CWF Spec Section 08 34 16 VERTICAL LIFT FABRIC HANGAR DOOR.pdf

LSGA239001 JAXCWF-0

IFC B-3 Submission 100%

SECTION TABLE OF CONTENTS

DIVISION 08 - OPENINGS

SECTION 08 34 16

VERTICAL LIFT FABRIC HANGAR DOOR

05/17

PART 1 GENERAL

1.1 REFERENCES

1.2 RELATED REQUIREMENTS

1.3 SUBMITTALS

1.3.1 Door Materials

1.3.2 Door Structure

1.3.2.1 Adjustable Frequency Motor Drive

1.3.3 Operation and Maintenance Manuals

1.4 QUALITY ASSURANCE

1.4.1 Manufacturer's Qualifications

1.4.2 Installer's Qualifications

1.4.3 Warranty

1.5 DELIVERY AND STORAGE

1.6 DESIGN REQUIREMENTS

1.6.1 Door Design and Components

1.6.1.1 Steel Door Components

1.6.2 Loads

1.6.2.1 Wind Loads

1.6.3 Deflections

1.6.4 Drive Mechanism

1.6.5 Door Seals

1.6.6 Pneumatic Locking Mechanism

1.6.7 Electrical Requirements

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Structural Steel

2.1.2 Formed Steel

2.1.3 Galvanized Steel

2.1.4 Sheet Steel

2.1.5 Galvanized Sheet Steel

2.1.6 Hardware

2.1.7 Weatherstripping

2.1.8 Fasteners

2.1.9 Sealant

2.1.10 Light Fixtures

2.1.11 Personnel Emergency Pass Doors and Plenum Access Doors

2.1.12 Concrete and Non-Shrink Grout

2.1.13 Filter Assembly

2.1.14 Differential Pressure Switches

2.1.15 Door Drive Mechanism

2.1.15.1 Worm Gear Motor

2.1.15.2 Gear Reducer

2.1.15.3 Motor

SECTION 08 34 16 Page 1 Tuesday February 25, 2025 Version 0

2.1.15.4 Chain and Sprocket Drive

2.1.15.5 Drive Wheel Truck Assembly

2.1.15.6 Drive Wheel

2.1.15.7 Shafting

2.1.15.8 Tapered Roller Bearings

2.1.15.9 Fabricated Truck

2.1.15.10 Seals and Seal Housing

2.1.15.11 Bearing Lubrication Components

2.1.15.12 Door Drive Mechanism Enclosure

2.1.16 Lock Pins

2.1.16.1 Operating Mechanism

2.1.16.2 Top Pin

2.1.16.3 Bottom Pin

2.1.16.4 Air System

2.1.17 Top Lock Pin Maintenance Platform

2.1.17.1 Metal Grating

2.1.17.2 Handrails

2.1.17.3 Jointing

2.1.17.4 Ladders

2.1.17.5 Safety Chains

2.1.17.6 Structural Framing

2.1.18 Electrical Equipment

2.1.18.1 Plenum Lights

2.1.18.2 Controls

2.1.18.3 Control Cabinet

2.1.18.4 Joysticks

2.1.18.5 Limit Switches

2.1.18.6 Klaxon Horns

2.1.18.7 Explosion Proof Control Devices

2.1.18.8 Interconnecting Cable

2.1.18.9 Conduit, Wire and Fittings

2.1.18.10 Rotating Beacons

2.2 FABRICATION

2.2.1 Doors

2.2.2 Latches

2.2.3 Tractor Pulls

2.2.4 Exterior Covering

2.2.5 Interior Covering

2.2.6 Weatherstripping

2.2.7 Support Rail

2.2.8 Services

2.2.9 Perforated Aluminum

2.2.10 Electrical

2.3 FINISHES

2.3.1 Ferrous Metal

2.3.2 Factory-Finished Panels

2.4 SINAGE

PART 3 EXECUTION

3.1 GENERAL INSTALLATION REQUIREMENTS

3.2 ERECTION

3.2.1 Erection Procedure

3.2.1.1 Templates

3.2.1.2 Door Rails

3.2.1.3 Door Bottom Lock Pin Receivers

3.2.1.4 Door Leafs

3.2.1.5 Electrical

3.2.1.6 Touch-Up Coating

SECTION 08 34 16 Page 2

3.3 FIELD INSPECTION AND TESTS

3.3.1 Inspection General

3.3.2 Manufacturer's Field Engineer

3.3.3 Operation

3.3.4 Tests

3.3.5 Corrections

3.4 PERSONNEL EQUIPMENT SYSTEMS ORIENTATION

-- End of Section Table of Contents --

SECTION 08 34 16 Page 3

SECTION 08 34 16

VERTICAL LIFT FABRIC HANGAR DOOR

05/17

PART 1 GENERAL

1.1 REFERENCES

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

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2017) Steel Construction Manual

AISC 360 (2016) Specification for Structural Steel Buildings

AMERICAN IRON AND STEEL INSTITUTE (AISI)

AISI SG03-3 (2002; Suppl 2001-2004; R 2008) Cold-Formed Steel Design Manual Set

AMERICAN LADDER INSTITUTE (ALI)

ALI A14.3 (2008; R 2018) Ladders - Fixed - Safety Requirements

AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING

ENGINEERS (ASHRAE)

ASHRAE 52.2 (2012) Method of Testing General Ventilation Air-Cleaning Devices for Removal Efficiency by Particle Size

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2020; Errata 1 2021) Structural Welding Code - Steel

ASTM INTERNATIONAL (ASTM)

ASTM A29/A29M (2023) Standard Specification for General Requirements for Steel Bars, Carbon and Alloy, Hot-Wrought

ASTM A36/A36M (2019) Standard Specification for Carbon Structural Steel

ASTM A123/A123M (2017) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A519/A519M (2023) Standard Specification for Seamless Carbon and Alloy Steel Mechanical Tubing

SECTION 08 34 16 Page 4

ASTM A653/A653M (2023) Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

ASTM A1008/A1008M (2023) Standard Specification for Steel, Sheet, Cold-Rolled, Carbon, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, Solution Hardened, and Bake Hardenable

ASTM A1011/A1011M (2023) Standard Specification for Steel Sheet and Strip, Hot-Rolled, Carbon, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, and Ultra-High Strength

ASTM A1018/A1018M (2023a) Standard Specification for Steel, Sheet and Strip, Heavy-Thickness Coils, Hot-Rolled, Carbon, Commercial, Drawing, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, and Ultra-High Strength

ASTM B88 (2022) Standard Specification for Seamless Copper Water Tube

ASTM B103/B103M (2023) Standard Specification for Phosphor Bronze Plate, Sheet, Strip, and Rolled Bar

ASTM C920 (2018) Standard Specification for Elastomeric Joint Sealants

ASTM D740 (2011) Methyl Ethyl Ketone

ASTM D4614 (2011) Standard Specification for Ethyl Acetate (All Grades)

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 519 (2022) Standard for Harmonic Control in Electrical Power Systems

NATIONAL ASSOCIATION OF ARCHITECTURAL METAL MANUFACTURERS (NAAMM)

NAAMM MBG 531 (2017) Metal Bar Grating Manual

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2020) Enclosures for Electrical Equipment (1000 Volts Maximum)

NEMA ICS 1 (2022) Standard for Industrial Control and Systems: General Requirements

NEMA ICS 2 (2000; R 2020) Industrial Control and Systems Controllers, Contactors, and Overload Relays Rated 600 V

SECTION 08 34 16 Page 5

NEMA ICS 4 (2015) Application Guideline for Terminal Blocks

NEMA ICS 6 (1993; R 2016) Industrial Control and Systems: Enclosures

NEMA MG 1 (2021) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2023; ERTA 4 2023; ERTA 5 2023; ERTA 6

2023) National Electrical Code

NFPA 220 (2024) Standard on Types of Building Construction

NFPA 409 (2022) Standard on Aircraft Hangars

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE AMS-C-22542 (2012; Rev A; Stabilized (S) 2012) Cleaning Compound, High Pressure Cleaner, Liquid

SAE J514 (2012) Hydraulic Tube Fittings

SAE J1405 (2012) Optional Test Procedures for Hydraulic Hose Assemblies

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-D-16791 (1990; Rev G, Am 1 1993; Notice 1 2020) Detergents, General Purpose (Liquid, Non-Ionic)

MIL-DTL-5541 (2006; Rev F) Chemical Conversion Coatings on Aluminum and Aluminum Alloys

MIL-DTL-15021 (2014; Rev B) Hook, Snap Bolt, Swivel-Eye, and Rings

MIL-R-24243 (1994; Rev C, Notice 1 2020) Rivets, Blind, Nonstructural, Retained Mandrel, Open End, Domed Head, Aluminum Alloy, Carbon Steel, Corrosion Resistant Steel

MIL-T-81772 (2019; Rev C) Thinner, Aircraft Coating

UFC 1-200-01 (2022) DoD Building Code

UFC 3-301-01 (2023) Structural Engineering

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

CID A-A-857 (Rev B, Notice 3) Thinner, Dope and Lacquer (Cellulose Nitrate)

SECTION 08 34 16 Page 6

FS RR-C-271 (Rev H; Am 1) Chains and Attachments, Carbon And Alloy Steel

UNDERWRITERS LABORATORIES (UL)

UL 900 (2015; Reprint Aug 2022) UL Standard for SafetyStandard for Air Filter Units

1.2 RELATED REQUIREMENTS

Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM, 03 30 00 CAST-IN-PLACE

CONCRETE, 05 12 00 STRUCTURAL STEEL, 08 11 13 STEEL DOORS AND FRAMES,

08 71 00 DOOR HARDWARE, and 09 90 00 PAINTS AND COATINGS apply to this section with additions and modifications specified herein.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" classification.

Submittals not having a "G" classification are for information only.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-01 Preconstruction Submittals

Manufacturer's Qualifications; G

Installer's Qualifications; G

SD-02 Shop Drawings

Door Materials; G

SD-05 Design Data

Door Structure; G

Calculations; G

SD-10 Operation and Maintenance Data

Lubrication; G

Air System; G

Electrical Equipment; G

1.3.1 Door Materials

Submit design drawings covering door structure, all operating devices, mechanical systems and "U" value

Show all details for construction, installation and operation; size, shapes and thickness of materials, joints and connections; reinforcing;

hardware; mechanical devices; electrical devices; and all design and detail data for work of other trades affected by hangar doors.

Submit the door manufacturer's complete schematic compressed air and wiring diagrams, field piping and wiring diagrams, and a complete physical

SECTION 08 34 16 Page 7 location drawing showing the location of all pressure regulators, gages, metering valves, lubricators, filter-dryers, interlocking valves and controls with the runs of pipe and conduit, pipe size and conduit size, wire number and wire size in each conduit, junction box location and full control mounting details

1.3.2 Door Structure

Submit design calculations covering door structure, all operating devices, mechanical systems and "U" value. A Registered Professional Engineer shall prepare and sign structural calculations.

1.3.2.1 Adjustable Frequency Motor Drive

IEEE 519 .

1.3.3 Operation and Maintenance Manuals

Drawings and instructions showing all lubrication points, proper lubricants, lubrication frequency schedule and complete operating instructions. Complete compressed air system schematic and electrical equipment wiring diagrams.

Furnish the above in duplicate to the Contracting Officer.

1.4 QUALITY ASSURANCE

1.4.1 Manufacturer's Qualifications

Use a corrosion control hangar door product from a manufacturer who is regularly engaged in the design, fabrication, erection, and service of corrosion control hangar doors of type and size required for this project. The manufacturer shall have at least 5 years of similar corrosion control hangar door design experience. Similar doors must have comparable function and design including size, configuration, type of use, retractable or moving elements, safety features, controls, and other key engineering elements as the door being specified. It is acceptable to show that a series of similar doors collectively meet all comparable elements to the door being specified, although not necessarily individually. Manufacturer must submit written evidence on similar past door designs and installations listing the name, location, contact information of owners, installation dates, overall sizes, features, and other relevant information for experience and qualifications evaluation.

Only manufacturers who can submit this evidence of actual installations where the products have proven practical, durable, and require a minimum of maintenance, will be qualified under this specification.

1.4.2 Installer's Qualifications

Installation of the door(s) shall be supervised by a manufacturer's representative and shall be in accordance with approved shop drawings.

Installers shall be skilled and experienced in the erection of corrosion control hangar doors of the type specified herein. Installers must submit written evidence of similar past door installations listing the name, locations, contacts information of owners, installation dates, overall sizes, features, and other relevant information for experience and qualifications evaluation.

SECTION 08 34 16 Page 8

1.4.3 Warranty

The door manufacturer shall provide a three-year warranty for all mechanical and electrical components against defects in material and workmanship beginning on the date of Project Acceptance.

1.5 DELIVERY AND STORAGE

Deliver materials which are not shop-installed in the doors in original packages, containers, boxes or crates bearing the manufacturer's name, brand and model number. Store all materials and equipment in dry locations with adequate ventilation, free from dust or water, and to permit access for inspection and handling. Handle doors carefully to prevent damage. Remove damaged items that cannot be restored to like-new condition and provide new items.

1.6 DESIGN REQUIREMENTS

1.6.1 Door Design and Components

The hangar doors and components indicated in the construction documents are representative of a commercially-available door. Basis of Design is the S1500 Single Door 580 Profile by Megadoor. Other approved equeals are can be considered. Design and fabricate the door to fit within the space allocated and in accordance with the criteria specified herein. Design doors to operate properly without binding, interference, or damage to weather stripping or the adjacent structure. Door must be of limited combustible construction in accordance with NFPA 220 and NFPA 409 .

Submit Calculations sealed by the door manufacturer's florida registered professional engineer for review.

1.6.1.1 Steel Door Components

Design all supporting, steel bracing and framing steel members in accordance with the specified loads and the requirements of AISC 325 and AISC 360 . Design all cold formed steel in accordance with AISI SG03-3 .

Weld steel in accordance with the AWS D1.1/D1.1M Standards.

1.6.2 Loads

Design the door for the loads in accordance with UFC 1-200-01 , UFC 3-301-01 and all other applicable criteria.

1.6.2.1 Wind Loads

In the closed position, design doors and all components to withstand the wind pressures indicated by the Engineer of Record. Design all door components to withstand both the highest positive and negative pressures based on actual tributary area from the wind load indicated.

In addition, design doors and all components to be operational during wind events which cause a positive or negative service load pressure of 15 psf on the surface of the door.

1.6.3 Deflections

For any door member, the deflection due to design wind load shall not exceed the member's length divided by 120. Design the differential

SECTION 08 34 16 Page 9 deflection at the door seals to be less than 2 inches.

Design Doors as a system to withstand the upward and downward deflections of the door header structure.

1.6.4 Drive Mechanism

Basis of Design is the 580 Wire Rope Door hoist - Megadoor the drive mechanism to operate the door against a wind pressure of 5 pounds per square foot perpendicular to the leaf. Design the drive so that when stopped at any point, the door automatically locks in place against a 115 mph wind. Provide sufficient wheel traction to lock hangar doors when the track is wet. Design for the effect door sway and vibration will have on wheel traction in a 115 mph wind.

1.6.5 Door Seals

Use sealing system between door leaf and building, between door leaf and foundation, and between leaf, designed to provide an air tight closure with the building and the ventilation supply air plenum. Coordinate the design of the door seal system with the building architectural and structural details, and the mechanical ventilation systems. Use fully adjustable door seal system to permit initial setting during installation of the doors, and to permit future adjustments. Use door sealing system designed for ease of replacement and that incorporates commercially available components.

1.6.6 Pneumatic Locking Mechanism

Provide manual and pneumatic control devices, piping, tubing and hose for the locking mechanisms. Include the flexible connection to the building air system. Use air system designed to accommodate the non-lubricated building air supply available. Use system designed to maintain air loading of the cylinders at all times except when the lock pins are to be retracted. Locate compressed air accessories, including the filter / regulator assembly, and control valves where they will be readily accessible for maintenance. Secure all tubing runs in the door plenum to the door frame using cushion clamp assemblies spaced to prevent sag in runs. Arrange all tubing runs to prevent accumulated moisture from reaching the air cylinders. Locate air system accessories to be readily accessible for inspection and servicing. Provide manual release of the automatic door in the event of power failure. Accomplish disengagement of the air cylinder by venting the air supply to the cylinder, removing the air loading on the piston. Provide manual retraction of the locking pins by means of a hand pull attachment through a corrosion resistant wire rope cable system.

1.6.7 Electrical Requirements

Use electrical wiring and equipment approved for Class 1, Division 1 locations as described in Article 501 of NFPA 70 . Use electric motor (460 V, 3-phase) as prime mover.

SECTION 08 34 16 Page 10

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Structural Steel

ASTM A36/A36M.

2.1.2 Formed Steel

AISI SG03-3 .

2.1.3 Galvanized Steel

Hot dipped galvanized frames in accordance with ASTM A123/A123M .

2.1.4 Sheet Steel

ASTM A1011/A1011M , hot-rolled sheet steel, commercial quality, or ASTM A1008/A1008M , cold-rolled steel sheet, commercial quality.

2.1.5 Galvanized Sheet Steel

ASTM A653/A653M , coating designation G90 galvanized steel sheet, commercial quality.

2.1.6 Hardware

Basis of Design Door Hoist VL3190 Assa Abloy. Provide hardware suitable for use on hangar doors and designed to accommodate actual dead loads plus wind loads specified herein.

2.1.7 Weatherstripping

Rubber bulb seals shall be resistant to incidental contact with the following chemicals and solvents used in the facility:

MATERIAL MILITARY OR FEDERAL SPECIFICATION

MEK ASTM D740

Dope and Lacquer Thinner CID A-A-857

Aircraft Coating Thinner MIL-T-81772

High Pressure Cleaning Compound SAE AMS-C-22542

Ethyl Acetate ASTM D4614

Non-Ionic Detergent MIL-D-16791

Conversion Coating MIL-DTL-5541

2.1.8 Fasteners

Hot dipped galvanized.

SECTION 08 34 16 Page 11

2.1.9 Sealant

Single-component or multi-component elastomeric type conforming to ASTM C920, Type S or M, Grade NS, Class 12.5, Use NT. Provide a sealant that has been tested on the type(s) of substrate to which it will be applied.

2.1.10 Light Fixtures

The door manufacturer shall provide all light fixtures indicated in or on the door. Conform to the electrical drawings and the requirements specified in 26 20 00 INTERIOR WIRING SYSTEMS.

2.1.11 Personnel Emergency Pass Doors and Plenum Access Doors

Provide doors in each hangar door leaf for personnel access to the building, and for access to the air plenum for maintenance of the drive mechanism and lock pin mechanisms. Doors shall be exterior, hollow metal, flush type, insulated, with gasketed frame to provide an airtight seal.

Doors shall conform to 08 11 13 STEEL DOORS AND FRAMES. Provide hardware conforming to 08 71 00 FINISH HARDWARE, as follows:

a. Personnel Pass Doors:

1-1/2 Pairs, Hinges A5111 (Temp.) 5 by 4-1/2

1 Each Exit Type 2, Function 01

1 Each Door Closer C02061, Size IV

1 Each Kickplate J102

1 Set Airtight Seals As specified

b. Personnel Pass Doors:

1 Pair, Hinges A5111 (Temp.) 5 by 4-1/2

1 Each Lockset Series 1000, Grade 1, Function F04

1 Each Door Closer C02011, Size 111

1 Set Airtight Seals As specified

2.1.12 Concrete and Non-Shrink Grout

Pour in place normal concrete having a strength of 3000 psi. Concrete and non-shrink grout shall conform to the requirements of 03 30 00

CAST-IN-PLACE CONCRETE.

2.1.13 Filter Assembly

The filter system for the hangar doors shall consist of a replaceable media filter system in a permanent frame filter bank mounted in the door frame as indicated. The filter frame bank shall consist of universal modular frames, nominal 24 inch by 24 inch, fastened to each other to form

SECTION 08 34 16 Page 12 an assembly. Fabricate frames from 16 gage galvanized steel and include filter holding clips to permit easy removal of the filters without removal of the clips. Fasten frames to each other and to the supporting door frame by means of stainless steel break mandrel rivets (pop rivets) conforming to MIL-R-24243 . Use replaceable filters of the extended surface type, nominal 24 inch by 24 inch by 2 inch deep, with a 30 percent efficiency when rated by ASHRAE 52.2 . Filters shall meet the fire-resistant requirements of UL 900 , Class 1. Use pleated type filters with a welded wire media support grid and nonflammable enclosing frame bonded to the filter media. Provide one complete set of replacement filters for each door leaf.

2.1.14 Differential Pressure Switches

Provide each door leaf with a differential pressure switch to annunciate when the filters are dirty and require replacement. Provide 4 inch diaphragm operated differential pressure switches to activate a single pole double throw snap switch. Restrain motion of the diaphragm by a calibrated stainless steel spring adjustable through the full range.

Transmit spring range the snap switch by means of a direct mechanical linkage. Switch shall be rated for a temperature range of minus 30 degrees F to 180 degrees F, and a pressure of 10 psig. The operating range shall be 1/2 to 2 inch water column with a maximum dead bank of 0.12 inches water column, and repetitive accuracy of 2 percent of range. Use U.L. listed switch mounted in an explosion-proof housing suitable for use in a Class 1, Division 1, Group D hazardous area. Use 1/8 inch NPT pressure sensing connection. Use 1/2 inch NPT electrical connection. Use switch rated 15 amps, 120 volt A.C., resistive load.

2.1.15 Door Drive Mechanism

Each door leaf shall be driven by a single drive wheel operating on an embedded standard crane rail. The drive wheel shall be driven by an electric worm gear motor through a double reduction chain and sprocket.

The drive mechanism shall be capable of operating the door under the design loads specified herein. For areas classified as Class 1, Division 1, Group D hazardous areas, all moving parts exposed within the door plenum and the aircraft by shall be non-sparking, except where protected by drive system sealed enclosure. Limit the acceleration of the door to reduce the potential hazard of the drive wheel sparking the rail.

Incorporate machinery in the drive mechanism to permit the door leaf to be operated manually by means of a tractor in the event of a power failure or motor drive failure. The drive mechanism shall be of the design indicated, or shall be of a comparable, previously-proven design for a similar type door which shall be approved by the CQC Representative.

2.1.15.1 Worm Gear Motor

The gear motor shall consist of a multiple reduction helical worm gear reducer with an integrally mated A.C. motor and electric brake.

2.1.15.2 Gear Reducer

The gear reducer shall be A.G.M.A. rated for the design torque with a service factor of 1.0. Use gear reducer housing of high strength cast aluminum or cast steel. The worm shall be machined of high strength leaded alloy steel carburized and hardened to 60-62 Rockwell C, tempered, honed and ground after hardening. The worm gear shall be cast bronze.

The output shaft shall be high strength alloy steel. Bearings shall be

SECTION 08 34 16 Page 13 either tapered or ball rollers on the work shaft and tapered rollers on the output shaft. Use dual lip spring-loaded seals to protect against leakage and foreign matter. Use gear reducer with a large oil reservoir for adequate splash lubrication for cool operation and an easily accessible oil fill, level and drain holes for maintaining proper oil level. The gear reducer shall have an adaptable base, machined for direct mounting to the support structure.

2.1.15.3 Motor

Use integrally mated motor suitable for variable speed operation with input power from an adjustable frequency drive unit, explosion-proof for areas designated as Class 1, Division 1, Group D hazardous areas, totally-enclosed, wash-down (TEWD) constant torque, NEMA Design D, 3 phase, 60 hertz, 460 volt service, with Class B insulation, time and temperature rating 30 minutes 167 degrees F temperature rise over 104 degrees F ambient, 1.2 service factor and with sealed bearings. Include in motor an integrally mounted disc brake in an explosion-proof enclosure. Brake shall have a manual release with automatic reset.

Extend shaft through brake for manual operation. Select motor for starting torque and not stall torque. Motor shall conform to NEMA MG 1 standard.

2.1.15.4 Chain and Sprocket Drive

Accomplish double reduction chain and sprocket drive through a sprocket mounted on the output shaft of the gear motor, a sprocket mounted on the drive wheel shaft and an intermediate jack shaft with sprockets. Use single or double strand type sprockets to match the ANSI pitch chain with hardened steel teeth. Use sprockets designed to have a minimum of 40 percent tooth contact. Use jack shaft designed with a clutch mechanism to permit disengaging the gear motor drive from the drive wheel to permit manual operation of the door. Use jackshaft fabricated from high strength alloy steel and supported by two pillow blocks or flanged bearings. Use bearings designed for an L10 life of 20,000 hours, with self-aligning double row spherical bearings in a cast iron housing, a spring locking collar, spring loaded lip seals and grease fittings. Use manual clutch mechanism with a handle of sufficient length to facilitate manual operation and a latching device to assure positive engagement under normal operation when not mechanically retracted for manual operation. Fit the chain and sprocket drive system with an automatic oil lubricator readily accessible for inspection. Use roller chain of single or double strand conforming to ANSI standards for dimensions. Use roller chain of heavy series type rated for occasional shock loading. Use press fit riveted type pins. Use press fit cotter pin type connecting pin.

2.1.15.5 Drive Wheel Truck Assembly

Mount each drive wheel on a removable truck assembly, as indicated, to permit removal and servicing without dismantling the door.

2.1.15.6 Drive Wheel

Use wheel fabricated from heat treated chromium-molybdenum alloy, AISI strength. Use wheels designed to operate on a standard crane rail as specified herein. Use wheels conforming to the following dimensions after machining:

SECTION 08 34 16 Page 14

a. Diameter of tread

21.0 inch to 0.005 inch

b. Width of tread 3 1/4 inch

c. Bore As required

After machining, flame harden wheels to 325 to 375 brinell hardness.

2.1.15.7 Shafting

Fit and weld wheels to a high strength steel tube shaft. Machine tube shaft from hot finished seamless carbon steel mechanical round tubing conforming to ASTM A519/A519M , and steel conforming to ASTM A1018/A1018M with a wall thickness as required by design. Machine tubing shaft to receive bearings so that the combination with the wheel shall be concentric with the bearings and support shaft within a tolerance of 0.002 inches. Run tube shaft on tapered roller bearings press fit into the ends of the tube. Ends of tube are supported by a high strength machined inner shaft mounted directly to the wheel truck. Machine inner shaft from medium carbon, high manganese, free machining, cold finished, Stress proof steel shafting, drawn, ground and polished with a tensile strength of 125,000 psi and a yield strength of 100,000 psi. Drill and tap inner shaft to accommodate lubrication tubing and to permit distribution of grease to both bearings.

2.1.15.8 Tapered Roller Bearings

Use self-aligning, cylindrical bore, spherical roller type bearings, sized for the static and dynamic forces with an LB-10 minimum life rating of 20,000 hours. Use manufacturer's standard precision machined self-locking bearing nut for retaining the bearings on the shaft. Machine bearing sleeve for preloading the tapered roller bearings from Stress proof steel shafting used to support the wheels.

2.1.15.9 Fabricated Truck

Use plate conforming to ASTM A36/A36M except as indicated and specified herein.

2.1.15.10 Seals and Seal Housing

Fabricate seal housing as indicated for clearance fit to shaft and sleeve. Use double lip, spring loaded seal to retain bearing lubricating grease and protect the bearings from dirt.

2.1.15.11 Bearing Lubrication Components

Use copper tubing the size indicated conforming to ASTM B88, Type L, for use with compression type fittings. Use brass fittings conforming to SAE J514 to connect tubing to shaft and to truck. Use male connector fitting for connection to shaft, male pipe end and flare tube end to receive tubing. Use "Triple-Lok" fittings as manufactured by Parker Hannafin, or approved equal. Provide alemite grease fitting to mate with bulkhead female pipe fitting.

2.1.15.12 Door Drive Mechanism Enclosure

Design and fabricate drive mechanism enclosure to be readily removable to

SECTION 08 34 16 Page 15 facilitate inspection and maintenance of the mechanical drive components.

Fabricate enclosure to airtight to maintain the integrity of the pressurized air plenum.

2.1.16 Lock Pins

Equip leading edge of doors with top and bottom automatic lock pins designed to restrain the door in the full open or full closed positions, under the design operating wind forces. Assure that doors are properly aligned in the fully closed position with seals compressed. Use non-sparking lock pin mechanisms designed to accommodate thermal expansion and contraction of the doors, with sufficient range of action horizontally to seat under full wind load deflections (inward or outward). Seat bottom lock pins in special receptacles set in the concrete slab designed to accommodate the full travel of the pin, and designed to prevent dirt and water from accumulating inside. Use air operated lock pins designed for normal operating conditions with mechanism to manually release the pins in the event of a failure of the control system. Use lock pin mechanism of the design indicated, or of a comparable, previously proven design for a similar type door approved by the CQC Representative.

2.1.16.1 Operating Mechanism

Use direct action double acting air cylinder operating mechanism for opening and closing the lock pins. Use cylinders sized to operate the lock pins when binding in the receivers under full wind loads or other combination of loads including thermal expansion and contraction of the doors, and settlement deflection of the doors with available 80 psig air.

Use cylinder of corrosion-resistant construction suitable for industrial application and rated for 200 psig non-lubricated air service. Machine cylinder barrel head from high strength steel tubing, honed to a 10-15 micron-inch finish and hard chrome plated inside and outside. Fit head with easily externally removable precision machined high strength fine grained iron, bronze or aluminum rod bearing, incorporating seals and rod wiper to prevent dirt form entering cylinder. Use cylinders cushioned at both ends with built-in adjustable needle valves to allow adjustment of the cushion effect. Fit piston with double seals for minimum friction under varying dynamic pressures. Machine cylinder rod from high strength steel, 90,000 to 100,000 psi minimum yield, hard chrome plated, and sized for operating the pin with a factory safety of five based on yield strength. Pre-lubricate cylinder with a permanent type dry lubricant.

LR2 Permanently Lubricated Air Cylinders or Universal "A-2" Series Heavy Duty Pre-Lubricated Pneumatic Cylinders as manufactured by Schrader Bellows of Akron, Ohio conform to this specification.

2.1.16.2 Top Pin

Machine top pin cold drawn ASTM A29/A29M, Grade 1018 steel bar stock.

Hard chrome plate top pin after machining. Machine pin bottom to mate with the clevis fitting on the air cylinder. Use two sets of bronze guide rollers to guide pin for the full stroke. Use bronze rollers designed to accommodate the maximum forces under the design loadings plus: forces due to temperature expansion and contraction of the door,; forces due to settlement of the door; and other binding forces on the top pin when engaged in its receiver. Use top pin latching receiver assembly designed to accommodate the maximum pin loading and to mate with the 1/2 inch building truss plate provided for the lock mechanism. Use receiver assembly provided with a phosphor bronze liner sheet conforming to ASTM B103/B103M with a hard temper, minimum tensile strength of 80,000 psi

SECTION 08 34 16 Page 16 and Rockwell Hardness Number B86.

2.1.16.3 Bottom Pin

Machine bottom pin from cold drawn ASTM A29/A29M, Grade 1018 steel cold finished round stock. Machine pin to thread to the cylinder rod. Guide pins at the bottom of door with UHMW supported in a fabricated steel bracket. Engage pin in sockets embedded on the floor. Use sockets with UHMW sleeves.

2.1.16.4 Air System

Use air system for operating the lock pins consisting of shop compressed air available near each door at 1/2 inch valved connection on the aircraft by wall as indicated. The compressed air is classified as industrial plant grade air at a pressure of 100 to 125 psig. The door manufacturer shall provide appropriate air accessories such as valves, regulators, filters, dryers and gages for the operating and control equipment, to ensure trouble-free service.

a. Air Filter: Each door leaf control air system shall be served by a primary filter separator provided immediately ahead of the pressure regulator. Use filter separator sized for the maximum air flow. Use filter separator capable of separating free water from other liquids, and particulates larger than 5 microns that may cause damage to the pneumatic equipment. Use filter separator with a transparent bowl guard, non-corrosive filter element. Include an automatic drain and replaceable filter elements for filter separator. Provide two spare filter elements for each filter.

b. Pressure Regulator: Serve each door leaf control air system by a pressure regulator to reduce the 100 to 125 psig plant supply air to 90 psig to provide the regulate air supply for the cylinders. Use relieving regulators with T-bar stem locking handle. Include a pressure gage with a range of 5 to 125 psig.

c. Air Exhaust Mufflers: Pipe venting and exhaust of control air systems through a muffler to reduce noise level. Use expansion chamber muffler with a built-in resonator and air disseminator. Use muffler constructed entirely of corrosion-resistant metal.

d. Directional Control Valves: Control operated cylinders by means of a solenoid pilot operated directional control valve suitable for operation in a hazardous location classified as Class 1, Division 1, Group D, approved for rain tightness. Use 2-position, 4-way, single solenoid, pilot actuated, spring return type for solenoid control valve. Use valves rated by manufacturer as suitable for the non-lubricated air service provided. Use internally supplied pilot.

Use continuous duty rated solenoid suitable for 115-120 volt A.C.

service with Class "A" (221 degrees F) insulation.

e. Piping System: Use Type K, fully annealed seamless copper tube conforming to ASTM B88 for lock pin pneumatic control piping, including field piping and prefabricated shop assembled components.

All fittings employed in the piping system, conforming to SAE J514 , except the fitting material shall be brass and bronze compatible with the copper tubing. All factory assembled components shall employ cushion type tubing supports for supporting the tubing runs. Use SAE J1405 air hose rated for 250 psig for flexible hose connection

SECTION 08 34 16 Page 17 between the building supply and the door. Use hose constructed of a synthetic rubber inner tube, a single partial stainless steel wire braid reinforcement covered by a protective synthetic rubber layer and an outer synthetic rubber impregnated textile cover. Fit hose with brass swivel type reusable fittings.

2.1.17 Top Lock Pin Maintenance Platform

Provide a platform, as required, for maintenance of the top lock pin mechanism.

2.1.17.1 Metal Grating

Platform metal grating shall conform to NAAMM MBG 531.

2.1.17.2 Handrails

Fabricate handrails from standard-weight steel pipe, nominal inside diameter 1-1/2 inches. Use hot-dipped zinc-coated finished railing assemblies conforming to ASTM A123/A123M . Complete railing with standards, brackets, caps, plugs, toe guards and all other accessories and fastenings for complete job. Fabricate railings in one length for each run and securely anchor to the supporting structure. Conform railing to the requirements of Occupational Safety Health Act Article 1926.500.

2.1.17.3 Jointing

Perform jointing of posts, rail and corners by fitting post to top rail and intermediate rail to post, mitering corners, groove welding joints and grinding smooth. Butt railing slices and reinforce with tight fitting interior sleeve not less than 6 inches in length. Railings may be bent at corners in lieu of jointing, provided bends are made in suitable jigs and that the pipe is not crushed. Weld posts welded directly to the steel platform structure.

2.1.17.4 Ladders

Fabricate vertical ladders conforming to ALI A14.3 of 2-1/2 inches by 3/8 inches steel flats for strings and 3/4 inch diameter steel rods for rungs. Space rungs a maximum one foot apart, and plug weld or shoulder and head into strings. Hot dip galvanized ladder assemblies after fabrication in conformance to ASTM A123/A123M . Install ladder so that rungs are not less than 7 inches from the finished wall surface or other structural element. Secure ladder to adjacent construction with heavy clip angles welded to the string and secured to structure as indicated.

Install intermediate clip angles not over 48 inches on centers. Install brackets as required for securing to ladders. Provide safety cage and spreaders as required.

2.1.17.5 Safety Chains

Construct safety chains of 3/16 inch, zinc-coated, steel welded chain conforming to FS RR-C-271 , Type 1, Group C, Class 4 with snap bolt hook with ring on both ends and eye bolt on both ends. Use swivel eye snap bolt hooks conforming to MIL-DTL-15021 . Use galvanized eye bolts with 3/8 inch bolt and 3/4 inch eye diameter for attachment of chains. Supply two chains, 4 inches longer than the anchorage spacing, for each guarded area. Mount top chain 3 feet to 6 feet above the platform floor. Mount lower chain 2 feet to zero inches above the platform floor.

SECTION 08 34 16 Page 18

2.1.17.6 Structural Framing

Provide additional structural framing welded to the tubular structure to accommodate the platform load.

2.1.18 Electrical Equipment

Provide electric motors, wire and equipment specified under this section conforming to 26 20 00 INTERIOR DISTRIBUTION SYSTEM, NFPA 70 and NEMA ICS 1 , NEMA ICS 2 and NEMA ICS 6 . All electrical wiring entrances and equipment within the door and mounted on the door within the aircraft bay shall be constructed to NEMA ICS 6 standards NEMA 250 Type 4/7 for hazardous locations. Use watertight, NEMA ICS 6 , Type 4 enclosures for all electrical wiring and equipment on the exterior of the door.

2.1.18.1 Plenum Lights

Provide fluorescent or LED lights within the door plenum to provide lighting for servicing the drive mechanism and the lock pin mechanisms.

Light levels at each maintenance spaces shall be 5 footcandles. Use a switch mounted in the personnel access vestibule adjacent to the plenum access door for light control. Use combination explosion-proof and weatherproof switch for plenum lights. Use 120 volts A.C. obtained from the door drive control transformer as indicated for circuit lighting.

2.1.18.2 Controls

Use two joysticks as part of the controls for each door. Require that operator maintain constant contact with joystick for door drive motor to be engaged or energized. Locate a pushbutton on each side of the door at the "seeing" end with control configuration such that either of the two joysticks can maintain door movement. Locate joysticks such that the operator can "walk" the door to either the open or closed position and have view of the direction of travel while maintaining the hand activation of the joystick. Design door to automatically stop if the operator's hand is removed from the joystick. Include an audible and visual alarm to be activated when the door is in motion. Alarms shall have a distinct warning sound and visual display that is different than all other warning systems in the hangar bay.

Include proximity sensorsand or switches to detect "near end of travel" and "end of travel" in door and door apron. Include adjustable acceleration and deceleration ramping from zero to maximum speed and from maximum to zero speed in door motor drive. Include an automatic "soft start" with gradual acceleration to a pre-set maximum speed. Include capability to adjust maximum speed. Include automatic deceleration and a gradual stop when a "near end of travel" point is reached. Include automatic disengagement or de-energization when door "end of travel" is reached. Include capability of door motor drive reversing, such that the door can be powered open and powered close.

2.1.18.3 Control Cabinet

House all applicable control components for the door in each control cabinet. Use factory installed and wired control cabinet components for each door. Locate control cabinet on the exterior face of door and size for the electrical control equipment indicated and specified herein.

Surface mount cabinet: NEMA ICS 6 Type 4 classification. Fabricate

SECTION 08 34 16 Page 19 cabinet of 14 gauge steel minimum with all seams continuously welded. Use a 12-gage back panel, for mounting equipment and devices, mounted on collar studs welded to the back face of the enclosure. Use heavy duty continuous hinged door constructed with rolled edge. Attach a neoprene gasket to doors with oil resistant adhesive and steel retaining strips.

Provide stainless steel door clamps to hold the door securely closed.

Punch holes in door to accept control switches and indicator lights as indicated. Include an exterior flange mounted NEMA ICS 6 Type 4 disconnect switch. Interlock the padlockable operating switch handle with the cabinet door so that the door can only be opened when the disconnect switch is open. Size the switch based on the voltage and electrical load in accordance with NFPA 70 . Cabinets shall contain the following equipment.

a. A microprocessor-based adjustable frequency motor drive unit (for each door) such that the door drive motor (460 volt, 3 phase) shall have variable speed capability. Make drive until capable of reversing.

Motor protection in compliance with NFPA 70 , Article 430. Make drive until capable of producing a controlled adjustable frequency/voltage output at suitable power levels to successfully operate the door drive mechanism.

Use UL listed adjustable frequency drive unit in compliance with IEEE 519 . Use additional supplemental equipment as necessary to comply with IEEE 519 . Submit a mathematical analysis by the drive until vendor verifying compliance.

The adjustable frequency drive units shall have as a minimum the following features:

(1) Ambient operating temperature range:

(a) 32 to 104 degrees F.

(b) Humidity 5-95", non-condensing.

(2) Electrical:

(a) Input Voltage: 460 VAC < plus 10 percent, minus 5 percent.

3-phase.

(b)Input Frequency: 58-62 Hz.

(c) Output Voltage: 0-460 VAC, 3-phase.

(d) Output Frequency: 3 -60 Hz. The output shall be as a result of a sine coded pulse width modulated (PEM) output from the inverter section. Frequency regulation shall be plus 0.5 percent of maximum.

(e) Current ratings: continuous for 100 percent of drive rating, 120 percent for one minute.

(f) Electronic circuitry protection.

(g) Minimum .94 power factor.

(3) Programmable functions:

(a) Acceleration rate.

(b) Deceleration rate.

(c) Voltage boost.

(d) Maximum frequency.

(e) Output current limit.

(f) Motor overload.

(g) Reduced volts per Hertz.

(4) LED or digital display of the following:

(a) Overvoltage.

SECTION 08 34 16 Page 20

(b) Undervoltage.

(c) Ground fault. .

(d) Instantaneous current

(e) Overtemperature.

b. Use control transformers rated 2 KVA 480-120 volts, 60 Hz.

c. Use door mounted indicator lights, NEMA ICS 6 , Type 4 transformer style, push-to-test type for operation up to 120 volts AC/DC. Use colored lens as indicated. Square D Type SK control units conform to this specification.

d. Door mount push-button switches, NEMA ICS 6 , Type 4, 4X momentary contact type for operation on 120 volts AC. Use black buttons, except use red for "off" and "open" buttons. Include extended guards for pushbuttons to protect against accidental operation.

e. Use control relays rated at not less than 250 V, 60 Hz, 10 A contacts, 120 V, 60 Hz coils. Use plug in type, suitable for mounting to the back panel of the control cabinet with clamp type terminals. Furnish a minimum of one spare contact per relay. Use break coil relays rated for 600 V.

f. Use programmable logic controller (PLC) to perform all control and timing of door operation. I/O no greater than 1200 AC or DC. Use relay suitable for mounting to the back panel.

g. Use Factory Mutual approved intrinsically safe barrier relays for hazard classification Class 1, Division 1, Group D. Suitable for use with a "close" pushbutton. Capable of switching a 120 V, 60 Hz, 5A load and withstanding 20 A inrush in one second. Use encapsulated, irreparable, and vibration resistant relay.

h. Use solid-state pulsating type piezoelectric horns suitable for use at 120 V, 60 Hz. Produce a one-half second intermittent 3900 Hz tone of approximately 50 percent duty cycle. Minimum sound level 85 dB at 2 feet on axis. Suitable for door mounting with screw type terminals.

i. Use barrier type terminal blocks made of thermosetting phenolic or nylon rated for 600 V, 20A with a maximum operating temperature of 250 degrees F. Use tabular screw blocks with pressure plate terminals.

Locate marking strips on the top of the terminal block and center between the binding screws to permit full access to the binding screws with the marking strip in place.

j. Use 120 V fuses, 1-1/4 inch, quick blow cartridge type in suitable fuse block for back panel mounting. Capable of handling 20 A continuous with screw or clamp type terminals.

k. Fabricate nameplates from plastic laminate 3-ply engraving stock, minimum thickness 1/32 inch, dark blue with white core. Characters a minimum of 1/8 inch high, all capitals, gothic, unless noted otherwise. Engrave information; locate as indicated. Unless noted otherwise, determine nameplate length and height to fit legend and to present a neat and pleasing appearance. Engrave legend plates at pushbuttons and indicator lights engraved as indicated.

l. Provide cooling fans if necessary for proper cooling of cabinet components.

SECTION 08 34 16 Page 21

2.1.18.4 Joysticks

On the control cabinet door and the interior face of the door, use bidirectional spring-return-to-center type joysticks with normally open contacts as indicated. Handle 3-3/4 inches long, threaded to accept a spherical phenolic knob. Comply with NEMA ICS 4 , suitable for 120 volts 60 hertz operation. Install joystick on the interior face of the door in a NEMA ICS 6 Type 4 enclosure. As of publication, Cutler Hammer File E20 two position joysticks conform to this specification.

2.1.18.5 Limit Switches

Use heavy duty type limit switches, mechanically actuated, in a NEMA ICS 6 Type 4, 7 explosion proof weathertight enclosurein a NEMA ICS 6 Type 4 weathertight enclosure. Use contacts rated 10 amperes, 600 volts, DPDT.

Use limit operable in ambient temperatures from minus 10 to 185 degrees F.

Microswitch Type LCS and HDLS limit switches conform to this specification.

2.1.18.6 Klaxon Horns

Use weatherproof, A.C. vibration type horns for annunciation of door movement suitable for operation on 120 volts 60 hertz. Use horns with adjustable volume, range of 78 to 128 db SPL measured on axis at 10 feet.

2.1.18.7 Explosion Proof Control Devices

On the door interior face use weathertight and explosion proof indicator lights and pushbutton (Class 1, Division 1, Group D, hazardous area), suitable for use in 120 volt 60 hertz control circuit. Use NEMA ICS 6 , Type 4, 7 enclosures as indicated.

2.1.18.8 Interconnecting Cable

Between each door and building interface junction box, use cable Type SO, UL listed, neoprene jacketed, 600 volt rated, of the number of conduits and gage indicated. Use cable consisting of multiple stranded bare copper conductors, with a flexible heavy duty black neoprene jacket overall suitable for exterior installation to resist ozone, sunlight, moisture, oil and abrasion. Supply cable of sufficient length to accommodate the door swing.

2.1.18.9 Conduit, Wire and Fittings

a. Conduit: rigid hot dipped galvanized steel with thread connections.

b. Within the control cabinet, use stranded copper wire type SIS.

Minimum size power wiring: No.12 AWG. Minimum size control wiring:

No.14 AWG. In conduit, use stranded copper wire Type THWN No.14 for control and No.12 for Power.

c. Within the door and on the interior wall use explosion proof and weathertight boxes and fittings, NEMA ICS 6 Type 4, 7.

d. Use conduit seals suitable for Class 1, Division 1, Group D hazardous area.

e. Use watertight fittings for Type SO cable.

SECTION 08 34 16 Page 22

f. In hazardous areas use flexible conduit suitable for installation in a Class 1, Division 1, Group D hazardous area.

2.1.18.10 Rotating Beacons

Use rotating beacons rated 120 volts or 360 degree rotation, weatherproof, red dome, gasketed aluminum shock mount housing, suitable for 1 inch stanchion mounting.

2.2 FABRICATION

2.2.1 Doors

Use door leaves fabricated from hot rolled sections or structural tubing in accordance with AISC 325 and AWS D1.1/D1.1M . Welded joints except where impractical. All joints shall develop 100 percent of the strength of the framing members. Prepare splices accurately to facilitate field assembly in accordance with standard practice. Use frames and framing members true to dimensions and square in all directions; no leaf shall be bowed, warped or out of line in the vertical or horizontal plane of the door opening by more than 1/8 inch in 20 feet. Provide bracing so that the completed leaf assembly will be adequately braced to withstand shipping, assembly and operational loads. Ground smooth exposed welds and welds which interfere with the installation of parts such as wall panels and cove sheets.