panel from getting scratched.

PART 2 PRODUCTS

2.1 PERFORMANCE REQUIREMENTS

A. Delegated Design: Engage a qualified professional engineer, licensed in the jurisdiction in which the project is located to design translucent corrugated-polycarbonate-panel and ventilator installation attachment to building structure.

B. Structural Loads: As indicated on Drawings.

C. Deflection Limits:

1. Overhead Panel Assemblies: Limited by structural engineer determination of deflection amount of clear span for each assembly component.

CDCR-SDD 20250220 08 45 13 – 4 Feb. 26, 2025

D. Structural-Test Performance: Panel assemblies tested according to ASTM E330, as follows:

1. When tested at positive and negative wind-load design pressures, assemblies do not show evidence of deflection exceeding specified deflection limits.

2. When tested at percent determination of structural engineers positive and negative wind-load design pressures, assemblies, including anchorage, does not show evidence of material failures, structural distress, and permanent deformation of main framing members exceeding structural engineer’s determination percent of span.

3. Test Durations: As required by design wind velocity, but not less than structural engineer’s determination of requirements of seconds.

E. Windborne-Debris Impact Resistance: Passes ASTM E1886 missile-impact and cyclic-pressure tests in accordance with ASTM E1996 for Wind Zone 1for basic protection.

1. Verify Missile Test requirements with structural engineer.

F. Verify Water Penetration under Static and Dynamic Pressure: requirements with structural engineering drawings.

1. Maximum Water Leakage: No uncontrolled water penetrating translucent corrugated polycarbonate panels.

G. Thermal Movements: Allow for thermal movements from ambient- and surface-temperature changes. Base calculations on surface temperatures of materials due to both solar heat gain and nighttime-sky heat loss.

1. Thermal Transmittance ( U-Factor): Summer, C-236 →1.04. Winter, C-236 →1.14.

2. Heat Deflection Temperature F load: 264 (psi), ASTM D-648 → 275.

3. Coefficient of Linear Thermal.

4. Expansion 10(-5)/F, ASTM D-696 → 3.6

5. Thermal Conductivity BTU in /(hr.ft2 F), ASTM C-177 → 1.46

2.2 TRANSLUCENT CORRUGATED-POLYCARBONATE PANELS

A. Translucent Corrugated-Polycarbonate Panels: Translucent, extruded-polycarbonate sheet with corrugated cross section that is coextruded with a UV-protective layer.

1. Basis of Design Product: Panels: Duralight Plastics: Greca Lexan Soft Lite LCS100 corrugated sheet. Corrugation depth: 0.625 inches. Corrugations: 3-inch contours, light transmission: 84%.

a. Panel Thickness: Nominal Gauge 0.03 inches, Weight: 0.25 lb/s.f., Haze: (Diffusion)

100 percent, Size: 51 inches wide by up to 38 feet long.

1) High Top Ridge Cap: Verify in field whether Duralight Plastics profile will fit.

Otherwise, provide 24-gauge metal ridge cap with turned eased edges, gable end caps and gutters – see drawings. All metal roofing ridge cap, end caps, flashing and gutters shall be painted to match the translucent corrugated polycarbonate panel color. Do not paint ventilators. Paint per Section 09 96 00 – High Performance Coatings.

b. UV Resistance: On outer surface

c. Color: Soft Lite (actual color to be selected from manufacturer’s standard colors)

d. Panel Performance:

1) Plastic Self-Ignition Temperature: 650 deg F or more according to

ASTM D1929.

2) Smoke Developed Index: 450 or less according to ASTM E84, or 75 or less according to ASTM D2843.

CDCR-SDD 20250220 08 45 13 – 5 Feb. 26, 2025

3) Combustibility Classification: Class CC2 based on testing according to

ASTM D635.

4) Roof Covering Classification: Class A according to ASTM E108 or UL 790.

5) Color Change: Not more than 3.0 units Delta E, when measured according to

ASTM D2244, after outdoor weathering compliant with procedures in

ASTM D1435.

a) Outdoor Weathering Conditions: 60 months in Arizona or 120 months in a moderate North American climate.

6) Impact Resistance: No failure at impact of Gardner Impact Strength greater than

240 in-lbs. or ISO 6603/1, value 37 ft.lb./inch.

e. Panel orientation: Label side up.

2. Basis of Design Product: Panels: SunTuf 3” translucent corrugated polycarbonate sheet.

Corrugation depth: 5/8 inch. Corrugations: 3-inch contours. Light transmission: 85%.

a. Panel Thickness: 0.039 inches

b. Flame Spread: 4.7 (Class A), UL 723 (E-84)

c. Self-Ignition (F°) 977, ASTM D-1929

d. Color: Actual color to be selected from manufacturer’s standard colors.

1) SunTuf Ridge Cap: Verify in field whether SunTuf’s profile will fit. Otherwise, provide 24-gauge metal ridge cap with turned eased edges, gable end caps and gutters – see drawings. All metal roofing ridge cap, end caps, flashing and gutters shall be painted to match the translucent polycarbonate panel color. Do not paint ventilators. Paint per Section 099600 – High Performance Coatings.

e. Size: 49.6 inches wide by 8 feet, 12 feet, or 16 feet lengths.

f. Panel Orientation: Label side up

g. Smoke Developed: 47 /UL 723 (E-84)

h. Haze/Diffusion: 100 (ASTM D-1003)

2.3 METAL FRAMING SYSTEMS

A. Components: Existing metal roof framing members reinforced as required to support imposed loads. See structural drawings.

1. Construction: Existing metal trusses and purlins.

B. Fasteners and Accessories: Corrosion-resistant, nonstaining, and nonbleeding fasteners and accessories; compatible with adjacent materials. See drawings.

1. At closures, retaining caps, or battens, use ASTM A193 300 series stainless-steel screws.

2. At movement joints, use slip-joint linings, spacers, and sleeves of material and type recommended in writing by manufacturer.

3. At panel attachment use #10 or #12 hex head self-drill, self-tap screw. 2 inch or 2½ inch screw. Use at least a 10mm or larger neoprene bonded washer.

C. Concealed Flashing: Corrosion-resistant, nonstaining, nonbleeding flashing compatible with adjacent materials.

D. Exposed Flashing and Closures: 24-gauge metal sheet not less than .024 inch thick, finished to match panel.

E. Framing Gaskets: Manufacturer's standard gasket system with low-friction surface treatment designed specifically for retaining translucent corrugated-polycarbonate panels.

CDCR-SDD 20250220 08 45 13 – 6 Feb. 26, 2025

F. Frame-System Sealants: As recommended in writing by manufacturer.

2.4 SEALANTS

A. 100% Silicone sealant compatible with polycarbonate material and approved by panel manufacturer.

2.5 PAINTING

A. Existing exposed building steel structure.

1. Manufacturer: Tnemec Company Inc. Contact: Tony Hobbs, 310-804-2326, or comparable approved products by an acceptable manufacturer.

2. System: Zinc/Epoxy/Fluoropolymer.

3. Surface Preparation: SSPC-SP6 Commercial Blast Clean with 2 mils angular anchor profile.

4. Prime Coat: Tnemec 94-H20 Hydro-Zinc @ 2.5 to 3.5 mils DFT.

5. Intermediate Coat: Tnemec L69 Epoxoline @ 4.0 to 6.0 mils DFT.

6. Finish Coat: Tnemec 1071V Fluoronar @ 2.0 to 3.0 mils DFT.

7. Color: As selected by architect or CDCR from manufacturer’s full range of white colors as panel manufacturer’s recommended color.

PART 3 EXECUTION

3.1 EXAMINATION

A. Examine areas and conditions, with Installer present, for compliance with requirements for installation tolerances and other conditions affecting performance of the Work.

B. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 SAFETY MEASURES (DURING INSTALLATION AND AFTERWARDS)

A. General: Comply with manufacturer's written instructions.

1. Use ladders, crawling boards and other safety equipment required for safe installation. Be sure to wear appropriate personal protection equipment such as proper gloves, safety glasses, etc. Use all safety measures required according to local safety regulations.

2. Always use appropriate scaffolding to service panels. Scaffolding should provide proper worker safety and ensure proper placement and distribution of weight to avoid damage to panels. Do not walk on panels for fear of falling and other severe bodily harm.

3. Never leave panels unattended on the roof until all the required fasteners have been appropriately installed or the panels secured to the supporting structure.

4. Always follow local and/or national building and OSHA safety codes.

B. Install components plumb and true in alignment with established lines and elevations. See drawings.

C. Erection Tolerances: Install panels to comply with the following maximum tolerances:

1. Alignment: Limit offset from true alignment to 1/32 inch where surfaces abut in line, edge to edge, at corners, or where a reveal or protruding element separates aligned surfaces by 1/8 inch.

CDCR-SDD 20250220 08 45 13 – 7 Feb. 26, 2025

2. Location and Plane: Limit variation from true location and plane to 1/8-inch total length.

3.3 INSTALLATION

A. General: Comply with manufacturer's written instructions.

1. Do not install damaged components.

2. Rigidly secure nonmovement joints.

3. Seal joints watertight unless otherwise indicated.

4. Install panels with the label side out.

B. Install components plumb and true in alignment with established lines and elevations. See drawings.

C. Additional testing and inspecting, at Contractor’s expense, will be performed to determine compliance of replaced or additional work with specified requirements.

3.4 SAWING, CUTTING AND DRILLING

A. Panels can be cut or sawed by manual or power tools. A bench/table circular saw is best for straight long cuts. For better results, cut a few panels together. Portable circular saws are suitable for on-site straight cuts. A jigsaw is used for cutting a limited length of irregular or curved lines. Hand tools such as handsaw, metal shears or hand-held cutting knives can be used for localized limited work.

B. Sawing with plywood saw blade, installed in reverse direction, with small teeth, or special blades for plastics spinning at high speeds, with a slow feed rate. Panels should be clamped during sawing to avoid vibrations. Avoid intersecting cuts. Drill a hole at intersection point, then cut the panel up to the hole.

C. Drilling is done using a power drill, with regular high-speed steel bits intended for metal rotating at about 1,000 RPM. Better results are achieved using bits ground to shallower tip angle than for metal. Clamp the drilled panel down to avoid vibrations or movement during operation.

3.5 SEALING PANELS

A. Self-adhesive XPE Sealing tape (Expanded Cross-Linked Polyethylene): Resilient, closed cells, self-adhesive foamed polyethylene to be applied at sides and end laps on top of the overlapped area. Cross section dimensions may vary according to specific requirements. A typical XPE tape is ¾” in width, 3/16” in thickness and comes with pressure sensitive adhesive on one side, protected by silicone paper.

B. Butyl-Rubber or Expanding Sealing Tape: Elastomer or Expanding Sealing Tape to be applied at side and end-laps, on top of the overlapped area. Do not use mastic tape.

C. Install as follows: Remove bottom protective paper strip progressively, as installation advances. Apply carefully by hand.

D. Single seal end-lap: Apply along fasteners’ centerline at the end-lap, following the profile shape.

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E. Double seal end-lap: Apply above and below fasteners’ centerline at end-lap, following the profile shape.

F. Single seal side-lap of metal over panel: Apply between to the down facing corrugation of the panel and the panel to prevent capillary action.

G. With butyl-rubber only: Remove top protective paper strip before laying the overlapping panel.

Lay the edge of lapping panel and apply moderate hand pressure on the top panel along the side corrugation to ensure a proper seal.

H. Top and bottom contoured end closures: Top or bottom matching closure strips close the opening above or below the panel and its corrugations.

I. Install as follows: Place the closure strip at the top or bottom edge fasteners’ centerline and insert the fasteners through said strip so it will be held firmly in place. A few dabs of silicone could hold the strip temporarily in place until the top panel is laid and screw are inserted.

1. Location A: Where panel runs reach the top or bottom of roof, or at the roof ridge, the space left between the panel’s profile and the purlin, or girt, should be closed and sealed with a contoured foam, polyethylene (XPE) closure strip matching the panel profile.

2. Location B: Where panel runs reach a top trim, or at a ridge-cap, a top closure strip should be used at the top edge above the panel.

J. Do not install panels below 40° F or above 80° F.

K. Allow for expansion and contraction at fasteners: For panels longer than 12 feet, pre-drill panels at all fastening points with a 3/8” hole to allow for increased expansion and contraction due to longer length. For panels 12 feet in length or less, pre-drill a hole 1/16” larger than the diameter of the fastener shank.

L. Drive fasteners perpendicular at 90 degrees to panel face: Use an adjustable torque power screwdriver to ensure against over tightening. Avoid distortion of washer/gasket and panel.

M. Installation Direction: Starting installation from the bottom up, on one side, and work to the left or right accordingly. Never start working from both ends to the middle. Always lap the top panel over the lower one.

N. Keep panel straight, flush and taut during installation.

O. Panels shall run perpendicular to the existing purlins, and the panel profiles/ridges/flutes shall align with one another, from the roof edge to the ridge.

P. Panels shall be installed with the label side out and overlap in accordance with manufacturers installation guide.

Q. Panels shall be installed per manufacturer’s installation guide.

R. Panels shall be divided into four equal lengths from the roof edge to the ridge.

S. Provide foam closure strips per manufacturers requirements.

3.6 CLEANING

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A. Cleaning: Hose the panels with clean lukewarm water.

1. In polluted, oily environments, mild household detergent may be used, assisted by a soft rag or soft bristled brush. Never use aggressive or abrasive cleaning agents or glass window cleaners. They may scratch or chemically attack the panel. Large areas can be washed by high pressure water jet, optionally, in conjunction with diluted detergent. Dry with soft cotton rags to avoid spotting.

B. Repair: Minor damages to the panel may be repaired. Small punctures can be stopped by dabs of approved silicone sealant.

C. Study and preparation: Prior to actual installation study the panel installation guide carefully.

Make sure all the instructions are understood, and all required material, accessories and tools are available.

D. Information: Please contact panel distributor regarding any applications, request and inquiries you may have before starting installation.

3.7 FIELD QUALITY CONTROL

A. Testing Agency: Owner will engage a qualified testing agency to perform tests and inspections.

1. Water-Spray Test: Before installation of interior finishes has begun, panel assemblies shall be tested according to AAMA 501.2 and shall not show evidence of water penetration.

2. Water Penetration under Static Pressure: Before installation of interior finishes has begun, areas shall be tested according to ASTM E1105.

a. Test Procedures: Test under uniform or cyclic static-air pressure. See engineering requirements.

b. Water Penetration: None.

B. Repair or remove work where test results and inspections indicate that it does not comply with specified requirements.

C. Additional testing and inspecting, at Contractor's expense, will be performed to determine compliance of replaced or additional work with specified requirements.

D. Prepare test and inspection reports.

E. Never use soft PVC (vinyl) washer/gaskets. Soft PVC is totally incompatible to polycarbonate and will harm the panel.

F. Never apply paints, shading compounds, paint thinners or any material that may chemically attack panels, without first verifying compatibility to polycarbonate with the manufacturer of the material in question.

G. Silicone sealant: Please check with manufacturer of any sealant to ensure compatibility with polycarbonate panels. Incompatible sealants will void warranty.

H. Butyl-Rubber seals: Side-laps and end-laps of any panels profile should be treated with butyl-rubber or expanding tape placed between the overlapping panels at all edges in shallow pitch roofs (less that 5 percent) double (parallel) sealing strips are recommended at end-laps.

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I. Shaped foam closures: Expanded foam polyethylene (XPE) closure strips are used to seal the space between the upper or lower panel profile to edge purlins or ridge caps. Matching XPE top and bottom strips are available for each major panel profile. The strip is held in place by the screw fixing the panel to the purlin.

END OF SECTION