ANC_SSS_-_RTA_-_Amendment_1_-_Spec_08_22_20.pdf

Soil, Sand and Salt Storage Facility - Arlington National Cemetery

SECTION 08 22 20

FIBERGLASS REINFORCED PLASTIC (FRP) DOORS AND FRAMES

05/09

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 the basic designation only.

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)

ASCE 7 (2010; Change 2010; Change 2011; Errata 2011; Change 2011) Minimum Design Loads for Buildings and Other Structures

ASTM INTERNATIONAL (ASTM)

ASTM D2344/D2344M (2000; R 2006) Standard Test Method for Short-Beam Strength of Polymer Matrix Composite Materials and Their Laminates

ASTM D256 (2010) Determining the Izod Pendulum Impact Resistance of Plastics

ASTM D635 (2010) Standard Test Method for Rate of Burning and/or Extent and Time of Burning of Self-Supporting Plastics in a Horizontal Position

ASTM D638 (2010) Standard Test Method for Tensile Properties of Plastics

ASTM D695 (2010) Standard Test Method for Compressive Properties of Rigid Plastics

ASTM D696 (2008) Standard Test Method for Coefficient of Linear Thermal Expansion of Plastics Between -30 degrees C and 30 degrees C With a Vitreous Silica Dilatometer

ASTM D790 (2010) Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials

ASTM E2074 (2000e1) Standard Test Method for Fire Tests of Door Assemblies, Including Positive Pressure Testing of Side-Hinged and Pivoted Swinging Door Assemblies

ASTM E2112 (2007) Standard Practice for Installation of Exterior Windows, Doors and Skylights

ASTM E283 (2004; R 2012) Determining the Rate of Air

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Leakage Through Exterior Windows, Curtain Walls, and Doors Under Specified Pressure Differences Across the Specimen

ASTM E331 (2000; R 2009) Water Penetration of Exterior Windows, Skylights, Doors, and Curtain Walls by Uniform Static Air Pressure Difference

ASTM E84 (2012c) Standard Test Method for Surface Burning Characteristics of Building Materials

BUILDERS HARDWARE MANUFACTURERS ASSOCIATION (BHMA)

ANSI/BHMA A156.115 (2006) Hardware Preparation in Steel Doors and Steel Frames

INTERNATIONAL CODE COUNCIL (ICC)

ICC IBC (2009; Errata First Printing) International Building Code

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 241 (2013) Standard for Safeguarding Construction,Alteration, and Demolition Operations

NFPA 252 (2012) Standard Methods of Fire Tests of Door Assemblies

NFPA 80 (2013) Standard for Fire Doors and Other Opening Protectives

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910 Occupational Safety and Health Standards

29 CFR 1926 Safety and Health Regulations for Construction

UNDERWRITERS LABORATORIES (UL)

UL 10B (2008; Reprint Apr 2009) Fire Tests of Door Assemblies

UL Fire Resistance (2012) Fire Resistance Directory

1.2 ADMINISTRATIVE REQUIREMENTS

1.2.1 Pre-Installation Meeting

Within 60 days of Contract Award, the Contracting Officer will schedule a Pre-Installation meeting. For that meeting, submit the following for review and approval:

Shop Drawings

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a. Doors

b. Frames

c. Door Hardware Components and Accessories

d. Weather-stripping

Include fabrication, installation details, schedule and location for doors, frames, hardware components and accessories, showing plans, elevations, sections, details, method of glazing within the door, construction and installation attachments to other work.

Submit manufacturer's catalog data, including material descriptions for doors, frames, and accessories, dimensions of individual components and profiles, and finishes for each type of door, frame, hardware components and accessories of size, design, and location indicated.

Submit documentation substantiating that the items provided within this section are from a manufacturer having a minimum of 5 years experience in the design and manufacture of similar products and systems.

Submit Sample Warranty

1.3 SUBMITTALS

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

submittals not having a "G" designation are for Contractor Quality Control approval. 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

Doors; G

Frames; G

Door Hardware Components and Accessories; G

Weather-stripping; G

SD-03 Product Data

Doors; G

Frames; G

Door Hardware Components and Accessories; G

Weather-stripping; G

Thresholds; G

SD-07 Certificates; G

Sample Warranty; G

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1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Delivery

Deliver FRP doors, frames, components and accessories in manufacturer's original unopened packaging. Mark and remove damaged materials from the project site. Where materials are covered by a referenced specification, label the package with the specification number, type, and class, as applicable. Deliver materials in sufficient quantity to allow work to proceed without interruption.

1.4.2 Storage

Protect materials against moisture absorption and contamination or other damage.

Store all materials on clean raised platforms or pallets one level high in dry locations with adequate ventilation, such as an enclosed building or closed trailer.

Do not store materials in buildings under construction until concrete, mortar, and plaster work is finished and dry.

Do not store materials outdoors unless approved by the Contracting Officer Contract Administrator. Completely cover materials stored outdoors, on and off roof, with waterproof canvas protective covering. Do not use polyethylene sheet as a covering. Tie covering securely to pallets to make completely weatherproof. Provide sufficient ventilation to prevent condensation.

Do not store materials in contact with other materials that might cause staining, denting, or other surface damage.

1.4.3 Handling

Prevent damage to corners, edges and ends of materials. Do not install damaged materials in the work. Select and operate material handling equipment to prevent damage to materials.

1.5 EXISTING CONDITIONS

1.5.1 Field Measurements

Take Field measurements prior to the preparation of drawings and fabrication.

1.6 SAMPLE WARRANTY

Submit sample material and workmanship warranties meeting specified requirements. Provide revision or amendment to standard manufacturer warranty as required to comply with the specified requirements.

Furnish the manufacturer's 10 year no dollar limit for materials and installation, workmanship, and deterioration of factory-applied finishes within specified warranty period. Provide warranty directly to the Government and commence warranty effective date at time of Government's acceptance of the work.

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PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

Provide door and frame components including, but not limited to, astragals, cores, faces, stiles, rails, heads, jambs, and internal reinforcement, which are FRP structural shapes manufactured by the pultrusion process.

Ensure all structural shapes are composed of fiberglass reinforcement and resin in qualities, quantities, properties, arrangements and dimensions as necessary to meet the design requirements in accordance with ASCE 7, ICC IBC and dimensions specified.

Ensure fiberglass reinforcements are a combination of continuous roving, continuous strand mat, and surfacing veil in sufficient quantities as needed by the application and/or physical properties required.

Verify resins are of isophthalic polyester with chemical formulation necessary for corrosion resistance, strength and other physical properties as required.

2.1.1 Finish Surfaces

Ensure all finished surfaces of FRP items and fabrications are smooth, resin-rich, free of voids and without dry spots, cracks, and un-reinforced areas. Completely cover all glass fibers with resin to protect against their exposure due to wear or weathering. All stiles, rails, heads, jambs, and internal reinforcement are to be integrally pigmented .

2.1.2 Ultraviolet Protection

Provide documentation that all pultruded structural shapes are further protected from ultraviolet (UV) attack with:

a. Integral UV inhibitors within the resin

b. Synthetic surfacing veil to help produce a resin rich surface

c. UV resistant coating for outdoor exposures.

2.1.3 Flame Spread Rating

All FRP products to have a flame spread rating of 25 or less as per ASTM E84 Tunnel Test.

2.1.4 Structural Properties

Meet minimum longitudinal structural properties with structural shapes in the door and frame system as follows:

Tensile Strength: ASTM D638 30,000 psi

Compressive Strength: ASTM D695 30,000 psi

Flexural Strength: ASTM D790 30,000 psi

Flexural Modulus: ASTM D790 1,600,000 psi

Short Beam Shear: ASTM D2344/D2344M 4,500 psi

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Impact, Notched: ASTM D256 25 ft-lb/in

Thermal Expansion: ASTM D696 .000008 in/in/F

Fire Resistance: ASTM E84 Class I

2.2 DESIGN REQUIREMENTS

2.2.1 FRP Door and Frame

Provide complete swing-type FRP doors with frames of the size, design and location indicated, including but not limited to, framing members, subframes,door light,trim, molding, and accessories.

Provide complete door hardware schedule, design and location as specified in specification Section 08 71 00 DOOR HARDWARE.

Provide complete door glazingschedule, design and location as specified in specification Section 08 81 00 GLAZING.

2.2.1.1 FRP Door

Provide and install a seamless press-molded constructed FRP door. Laminate FRP face sheets to be applied while wet and uncured to an internal door stile and rail subframe/core assembly which is pressure molded under heat.

Integrally fuse the composite door panel over the entire surface area, do not adhesive-bond at the perimeter stile and rail.

Provide door stiles and rails which are high-modulus pultruded FRP square or rectangular tube subframe. Miter and join tubes internally at the corners with solid polymer blocks to yield a one piece unit. Provide a mid-rail tube across the width of the door at lockset height and additional horizontal rails where specified. Chemically weld all connections. No mechanical fastening at to tube joints is permitted.

Provide a triangular shaped 3/8 inch phenolic resin impregnated kraft paper honeycomb cell core for maximum rigidity and compressive strength. Use polyurethane foam or balsa wood cores are not permitted.

Provide internal reinforcement composed of high-modulus pultruded tubular FRP or high-density polymer compression blocks at all hardware and corner locations. No aluminum, steel, or wood blocking for reinforcement is permitted. A minimum pull-out force strength of 900 lbs per screw is required for all hinge locations.

Door faces are to utilize a chemical resistant thermosetting polyester resin with fiberglass reinforcing layers. Provide structural reinforcement which is knitted multi-layer material with layers of unidirectional fiberglass orientated in both vertical and horizontal directions for high stiffness, impact and warp resistance. Furnish door faces as indicated by the door elevation drawings.

The exposed finish of the FRP door faces are to be an ultra-violet light stabilized marine grade Neopentyl Glychol (NPG)-isophthalic polyester gelcoat integrally molded to a 25/30 mil wet thickness.

Cutouts for door lights and louvers are to be manufactured and not field fabricated. Cutouts are to be totally enclosed by internal pultruded FRP stiles and rails as specified and incorporated into the door subframe with

SECTION 08 22 20 Page 6 the opening completely fused to both door faces.

2.2.1.2 FRP Frame

Provide a FRP Door Frame utilizing a high-modulus pultruded structural FRP shape. Fabricate pultruded frame with a wall thickness of not less than 3/16 inch. Frames are to be one piece factory constructed with molded stop. Jambs and header to utilizing miter corner connections chemically weld with FRP material ground for a visibly smooth frame face. Post and beam or mechanical fastened corners and joints are not acceptable. Provide sizes and shapes as detailed on the approved drawings.

Provide hardware reinforcement connections utilizing a chemical weld with FRP material at required locations. A minimum pull-out force strength of 1,100 lbs per screw is required for all hardware locations.

Frame finish is to be identical to door color and finish. Integrally mold a 20min. wet mil resin rich gel coat into the frame during manufacturing.

2.2.2 Fire-Rated Labeled FRP Door

Provide a Fire-Rated Door Assembly with a 90 minute rating complying with NFPA 80 and UL Fire Resistance that are listed and labeled by a qualified testing agency, or Underwriters Laboratories (UL), Factory Mutual Engineering and Research (FM),or Warnock Hersey International (WHI, for the fire-protection ratings indicated in the door and frame schedule. Base the door testing at positive pressure according to ASTM E2074, NFPA 252, and UL 10B. Provide certification for Oversized Fire-Rated Door Assembly units exceeding the size of tested assemblies, by a qualified testing agency, that the door complies with standard construction requirements for tested and labeled fire-rated door assemblies except for the size. Ensure door labels are permanently affixed at the factory to the hinge edge of the door and do not paint.

Provide and install a seamless press-molded constructed FRP door. Laminate FRP face sheets to be applied while wet and uncured to an internal door stile and rail subframe/core assembly which is pressure molded under heat.

Integrally fuse the composite door panel over the entire surface area; do not adhesive-bond at the perimeter stile and rail.

Ensure door is provided with a fire resistant mineral core for maximum rigidity and compressive strength. Molding pressure and resin gel time are to be sufficient to allow for full penetration of resin into the cellular structure of the core to maximize shear and peel strengths at the door faces and core to reduce the possibility of delamination. Verify that the mineral core has been completely enclosed with an intumescent and FRP laminated edge perimeter, with the intumescent moldedinto the FRP door structure with a minimum 1/8" thick perimeter FRP edge banding prior to machining. Only Category A type door construction is permitted. Category B type construction with exposed edge intumescent components or products is prohibited.

Hardware reinforcement to be high-modulus pultruded tubular FRP or high-density polymer compressions blocks at all hardware and corner locations. No aluminum, steel, or wood blocking for reinforcement is permitted. A minimum pull-out force strength of 1,100 lbs per screw is required for all hinge locations.

Door faces are to utilize a chemical resistant thermosetting polyester

SECTION 08 22 20 Page 7 acronan Polygon acronan resin formulated for the specified environment with a maximum flame spread of 25 in accordance with ASTM E84, and self-extinguishing in accordance with ASTM D635 with fiberglass reinforcing layers. Provide structural reinforcement of knitted multi-layer material with layers of unidirectional fiberglass orientated in both vertical and horizontal directions for high stiffness, impact and warp resistance. Furnish door faces as indicated by the door elevation drawings.

Ensure the exposed finish of the FRP door faces with an ultra-violet light stabilized marine grade Neopentyl Glychol (NPG)-isophthalic polyester gelcoat integrally molded to a 25/30 mil wet thickness.

2.2.3 Labeled FRP Frame

Provide a Fire-Rated Door Frame with a 90 minute rating complying with NFPA 80 that are listed and labeled by a qualified testing agency, Underwriters Laboratories (UL) or Factory Mutual Engineering and Research (FM)or Warnock Hersey International (WHI), for the fire-protection ratings indicated in the door and frame schedule. Permanently affix frame labels, at the factory, to the hinge side of the door jamb. Do not paint.

Provide a Fire-Rated Door Frame utilizing a high-modulus pultruded structural FRP shape. Fabricate pultruded frame with a wall thickness of not less than 3/16 inch. Provide one piece factory constructed frames with molded stop. Utilize miter corner door jambs and header connections chemically welded with FRP material ground for a visibly smooth frame face. Post and beam or mechanical fastened corners and joints are not acceptable. Provide sizes and shapes to be as detailed on the approved drawings.

Provide a minimum density of 25 pounds per cubic foot fire resistant composite formulated core for the specified environment with a maximum flame spread of 25 in accordance with ASTM E84, and self-extinguishing as per ASTM D635.

Frame finish is to be identical to door color and finish.

2.2.4 Frame Anchors

Provide anchorage devices and fasteners where necessary for fastening fabricated FRP door frame to the adjacent construction-in-place as recommended by the FRP frame manufacturer.

2.2.5 Jamb Anchors

Provide anchors of the material, type, number, and spacing as required by the FRP frame manufacturer.

Provide Expansion Type Anchor for oncrete of hot-dip galvanized steel a minimum 3/8 inch diameter bolt with expansion shield or insert.

2.3 HARDWARE PREPARATION

Provide hardware reinforcing as specified. Prepare doors and frames for hardware in accordance with the applicable requirements of FRP door and frame manufacturer. For additional requirements refer to ANSI/BHMA A156.115.

Provide door hardware components and accessories as indicated including weather-strippingthresholds.

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2.4 PERFORMANCE REQUIREMENTS

2.4.1 Structural

Design doors and frames to withstand the specified design wind load acting normal to the plane of the entrance wall either inward or outward. in accordance with ASCE 7 and ICC IBC.

2.4.2 Air Infiltration

When tested in accordance with ASTM E283, air infiltration is not to exceed

0.06 cubic feet per minute per square footof fixed area at a test pressure of 6.24 pounds per square foot 50 mile per hour wind.

2.4.3 Water Penetration

When tested in accordance with ASTM E331, no water penetration is allowed, at a pressure of 8 pounds per square foot of fixed area.

2.4.4 Provisions for Thermal Movement

Design doors and frames to provide for expansion and contraction of the component parts caused by an ambient temperature range of 0 to 100 degrees F causing buckling, opening of joints, overstressing of fasteners, or other harmful effects.

PART 3 EXECUTION

3.1 INSTALLATION

Conform all work to the requirements of 29 CFR 1910, 29 CFR 1926,and

NFPA 241.

3.1.1 FRP Frame

Set FRP door frame plumb and true, aligned, and secured with the adjacent construction-in-place, in conformance with ASTM E2112. Anchor frame as specified and in accordance with the FRP door manufacturer's requirements.

Installation Tolerances

a. Squareness: Plus or minus 1/16 inch, measure at the door rabbet on a line 90 degrees from the jamb perpendicular to the frame head.

b. Alignment: Plus or minus 1/16 inch, measure at the jamb on a horizontal line parallel to the wall plane.

c. Twist: Plus or minus 1/16 inch, measure at the opposite face corners of the jambs on parallel lines, and perpendicular to the wall plane.

d. Plumb and True: Plus or minus 1/16 inch, measure at the jambs to the floor.

3.1.2 FRP Door

Fit and hang door in accordance with clearances specified below:

Clearance Tolerances

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a. Jambs and Head: Plus 1/8 inch or minus 1/16 inch.

b. Pairs of Doors: Plus 1/8 inch or minus 1/16 inch.

c. Bottom of Door and Top of Threshold: Maximum 3/8 inch.

d. Bottom of Door and Top of finish floor (No Threshold: Maximum 3/4 inch.

3.2 PROTECTION

Protect doors and frames from damage. Repair damaged doors and frames prior to final completion and acceptance of the project or replace with new, as directed by the Contracting OfficerContract Administrator.

Thoroughly clean all surfaces of the door and frame prior to final completion and acceptance of the project.

3.3 ADJUSTMENT

Check and re-adjust all operating hardware items immediately before final inspection. Leave work in complete and proper operating condition. Remove and replace defective work, including all FRP that is warped, bowed, or otherwise unacceptable to the Contracting OfficerContract Administrator.

3.4 WARRANTY

Submit approved Warranty made out to the Government, to the Contracting Officer no later than 10 days prior to final inspection, -- End of Section --

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