07 60 00.pdf

Reroofing, Ally L/D 4 & 5, Conemaugh & Mahoning Dam

SECTION TABLE OF CONTENTS

DIVISION 07 - THERMAL AND MOISTURE PROTECTION

SECTION 07 60 00

SHEET METALWORK, GENERAL

PART 1 GENERAL

1.1 REFERENCES

1.2 GENERAL REQUIREMENTS

1.3 SUBMITTALS

1.4 DELIVERY, STORAGE, AND HANDLING

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Accessories

2.1.2 Aluminum Extrusions

2.1.3 Bituminous Cement

2.1.4 Sealant

2.1.5 Fasteners

2.1.6 Felt

2.1.7 Polyvinyl Chloride (PVC) Reglets

2.1.8 Aluminum Alloy Sheet and Plate

2.1.9 Stainless Steel

2.1.10 Solder

2.1.11 Roof Drains

2.1.12 Aluminum Access Door

PART 3 EXECUTION

3.1 GENERAL REQUIREMENTS

3.2 EXPANSION JOINTS

3.3 PROTECTION OF ALUMINUM

3.3.1 Paint

3.3.2 Nonabsorptive Tape or Gasket

3.4 CONNECTIONS AND JOINTING

3.4.1 Soldering

3.4.2 Riveting

3.4.3 Seaming

3.5 CLEATS

3.6 FLASHINGS

3.6.1 Base Flashing

3.6.2 Counter Flashings

3.7 FLASHING FOR ROOF DRAINS

3.8 FLASHING FOR SINGLE PIPE VENTS

3.9 REGLETS

3.10 GRAVEL STOPS AND FASCIAS

3.10.1 Edge Strip

3.10.2 Joints

3.11 METAL DRIP EDGE

3.12 GUTTERS

SECTION 07 60 00 Page 1 Underlined or Struck-Through Text Revised By Amendment W911WN-09-B-0018-0001

3.13 DOWNSPOUTS

3.13.1 Terminations

3.14 EAVE FLASHING

3.15 SHEET METAL COVERING ON FLAT, SLOPED, OR CURVED SURFACES

3.16 ALUMINUM ACCESS DOOR

3.17 CONTRACTOR QUALITY CONTROL

-- End of Section Table of Contents --

SECTION 07 60 00 Page 2

SECTION 07 60 00

SHEET METALWORK, GENERAL

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 in the text by basic designation only.

ASME INTERNATIONAL (ASME)

ASME A112.21.2M (1983) Roof Drains

ASTM INTERNATIONAL (ASTM)

ASTM A 167 (1999) Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM B 32 (1996) Solder Metal

ASTM B 209 (1996) Aluminum and Aluminum-Alloy Sheet and Plate

ASTM B 221 (1996) Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wire, Profiles, and Tubes

ASTM C 920 (1998) Elastomeric Joint Sealants

ASTM D 226 (2006) Standard Specification for Asphalt-Saturated Organic Felt Used in Roofing and Waterproofing

ASTM D 1784 (1999a) Rigid Poly(Vinyl Chloride) (PVC) Compounds and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds

ASTM D 2822 (1991; R 1997el) Asphalt Roof Cement

ASTM D 4022 (1994) Coal Tar Roof Cement, Asbestos Containing

ASTM D 4586 (2007) Asphalt Roof Cement, Asbestos-Free

FEDERAL SPECIFICATIONS (FS)

FS TT-P-28 (Rev G; Notice 1) Paint, Aluminum, Heat Resisting (1200 Degrees F.)

SECTION 07 60 00 Page 3

SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION

(SMACNA)

SMACNA Arch. Manual (1993; Errata; Addenda Oct 1997) Architectural Sheet Metal Manual

1.2 GENERAL REQUIREMENTS

Sheet metalwork shall be accomplished to form weathertight construction without waves, warps, buckles, fastening stresses or distortion, and shall allow for expansion and contraction. Cutting, fitting, drilling, and other operations in connection with sheet metal required to accommodate the work of other trades shall be performed by sheet metal mechanics. Installation of sheet metal items used in conjunction with roofing shall be coordinated with roofing work to permit continuous roofing operations.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES :

SD-02 Shop Drawings

Materials; G, RE

Drawings of all sheet metal items specified herein, showing weights, gauges or thicknesses; types of materials; expansion-joint spacing; fabrication details; and installation procedures.

1.4 DELIVERY, STORAGE, AND HANDLING

Materials shall be adequately packaged and protected during shipment and shall be inspected for damage, dampness, and wet-storage stains upon delivery to the jobsite. Materials shall be clearly labeled as to type and manufacturer. Sheet metal items shall be carefully handled to avoid damage. Materials shall be stored in dry, ventilated areas until immediately before installation.

PART 2 PRODUCTS

2.1 MATERIALS

Lead and lead-coated metal shall not be used. Any metal listed by SMACNA Arch. Manual for a particular item may be used, unless otherwise specified or indicated. Materials shall conform to the requirements specified below and to the thicknesses and configurations established in SMACNA Arch. Manual. Different items need not be of the same metal.

2.1.1 Accessories

Accessories and other items essential to complete the sheet metal installation, though not specifically indicated or specified, shall be provided.

SECTION 07 60 00 Page 4

2.1.2 Aluminum Extrusions

ASTM B 221, Alloy 6063, Temper T5.

2.1.3 Bituminous Cement

Type I asphalt cement conforming to ASTM D 2822 or ASTM D 4586. For coal tar roofing; coal tar cement conforming to ASTM D 4022.

2.1.4 Sealant

Elastomeric sealants shall conform to ASTM C 920 and the following:

a. Polysulfide Sealant: Type S, Grade NS, Class 25, Use NT, A.

b. Polyurethane sealant: Grade NS, Class 25, Use NT, A.

c. Silicone sealant: Type S, Grade NS, Class 25, Use NT, A.

2.1.5 Fasteners

Fasteners shall be compatible with the fastened material and shall be the type best suited for the application.

2.1.6 Felt

ASTM D 226, Type I.

2.1.7 Polyvinyl Chloride (PVC) Reglets

ASTM D 1784, Class 14333D, 0.075 inch minimum thickness.

2.1.8 Aluminum Alloy Sheet and Plate

ASTM B 209, anodized, form, alloy, and temper appropriate for use. Color of exposed surfaces shall be dark bronze.

2.1.9 Stainless Steel

ASTM A 167, Type 302 or 304; fully annealed, dead soft temper.

2.1.10 Solder

ASTM B 32, 95-5 tin-antimony.

2.1.11 Roof Drains

Where indicated to be replaced, roof drains shall conform to ASME A112.21.2M, with dome and integral flange, and shall have a device for making a watertight connection between roofing and flashing. Design shall be as similar to the original as indicated on the Reference Drawings. The Contractor shall ensure new roof drain is adequate and can be installed without demolition of the roof deck. Unless otherwise noted, the whole assembly shall be galvanized heavy pattern cast iron. On roofs other than concrete construction, roof drains shall be complete with underdeck clamp, sump receiver, and an extension for the insulation thickness where applicable. A clamping device for attaching flashing or waterproofing membrane to the seepage pan without damaging the flashing or membrane shall be provided when required to suit the building construction. Strainer

SECTION 07 60 00 Page 5 openings shall have a combined area equal to twice that of the drain outlet. The outlet shall be equipped to make a proper connection to threaded pipe of the same size as the downspout. An expansion joint of proper size to receive the conductor pipe shall be provided. The expansion joint shall consist of a heavy cast-iron housing, brass or bronze sleeve, brass or bronze fastening bolts and nuts, and gaskets or packing. The sleeve shall have a nominal thickness of not less than 0.134 inch.

Gaskets and packing shall be close-cell neoprene, O-ring packing shall be close-cell neoprene of 70 durometer. Packing shall be held in place by a packing gland secured with bolts.

2.3.5 Trench Drain System

Trench drain shall be a precast polymer concrete trench system, as shown on the drawings, and shall be similar or equal to PolyDrain System, as manufactured by ABT Inc., 359-T Murdock Rd. P.O. Box 837, Troutman, NC 28166 (800) 438-6057, and available from AR Chambers and Son, 111 - 35th St., Pittsburgh, PA 15201, (412) 681-8955. The system shall consist of interlocking trench drain channels with built-in invert slope, heavy duty stainless steel slotted grate and fasteners. Trench drain width shall be minimum 4 inch width. Installation supports, grating locking devices and end plates shall also be furnished. Epoxy resin bonding agent for bonding fresh embedment concrete to hardened lock wall concrete for the installation of the trench drains shall be a two component material formulated to meet the requirements of ASTM C 881/C 881M, Type V. The grade and class shall be appropriate for the application and temperature conditions for which it is used. The epoxy resin shall contain 100% solids and be moisture insensitive.

2.1.12 Aluminum Access Door

Aluminimum door with hardware shall be furnished and installed to replace the existing roof access doors on the powerhouses at Allegheny Locks 4 and 5.. Aluminum doors and frames shall be constructed of aluminum conforming to ASTM B 209 anodized clear finish. Hardware shall be stainless steel or aluminum. Doors shall be sized to fit the particular opening, and existing opening shall be field-verified prior to fabrication. Door shall be weatherproof with full gasketing and threshold. Doors shall swing outward onto the roof so that door seals shut against door opening.

PART 3 EXECUTION

3.1 GENERAL REQUIREMENTS

Gutters and downspouts shall be designed and fabricated in conformance with SMACNA Arch. Manual; louvers shall be fabricated in conformance with SMACNA Arch. Manual and as indicated. Unless otherwise specified or indicated, exposed edges shall be folded back to form a 1/2 inch hem on the concealed side, and bottom edges of exposed vertical surfaces shall be angled to form drips. Bituminous cement shall not be placed in contact with roofing membranes other than built-up roofing.

3.2 EXPANSION JOINTS

Expansion joints shall be provided as specified herein. Expansion joints in continuous sheet metal shall be provided at 40 foot intervals for stainless steel and at 32 foot intervals for aluminum, except extruded aluminum gravel stops and fascia which shall have expansion joints at not more than 12 foot spacing. Joints shall be evenly spaced. An additional

SECTION 07 60 00 Page 6 joint shall be provided where the distance between the last expansion joint and the end of the continuous run is more than half the required interval spacing.

3.3 PROTECTION OF ALUMINUM

Aluminum shall not be used where it will be in contact with copper or where it will contact water which flows over copper surfaces. Aluminum that will be in contact with wet or pressure-treated wood, mortar, concrete, masonry, or ferrous metals shall be protected against galvanic or corrosive action by one of the following methods:

3.3.1 Paint

Aluminum surfaces shall be solvent cleaned and given one coat of zinc-molybdate primer and one coat of aluminum paint conforming to

FS TT-P-28.

3.3.2 Nonabsorptive Tape or Gasket

Nonabsorptive tape or gasket shall be placed between the adjoining surfaces and cemented to the aluminum surface using a cement compatible with aluminum.

3.4 CONNECTIONS AND JOINTING

3.4.1 Soldering

Soldering shall apply to stainless steel items. Edges of sheet metal shall be pretinned before soldering is begun. Soldering shall be done slowly with well heated soldering irons so as to thoroughly heat the seams and completely sweat the solder through the full width of the seam. Edges of stainless steel to be pretinned shall be treated with soldering acid flux.

Soldering shall follow immediately after application of the flux. Upon completion of soldering, the acid flux residue shall be thoroughly cleaned from the sheet metal with a water solution of washing soda and rinsed with clean water.

3.4.2 Riveting

Joints in aluminum sheets 0.040 inch or less in thickness shall be mechanically made.

3.4.3 Seaming

Flat-lock and soldered-lap seams shall finish not less than 1 inch wide.

Unsoldered plain-lap seams shall lap not less than 3 inches unless otherwise specified. Flat seams shall be made in the direction of the flow.

3.5 CLEATS

A continuous cleat shall be provided where required to secure loose edges of the sheet metalwork. Butt joints of cleats shall be spaced approximately 1/8 inch apart. The cleat shall be fastened to supporting wood construction with nails evenly spaced not over 12 inches on centers.

Where the fastening is to be made to concrete or masonry, screws shall be used and shall be driven in expansion shields set in concrete or masonry.

SECTION 07 60 00 Page 7

3.6 FLASHINGS

Flashings shall be installed at locations required and as specified below.

Sealing shall be according to the flashing manufacturer's recommendations.

Flashings shall be installed at intersections of roof with vertical surfaces and at projections through roof. Except as otherwise indicated, counter flashings shall be provided over base flashings. Perforations in flashings made by masonry anchors shall be covered up by an application of bituminous plastic cement at the perforation. Flashing shall be installed on top of joint reinforcement. Flashing shall be formed to direct water to the outside of the system.

3.6.1 Base Flashing

Metal base flashing shall be coordinated with roofing work. Metal base flashing shall be set in plastic bituminous cement over the roofing membrane, nailed to nailing strip, and secured in place on the roof side with nails spaced not more than 3 inches on centers. Metal base flashing shall not be used on built-up roofing.

3.6.2 Counter Flashings

Except as otherwise indicated, counter flashings shall be provided over base flashings. Counter flashing shall be installed as shown in SMACNA Arch. Manual. Where bituminous base flashings are provided, the counter flashing shall extend down as close as practicable to the top of the cant strip. Counter flashing shall be factory formed to provide spring action against the base flashing.

3.7 FLASHING FOR ROOF DRAINS

Set flashing on finished felts in a full bed of asphalt roof cement, ASTM D 4586. Extend roofing plies to edge of drain bowl opening at roof drain deck flange. Neatly fit and press primed roof drain flashing into heavy coat of asphalt roof cement applied to top of roofing plies. Strip in and completely cover flashing with two layers of modified bitumen sheet, extending the first sheet 150 mm (6 inches) on the roofing beyond the edge of flashing. Extend the cap sheet 150 mm (6 inches) beyond the previous flashing ply. Bond the two layers to the metal flashing and to each other with hot asphalt. Securely clamp membrane, metal flashing, and strip flashing in the flashing clamping ring. Secure clamps so that strip flashing and metal flashing are free from wrinkles and folds. Trim membrane, flashing, and stripping flush with inside of clamping ring.

3.8 FLASHING FOR SINGLE PIPE VENTS

Set flange of sleeve in bituminous plastic cement and nail 3 inches on centers. Bend the top of sleeve over and extend down into the vent pipe a minimum of 2 inches. For long runs or long rises above the deck, where it is impractical to cover the vent pipe with lead, use a two-piece formed metal housing. Set metal housing with a metal sleeve having a 4 inch roof flange in bituminous plastic cement and nailed 3 inches on centers. Extend sleeve a minimum of 8 inches above the roof deck and lapped a minimum of 3 inches by a metal hood secured to the vent pipe by a draw band. Seal the area of hood in contact with vent pipe with an approved sealant.

3.9 REGLETS

Reglets shall be a factory fabricated product of proven design, complete

SECTION 07 60 00 Page 8 with fittings and special shapes as required. Open-type reglets shall be filled with fiberboard or other suitable separator to prevent crushing of the slot during installation. Reglet plugs shall be spaced not over 12 inches on centers and reglet grooves shall be filled with sealant.

Friction or slot-type reglets shall have metal flashings inserted the full depth of slot and shall be lightly punched every 12 inches to crimp the reglet and counter flashing together. Polyvinyl chloride reglets shall be sealed with the manufacturer's recommended sealant.

3.10 GRAVEL STOPS AND FASCIAS

Prefabricate in the shapes and sizes indicated and in lengths not less that 8 feet. Extend flange at least 4 inch onto roofing. Provide prefabricated, mitered corners internal and external corners. Install gravel stops and fascias after all plies of the roofing membrane have been applied, but before the flood coat of bitumen is applied. Prime roof flange of gravel stops and fascias on both sides with an asphalt primer.

After primer has dried, set flange on roofing membrane and strip-in.Nail flange securely to wood nailer with large-head, barbed-shank roofing nails

1.5 inch long spaced not more than 3 inch on center, in two staggered rows.

3.10.1 Edge Strip

Hook the lower edge of fascias at least 3/4 inch over a continuous strip of the same material bent outward at an angle not more than 45 degrees to form a drip. Nail hook strip to a wood nailer at 6 inchmaximum on center.

Where fastening is made to concrete or masonry, use screws spaced 12 inch on center driven in expansion shields set in the concrete or masonry.

Where horizontal wood nailers are slotted to provide for insulation venting, install strips to prevent obstruction of vent slots. Where necessary, install strips over 1/16 inch thick compatible spacer or washers.

3.10.2 Joints

Leave open the section ends of gravel stops and fascias 1/4 inch and backed with a formed flashing plate, mechanically fastened in place and lapping each section end a minimum of 4 inch set laps in plastic cement. Face nailing will not be permitted. Install prefabricated aluminum gravel stops and fascias in accordance with the manufacturer's printed instructions and details.

3.11 METAL DRIP EDGE

Provide a metal drip edge, designed to allow water run-off to drip free of underlying construction, at eaves and rakes prior to the application of roofing shingles. Apply directly on the wood deck at the eaves and over the underlay along the rakes. Extend back from the edge of the deck not more than 3 inch and secure with compatible nails spaced not more than 10 inch on center along upper edge.

3.12 GUTTERS

The hung type of shape indicated and supported on underside by brackets that permit free thermal movement of the gutter. Provide gutters in sizes indicated complete with mitered corners, end caps, outlets, brackets, and other accessories necessary for installation. Bead with hemmed edge or reinforce the outer edge of gutter with a stiffening bar not less than 3/4 by 3/16 inch of material compatible with gutter. Fabricate gutters in sections not less than 8 feet. Lap the sections a minimum of one inch in

SECTION 07 60 00 Page 9 the direction of flow or provide with concealed splice plate 6 inch minimum. Join the gutters, other than aluminum, by riveted and soldered joints. Join aluminum gutters with riveted sealed joints. Provide expansion-type slip joints midway between outlets. Install gutters below slope line of the roof so that snow and ice can slide clear. Support gutters on adjustable hangers spaced not more than 30 inch on center.

Adjust gutters to slope uniformly to outlets, with high points occurring midway between outlets. Fabricate hangers and fastenings from metals.

3.13 DOWNSPOUTS

Space supports for downspouts according to the manufacturer's recommendation for the substrate. Types, shapes and sizes are indicated.

Provide complete including elbows and offsets. Provide downspouts in approximately 10 foot lengths. Provide end joints to telescope not less than 1/2 inch and lock longitudinal joints. Provide gutter outlets with wire ball strainers for each outlet. Provide strainers to fit tightly into outlets and be of the same material used for gutters. Keep downspouts not less than one inch away from walls. Fasten to the walls at top, bottom, and at an intermediate point not to exceed 5 feet on center with leader straps or concealed rack-and-pin type fasteners. Form straps and fasteners of metal compatible with the downspouts.

3.13.1 Terminations

Neatly fit into the drainage connection the downspouts terminating in drainage lines and fill the joints with a portland cement mortar cap sloped away from the downspout. Provide downspouts terminating in splash blocks with elbow-type fittings. Provide splash pans as specified.

3.14 EAVE FLASHING

One piece in width, applied in 8 to 10 foot lengths with expansion joints spaced as specified in paragraph entitled "Expansion and Contraction."

Provide a 3/4 inch continuous fold in the upper edge of the sheet to engage cleats spaced not more than 10 inch on center. Locate the upper edge of flashing not less than 18 inch from the outside face of the building, measured along the roof slope. Fold lower edge of the flashing over and loose-lock into a continuous edge strip on the fascia. Where eave flashing intersects metal valley flashing, secure with one inch flat locked joints with cleats that are 10 inch on center.

3.15 SHEET METAL COVERING ON FLAT, SLOPED, OR CURVED SURFACES

Except as specified or indicated otherwise, cover and flash all minor flat, sloped, or curved surfaces such as crickets, bulkheads, dormers and small decks with metal sheets of the material used for flashing; maximum size of sheets, 16 by 18 inch. Fasten sheets to sheathing with metal cleats. Lock seams and solder. Lock aluminum seams as recommended by aluminum manufacturer. Provide an underlayment of roofing felt for all sheet metal covering.

3.16 CONTROL SHELTER ROOF AND TRENCH DRAIN SYSTEM

Roof drains shall be reconfigured for control shelters at the locations shown and in the manner shown on the Sketch PINCMT-1 attached to the end of this Section. In general new roof drains on the control shelters shall drain into new galvanized steel pipe downspouts into trench drains embedded in the top of the concrete lock walls. The trench drains shall be

SECTION 07 60 00 Page 10 installed into saw cut trenches in the top of the lock walls. Saw cutting shall be performed in a neat and workman-like manner with straight edges and without damage to concrete to remain. It is noted for the Contractor that reinforcing steel will likely be encountered while saw cutting.

Unless specified otherwise, the trench drains shall be installed in accordance with heManufacturer's instructions. Minimum width of saw cut trench shall be as recommended by the Manufacturer. Concrete for embedment shall be minimum 3,000 psi compressive strength, and epoxy bonding agent shall be used to bond the new embedment concrete to the existing lock wall concrete. The contractor shall submit a plan for the installation of the trench drain system, to include proposed method of sawcutting and concrete removal and installation of trench drains.

3.16 ALUMINUM ACCESS DOOR

Aluminum access doors and frames shall be installed plumb and square in accordance with the manufacturer's instructions without warping the frames or the doors. Doors shall be positioned to swing outward onto the roof.

Doors shall positively seal against all sides of frames and threshold to prevent roof runoff from entering past the door. The contractor shall test integrity of the door seal for proper installation by ponding a minimum of 4 inches of water for one hour onto the finished roof. Installation of the doors will not be accepted until there is no leakage past the doors.

3.17 CONTRACTOR QUALITY CONTROL

The Contractor shall establish and maintain a quality control procedure for sheet metal used in conjunction with roofing to assure compliance of the installed sheet metalwork with the contract requirements. Any work found not to be in compliance with the contract shall be promptly removed and replaced or corrected in an approved manner. Quality control shall include, but not be limited to, the following:

a. Observation of environmental conditions; number and skill level of sheet metal workers; condition of substrate.

b. Verification of compliance of materials before, during, and after installation.

c. Inspection of sheet metalwork for proper size and thickness, fastening and joining, and proper installation.

d. A roofing technician responsible directly to the Contractor and experienced in the construction of similar roofing systems and related work shall perform the quality control functions and be on the site when roofing operations are in progress.

The actual quality control observations and inspections shall be documented and a copy of the documentation furnished to the Contracting Officer at the end of each day.

-- End of Section --

SECTION 07 60 00 Page 11