Attch 30 08 34 16 CORROSION CONTROL HANGAR DOORS.pdf

LOW OBSERVABLE COMPOSITE REPAIR FACILITY W91236-21-R-2023

Langley Air Force Base

SECTION 08 34 16

CORROSION CONTROL HANGAR DOORS

05/17

AMENDMENT 31 JAN 22

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) Structural Welding Code - Steel

ASTM INTERNATIONAL (ASTM)

ASTM A29/A29M (2016) 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 A653/A653M (2020) Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by

SECTION 08 34 16 Page 1 the Hot-Dip Process

ASTM A992/A992M (2011; R 2015) Standard Specification for Structural Steel Shapes

ASTM A1008/A1008M (2018) 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 (2018a) 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 B88 (2016) Standard Specification for Seamless Copper Water Tube

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)

ASTM E84 (2020) Standard Test Method for Surface Burning Characteristics of Building Materials

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 519 (2014) Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2018) Enclosures for Electrical Equipment (1000 Volts Maximum)

NEMA ICS 1 (2000; R 2015) Standard for Industrial Control and Systems: General Requirements

NEMA ICS 2 (2000; R 2005; Errata 2008) Industrial Control and Systems Controllers, Contactors, and Overload Relays Rated 600 V

NEMA ICS 4 (2015) Application Guideline for Terminal Blocks

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

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2020; ERTA 20-1 2020; ERTA 20-2 2020; TIA

SECTION 08 34 16 Page 2

20-1; TIA 20-2; TIA 20-3; TIA 20-4)

National Electrical Code

NFPA 220 (2018) Standard on Types of Building Construction

NFPA 409 (2016; ERTA 2016) 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) Detergents, General Purpose (Liquid, Non-Ionic)

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

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 (2019) DoD Building Code

UFC 3-301-01 (2019) Structural Engineering

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

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

UNDERWRITERS LABORATORIES (UL)

UL 900 (2015) Standard 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, 11 51 00 INSULATED PAINT BOOTH, 09 97 13.27

EXTERIOR COATING OF STEEL STRUCTURES and 09 90 00 PAINTS AND COATINGS apply to this section with additions and modifications specified herein.

Section 11 51 00 INSULATED PAINT BOOTH.

Work Included: Contractor shall provide complete turnkey product under this contract. Contractor is responsible for furnishing and installing

SECTION 08 34 16 Page 3 four (4) complete Corrosion Control Hangar Doors. Furnish doors of the dimensions and capacity specified, including three (3) Plenum doors at paint bays and one (1) door at wash bay. Doors shall include controls, motors, operators, structural framework, insulated mental panels, bubble seals, access doors for personnel and for ARFF hose access, interior lighting, and operational safety controls. Paint booth doors shall shall include air intake plenum system and filter wall. All four (4) doors shall be provided by the same vendor. Plenum Doors to be provided by same vendor of the Paint Booth System (see specification 11 51 00 INSULATED PAINT BOOTH) Work shall include the coordination with other construction contractors to incorporate systems by other trades. Drawings and specifications as shown are to communicate design intent. Contractor and Subcontractors responsible for final engineering design and specifications.

See Architectural Drawings A-701, A-312, and A-553 for additonal information as well as additional drawings and specifications throughout the contract documents. Contractor is responsible for all coordination between disciplines.

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.

"G, AE" code is applied where Architect/Engineer review and approval is required. "G, RO" code is applied where Government, Resident Office review and approval is required. Submittals with an "S" are for inclusion in the Sustainability eNotebook, in conformance to Section 01 33 29 SUSTAINABILITY REPORTING. Submit the following in accordance with Section

01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Manufacturer's Qualifications; G, AE

Installer's Qualifications; G, AE

SD-02 Shop Drawings

Door Materials; G, AE

SD-05 Design Data

Door Structure; G, AE

SD-10 Operation and Maintenance Data

Lubrication; G, AE

Air System; G, AE

Electrical Equipment; G, AE

1.3.1 Door Materials

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

SECTION 08 34 16 Page 4

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 location drawing showing the location of all pressure regulators, hydraulic openers, 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

1.3.1.1 Intergration with Paint Booth System

All submittals for paint booth doors shall be provided as an integral part of the paint booth Submittals specified under section 11 51 00. The submittals shall cover the entire paint booth system.

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 10 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.

SECTION 08 34 16 Page 5

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.

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 corrosion control hangar doors and components indicated in the construction documents are representative of a commercially-available door. Design and fabricate the door as part of the complete package paint booth specified under section 11 51 00 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 .

Three of the doors are to provide plenum functions, and to be considered a part of the Paint Booth System, delivered in whole by the same vendor. The fourth door is not to be a part of a Paint Booth System, however, it must match the plenum doors for finish, operation, controls, and materials.

Submit Calculations sealed by the door manufacturer's 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

SECTION 08 34 16 Page 6 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 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

Design the drive mechanism to operate the door against a wind pressure of 5 pounds per square foot perpendicular to the door face. Design the drive so that when stopped at any point, the door automatically locks in place against a 127 mph wind. Design for the effect door sway and vibration will have on wheel traction in a 127 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 utilizes commercially available components.

1.6.6 Hydraulic Locking Mechanism

Provide manual and hydraulic control devices, piping, tubing and hose for the locking mechanisms. Use system designed to maintain air loading of the cylinders at all times except when the lock pins are to be retracted.

Locate hydraulic 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 hydraulic 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 cylinder, removing the 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.

SECTION 08 34 16 Page 7

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.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Structural Steel

ASTM A36/A36M.

ASTM A992/A992M .

2.1.2 Formed Steel

AISI SG03-3 .

AMENDMENT 31 JAN 22* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *

2.1.3 Galvanized Steel

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

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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 Exterior Covering

Preform the hanger door/plenums' exterior wall from siding panels over rigid insulation boards, assembled in accordance with the siding manufacturer's standard detail. Provide panels with factory finish 500 PVDF fluoropolymer

2.1.6.1 Exterior Wall Panels

Coated steel sheets conforming to the requirements of Section 07 42 63 FABRICATED WALL PANEL ASSEMBLIES, with ribbed exterior face, 1-1/2 inch panel, depth and thickness to meet design loads and purlin spacing, but not less than 22 MFG STD gage, with factory finish 500 PVDF fluoropolymer.

Match finish with building metal panels. Provide panels with ridgid insulation, Class 1 fire resistence, min r-12. Assembly thickness by manufacturer.

2.1.6.2 Liner Panels

Coated steel sheets conforming to the requirements of Section 07 42 63 FABRICATED WALL PANEL ASSEMBLIES, or galvanized steel sheets conforming to

SECTION 08 34 16 Page 8

RoseborS Line

RoseborS Line

ASTM A653/A653M , coating designation G90, with flush interior face, 1-7/8 inch panel depth and thickness to meet design loads and purlin spacing, but not less than 22 MFG STD gage, with factory finish. Infill area with vendor plenum air distribution panels.

2.1.6.3 Insulation

Permanently secure insulation materials in place between the face and line panels. Design the doors to have an air-to-air "U" value not more than 0.05, a flame spread rating of 75 or less and a smoke-developed rating of 100 or less when tested in accordance with ASTM E84. Do not use cellular plastics.

2.1.6.4 Accessories

Sheet metal flashings, trim molding, closure strips, caps, subgirts and other similar sheet metal accessories used in conjunction with the preformed panels shall be of the same material and finish as the panels.

Metal shall be of a thickness not less than that used for the panels.

2.1.7 Hardware

Provide hardware suitable for use on hangar doors and designed to accommodate actual dead loads plus wind loads specified herein.

2.1.7.1 Pivots

Provide pivots with heavy duty thrust bearings sealed against dust and water, and with drip-type lubrication fittings requiring infrequent attention. They shall be of sufficient strength to resist all loads specified herein, with a factor of safety of 2. Provide for expansion and contraction over a temperature range of 80 degrees F. Design the top pivot to provide movement in the plane of the door to accommodate a differential settlement and the slope of the ground support surface for the full range of swing travel of the door. Design the top pivot to provide movement in the plane of the door in the closed position to accommodate a horizontal displacement of the building of vertical door alignment adjustments at the top and bottom pivot points. The bottom pivot point shall be self-aligning and installed in a cement case with removable weather tight cover, and shall be designed to resist axial and radial thrust loads.

2.1.8 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

SECTION 08 34 16 Page 9

MATERIAL MILITARY OR FEDERAL SPECIFICATION

High Pressure Cleaning Compound SAE AMS-C-22542

Ethyl Acetate ASTM D4614

Non-Ionic Detergent MIL-D-16791

Conversion Coating MIL-DTL-5541

2.1.9 Fasteners

Hot dipped galvanized.

2.1.10 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.

2.1.11 Light Fixtures

The door manufacturer shall provide all light fixtures indicated in or on the door. Within accessible plenum spaces, provide light fixtures for maintainence use. Conform to the electrical drawings and the requirements specified in 26 20 00 INTERIOR WIRING SYSTEMS.

2.1.12 Personnel Doors and Plenum Access Doors

Provide doors in each hangar door leaf for personnel access to the 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

SECTION 08 34 16 Page 10

1 Each Lockset Series 1000, Grade 1, Function F04

1 Each Door Closer C02011, Size 111

1 Set Airtight Seals As specified

Provide, at each door, one 18" x 18" pass door through the door system to allow passage of a fire fighter hose. Provide harware for hinge function and lock for security.

2.1.13 Concrete and Non-Shrink Grout

Pour in place normal concrete having a strength of 4500 psi. Concrete and non-shrink grout shall conform to the requirements of 03 30 00

CAST-IN-PLACE CONCRETE.

2.1.14 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 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.

2.1.15 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.

2.1.16 Door Drive Mechanism

Each door leaf shall be driven by a hydraulic arm operator. 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

SECTION 08 34 16 Page 11 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 matching expanded facility B361 installation, which shall be approved by the CQC Representative.

2.1.16.1 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. Provide alemite grease fitting to mate with bulkhead female pipe fitting.

2.1.16.2 Door Drive Mechanism Enclosure

Design and fabricate drive mechanism enclosure to be readily removable to facilitate inspection and maintenance of the mechanical drive components.

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

2.1.17 Lock Pins

Equip leading edge of doors with 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.

2.1.17.1 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

SECTION 08 34 16 Page 12 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.

2.1.17.2 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.

2.1.17.3 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.

SECTION 08 34 16 Page 13

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 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.

AMENDMENT 31 JAN 22* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *

2.1.18 Internal Access

Provide a platform an ext er nal weat her pr oof ed access panel as a means t o access t he t op pi n mechani sm. Panel s shal l be s i zed ( mi n 36" X36" ) and l ocat ed above al l ser vi ceabl e equi pment , as required, for maintenance of the top lock pin mechanism.

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2.1.18.1 Handrails (As Required Internal to Doors)

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.

2.1.18.2 Jointing (As Required Internal to Doors)

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.

2.1.18.3 Ladders (As Required Internal to Doors)

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.

2.1.18.4 Fire Hose Access

Provide 18" x 18" min. fire hose access doors through door assembly.

Provide all hardware required for door operation, including hinges, latches, and locks.

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RoseborS Line

2.1.18.5 ACCESS DOORS

Provide 3'-0" wide by 7'-0" access doors, from internal face of plenum door, to allow service access to components within the plenum doors.

Provide all hardware required for door operation, including hinges, latches, and lockets, conforming to facility standards.

2.1.19 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.

2.1.19.1 Plenum Lights

Provide 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.

2.1.19.2 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 sensors and 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.

2.1.19.3 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

SECTION 08 34 16 Page 15 for the electrical control equipment indicated and specified herein.

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

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(4) LED or digital display of the following:

(a) Overvoltage.

(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.

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

2.1.19.4 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.

2.1.19.5 Limit Switches

Use heavy duty type limit switches, mechanically actuated, in a NEMA ICS 6 Type 4, 7 explosion proof 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.

2.1.19.6 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.

2.1.19.7 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.

2.1.19.8 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.

2.1.19.9 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.

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e. Use watertight fittings for Type SO cable.

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

2.1.19.10 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. Seal flat cover sheets with sealant and fasten to frame either by edge welding, plug welding or threaded fasteners on 12 inch centers. Prepare, prime, and coat structural framing and miscellaneous steel as specified in paragraph FINISHES. Seal joints in assembled door/plenum to provide an airtight plenum.

2.2.2 Latches

Provide automatic latching devices at top and bottom of doors to take over positioning of the doors during closing, compress the seals, and anchor the door against full wind and seismic loads. Use devices with sufficient throw to allow for thermal expansion and contraction of the doors, and sufficient range of action horizontally to set under full wind deflection, inward or outward. Provide an automatic foot bolt to anchor the door in fully open position. seat bottom bolts in dust-proof strikes set in concrete pavement. Interlock latching devices with motors to prevent door operation unless the bolts are fully retracted.

2.2.3 Tractor Pulls

Provide tractor pulls so that leaves can be towed by a tractor or similar equipment. The tractor pull shall be designed for a drive force to tow door of 5000 pounds whichever is greater. Minimum thickness steel plate shall 3/8 inch.

2.2.4 Exterior Covering

Install exterior covering on the assembled door structure in accordance with the siding manufacturer's recommendation and approved shop drawings.

Form and seal joints so that both sides of the covering are weathertight and the plenum is airtight.

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2.2.5 Interior Covering

Fabricate interior wall of hangar door/plenums of aluminum sheet, perforated in a regular pattern with holes 1/2 inch diameter providing the total free area per door leaf indicated. Use sheet sufficiently thick to meet design loads and purlin spacing. Install sheets with the smooth side of punched holes on the exterior face of the door. Fasten sheets in place to vertical and horizontal framing members at 12 inches on center maximum with No. 14 or larger, self-tapping screws. Seal joints to provide an airtight plenum.

2.2.6 Weatherstripping

Install resilient bulb seals as required, to provide a weathertight seal around the perimeter of the door leaves and an airtight seal at the perimeter of the plenum opening mating surfaces with the supply ducts at the door head. Provide seals with molded or vulcanized corners.

Reinforce bottom seals with woven fabric. Install seals designed to allow for horizontal displacement of the building at the head of the door plus or minus 3 inches in the plane of the door in the closed position under seismic loading.

2.2.7 Services

The door manufacturer shall provide all piping, wiring and devices in the door.

2.2.8 Perforated Aluminum

Attach the aluminum perforated sheets to the door frame with plated fasteners with neoprene washers at not more than 12 inches on centers.

Protect dissimilar metals with bituminous paint. The thickness of the sheet .10 5052 alloy H32 hardness. Holes shall be inch at 1 inch on centers. 8 percent open.

2.2.9 Electrical

All manual and automatic control devices, control cabinets, light fixtures, door mounted interface junction boxes with cable and all conduit and wiring mounted on the doors and specified herein shall be provided under this section. Raceways and interconnect wiring within the aircraft bays will be provided under 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Use color coded wiring, clearly labeled with identification numbers in accordance with approved shop drawings. Make individual wire identification at all terminations with wire numbers stamped on durable plastic heat-shrinkable sleeving, 3/4 inch minimum length. Neatly train and lace wiring within the cabinet or run in plastic wiring ducts. Make cable connections to boxes watertight cable clamps. Make conduit connections to motor and limit switches with flexible conduit explosion proof in Class 1, Division 1, Group D hazardous areas or liquid tight flexible conduit to permit servicing of equipment and of sufficient length to permit field adjustment. Secure conduit to the door structure.

Provide conduits entering hazardous areas and areas with arcing devices with conduit seals in accordance with NFPA 70 . Install conduit runs to permit easy access to junction boxes and not to interfere with the operation of the door or with servicing of components. Electrical installation shall conform to the requirements of 26 20 00 INTERIOR WIRING SYSTEMS, and NEMA ICS 1 .

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2.3 FINISHES

2.3.1 Ferrous Metal

Clean, prepare, and coat…