SECTION METAL FABRICATIONS

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1 SECTION METAL FABRICATIONS This performance guide specification is part of an architectural specification and is intended to provide a guideline for product selection and may not be appropriate for needs of specific projects. Use of this specification is voluntary and the user needs to edit the guide specification to fit the needs of a specific project, applicable laws and regulations, end user requirements and safety considerations. This performance guide specification provides no guarantee as to product performance, merchantability, or fitness for a particular purpose. Please read the full disclaimer here. PART 1 - GENERAL 1.1 SUMMARY A. General: Read this Section in conjunction with other related Sections. B. Prescriptive Work 1. Supply, deliver, install and warrant the work in strict compliance with the materials and workmanship requirements of the Architectural Specification. 2. Where required to prepare Shop Drawings, these shall be limited to final detailing of components, systems, etc. indicated on the Design Drawings, necessary to demonstrate their safe installation. 3. Where products are offered by the Contractor for acceptance by the Engineer, provide full supporting documentation in respect of the complete system or installation. C. Section Includes 1. Floor grillage/ platforms D. Related Work Sections and documentation 1. Section Shop Applied Coatings for Metal. 2. Section Metal Fastenings. 3. Section Joint Sealants. 4. Section Metal Railings. 5. Section Metal Stairs. 6. Section Glazing. 7. Structural Engineer's specification. 8. Estidama Pearl Rating System (PRS) - The Pearl Rating System for Estidama, 1

2 Building Rating System: Design and Construction document by Abu Dhabi Urban Planning Council (UPC). 9. Main Contractor Estidama PBRS and LEED CS Toolkit document. 10. LEED Green Building Rating System for Core and Shell Development, by U.S. Green Building Council, Inc. (USGBC). PART 2 - PRODUCTS 2.1 PRODUCT SELECTION A. General 1. Do not use products that bear names, logos or references on visible surfaces. B. Bridge Platform Assembly 1. Bridge platform assembly comprising glass panel platform supported by steel supports including all necessary brackets and fastenings to complete the installation. 2. Floor Assembly Components: Glass flooring units comprising triple laminated glass panels with slip resistant surface finish supported by steel angles, silicone pointed. 3. Framework: Fabricated steel angle brackets. 4. Finish: To be confirmed by the Engineer during the next project stage. 5. Size/ Configuration: As indicated on the Design Drawings. 6. Support: Structural steel framing and channels. Refer to the Structural Engineer's specification and drawings. 2.2 PERFORMANCE REQUIREMENTS A. Specific Movements 1. The work shall be fabricated and installed to withstand all movements of the building structure under all specified design loads or combination of loads without damage or any reduction in the performance of the work. 2. All fastenings shall be capable of providing adequate adjustment with the minimal use of packing shims, which shall be agreed with the Engineer. 3. All necessary movement joints shall accommodate the maximum movements that can be derived from the specified design loads and movements. Under maximum movements the joints shall meet the requirements of the Architectural Specification. 4. The work shall resist all specified static and dynamic loads likely to be encountered without causing permanent deformation of components or the failure of members or seals and shall transmit such loads safely to the points of support. 5. The work shall not deflect under loading in any way that is detrimental to any elements of the work or adjacent structural or building elements. 2

3 6. The work shall accommodate the following movements without any permanent deformation or reduction in the specified performance: a) Deflection under design loads. b) The effects of internal/ external wind and pressure loadings. c) Changes in dimension and shape of components arising from building movements, including settlement, creep, twisting and racking. d) Movement of any joint whether designed to permit movement or not. e) Thermal movements. B. Specific Live Loads 1. The work shall be capable of accommodating the following specified live loads without any reduction in performance: a) All loads resulting from movements of the building structure and support structure. b) A horizontal line load applied to the work, due to the occupants and vehicles, in accordance with the International Building Code (IBC) and Structural Engineer's requirements. c) Impact loads, or transferred impact loads, that occur during the service life of the work, without deterioration in performance and without sustaining nonrepairable damage. d) Loads imposed during replacement. C. Deflections 1. ***The maximum allowable deflection of any element of the work, when carrying full design loads, shall not exceed ***15mm or 1/ 175*** of their clear span in a direction normal to the plane of that element, whichever is the lesser value.*** 2. The work shall not deflect under loading in any way that is detrimental to any element of themselves or adjacent structural or building elements. 3. All components, couplings and fastenings shall be capable of accommodating all of the above deflection without permanent distortion, deformation or failure. 4. The work shall accommodate differential structural movements arising from any loads imposed by adjacent structures. 5. The magnitude of the allowable deflections shall be reduced if they are detrimental to any part of the work, their support structure or internal finishes. 3

4 D. Structural Integrity 1. The work indicated on the Shop Drawings and described in the Architectural Specification shall be in accordance with the conditions specified in the IBC, unless stated otherwise. 2. Construction of barriers shall be in accordance with the conditions specified in the IBC, unless stated otherwise. E. Specific Fire Performance Requirements 1. Refer to the Life Safety Drawings and the NFPA. 2. Surface Spread of Flame Classification: In accordance with UL 723 and ASTM E 84. F. ***Demountability*** 1. Elements of the work shall be individually and independently removable ensuring access for maintenance and/ or replacement of solid units in the event of breakage or damage. 2. The removal of units shall not affect the performance or safety of adjacent or any other part of the work. G. Thermal Movements: Allow for thermal movements from ambient and surface temperature changes acting on exterior metal fabrications by preventing buckling, opening of joints, overstressing of components, failure of connections, and other detrimental effects. 1. Temperature Change: ***67 C, ambient; 100 C***, material surfaces. H. Durability 1. The work shall retain its original appearance and performance throughout the life of the building without failure when maintained in accordance with an agreed maintenance program. Failure shall be defined as the occurrence of one or more of the following defects arising from deficiencies in design, material selection or workmanship. a) Collapse, damage or excessive deflection resulting from the application of specified loads. b) Distortion, displacement or other damage to a woven metal fabric that renders it unserviceable or unattractive. c) Atmospheric corrosion, stress corrosion, bi-metallic/ electro-chemical corrosion or other premature deterioration of a material. d) Degradation of protective coatings causing galvanised items to suffer corrosion 4

5 during their life and painted items to suffer coating breakdown in the period up to first maintenance. e) Component parts that may suffer damage under design safety loading shall permit easy replacement with the minimum amount of disturbance to the building users. I. Impact and Abrasion Resistance 1. The work shall resist abrasion from agreed cleaning methods and maintenance systems without any noticeable change in surface appearance. Generally, surfaces shall be sufficiently hard to resist all reasonable impacts from hand-held objects. 2. Impact tests shall be carried out to all work adjacent to pedestrian areas in accordance with the conditions specified in the IBC, unless stated otherwise. 3. The extent of any damage determined through testing shall be recorded and, where possible, quantified. Details shall be submitted to the Engineer. 4. Details of tests shall be provided to demonstrate the performance of materials and finishes in resisting abrasion from pedestrian traffic (hands, rings, luggage, cloth, shoes, etc.) and any other abrasion resulting from adjacent traffic movements. J. Glazing: Refer to Section Glazing. 2.3 MATERIALS A. Low Toxicity Materials: All building materials shall comply with the low toxicity material requirements as stated in PBRS Credit SM-1 within the UPC's Pearl Building Rating System: Design & Construction document. 1. To meet this PBRS Credit, all building materials must not contain materials or compounds with over 1% of constituent materials with the designated R-phrases listed in the UPC document. Submit confirmation that materials comply with the EU Risk Phrases (R-Phrases) Directive 67/ 548/ EEC. Annex III. B. General 1. Metal Surfaces, General: Provide materials with smooth, flat surfaces unless otherwise indicated. For metal fabrications exposed to view in the completed Work, provide materials without seam marks, roller marks, rolled trade names, or blemishes. C. Glazing: Refer to Section Glazing. D. Sealants: Refer to Section Joint Sealants. E. Ferrous Metals in accordance with the following. 5

6 1. Steel Plates, Shapes, and Bars: ASTM A 36/ A 36M. 2. Stainless-Steel Sheet, Strip, and Plate: ASTM A 240/ A 240M or ASTM A 666, Type 304/ Type 316L. 3. Stainless-Steel Bars and Shapes: ASTM A 276, Type 304/ Type 316L. 4. Stainless Steel Castings: ASTM A 743/ A 743M. 5. Steel Pipe: ASTM A 53/ A 53M, standard weight (Schedule 40) unless otherwise indicated. 6. Slotted Channel Framing: Cold-formed metal box channels (struts) complying with MFMA-4. F. Fasteners in accordance with the following. 1. General: Unless otherwise indicated, provide Type 304/ Type 316 stainless-steel fasteners for exterior use and zinc-plated fasteners with coating complying with ASTM B 633 or ASTM F 1941M, Class Fe/ Zn 5, at exterior walls. Select fasteners for type, grade, and class required. a) Provide stainless-steel fasteners for fastening stainless steel. b) Provide stainless-steel fasteners for fastening nickel silver. c) Provide bronze fasteners for fastening bronze. 2. Steel Bolts and Nuts: Regular hexagon-head bolts, ASTM F 568M, Property Class 4.6; with hex nuts, ASTM A 563M; and, where indicated, flat washers. 3. Steel Bolts and Nuts: Regular hexagon-head bolts, ASTM A 325M, Type 3; with hex nuts, ASTM A 563M, Class 8S3; and, where indicated, flat washers. 4. Stainless-Steel Bolts and Nuts: Regular hexagon-head annealed stainless-steel bolts, ASTM F 738M; with hex nuts, ASTM F 836M; and, where indicated, flat washers; Alloy ***Group A1/ Group A4***. 5. Anchor Bolts: ASTM F 1554, Grade 36, of dimensions indicated; with nuts, ASTM A 563; and, where indicated, flat washers. a) Hot-dip galvanize or provide mechanically deposited, zinc coating where item being fastened is indicated to be galvanized. 6. Eyebolts: ASTM A Machine Screws: ASME B18.6.7M. 8. Lag Screws: ASME B M. 9. Plain Washers: Round, ASME B18.22M. 6

7 10. Lock Washers: Helical, spring type, ASME B M. 11. Anchors, General: Anchors capable of sustaining, without failure, a load equal to six times the load imposed when installed in unit masonry and four times the load imposed when installed in concrete, as determined by testing according to ASTM E 488, conducted by a qualified independent testing agency. 12. Cast-in-Place Anchors in Concrete: Either threaded type or wedge type unless otherwise indicated; galvanized ferrous castings, either ASTM A 47/ A 47M malleable iron or ASTM A 27/ A 27M cast steel. Provide bolts, washers, and shims as needed, all hot-dip galvanized per ASTM F Post-Installed Anchors: ***Torque-controlled expansion anchors*** or ***chemical anchors***. a) Material for Interior Locations: Carbon-steel components zinc plated in accordance with ASTM B 633 or ASTM F 1941M, Class Fe/ Zn 5, unless otherwise indicated. b) Material for Exterior Locations and Where Stainless Steel is Indicated: Alloy ***Group A1/ Group A4*** stainless-steel bolts, ASTM F 738M, and nuts, ASTM F 836M. 14. Slotted-Channel Inserts: Cold-formed, hot-dip galvanized-steel box channels (struts) complying with MFMA-4, provide with temporary filler and tee-head bolts, complete with washers and nuts, all zinc-plated in accordance with ASTM B 633, Class Fe/ Zn 5, as needed for fastening to inserts. G. Miscellaneous Materials 1. Welding Rods and Bare Electrodes: Select according to AWS specifications for metal alloy welded. 2. Shop Primers: Provide primers that comply with ***Sections Painting***. ***Section High-Performance Coatings. *** ***Sections Painting and Section High-Performance Coatings. *** 3. Galvanizing Repair Paint: High-zinc-dust-content paint complying with SSPC-Paint 20 and compatible with paints specified to be used over it. 4. Bituminous Paint: Cold-applied asphalt emulsion complying with ASTM D Nonshrink, Metallic Grout: Factory-packaged, ferrous-aggregate grout complying with ASTM C 1107, specifically recommended by manufacturer for heavy-duty loading applications. 7

8 6. Nonshrink, Nonmetallic Grout: Factory-packaged, nonstaining, noncorrosive, nongaseous grout complying with ASTM C Provide grout specifically recommended by manufacturer for interior and exterior applications. 7. Concrete: Comply with requirements in Section Cast-in-Place Concrete for normal-weight, air-entrained, concrete with a minimum 28-day compressive strength of 20 MPa. H. All painting and coating shall comply with LEED CS-IEQ Credit 4.2 Low Emitting Materials - Paints and Coatings requirements given in the USGBC document. 2.4 FABRICATION, GENERAL A. General 1. Systems shall include fastenings, brackets, support framing and all other components/ accessories necessary to complete the work in accordance with the Architectural Specification and the design intent indicated on the Design Drawings 2. Shop Assembly: Preassemble items in the shop to greatest extent possible. Disassemble units only as necessary for shipping and handling limitations. Use connections that maintain structural value of joined pieces. Do not weld joints designed to be bolt fixed. Clearly mark units for reassembly and coordinated installation. 3. Cut, drill, and punch metals cleanly and accurately. Remove burrs and ease edges to a radius of approximately 1mm unless otherwise indicated. Remove sharp or rough areas on exposed surfaces. 4. Form bent-metal corners to smallest radius possible without causing grain separation or otherwise impairing work. 5. Form exposed work with accurate angles and surfaces and straight edges. 6. Welding/ Brazing General: a) Weld corners and seams continuously in accordance with the following: 1. Thoroughly clean surfaces to be joined. 2. Ensure accurate fit using clamps and jigs where practicable. Use tack welds only for temporary attachment. 3. Make joints with parent and filler metal fully bonded throughout with no inclusions, holes, porosity or cracks. 4. Prevent weld spatter falling on surfaces of materials that will be self-finished 8

9 and visible in completed work. 5. Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals. 6. Obtain fusion without undercut or overlap. 7. Remove welding flux immediately. 8. At exposed connections, finish exposed welds and surfaces smooth and blended so no roughness shows after finishing and contour of welded surface matches that of adjacent surface. 9. Metal arc welding shall be to AWS D1.1/ D1.1M, "Structural Welding Code - Steel" and AWS D1.2/ D1.2M, "Structural Welding Code - Aluminum.", or other methods subject to review by the Engineer. 10. Where site or shop welding is required, it shall be by the process known as manual inert gas tungsten-arc welding and it shall be carried out by a procedure qualified and certified to AWS D1.1/ D1.1M, "Structural Welding Code - Steel" and AWS D1.2/ D1.2M, "Structural Welding Code - Aluminum". 7. Form exposed connections with hairline joints, flush and smooth, using concealed fasteners or welds where possible. Where exposed fasteners are required, use Phillips flat-head (countersunk) fasteners unless otherwise indicated. Locate joints where least conspicuous. 8. Fabricate seams and other connections that will be exposed to weather in a manner to exclude water. Provide weep holes where water may accumulate. 9. Cut, reinforce, drill, and tap metal fabrications as indicated to receive finish hardware, screws, and similar items. 10. Provide for anchorage of type indicated; coordinate with supporting structure. Space anchoring devices to secure metal fabrications rigidly in place and to support indicated loads. 11. Wall mounting brackets shall be two part, with the connection plate fixed to either structural concrete walls, or concealed mild steel members with suitable countersunk fastenings prior to commencement of the following trades. 12. Infills shall be to profiles positioned horizontally at centers indicated on the Design Drawings, and in accordance with IBC requirements. Where necessary, rods shall be factory bent to suit balustrade layout. 13. Metals used in exposed work shall have smooth surfaces, free of blemishes 9

10 including pitting, seam marks, roller marks, waves, striations, tool and die marks. Profiles shall be true to angle or curvature as required with sharp edges and corners. 14. Fabricate metal items free of stress corrosion or cracking. 15. Select materials and methods of fabrication to achieve accuracy and fit. 16. Fabricate members and components straight, free of distortion and to the specified tolerances. Heat-treat components to relieve residual stresses. 17. Visible surfaces to be true to line and level, free from imperfection, with sharp angles and straight corners. 18. Incorporate dowels and spigots into joints to accurately align components. 19. Isolate dissimilar materials to prevent galvanic action. 20. Do not permit contact between dissimilar metals in components that are to be fixed where moisture may be present or occur. 21. Clearly mark items for proper assembly and installation, using methods that will not mar protective finishes. 22. Paint finished components shall have fully welded connections, unless otherwise accepted, to protect unprotected joint faces from corrosion. 23. ***The Detailed Design of sections, material thicknesses and the dimensions indicated on the Design Drawings shall be maintained within specified tolerances.*** 24. Before and after making permanent connections in frames and other structural elements, which are assembled before delivery to Site, the fit shall be checked for accuracy. 25. Unless otherwise specified, concealed items shall be mill finished aluminum in internal conditions only, or ***hot dip galvanized steel***. Any cut edges shall be treated to ensure that the level of protection is maintained. 26. Finished components shall be rigid and free from distortion, cracks, burrs and sharp arrises. Moving parts shall move freely and without binding. 27. Unless specified otherwise, miter corner junctions of identical sections. 28. Cold Formed Work: Use brake presses or cold rolling to produce accurate profiles with straight arrises. 29. Adhesive Bonding: a) Prepare surfaces of metals to receive adhesives by degreasing and abrading mechanically or chemically. 10

11 b) Use adhesives to the manufacturer's written recommendations. c) Form bond under pressure. 30. ***Lightning Protection and Earth Bonding:*** a) Bonding between the work and structural steelwork shall be carried out at intervals as indicated on the Design Drawings. The first level of bonding to the structural steelwork shall be at the highest floor level of each part of the building. b) All straps/ connections shall be concealed. 31. Fabrication Tolerances - Non-cumulative: a) Deviations in panel length, width and diagonal dimension tolerances shall not exceed ±1mm. b) Straightness: L/ 1000 or 2mm, whichever is the lesser. c) Squareness of Cut Profiles: Depth of profile/ d) Squareness of Fabricated Items: Maximum ***2***mm difference between diagonals. e) Flatness of Fabricated Items: Maximum ***2***mm difference between one corner and another. f) Plumbness: ± ***2 to 1***mm/ m. g) Level: ± ***1***mm/ m. h) The twist and warping shall not cause any point of the panel to be more than 0.5mm out of plane. The twist and warping shall not cause any point of the structural frame to be more than 2mm out of plane. B. Miscellaneous Framing and Supports 1. General: Provide steel framing and supports not specified in other Sections as needed to complete the Work. 2. Fabricate units from steel shapes, plates, and bars of welded construction unless otherwise indicated. Fabricate to sizes, shapes, and profiles indicated and as necessary to receive adjacent construction. a) Fabricate units from slotted channel framing where indicated. b) Furnish inserts for units installed after concrete is placed. C. Miscellaneous Steel Trim 1. Unless otherwise indicated, fabricate units from steel shapes, plates, and bars of profiles indicated with continuously welded joints and smooth exposed edges. Miter 11

12 corners and use concealed site splices where possible. 2. Provide cutouts, fittings, and anchorages as needed to coordinate assembly and installation with other work. a) Provide with integrally welded steel strap anchors for embedding in concrete or masonry construction. D. Steel Weld Plates and Angles 1. Provide steel weld plates and angles not specified in other Sections, for items supported from concrete construction as needed to complete the Work. Provide each unit with no fewer than two integrally welded steel strap anchors for embedding in concrete. 2.5 FINISHES, GENERAL A. General 1. Refer to Section Shop Applied Coatings for Metal. 2. Finish metal fabrications after assembly. 3. Finish exposed surfaces to remove tool and die marks and stretch lines, and to blend into surrounding surface. B. Steel and Iron Finishes 1. Galvanizing: Hot-dip galvanize items as indicated in accordance with ASTM A 153/ A 153M for steel and iron hardware and with ASTM A 123/ A 123M for other steel and iron products. a) Do not quench or apply post galvanizing treatments that might interfere with paint adhesion. 2. Shop prime iron and steel items not indicated to be galvanized unless they are to be embedded in concrete, sprayed-on fireproofing, or masonry, or unless otherwise indicated. a) Shop prime with primers specified in ***Section Exterior Painting/ Section Interior Painting/ Section High Performance Coatings.*** 3. Preparation for Shop Priming: Prepare surfaces in accordance with ***SSPC-SP 6/ NACE No. 3, "Commercial Blast Cleaning."/ SSPC-SP 3, "Power Tool Cleaning."/ requirements indicated below:*** a) Exterior Items: SSPC-SP 6/ NACE No. 3, "Commercial Blast Cleaning." b) Items Indicated to Receive Zinc-Rich Primer: SSPC-SP 6/ NACE No. 3, 12

13 "Commercial Blast Cleaning." c) Items Indicated to Receive Primers Specified in Section High-Performance Coatings: SSPC-SP 6/ NACE No. 3, "Commercial Blast Cleaning." d) Other Items: SSPC-SP 3, "Power Tool Cleaning." 4. Shop Priming: Apply shop primer in accordance with SSPC-PA 1, "Paint Application Specification No. 1: Shop, Site, and Maintenance Painting of Steel," for shop painting. a) Stripe paint corners, crevices, bolts, welds, and sharp edges. End of Section 13

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