AMD_0004_Specifications_W912ER18R0015.pdf

Pier Side Mini-Mart, NSA 2, Bahrain 405346

SECTION TABLE OF CONTENTS

DIVISION 08 - OPENINGS

SECTION 08 39 54

BLAST RESISTANT DOORS Revised by Amendment 0004

PART 1 GENERAL

1.1 REFERENCES

1.2 SYSTEM DESCRIPTION

1.2.1 Design Requirements

1.2.1.1 Static Material Strength

1.2.1.2 Dynamic Material Strength

1.2.1.3 Structural Member Design

1.2.1.4 Dynamic Analysis and Deformation

1.2.1.5 Rebound Resistance

1.2.2 Blast Effects

1.2.2.1 Overpressure

1.2.2.2 Overpressure Direction

1.2.2.3 Fragment Resistance

1.2.3 Blast Door Operation

1.2.4 Other Submittals Requirements

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.5 DELIVERY, STORAGE,AND HANDLING

1.6 WARRANTY

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Concrete and Concrete Reinforcement

2.1.2 Steel Sheet and Strip

2.1.3 Fasteners

2.2 HARDWARE

2.2.1 Hinges

2.2.1.1 General Requirements

2.2.1.2 Hinge Description

2.2.2 Latching System

2.2.2.1 Latching Points

2.2.2.2 Latching System Operation

2.2.2.3 Latching Mechanism

2.2.2.4 Safety Cover

2.2.2.5 Cover Plate

2.2.2.6 Latches

2.2.2.7 Handle

2.2.3 Mortise Lock and Latch Set

2.2.4 Keying

2.2.5 Exit Device

2.2.6 Door Stop

2.2.7 Surface Door Closer

2.2.8 Overhead Door Holder

2.2.9 Gasket Seal

SECTION 08 39 54 Page 1 W912ER18R0015 Amendment 0004

2.2.10 Door Silencer

2.3 ACCESSORIES

2.3.1 Subframe

2.3.2 Nameplate

2.3.3 Removable Threshold

2.4 FABRICATION

2.4.1 Shop Assembly

2.4.2 Mullion

2.4.3 Thermal Insulation

2.4.4 Shop Finishing

2.4.5 Clearance

2.5 BLAST DOOR ASSEMBLIES

2.5.1 Door ; Metal

2.5.1.1 Type

2.5.1.2 Overpressure

2.5.1.3 Rebound

2.5.1.4 Hardware

2.5.1.5 Operating Forces

2.5.1.6 Accessories

2.6 TESTS, INSPECTIONS, AND VERIFICATIONS

2.6.1 Prototype Static Test

2.6.2 Prototype Blast Test

2.6.3 Shop Operating Test

2.6.4 Air Leakage Test

2.6.5 Sound Rating Test

2.6.6 Fire Rating Test and Inspection

PART 3 EXECUTION

3.1 INSTALLATION

3.2 TESTS

3.3 MANUFACTURER'S FIELD SERVICE

-- End of Section Table of Contents --

SECTION 08 39 54 Page 2

SECTION 08 39 54

BLAST RESISTANT DOORS

Revised by Amendment 0004

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 BEARING MANUFACTURERS ASSOCIATION (ABMA)

ABMA 11 (1990; R 2008) Load Ratings and Fatigue Life for Roller Bearings

ABMA 9 (1990; ERTA 2012; S 2013) Load Ratings and Fatigue Life for Ball Bearings

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2011) Steel Construction Manual

AISC 360 (2010) Specification for Structural Steel Buildings

AMERICAN IRON AND STEEL INSTITUTE (AISI)

AISI S100 (2007; Supp 1: 2009; Supp 2: 2010) North American Specification for the Design of Cold-Formed Steel Structural Members

AMERICAN WELDING SOCIETY (AWS)

AWS A2.4 (2012) Standard Symbols for Welding, Brazing and Nondestructive Examination

AWS D1.1/D1.1M (2010; Errata 2011) Structural Welding Code - Steel

AWS D1.3/D1.3M (2008; Errata 2008) Structural Welding Code - Sheet Steel

AWS D1.4/D1.4M (2011) Structural Welding Code - Reinforcing Steel

ASTM INTERNATIONAL (ASTM)

ASTM A123/A123M (2013) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

ASTM A153/A153M (2009) Standard Specification for Zinc

SECTION 08 39 54 Page 3

Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A307 (2012) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength

ASTM A325M (2013) Standard Specification for Structural Bolts, Steel, Heat Treated, 830 MPa Minimum Tensile Strength (Metric)

ASTM A354 (2011) Standard Specification for Quenched and Tempered Alloy Steel Bolts, Studs, and Other Externally Threaded Fasteners

ASTM A449 (2010) Standard Specification for Hex Cap Screws, Bolts, and Studs, Steel, Heat Treated, 120/105/90 ksi Minimum Tensile Strength, General Use

ASTM A490M (2012) Standard Specification for High-Strength Steel Bolts, Classes 10.9 and 10.9.3, for Structural Steel Joints (Metric)

ASTM A534 (2009) Standard Specification for Carburizing Steels for Anti-Friction Bearings

ASTM A563M (2007; R 2013) Standard Specification for Carbon and Alloy Steel Nuts (Metric)

ASTM A574M (2012) Standard Specification for Alloy Steel Socket-Head Cap Screws (Metric)

ASTM A606/A606M (2009a) Standard Specification for Steel Sheet and Strip, High-Strength, Low-Alloy, Hot-Rolled and Cold-Rolled, with Improved Atmospheric Corrosion Resistance

ASTM A615/A615M (2013) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A653/A653M (2013) Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

ASTM A706/A706M (2013) Standard Specification for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement

ASTM A780/A780M (2009) Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings

ASTM A792/A792M (2010) Standard Specification for Steel Sheet, 55% Aluminum-Zinc Alloy-Coated by

SECTION 08 39 54 Page 4 the Hot-Dip Process

ASTM E283 (2004; R 2012) Determining the Rate of Air Leakage Through Exterior Windows, Curtain Walls, and Doors Under Specified Pressure Differences Across the Specimen

ASTM E90 (2009) Standard Test Method for Laboratory Measurement of Airborne Sound Transmission Loss of Building Partitions and Elements

ASTM F436M (2011) Hardened Steel Washers (Metric)

ASTM F835M (2011) Alloy Steel Socket Button and Flat Countersunk Head Cap Screws (Metric)

BUILDERS HARDWARE MANUFACTURERS ASSOCIATION (BHMA)

ANSI/BHMA A156.13 (2012) Mortise Locks & Latches Series 1000

ANSI/BHMA A156.3 (2008) Exit Devices

ANSI/BHMA A156.4 (2013) Door Controls - Closers

ANSI/BHMA A156.8 (2010) Door Controls - Overhead Stops and Holders

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 898-1 (2013) Mechanical Properties of Fasteners Made of Carbon Steel and Alloy Steel — Part 1: Bolts, Screws and Studs with Specified Property Classes — Coarse Thread and Fine Pitch Thread

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 101 (2012; Amendment 1 2012) Life Safety Code

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

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

NFPA 80A (2012) Recommended Practice for Protection of Buildings from Exterior Fire Exposures

1.2 SYSTEM DESCRIPTION

Provide a blast resistant door which fits a Door Description as follows:

Structural steel doors shall be flush mounted in frames. Hollow metal doors shall be flush mounted in frames. Doors shall be the manually operated, side hinged, swinging type. Each door assembly shall include the door, frame, anchors, hardware, and accessories and shall be provided by a single manufacturer. Frames and anchors shall be capable of transferring blast and rebound reactions to the adjacent supporting structure. Resistance to blast shall be demonstrated either by design calculations or tests on prototype door assemblies.

SECTION 08 39 54 Page 5

1.2.1 Design Requirements

1.2.1.1 Static Material Strength

Obtain the static values for minimum yield strength (or yield point) and (ultimate) tensile strength for steel from the applicable material specification. For tensile strength specified in terms of a tensile strength range, the lowest tensile strength specified shall be selected for design. Structural steel having a minimum static yield strength (or yield point) less than 345 MPa and Grade 60 reinforcing bars shall be designed using an average yield strength computed as 1.1 times the minimum static yield strength or yield point. If the minimum static yield for structural steel exceeds 345 MPa, the expected yield strength used for design shall be equal to the minimum specified static yield strength or yield point without increase. The expected yield stress for steel sheet and strip used in design shall be computed as 1.21 times the specified static yield point.

1.2.1.2 Dynamic Material Strength

Compute the dynamic material strength by applying a dynamic increase factor that accounts for the increase in material strength due to strain rate effects. The dynamic increase factor for structural steel in flexure shall be applied to the average yield strength and shall be 1.29, 1.19, and 1.09 for structural steel having a minimum yield strength (or yield point) of 248 MPa, 345 MPa, and 689 MPa, respectively. The dynamic increase factor for structural steel having a minimum yield strength (or yield point) between these values shall be obtained by interpolation.

Optionally, for structural steel in these yield ranges, the dynamic increase factor shall be determined by a detailed analysis that accounts for the time to yield. The dynamic increase factor for structural steel having a minimum yield exceeding 689 MPa shall be 1.0. The dynamic increase factor for steel sheet and strip used in flexure shall be 1.1 applied to the average yield stress.

1.2.1.3 Structural Member Design

Obtain structural steel section properties for rolled shapes from AISC 325 , AISC 325 , or steel manufacturers' catalogs. The plastic moment capacity for single plate sections and sections built up from plates and shapes shall be computed as the average of the elastic and plastic section modulus multiplied by the dynamic yield strength, unless otherwise approved. Shear, welds, local buckling, and web crippling of structural steel shall be designed in accordance with AISC 325 , the plastic design provisions of AISC 360 , or by other approved methods except that for blast design, the load factors and resistance factors shall be equal to 1.0 and the dynamic yield strength shall be substituted for the static yield stress. Hollow metal doors shall be designed in accordance with AISI S100 except that for blast design, the dynamic yield strength shall be substituted for the static yield point.

1.2.1.4 Dynamic Analysis and Deformation

Design the door using an equivalent single degree of freedom or other approved dynamic analysis method. The maximum door deformation shall be selected by the door manufacturer except that the maximum deformation in flexure shall not exceed the deformation limits specified or indicated.

The deformation of structural steel members having a minimum yield

SECTION 08 39 54 Page 6 strength or yield point greater than 448 MPa shall not exceed the elastic deflection.

1.2.1.5 Rebound Resistance

Rebound resistance shall be the specified or indicated percentage of the door resistance at initial peak response.

1.2.2 Blast Effects

1.2.2.1 Overpressure

The spatial distribution of overpressure shall be uniform unless otherwise specified or indicated. For overpressure specified or indicated without duration, the overpressure waveform shall have a zero rise time and infinite duration.

1.2.2.2 Overpressure Direction

For overpressure identified as seating and for overpressure directions not otherwise specified or indicated, the positive phase overpressure shall be in the direction that causes the door to seat toward the frame.

1.2.2.3 Fragment Resistance

For doors specified or indicated to resist fragments, design the door and the door and frame interface to prevent fragment perforation and the latches and latching mechanism shall be shielded from fragment damage.

The fragment impact point shall be anywhere on the door and frame face exposed to overpressure.

1.2.3 Blast Door Operation

Measure the force required to set the door in motion from the 90-degree open position, and measure the force required to engage and release the latches at the latch handle with the door in the normal closed position.

1.2.4 Other Submittals Requirements

The following shall be submitted:

a. Detailed fabrication and assembly drawings for special doors or standard doors with appreciable modifications, indicating the door location and showing dimensions, materials, fabrication methods, hardware, and accessories in sufficient detail to enable the Contracting Officer to check compliance with contract documents.

These drawings need not be submitted for standard doors for which manufacturer's catalog data is submitted. Weld symbols used shall conform to AWS A2.4 .

b. Data on standard blast doors consisting of catalog cuts, brochures, circulars, specifications, and product data that show complete dimensions and completely describe overpressure ratings, rebound ratings, doors, frames, anchors, hardware, and accessories.

Manufacturer's instructions for installation and field testing.

c. Detailed structural analysis and design calculations demonstrating resistance to blast when blast resistance is not demonstrated by prototype tests. Design calculations shall demonstrate adequacy under

SECTION 08 39 54 Page 7 the blast effects specified or indicated. Include in the design calculations a sketch of the overpressure waveform; dimensioned sketches of blast resisting elements such as door members, frame members, latches, and hinges; section properties for blast resisting members including built-up sections; the standard under which steel is produced; static and dynamic material strength properties; the resistance, stiffness, mass, elastic natural period, and elastic deflection for flexural members; and the peak deflection, peak support rotation, and time to peak deflection for door members in flexure.

Design calculations shall cover initial response, rebound, and all secondary items such as shear, welds, local buckling, web crippling, hinges, and latches.

d. Steel mill reports covering the number, chemical composition, and tension properties for structural quality steels. When blast resistance is demonstrated by calculations, a certificate stating that the door assembly provided was manufactured using the same materials, dimensions, and tolerances shown in the calculations. When blast resistance is demonstrated by prototype testing, a certificate stating that door and frame provided was manufactured using the same materials, dimensions, and tolerances as the tested prototype and listing the hardware and frame anchors required to achieve blast resistance. Each certificate shall be signed by an official authorized to certify in behalf of the manufacturer and shall identify the door assembly and date of shipment or delivery to which the certificate applies.

e. Information, for DOOR DESCRIPTION, bound in manual form consisting of manufacturer's safety precautions, preventative maintenance and schedules, troubleshooting procedures, special tools, parts list, and spare parts data. All material shall be cross referenced to the door designations shown on the drawings.

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

Installation; G M

SD-03 Product Data

Door Description; G M Design Requirements; G M Manufacturer's Field Service

SD-06 Test Reports

Tests; G M Tests, Inspections, and Verifications; G M Fire Rating Test and Inspection; G M Prototype Static Test; G M Prototype Blast Test; G M

SECTION 08 39 54 Page 8

SD-07 Certificates

Materials

Thermal Insulation

SD-10 Operation and Maintenance Data

Door Description; G R

1.4 QUALITY ASSURANCE

Welders, welding operators, and weld inspectors shall be qualified in accordance with AWS D1.1/D1.1M except thatwelders performing arc welding of steel sheet and strip shall be qualified in accordance with

AWS D1.3/D1.3M .

1.5 DELIVERY, STORAGE,AND HANDLING

Store door assemblies, delivered and placed in storage, with protection from weather and dirt, dust, and contaminants.

1.6 WARRANTY

Furnish manufacturer's written warranty covering the blast door assembly for 2 years after acceptance by the Government. Warranty shall provide for repair and replacement of the blast door assembly and individual hardware and accessory items in the event of malfunction due to defects in design, materials, and workmanship except that the warranty need not cover finishes provided by others.

PART 2 PRODUCTS

2.1 MATERIALS

Only structural quality steel materials, for which tension properties have been obtained, shall be used to resist blast except that commercial quality steel sheet and strip shall be permitted for prototype tested hollow metal doors. Select steel used in the door, door frame, and door frame anchors, and non stainless steel fasteners that resist blast, from the materials specified.

2.1.1 Concrete and Concrete Reinforcement

Concrete is specified in Section 03 30 00.00 10 CAST-IN-PLACE CONCRETE.

Concrete reinforcement shall conform to ASTM A615/A615M or ASTM A706/A706M , Grade 60.

2.1.2 Steel Sheet and Strip

Steel sheet and strip shall conform to ASTM A653/A653M , Type A, B, and C;

ASTM A653/A653M ; ASTM A606/A606M ; or ASTM A792/A792M , Grades 33, 37, 40, and 50.

2.1.3 Fasteners

Steel studs and bolts shall conform to ASTM A307, ASTM A325M, ASTM A354, ASTM A449, or ASTM A490M as applicable. Steel nuts shall conform to ASTM A563M. Hardened circular, beveled, and clipped washers shall conform

SECTION 08 39 54 Page 9 to ASTM F436M. Steel hex cap screws shall conform to ISO 898-1 . Steel socket-headed cap screws shall conform to ASTM A574M. Steel button and flat-headed countersunk cap screws shall conform to ASTM F835M.

2.2 HARDWARE

2.2.1 Hinges

2.2.1.1 General Requirements

Hinges shall be specially manufactured to support the door and to resist blast induced loading. The number of hinges shall be determined by the blast door manufacturer. Welds used in hinges shall be continuous.

Attach hinges to the door and frame using mechanical fasteners, except that full surface hinges for doors with locks shall be attached to the door and frame by welding or approved tamper-resistant mechanical fasteners and hinges for doors with locks shall have approved nonremovable pins. Load ratings and fatigue life for ball and roller bearings shall be determined in accordance with ABMA 9 and ABMA 11 as applicable and, unless otherwise approved, the bearing steel shall conform to ASTM A534. Hinges shall be capable of operating for the minimum number of cycles specified without failure or excessive wear under the door service loads where one cycle consists of swinging the door back and forth between the normal closed position and the 90-degree open position, where failure or excessive wear means that the latches do not seat properly or the door does not swing smoothly due to hinge failure or wear, and where door service loads consist of the door weight plus any loads produced by hardware. Rolling bearings shall be factory grease lubricated and either sealed or provided with easily accessible lubrication fittings.

2.2.1.2 Hinge Description

Hinge Type 1 shall be capable of smooth operation for a minimum of 250,000 cycles. This type of hinge shall be provided with structural quality steel pins and leafs and either rolling bearings in both the thrust and radial directions or hardened steel washer (disc) thrust bearings and rolling radial bearings except that rolling thrust bearings and metallic journal radial bearings shall be permitted for hollow metal doors when the specified overpressure is less than 21 kPa. Hinge Type 2 shall be smooth operating and shall be provided with structural quality steel pins and leafs, steel base washer (disc) thrust bearings, and metallic journal radial bearings or other approved non rolling type bearings. Hinge Type 3 shall be provided with metallic bearings.

2.2.2 Latching System

2.2.2.1 Latching Points

The number of latching points shall be determined by the door manufacturer. For multiple latching points, latching points can be provided at the head, sill, and jambs. For jamb latching points, latching points shall be provided at the jambs only.

2.2.2.2 Latching System Operation

Latching systems shall be capable of operating for the same number of cycles specified for the door hinges where one latch operating cycle consists of engaging and releasing using the handle. Latches shall remain engaged until manually released and shall not release under blast loads or

SECTION 08 39 54 Page 10 rebound. Self-latching latches shall provide self-activating engagement when the door is swung to the normal closed position. Handles shall release latches under a clockwise motion.

2.2.2.3 Latching Mechanism

Latching mechanisms for hollow metal doors shall be mounted on the seating face of the door and safety covered. Latch handle axles shall be manufactured of hardened steel or stainless steel, and axles requiring lubrication shall be provided with easily accessible lubrication fittings.

2.2.2.4 Safety Cover

Safety covers shall consist of steel housings that enclose the latching mechanism such that only the operating rods are exposed.

2.2.2.5 Cover Plate

Cover plates for structural steel doors shall be manufactured of minimum 6 mm thick plate and shall enclose the entire latching mechanism.

2.2.2.6 Latches

Latches (latch bolts) shall be manufactured of structural quality steel and the latch bolt throw shall not be less than 19 mm. Latch bolts shall be the sliding type in which the latch bolt slides into a matching strike in the door frame . Manually operated latches shall draw the door toward the frame during latching.

2.2.2.7 Handle

Handles for doors with mortise lock and latch sets shall be manufactured of stainless steel. Latch handles shall be firmly fastened to axles.

Lever handles shall be perpendicular to the door edge when latches are engaged. Single lever handles shall be located at the stile opposite the hinges.

2.2.3 Mortise Lock and Latch Set

Lever handles shall release latches using a torque not exceeding 3 N-meters. Latches (latch bolts) shall be located at the stiles and operated from a single lever handle. Only one deadbolt shall be provided. The deadbolt shall be manufactured of structural quality steel and the deadbolt throw shall not be less than 25 mm. Mortise locks shall be provided with armored fronts. The function numbers for mortise locks shall be as defined in ANSI/BHMA A156.13 .

2.2.4 Keying

Keying shall conform to Section 08 71 00 DOOR HARDWARE. Change keys for locks shall be stamped with change number and the inscription "U.S.

Property - Do Not Duplicate." Unless otherwise specified, two change keys shall be provided for each lock. Locks shall be furnished with the manufacturer's standard construction key system.

2.2.5 Exit Device

Latches (latch bolts) shall release by depressing the actuation bar using a force of not more than 67 N applied perpendicular to the door in the

SECTION 08 39 54 Page 11 swing direction. The exit device shall conform to the finish test values specified in ANSI/BHMA A156.3 and shall be of plain design with straight, beveled, or smoothly rounded sides, corners, and edges. A touch bar may be provided in lieu of a conventional actuation bar (cross bar). The function numbers for exit devices shall be as defined in ANSI/BHMA A156.3 .

2.2.6 Door Stop

Door stops shall be designed to resist the impact of the door. The stop shall not scratch or scar the door finish when the door is opened against the stop.

2.2.7 Surface Door Closer

The surface door closer shall conform to ANSI/BHMA A156.4 . The size and grade shall be selected by the door manufacturer.

2.2.8 Overhead Door Holder

Overhead door holder shall be surface mounted. The holder shall have a spring or other device to cushion the door action and shall limit the door swing at 110 degrees. The holder shall have a built-in, hold-open capability at the swing limit specified. Overhead door holders for hollow metal doors weighing less than 90 kg shall conform to ANSI/BHMA A156.8 .

2.2.9 Gasket Seal

Sealed doors shall have the full door perimeter and all door penetrations sealed. Perimeter seals shall be the rubber gasket type. Gaskets shall be removable, capable of sealing the mating surfaces, and resistant to the atmospheric environment. One spare set of gasket seals shall be provided for each door assembly for which gasket seals are specified.

2.2.10 Door Silencer

Rubber door silencers shall cushion the impact of the door against the frame so that steel-to-steel contact is not made during closing.

2.3 ACCESSORIES

2.3.1 Subframe

At the Contractor's option, a subframe can be provided and built into the structure prior to installation of the frame. The subframe and subframe anchors shall be capable of transferring blast and rebound reactions to the adjacent structure, and the frame shall be capable of transferring these reactions to the subframe. The subframe shall be fabricated in the same manner specified for the frame.

2.3.2 Nameplate

Each door assembly shall have a permanently affixed nameplate that displays the manufacturer's name, place and year of manufacture, and the applicable peak overpressure, impulse, and rebound rating.

2.3.3 Removable Threshold

The sill shall be flush with the adjacent floor when the threshold is removed. The removable threshold shall be attached using approved

SECTION 08 39 54 Page 12 countersunk mechanical fasteners.

2.4 FABRICATION

2.4.1 Shop Assembly

Welding shall be in accordance with AWS D1.1/D1.1M except that arc welding of steel sheet and strip shall be in accordance with AWS D1.3/D1.3M and welding of concrete reinforcing bars shall be in accordance with AWS D1.4/D1.4M . Structural steel doors shall be of welded construction.

Fabricated steel shall be well-formed to shape and size, with sharp lines and angles. Intermediate and corner joints shall be coped or mitered.

Exposed welds shall be dressed smooth. The stiles and top of built-up structural steel doors shall be closed using channel shapes or plates.

When feasible, faceplates for structural steel doors shall be one piece.

When one-piece faceplates are not feasible, plates shall be joined using full penetration groove weld butt joints or other approved welds.

Hollow metal door frames shall be pressed steel or structural steel with welded joints. Steel frames or subframes installed in masonry walls shall be provided with adjustable anchors. Hollow metal doors shall be of unitized grid construction with welded grid junctions and shall have flat, one-piece face sheets spot welded to each face of the grid system. The edges of hollow metal doors shall be closed with seams continuously welded. Hollow metal doors shall be neat in appearance, free from warpage and buckle, and suitable reinforcing shall be provided for hardware.

2.4.2 Mullion

Mullions for double doors shall be fabricated in the same manner specified for frames. Removable mullions shall be attached to the frame with mechanical fasteners that are accessible for mullion removal or, in lieu of the removable mullion, an astragal shall be provided at the seating face of the inactive door leaf. Doors shall seat directly against the mullion, and the mullion or astragal shall be capable of transferring the door reactions to the frame.

2.4.3 Thermal Insulation

The interior cells between the unitized grid shall be completely filled with thermal insulation material. The U value through the door (panel) shall not exceed 1.36 W per square meter per degree K. Submit certification or test report for thermal insulated doors listing the type of hardware used to achieve the rating; see paragraph SOUND RATING TEST below.

2.4.4 Shop Finishing

Shop priming of steel surfaces shall conform to Section 09 90 00 PAINTS AND COATINGS, except that surfaces that will be embedded in concrete need not be primed and hollow metal doors shall be either dipped in primer after welding is completed, or exposed surfaces shall be primed and interior surfaces coated with an approved rust inhibitor. Galvanizing of doors and frames shall conform to ASTM A123/A123M or other approved methods. Surfaces that will be embedded in concrete need not be galvanized and the interior of hollow metal doors may be treated with an approved rust inhibitor in lieu of galvanizing. Galvanizing of exposed portions of concrete anchors, non stainless steel fasteners, and hardware other than factory finished hardware shall conform to ASTM A153/A153M or other approved methods.

SECTION 08 39 54 Page 13

2.4.5 Clearance

The clearance between the seated steel surfaces of structural steel doors and frames shall not exceed 1.6 mm. The lateral clearance between flush mounted structural steel doors and frames shall not exceed 6 mm at the head and jambs and the clearance between the meeting edges of pairs of doors shall not exceed 13 mm. The lateral clearance between hollow metal doors and frames shall not exceed 3 mm at the head and jambs and the clearance between the meeting edges of pairs of doors shall not exceed 6 mm.

The clearance between the door bottom and threshold shall not exceed 19 mm.

2.5 BLAST DOOR ASSEMBLIES

2.5.1 Door ; Metal

2.5.1.1 Type

Type shall be hollow metal with fixedorremovablemullion, galvanized.

2.5.1.2 Overpressure

Peak Incident Overpressures and Peak Reflected Pressures in the seating direction shall be as follows:

ELEVATION INCIDENT PRESSURE REFLECTED PRESSURE LOAD DURATION

FACING PRESSURE IMPULSE PRESSURE IMPULSE

(kPa) (kPA-msec) (kPa) (kPA-msec) (msec)

Northwest -- -- 38 1414 96 Southwest 18 730 -- --- 96 Southeast 18 730 -- --- 96 Northeast 18 730 -- --- 96 Mini-Mart: Overpressure shall be 41.4 kPa (6.0 psi) in the seating direction

2.5.1.3 Rebound

Rebound resistance shall be 50 percent.

2.5.1.4 Hardware

Mortise Hinges shall be Type 1. Jamb latching points and multiple lever handles operated from the seating face with manual latch engagement and lever latch bolts shall be provided. Exit device with jamb latch points shall be provided. A surface closer overhead door holder, and gasket seals shell be provided.

2.5.1.5 Operating Forces

Maximum operating forces shall conform to NFPA 101. Maximum force to engage and release latches shall be 90.

2.5.1.6 Accessories

A removable threshold shall be provided.

SECTION 08 39 54 Page 14

2.6 TESTS, INSPECTIONS, AND VERIFICATIONS

Submit shop and field operating test reports that include values for opening and closing forces and times, forces required to operate latches, and a description of all operating tests performed.

2.6.1 Prototype Static Test

Static tests on prototype door assemblies shall demonstrate that the door will resist the blast overpressure. Static tests will be accepted only if the door and frame proposed are manufactured using the same materials, dimensions, and tolerances as those in the prototype static test and the static overpressure used in the test is at least two times the blast overpressure. Static test reports shall be supplemented with calculations that demonstrate rebound resistance when rebound is not tested.

2.6.2 Prototype Blast Test

Blast tests on the prototype door assembly shall demonstrate that the door will resist the overpressure waveform. Blast tests will be accepted only if the door and frame proposed are manufactured using the same materials, dimensions, and tolerances as those in the prototype blast tests. The rise time of the test waveform shall be zero or subject to approval. For overpressure with finite duration, the overpressure waveform used in the test shall exceed the overpressure waveform in both peak overpressure and impulse and the blast test report shall be supplemented with calculations that demonstrate the specified or indicated rebound resistance when the positive phase waveform duration in the test exceeds the positive phase duration specified or indicated. Submit certified test reports demonstrating blast resistance. Include in the test reports the name and location of the testing agency or laboratory, a description of the testing apparatus, the date of the tests, a description of the door specimen tested, descriptions of loadings, the value of measured peak door deflection and peak permanent set and analysis and interpretation of test results.

2.6.3 Shop Operating Test

Prior to shipment, each door assembly shall be fully erected in a supporting structure and tested for proper operation. Such testing shall include opening, closing, and operating all moving parts to ensure smooth operation and proper clearance, fit, and seating. Determine the operating forces and opening and closing times. Prepare a test report and furnish three copies within 7 calendar days after testing.

2.6.4 Air Leakage Test

Factory test each door assembly for which door sealsorthermal insulation are specified for air leakage rate in accordance with ASTM E283. The rate of air leakage per unit length of crack shall not exceed 0.90 using a pressure difference of 76.7. Prototype tests can be substituted for door assembly tests when the prototype door, frame, and hardware tested are equivalent to that provided or when otherwise approved.

2.6.5 Sound Rating Test

The sound transmission class (STC) rating shall be determined in accordance with ASTM E90.

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2.6.6 Fire Rating Test and Inspection

Fire-rated door assemblies shall bear the listing identification label of the UL, or other nationally recognized testing laboratory qualified to perform tests of fire door assemblies in accordance with NFPA 252 and having a listing for the tested assemblies. Doors exceeding the size for which listing label service is offered shall be inspected in accordance with NFPA 80 , NFPA 80A, and NFPA 101 . A letter may be submitted by the testing laboratory (in lieu of a UL listing for fire door assemblies) which identifies the submitted product by manufacturer and type or model and certifies that it has tested a sample assembly and issued a current listing. Submit certificate of inspection conforming to NFPA 80 , NFPA 80A, and NFPA 101 for fire doors exceeding the size for which label service is available.

PART 3 EXECUTION

3.1 INSTALLATION

Install doors and frames in accordance with the manufacturer's written instructions. Pressed steel frames for hollow metal doors shall be fully grouted. Finish paint exposed surfaces in accordance with Section 09 90 00 PAINTS AND COATINGS. Repair galvanized surfaces damaged prior to final acceptance in accordance with ASTM A780/A780M to the same thickness as the original galvanizing.

3.2 TESTS

After installation is completed, field test each door for operation, clearance, fit, and seating by operating the door and hardware through at least 10 operating cycles. Test door and hardware operation using the forces specified. Provide personnel and equipment required to perform field testing. Unless waived, perform all field tests in the presence of the Contracting Officer. After testing is completed, prepare test reports and furnish three copies.

3.3 MANUFACTURER'S FIELD SERVICE

Perform installation and testing of door assemblies under the supervision of the door manufacturer's erection engineer. Upon completion of the work, and at a time designated by the Contracting Officer, provide the services of one engineer and other technical personnel, as required, for a period of not less than 4 hours to instruct Government personnel in the operation and maintenance of the blast doors and all other items furnished under this specification. Include in the instructions videotapes and use of the operation and maintenance manual. Submit an instruction outline and procedure for approval prior to scheduling the instruction and information describing training to be provided, training aids to be used, and background data on the personnel conducting the training.

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