SECTION 05500 METAL FABRICATIONS 00000000PART 1 - GENERAL 1.1 SECTION INCLUDES A.

Metal fabrications of iron and steel shapes, plates, bars, strips, tubes, pipes and castings as well as other metal systems as indicated on Drawings and as specified herein.

1.2

FABRICATION A. Shop fabricates metal fabrication units as far as practicable. Use materials of the required size and thickness to produce adequate strength and durability in the finished product for the intended use. Work to the dimensions shown or accepted on shop Drawings using proven details of fabrication and support. Use the type of materials shown or specified for the various components of work. Form exposed work true to line and level with accurate angles and surfaces and straight sharp edges. Ease exposed edges to a radius of approximately 1 mm.

B. C. 1.3

REFERENCES A. AAMA - American Architectural Manufacturer Association AMMA 603.8 AMMA 605.2 AAMA 606.1 AAMA 607.1 B. Pigmented Organic Coating on Extruded Aluminum. High Performance Organic Coatings on Architectural Extrusions and Panels Color Anodic Finishes for Architectural Aluminum Clear Anodic Finishes for Architectural Aluminum

ANSI - American National Standards Institute: ANSI A 14.3 ANSI A 202 Safety requirements for Fixed ladders Metal Bar Grating Manual

C.

ASTM - American Society for Testing and Materials ASTM A 27 ASTM A 36 ASTM A 48 ASTM A 53 Steel Castings, Carbon, for General Application Structural Steel Gray Iron Castings Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless
05500-1 Metal Fabrications

ITCC in Riyadh Residential Complex J10-13300

ASTM A 123 ASTM A 153 ASTM A 307 ASTM A 325 ASTM A 500 ASTM A 501 ASTM A 653 ASTM B 209 ASTM B 221 D.

Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products Zinc Coating (Hot-Dip) on Iron and Steel Hardware Carbon Steel Externally Threaded Standard Fasteners High Strength Bolts for Structural Steel Joints Cold-Formed Welded and Seamless Structural Tubing in Rounds and Shapes Hot-Formed Welded Structural Tubing and Seamless Carbon Carbon Steel Steel

Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy Coated (Galvannealed) by Hot-Dip Process. Aluminum and Aluminum-Alloy Sheet and Plate Aluminum-Alloy Extruded Bars, Rods, Wire, Shapes and Tubes

AWS - American Welding Society AWS-B3.0 AWS-D1.1 Welding Procedure and Performance Qualification Structural Welding Code-Steel

E.

SSPC - Steel Structures Painting Council SP-10 PS-12.00 Near-White Blast Cleaning Guide for Selecting Zinc-Rich Painting Systems

F.

SASO Saudi Arabian Standards Organization SASO 79 Aluminum and aluminum alloys products for architectural application Part 1: Sheets, strips, bars and structural Sections. Testing methods for aluminum and aluminum alloys products for building purposes Part 1: Sheets, strips, bars and structural Sections. Mechanical Testing of Welded Joints Test Methods of Welded Plain End Steel Tubes and Pipes for General Use Welded Plain End Steel Tubes and Pipes for General Use. Zinc coating on hot-dipped galvanized steel pipes.
05500-2 Metal Fabrications

SASO 80

SASO 39 SASO 1012 SASO 1013 SASO 1415

ITCC in Riyadh Residential Complex J10-13300

SASO 1416 1.4 SUBMITTALS A. B.

Testing methods of zinc coating on hot-dipped galvanized steel pipes

Product Data: Submit Manufacturer's product information, specifications and installation instructions for the miscellaneous metal fabrications. Shop Drawings: Submit complete shop drawings, including details of fabrication, assembly and erection of each metal fabrication indicated. Include plans, elevations, sections, and details of metal fabrications and connections. Show anchorage and accessory items. Samples: Submit samples of representative materials, finishes and finished products as required by the Engineer. Samples shall be full size, taken from Manufacturer's stock and complete as required for installation.

C.

1.5

TRANSPORTATION, HANDLING AND STORAGE A. Crate and pack material as required to prevent damage, corrosion and other forms of deterioration. Stack material out of mud and dirt and provide for proper drainage. Exercise care to avoid abrasions and other damage to finish coating. Protect from damage or soiling by adjacent construction operations. Keep material off ground by using pallets, platforms, or other supports. Protect material against corrosion and deterioration.

1.6

QUALITY ASSURANCE A. Field Measurements: Take field measurements prior to preparation of shop drawings and fabrication, to ensure proper fitting of the work. Coordinate fabrication schedule with construction progress to avoid delay of work. Shop Assembly: Preassemble items in the shop to greatest extent possible, so as to minimize field splicing and assembly of units at site. Fabricator's Qualifications: A firm having a minimum of 5 years successful experience in producing metal fabrications similar to that required for this Project. The fabricator shall be subject to approval of the Engineer. Installer's Qualifications: A firm having a minimum of 5 years successful experience in the installation of metal fabrications similar to that required for this project, and that has been licensed by the Manufacturer of the metal fabrications. The installer shall be subject to approval of the Engineer. Welding Work: Comply with the requirements of American Welding Society (AWS) - Standard Code for Arc and Gas Welding in Building Construction as well as AWS D1.1 - Structural Welding Code for welding procedures. Welders shall be subject to approval of the Engineer.

B. C.

D.

E.

00PART 2 PRODUCTS 2.1. MANUFACTURERS

ITCC in Riyadh Residential Complex J10-13300

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Metal Fabrications

A. 2.2.

Steelworks in building elevations shall be fabricated/ manufacturer by GAGE or approved equal.

MATERIALS A. General: Material shall conform to the requirements specified for the particular item(s), and where these requirements are not specified in detail, the material shall be suitable for the intended use, and as approved by the Engineer. Metal Surfaces: For fabrication of miscellaneous metal work which shall be exposed to view, materials shall be smooth and free of surface blemishes such as pittings, seam marks, roller marks, rolled trade names, and roughness. Structural steel shapes, plates and bars: Conform to ASTM A 36 or A 529. Steel Plates to be Bent or Cold-Formed: Conform to ASTM A 283, Grade C. Steel Bars for Grating: Conform to ASTM A 569 or ASTM A 36. Cold-Formed Steel Tubing: Conform to the requirements of ASTM A 500, Grade B. Hot-Formed Steel Tubing: Conform to the requirements of ASTM A 501. Steel Pipe: Conform to the requirements of ASTM A 53, Type E or S, Grade B; or ASTM A 501. Members Fabricated by Cold Forming: Conform to requirements of ASTM A 607, Grade 50. Galvanized Cold-Formed Members: Conform to requirements of ASTM A 123, galvanized to Designation G-90. Steel Casting: Conform to requirements of ASTM A 27, Grade 65-35, mediumstrength carbon steel. Gray Iron Castings: Conform to ASTM A 48, Class 30. Malleable Iron Castings: Conform to ASTM A 47. Cold-Rolled Carbon Steel Sheets: Conform to ASTM A 366. Galvanized Steel Sheet: Conform to the requirements of ASTM A 653 Grade C, galvanized, Designation G-90. Bolts for Structural framing: High strength bolts shall be heavy duty hexagonal structural bolts with heavy duty hexagonal nuts conforming to ASTM A 307, A 325 or A 490 as necessary for design loads and connection details. Concrete Inserts: Threaded or wedge type, galvanized ferrous castings, either malleable iron, ASTM A 47, or cast steel, ASTM A 27. Bolts, washers and shims shall be hot-dip galvanized, ASTM A 153. Anchor Bolts: Conform to ASTM A 307.

B.

C. D. E. F. G. H. I. J. K. L. M. N. O. P.

Q.

R.

ITCC in Riyadh Residential Complex J10-13300

05500-4

Metal Fabrications

S. T. U.

Structural Steel Primer Paint: SSPC-Paint 2, red lead iron oxide, oil alkyd. Finish Paint: Refer to Section 09900 - PAINTING. Non-Shrink Nonmetallic Grout: Premixed, non-corrosive, non-staining, nongaseous grout conforming to ASTM C 1107 with hydraulic cement and natural aggregate, requiring only the addition of water to produce flowable grout material having no drying shrinkage or settlement at any age. Compressive strength (50 mm cube) shall not be less than 34 MPa at 28 days when tested in accordance with ASTM C 109. Aluminum Extruded Bars, Rods, Shapes and Tubes: Conform to ASTM B 221, 6063-T6; aluminum sheets and plates to ASTM B 209, alloy 5052-H32; structural pipes and tubes (extruded) to ASTM B 429. Stainless Steel: 1. 2. 3. Bar stock: Conform to ASTM A 276, Type 304. Plates and Sheets: Conform to ASTM A 666, Type 304. Pipes: Conform to ASTM A 312, Type 304.

V.

W.

X.

Copper Alloys, Brass: 1. 2. 3. 4. Extruded Shapes: ASTM B 249, alloy UNS No. C36000 (free-cutting brass). Seamless Tube: ASTM B 135, alloy UNS No. C26000 (cartridge brass, 70 percent copper). Sand Castings: ASTM B 584, alloy UNS No. C85200 (high copper yellow brass). Plates and Bars: ASTM B 36, alloy UNS No. C26000 (cartridge brass, 70 percent copper).

Y.

Copper Alloys, Bronze: 1. 2. 3. 4. 5. 6. Extruded Shapes: ASTM B 455, alloy UNS No. C38500 (architectural bronze). Seamless Pipe: percent copper). ASTM B 43, alloy UNS No. C23000 (red brass, 85

Seamless Tube: ASTM B 135, alloy UNS No. C23000 (red brass, 85 percent copper). Composition Bronze castings: ASTM B 62, alloy UNS No. C83600 (85-55-5 or No.1 composition commercial red brass). Sand Castings: ASTM B 584, alloy UNS No. C86500 (No. 1 manganese bronze). Plates and Bars: ASTM B 36, alloy UNS No. C28000 (Muntz metal, 60
05500-5 Metal Fabrications

ITCC in Riyadh Residential Complex J10-13300

percent copper). Z. Fasteners: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. General: Provide zinc-coated fasteners for exterior use or where built into exterior walls. Select the fasteners for the type, grade and class required. Bolts and Nuts: Regular hexagonal head type, conforming to ASTM A 307, Grade A. Lag Bolts: Squared head type. Machine Screws: Cadmium plated steel. Wood Screws: Flat head carbon steel. Plain Washers: Round carbon steel. Masonry Anchorage Devices: Expansion shields. Toggle Bolts: Tumble-wing type. Lock Washers: Helical spring type carbon steel. Expansion Anchors: Anchor bolt and sleeve assembly of Alloy Group 1 or 2 stainless-steel bolts complying with ASTM F 593 and nuts complying with ASTM F 594 with capability to sustain, without failure, a load equal to six times the load imposed when installed in unit masonry and equal to four times the load imposed when installed in concrete, as determined by testing per ASTM E 488, conducted by a qualified independent testing agency Power Actuated Fasteners: a. b. Provide fasteners of special spring steel alloy conforming to ASTM A 227, Class 1 with a hardness of 52 - 56 Rockwell C, zinc-plated. Drive pin or threaded stud types as required.

11.

2.3.

FABRICATED ITEMS A. General: Use materials of size and thickness indicated on Drawings. Where not indicated, use sizes and thickness required to achieve strength and durability in finished product. Work to the dimensions indicated or approved on shop drawings, using proven details of fabrication and support. Fabrication shall be done in shop to fullest extent as possible with only assembly and installation works to be done on site. Form exposed work to the lines and levels with accurate angles and surfaces and straight sharp edges. Form the bent-metal corners to the smallest radius possible without causing grain separation or otherwise impairing work.
05500-6 Metal Fabrications

B.

ITCC in Riyadh Residential Complex J10-13300

C.

Railings and Handrails: Fabricate railings and handrails assemblies which when installed shall be capable of withstanding a concentrated load of 0.9 kN (200 lbf) applied at any point in any direction, and uniform load of 0.73 kN/m (50 lbf/ft) applied simultaneously in both vertical and horizontal directions. 1. Aluminum Handrail and Railing: Manufacturer standard system conforming to the following requirements: a. b. c. Extruded pipes: Alloy and temper for extrusions shall be 6063-T6 conforming to ASTM B 429. Size and shape: As indicated on the Drawings. For wall-mounted handrails provide same railing with manufacturer standard aluminum castings and fixing hardware as required for wall mounting. Fasteners: Aluminum, non-magnetic stainless steel, or other materials warranted by the manufacturer to be non-corrosive and compatible with aluminum components. Finish: Anodized, conforming to AA C22A42, minimum thickness 22 micron and color as approved by the Engineer. Shop-apply protective coating of clear acrylic lacquer or any coating in accordance with AAMA 602.2, not less than 0.5 mil dry film thickness, over anodized finish.

d.

e.

2.

Stainless Steel Handrail and Glass Railing: a. Construction: Manufacturer's standard stainless steel handrail conforming to the following: 1) 2) 3) 4) b. c. Tubing: ASTM A 554, grade MT 304. Pipe: ASTM A 312, grade TP 304. Castings: ASTM 743, grade CF 8 or CF 20. Plate: ASTM A 167, type 304.

Size and Shape: As indicated on Drawings. For wall-mounted handrails provide same railing with manufacturer standard brass castings and fixing accessories as required for wall mounting. Finish of Handrail: As indicated on Drawings and in accordance with the following: 1) 2) Bright, Directional Polish: AISI No. 4 finish. Satin, Directional Polish: AISI No. 6 finish.

d.

e.
ITCC in Riyadh Residential Complex J10-13300

Glass Railing System:

05500-7 Metal Fabrications

1)

Construction: Glass railing panels shall be fitted into continuous shoe moldings along curb at base of railing and into handrail from top of railing. Mounting: Flush-mounted type. Glass for the Railing: Clear tempered glass conforming to safety requirements of ANSI Z97.1. Size and thickness of glass panels shall be as recommended by the manufacturer, unless indicated otherwise on Drawings. Glass shall also comply with requirement of Section 08800 - GLAZING. Shoe Molding: Extruded aluminum section, Alloy 6063-T52 and shall be suitable for bending, where required. Shoe molding shall be installed as indicated on Drawings.

2) 3)

4)

f.

Miscellaneous Materials: 1) Handrail Accessories: Provide elbows and bends as well as end caps for the handrail using same material and finish as that of the handrail specified herein. Fittings: Fittings shall be concealed and fabricated of wrought aluminum or bronze. Exposed fittings, when approved by the Engineer, shall have a finish similar to that of the adjacent components. Glazing Accessories: Setting Blocks: Provide resilient setting block supports, Ushaped, at the lower glass edge inside the shoe moldings to cushion the glass edge and maintain it centered along the shoe molding. Setting block supports shall be neoprene or PVC. Spacers Spacers: Provide concealed PVC spacers, 6 mm thick between the adjacent glass panels along the shoe moldings. 4) 5) Mechanical Fasteners: Stainless steel or cadmium-plated steel as recommended by the Manufacturer. Filler Cement: Hydraulic type, conforming to the requirements of ASTM C 595. Cement shall be factoryprepared with accelerator. Filler cement shall be used to fill the gaps between the glass panels and the shoe molding.

2)

3)

3.

Stainless Steel Handrail and Balustrade: Handrail shall be of stainless steel pipe conforming to ASTM A312, Grade TP304 with bright mirror polish finish. Base channel shall also be stainless steel Type 304 as per details shown on the drawings. Size and shape shall be as shown on the drawings. Steel Pipe Railing and Handrail: Shall be of galvanized steel pipe, cold
05500-8 Metal Fabrications

4.
ITCC in Riyadh Residential Complex J10-13300

formed, conforming to ASTM A500, with galvanized steel balusters of same quality, all having painted finish complying with the requirements of Division 9 - FINISHES, color as approved. Size and shape shall be as shown on the drawings. D. Wrought Iron Railing: Wrought iron conforming to ASTM A 47, grade as recommended by fabricator for type of use indicated. Design, shape and size shall be as shown on the Drawings or as approved by the Engineer. If required, submit various decorative designs for the Engineer's selection and approval. Painted in accordance with Section 09900 - PAINTING, color as shown on the drawings. 1. Handrail: a. Brass Handrail: Polish brass extrusions or sections conforming to ASTM B 249, alloy UNS No. C36000 (free-cutting brass) or ASTM B 135, alloy UNS No. C26000 (cartridge brass, 70 percent copper), shape and size as shown on drawings. Brass shall have lacquer coating. Wooden Handrail: Handrail shall be of solid wood, architectural grade, clear all heart, type as shown on drawings. Fabricate to size and shape as shown on the drawings. Clear lacquer finish in accordance with Section 09900 - PAINTING.

b.

E.

Fence Grilles: 1. Fabricate fence grilles using galvanized steel tubular sections and shapes conforming to ASTM A 36, hot-dip galvanized in accordance with ASTM A 123, coat designation G-90. Fasteners and accessories shall be zinc-coated and manufacturers standard products. Size and shapes shall be as shown drawings. Fence grilles shall have a painted finish in accordance with Section 09900 - PAINTING. Color shall be as selected by the Engineer. Contractor to provide shop drawings for Engineers review and approval prior to fabrication.

F.

Entry Gates: 1. Gates: Fabricate entry gates, vehicular and pedestrian, using galvanized steel, tubular sections and shapes conforming to ASTM A 36, hot-dip galvanized in accordance with ASTM A 123, coat designation G-90. Fasteners and accessories shall be zinc-coated and manufacturers standard products. Pedestrian gate shall be manually operated. Vehicular gates shall be electrically operated (sliding) or manually swinging Gate where shown on drawings. Contractor to provide shop drawings for Engineers review and approval prior to fabrication. Shapes and Size: As shown on Drawings. Fabrication: a. Fabricate gates in accordance with approved shop drawings. Submit various decorative designs for the Engineer's selection and approval.
05500-9 Metal Fabrications

2. 3.

ITCC in Riyadh Residential Complex J10-13300

b.

Hardware: Provide complete heavy duty masonry hinges, gate latches, wheels, guide rail, locking devices, decorative latch assembly, and control system as recommended by the manufacturer.

4.

Vehicular Sliding Gate Operators: a. Vehicular sliding gate operator shall be suitable for size and intended function of the gate. Operator shall have quick release knob for manual operation of gates during power failure. Equipment shall be able to support weight of gate. Installation: Gate operating system shall be installed by manufacturer's authorized workmen experienced in the trade. Installation of system shall conform to manufacturer's written instructions and approved drawings. Warranty: Gate operating system shall be warranted against defects for one year from the date of substantial handover.

b. c.

d. 5. G.

Finish: Gates shall have a painted finish in accordance with Section 09900 PAINTING. Color shall be as selected by the Engineer.

Decorative Wrought Iron Doors: 1. Doors shall be of decorative wrought iron conforming to ASTM A 47, grade as recommended by fabricator for type of use indicated. Design, shape and size shall be as shown on the Drawings or as approved by the Engineer. Doors shall provided with extruded monolithic polycarbonate sheets (LEXAN) backing, UV resistant, burglar resistance rated per UL 972 with average impact strength of 638 to 850 J/m of width when tested per ASTM D 256, Test Method A (Izod). Doors shall be painted in accordance with Section 09900 - PAINTING, color as shown on the drawings or as approved by the Engineer. Hardware: Refer to section 08710.

2.

H.

Access Steel Doors: 1. Fabricate access doors and frames of galvanized steel plates, bars and shapes conforming to ASTM A 36, hot-dip galvanized in accordance with ASTM A 123, code designation G-90. Submit shop drawings for review and approval by the Engineer. Provide manufacturers standard heavy duty door hardware. Dimensions and Configuration: As shown on Drawings. Finish: Baked enamel paint finish; color as selected by the Engineer.

2. 3. I.

Bollards:

ITCC in Riyadh Residential Complex J10-13300

05500-10

Metal Fabrications

1.

Construction: Fabricate bollards using standard weight 150 mm dia. galvanized steel pipes, Schedule 80, conforming to ASTM A53. a. b. Fill pipes with concrete as indicated on Drawings. Cap bollards with rounded concrete.

2. 3. J.

Fixation: Base plate and bollard fixation shall be as approved by the Engineer. Finish: Painted, for all exposed surfaces in accordance with Section 09900 - PAINTING.

Aluminum Cladding for External Faade 1. Aluminum cladding for external faade shall be preformed and prefinished composite cladding, not less than 4mm thickness complying with ASTM B 209 with polyethylene or non-combustible mineral filled core sandwiched between two skins of 0.5 mm thick aluminum sheets. Aluminum cladding shall be installed on manufacturers standard aluminum framing system with concealed stainless steel fasteners as per the manufacturer recommendations and the Engineer approval. Cladding panels shall be with butt joints as shown on drawings. Color shall be as approved by the Engineer. Sizes of panels and shape shall be as shown on the drawings. Submit shop drawings showing design, sizes and fixing details for Engineers approval. Finish: Aluminum cladding surfaces shall have the manufacturers standard three-coat, shop applied, high performance polyvinylidene fluoride (PVDF) coating based on Hylar 5000 resin formulated by a licensed manufacturer, 60-80 micron thick. Color as approved by the Engineer.

2.

K.

Steel shell Structure with metal panel covering (Elevations) 1. Metal Structure shall consist of 100 mm galvanized steel pipes structurally engineered and shall conforming to ASTM A 53, type E and Section 05120 Structural Steel. All attachments are mechanical with no field welding. Frames shall have powder-coated finish; minimum 80 micron thick; color as selected by the Engineer. Aluminum panel covering. Shall be 0.5mm otherwise indicated, conforming to ASTM B209, Grade 1. and fixed aluminum wire mesh shall have anodized finish conforming to AA C22A42; 22 micron thick with shop-applied protective coating of clear acrylic lacquer or any coating in accordance with AAMA 602.2, 0.5 mil dry film thickness, over anodized finish; color as approved by the Engineer. Sizes and configurations shall be as shown on drawings. Provide sheet metal accessories components required for a complete sheet metal shell assembly including trim, corner units, clips, flashings, sealants, gaskets, fillers, and similar items.

2.

3.

ITCC in Riyadh Residential Complex J10-13300

05500-11

Metal Fabrications

4.

Provide materials and types of fasteners, solder, welding rods, protective coatings, separators, sealants, and other miscellaneous items as required for a complete shell system and as recommended by fabricator.

L.

Aluminum Louvers: 1. Aluminum louvers will have the following characteristics: a. b. c. d. The frames and blades are 16 gauge aluminum alloy 6063-T6 conforming to ASTM B 221. The edges of front and back of the frame are folded to give additional strength. The blade elements are set at 45 with a 5-3/4 pitch and have raised tip to prevent the ingress of rain. Louvers will be fitted with a bird screen constructed from expanded steel sheet galvanized after manufacture having a free area of 85%. The overall casing depth is will not be less that 300mm. Louvers will be painted under electrostatic polyester powder coated system color approved by the engineer.

e. f.

2. Motorized, Extruded-Aluminum Louvers a. Louver Construction: Provide motorized-blade louvers with extruded-aluminum frames and blades. Motorized louvers shall be an adjustable weather tight louver to protect generator rooms in case of fire when take signal from fire alarm system FASP to be closed to keep FM 200 fire fighting system effective against fire. Motorized louvers shape, sizes and design shall be as indicated on Drawings as per approved manufacturer shop drawings, instructions and recommendations and as per the Engineer approval..

b.

M.

Aluminum Structure Canopy: Aluminum structure Canopy shall be constructed of structural aluminum sections, shapes, plates and bars conforming to ASTM B 221, 6063-T6, for aluminum extruded bars, rods, shapes and Tubes and conforming to ASTM B 209, alloy 5052-H32 for aluminum sheets and plates and conforming to ASTM B 429 for structural pipes and tubes (extruded). Size and shape shall be as shown on drawings. Fixing mechanical fasteners shall be stainless steel or cadmium-plated steel as recommended by the Manufacturer. Submit detailed design shop Drawings as per approved manufactured recommendations for the Engineer approval. 1. Aluminum shade structure finish shall be anodized finish conform to AA C22A42; 22 micron thick; with shop-applied protective coating of clear acrylic lacquer or any coating in accordance with AAMA 602.2, 0.5 mil dry film thickness, over. Color shall be as approved by the Engineer .

N.

Aluminum Composite Panel

05500-12 Metal Fabrications

ITCC in Riyadh Residential Complex J10-13300

1.

Composite aluminum cladding for faade, roof and internal areas shall be preformed and prefinished composite cladding, not less than 4mm thickness complying with ASTM B 209 with polyethylene or noncombustible mineral filled core sandwiched between two skins of 0.5 mm thick aluminum sheets. Aluminum cladding shall be installed on manufacturers standard aluminum framing system with concealed stainless steel fasteners as per the manufacturer recommendations and the Engineer approval. Sizes of panels and shape shall be as shown on the drawings. Submit shop drawings showing design, sizes and fixing details for Engineers approval. Aluminum cladding for roof areas shall have additional stiffeners to withstand the weight of cleaning personnel. Aluminum cladding shall be suitable for external and internal areas. Composite aluminum panels shall have natural anodic Finish: AAMA 611, AA-M12C22A41, Class I, 0.018 mm or thicker unless otherwise indicated on drawings.

2.

O.

Aluminum Shade Structure: 1. Aluminum shade structure shall be constructed of structural aluminum sections, shapes, plates and bars conforming to ASTM B 221, 6063-T6, for aluminum extruded bars, rods, shapes and Tubes and conforming to ASTM B 209, alloy 5052-H32 for aluminum sheets and plates and conforming to ASTM B 429 for structural pipes and tubes (extruded). Size and shape shall be as shown on drawings. Aluminum shade structure shall be constructed of aluminum structure covered with polycarbonate shade cover units of sizes and shapes as shown on drawings. Aluminum shade structure shall be supported on concrete structure as shown on drawings. Fixing mechanical fasteners shall be stainless steel or cadmium-plated steel as recommended by the Manufacturer. Submit detailed design shop Drawings as per approved manufactured recommendations for the Engineer approval. a. Aluminum shade structure finish shall be anodized finish conform to AA C22A42; 22 micron thick; with shop-applied protective coating of clear acrylic lacquer or any coating in accordance with AAMA 602.2, 0.5 mil dry film thickness, over. Color shall be as approved by the Engineer.

P.

Manhole Covers and Frame: Gray cast iron casting, heavy duty, complying with ASTM A 48 or BS 497; Appendix A. Size shall be as shown on Drawings. 1. Covers and frames a. A15; loading up to 15 kN, for use inside buildings and areas obstructed for vehicles. Sealed and locked for use at hazardous environments. Dimensions and details shall be as shown on the drawings. B125; loading up to 125 kN, for use in landscaped and pedestrian precincts, light car parks and drives. Clear opening shall be 600 mm square. cover shall be hinged and locked.

b.

ITCC in Riyadh Residential Complex J10-13300

05500-13

Metal Fabrications

c.

D400; loading up to 400 kN, for use in service roads and at aircraft dispersal areas (for PGN up to 35). Clear opening shall be 600 mm square. Cover shall be hinged and locked. F900; loading up to 900 kN, for use at aerodromes (for widebody aircraft). Clear opening shall be 600 mm square. Covers shall be hinged and locked.

d.

2.

Grates and frames a. D400; loading up to 400 kN, for use in service roads and (for PCN up to 35). Clear opening 600 mm square. Grates shall be hinged and locked.

3.

Ancillary Items a. Steps, access ladders, anchors, etc. shall be made of mild steel galvanized in accordance with BS 729 or equivalent ASTM or DIN standards, all in accordance with section 404. Rubber gaskets for sealing shall be in accordance with the requirements of ASTM C 443. Bituminous treatment material for all castings shall comply with ASTM D 1187.

b. c. Q.

Steel Gratings: Heavy duty, straight bars, cast iron channel gratings and sides conforming to ASTM A 48. Gutter shall be medium gauge galvanized steel. Sizes shall be as shown on drawings. Ladders: 1. Fabricate and install ladders for locations shown on Drawings with dimensions, shape, details and anchorages as shown on Drawings and approved by the Engineer. Aluminum Ladders: Extruded aluminum bars and shapes shall be ASTM B 221 with riveted aluminum rungs. Provide non-slip surface on top of each 18 mm dia. rungs spaced at 300 mm on centers. Provide continuous side railing where shown on Drawings. Stainless Steel Ladders: Stainless steel parts conforming to ASTM A 312,and ASTM A 666, including rungs, brackets, railings and fasteners. Rungs shall be 25 mm diameter solid structure steel bar spaced at 300 mm on centers. Provide continuous side railing where shown on Drawings. Provide non-slip surface on top of each rung as recommended by manufacturer approved by the Engineer.

R.

2.

3.

S.

Steel Ladders (Vertical) 1. Fabricate ladders for the location shown with dimensions, spacings, details and anchorages as indicated. Comply with requirements of ANSI A14.3 Fabricate steel ladders of 20 mm diameter, non-slip steel rungs spaced
05500-14 Metal Fabrications

2.
ITCC in Riyadh Residential Complex J10-13300

300 mm o.c. with 15 mm thick by 64 mm wide steel bar side rails with eased edges. Fit rungs in centerline of side rails, plug weld and grind smooth on outer rail faces. 3. 4. Support each ladder at top and bottom and at intermediate points spaced not more than 1525 mm o.c. by means of welded or bolted steel brackets. Size brackets to support design dead and live loads indicated and to hold centerline of ladder rungs clear of the wall surface by not less than 178 mm. Extend side rails 1067 mm above top rung and return rails to wall or structure unless other secure handholds are provided. If the adjacent structure does not extend above the top rung, gooseneck the extended rails back to the structure to provide secure ladder access. Provide 32 mm pipe goosenecks at parapets and copings. Hot-dip galvanize exterior ladders after fabrication.

5.

6. 7. T.

Steel Stairs: 1. 2. Provide manufacturer standard prefabricated steel stair including wire mesh raisers and steel plate treads with concrete cover. Stair components shall be fabricated using Galvanized Steel plates and wire mesh. Treads shall be modular type, 6mm thick galvanized steel tread. Upper face of steel threads shall be covered with R.C concrete slabs of broom finish top surface protected with epoxy hardener, edges protected with steel angle. Raisers shall be manufactured of heavy galvanized steel 50 x 50 mm wire mesh. Secure treads and raisers on 260 mm galvanized steel channel using manufacturer standard fixing devices. Assemble treads and raisers to form the shape indicated on Drawings. Accessories: Provide manufacturer standard attachments, fasteners and accessories. Finish: steel stair shall have a painted finish in accordance with Section 09900 - PAINTING. Color shall be as approved by the Engineer.

3.

Fabrication: Fabricate stair of stock components to permit site assembly and installation. Assembly fasteners shall be concealed unless otherwise approve by the Engineer.

U. V.

Access Panels: Provide access panels where required, of material, size and shape as shown on Drawings and approved by the Engineer. Crescent for Mosque: 1. Construction: A structural steel framing suitable for supporting the shape as well as achieving the design indicated on Drawings. Structural steel shall
05500-15 Metal Fabrications

ITCC in Riyadh Residential Complex J10-13300

have a bronze cladding forming the final shape of the crescent. 2. Steel Frame: Galvanized structural steel metal furring conforming to ASTM A 36 and ASTM A 529 with a galvanized finish in compliance with ASTM A 525 Designation G-90. Bronze Cladding: Provide CDA (Copper Development Association) copper alloy of type and form complying with the following requirements: a. b. Extruded Shapes: Conform to ASTM B 455, alloy UNS No. C38500 (architectural bronze). Plates and Bars: Alloy UNS No. C2800 (Muntz Metal), composed of 58 to 61 percent copper; maximum 0.35 percent lead; maximum 0.25 percent tin; maximum 0.15 percent iron; 0.10 percent maximum other elements; and remainder: zinc. Castings: Provide bronze castings, copper alloy UNS C83600 (alloy 836), complying with the requirements of ASTM B 584.

3.

c. 4.

Finish: Provide NAAMM-M31-06X finish (fine satin directional textured mechanical finish with clear a organic coating). Type of organic coating shall be as recommended by manufacturer and approved by the Engineer.

W.

Roof Hatch: 1. Manufacturer's standard single leaf roof hatch to fit the opening as indicated on Drawings, complete with curbs, anchorage system, gaskets, roof flashing and other accessories required for a complete installation. Door and curbs shall be of aluminum sheets (sandwich panel) with not less than 50 mm thick rigid polyurethane insulation. Roof hatch shall be provided with manufacturer's standard hardware including safety post.

2.

X.

Catwalk 1. 2. 3. 4. Suspension Members, Beams, Joists, Balusters, Railing and Framing: Structural Steel, ASTM A 36. Floor Grating: Steel bars for grating shall conform to ASTM A 569 or ASTM A 36. Rods for grating crossbars shall be ASTM A 510. Floor Plates: Galvanized steel checkered plates conforming to ASTM A446 Grade C with a minimum thickness of 6 mm. Grid Pipes: Steel shade structure shall be fabricated of hot-dipped seamless galvanized steel pipe, cold formed, conforming to ASTM A 500, size and shape as shown on drawings. Welding: Conform to requirements of ANSI/AWS-D1.1 continuous type welding. Finish for Catwalk: Galvanized exposed finish.
05500-16 Metal Fabrications

5. 6.
ITCC in Riyadh Residential Complex J10-13300

Y.

Building External Logo: 1. Design: Refer to Drawings for design guidelines. Submit manufacturerdetailed design, construction details including method of fixation and material samples for Architects review and approval prior to manufacturing. Size: As shown on Drawings. Frames and sheets shall be anodized aluminum extruded bars, rods, sheets and tubes and conforming to ASTM B 221, 6063-T6; aluminum sheets and plates to ASTM B 209, alloy 5052-H32; structural pipes and tubes (extruded) to ASTM B 429. Logo Construction: a. Brass-cladded construction in accordance with the following requirements: 1) 2) 3) 5. Extruded Shapes: ASTM B 249, alloy UNS No. C36000 (free-cutting brass). Seamless Tube: ASTM B 135, alloy UNS No. C26000 (cartridge brass, 70 percent copper). Plates and Bars: ASTM B 36, alloy UNS No. C26000 (cartridge brass, 70 percent copper).

2. 3.

4.

Finish: CDA M21 (Mechanical finish: buffed, smooth specular).

Z.

External Logo and Directional Identifier: 1. Design: Refer to Drawings for design guidelines. Submit manufacturerdetailed design, construction details including method of fixation and material samples for Architects review and approval prior to manufacturing. Size: As shown on Drawings. Structure shall be fabricated using powder coated aluminum panels, sheets and plates conforming to ASTM B 209, alloy 5052-H32; with stainless steels sheet and frames conforming to ASTM A 666, Type 304. Concrete base shall conform to Division 3 Concrete.

2. 3.

AA.

Loading Dock Nosing: Fabricate stair nosing of heavy duty cast iron to profile and details shown on Drawings. Casting shall be free of fins, burrs and slag. Finish shall be as selected by the Engineer from manufacturers full range. Steel Plate Trench Cover for Transformer Areas: Provide heavy duty checkered steel plate covers to ASTM A 36 or A 529. Thickness shall be suitable for intended application and as recommended by checkered plate manufacturer. Plate shall be galvanized to ASTM A 123 - Zinc (Hot-Dip Galvanized). Road Blocker:

BB.

CC.

ITCC in Riyadh Residential Complex J10-13300

05500-17

Metal Fabrications

1.

Alligator teeth barrier shall consist of heavy duty steel structure, heavy duty spring and high quality axle steel for hinges/axles as per manufacturers standards. Spikes shall be hardened steel. Size and color shall be as approved by the Engineer.

2.4.

FABRICATION A. Shop fabricate metal fabrication units as far as practicable. Use materials of the required size and thickness to produce adequate strength and durability in the finished product for the intended use. Work to the dimensions shown or accepted on shop Drawings using proven details of fabrication and support. Use the type of materials shown or specified for the various components of work. Form exposed work true to line and level with accurate angles and surfaces and straight sharp edges. Ease exposed edges to a radius of approximately 1 mm unless otherwise shown. Form bent-metal corners to the smallest radius possible without causing grain separation or otherwise impairing the work. Weld corners and seam continuously and in accordance with the recommendations of AWS. At exposed connections, grind exposed welds smooth and flush to match and blend with adjoining surfaces. Form exposed connections with hairline joints which are flush and smooth, using concealed fasteners wherever possible. Use exposed fasteners of the type shown or, if not shown, use Phillips flathead (countersunk) screws or bolts. Provide for anchorage of the type shown, coordinated with the supporting structure and the progress schedule. Fabricate and space anchoring devices to provide adequate support for the intended use of the work. Cut, reinforce, drill and tap metal fabrications indicated to receive finish hardware and similar items of work. 1. Exposed fastenings: Compatible materials, generally matching in color and finish, and shall harmonize with the material to which fastenings are applied. Provide the necessary rebates, lugs and brackets to assemble the work in a neat and substantial manner. Turn edges of flanged items to form plaster keys where plaster occurs. Drill and/or punch holes for bolts and screws. Conceal fastening where practical. Provide thickness of metal and details of assembly or supports to give ample strength and stiffness. Form joints exposed to weather in a way to exclude water. Where dissimilar metals are in contact, or where aluminum is in contact with concrete, mortar, masonry, wet or pressure-treated wood or absorptive materials subject to wetting, protect the surfaces with a coat of bituminous paint, unless otherwise specified, to prevent galvanic or corrosive action.

B. C. D. E.

F.

G.

H.

2.

3.

4.

ITCC in Riyadh Residential Complex J10-13300

05500-18

Metal Fabrications

I.

Galvanizing: Provide a zinc coating for those items shown on the Drawings and specified to be galvanized using the hot-dip process after fabrication in accordance with the following: 1. 2. 3. ASTM A 153 for galvanizing of iron and steel hardware. ASTM A 123 for galvanizing of rolled, pressed and forged steel shapes, plates, bars and strip, 3 mm thick and heavier. ASTM A 386 for galvanizing of assembled steel products.

J.

Shop Prime Painting: 1. Shop prime paint metal fabrications, except those members or portions of members to be embedded in concrete or masonry, surfaces and edges to be field welded and galvanized surfaces, unless otherwise indicated. Remove scale, rust and other deleterious materials before the shop coat of paint is applied. Clean off heavy rust and loose mill scale in accordance with SSPC SP-2 Hand Tool Cleaning, or SSPC SP-3 Power Tool Cleaning or SSPC SP-6 Commercial Blast Cleaning. Remove oil, grease and similar contaminants in accordance with SSPC SP-1 Solvent Cleaning. Immediately after surface preparation, brush or spray on primer in accordance with the paint manufacturer's instructions, at a rate to provide a uniform dry film thickness of 0.05 mm for each coat. Use painting methods resulting in full coverage of joints, corners, edges and all exposed surfaces. Apply one shop prime coat to fabricated metal items, except apply two coats of paint to surfaces not accessible after erection. Change color of second coat to distinguish it from the first.

2.

3.

4.

000PART 3 - EXECUTION 3.1 INSPECTION A. Examine the areas and conditions under which metal fabrication items are to be installed. Do not proceed with the work until unsatisfactory conditions have been corrected.

3.2

PREPARATION A. Coordinate setting Drawings, diagrams, templates, instructions and directions for installation of anchorage such as concrete inserts, anchor bolts and miscellaneous items having integral anchors which are to be embedded in concrete or masonry construction. Coordinate the delivery of such items to the affected trades for installation. Take field measurements prior to fabrication and delivery of metal fabrications to ensure proper fit of work. Apply bituminous mastic coating to concealed surfaces of metal fabrications
05500-19 Metal Fabrications

B. C.

ITCC in Riyadh Residential Complex J10-13300

where metal will be in contact with dissimilar material, set in concrete or masonry, and potentially damp conditions to prevent corrosion of metal. 3.3 INSTALLATION A. Install units to allow for expansion and contraction from a minimum ambient temperature range of 0 - 49 degree C without causing deformation of units and over-stress of welds and fasteners. Set metal fabrications accurately in locations, alignments and elevations shown, plumb, level, true and free of rack, measured from established lines and levels. Fastening to In-place Construction: Provide anchorage devices and fasteners where necessary for securing metal fabrication items to in-place construction including threaded fasteners for concrete and masonry inserts, toggle bolts, through-bolts, wood screws and other connectors as required. Provide temporary bracing or anchors in formwork for items which are to be built into concrete, masonry or similar construction. Cutting and Fitting: 1. 2. Perform cutting, drilling, welding and fitting required for the installation of the metal fabrications. Fit exposed connections accurately together to form tight hairline joints. Weld connections which are not to be left as exposed joints but cannot be shop welded because of shipping size limitations. Grind joints smooth and touch-up shop paint coats. Do not weld, cut or abrade exposed surfaces which cannot be completely restored in the field. Drill holes for bolts and screws. Conceal fasteners where possible. Mill exposed ends and edges smooth, with corners slightly rounded.

B. C.

D. E.

3. 4. F.

Field Welding: Conform to AWS Code for procedures of manual shielded metalarc welding, appearance and quality of welds made and methods used in correcting welding work. Soldering: Conform to the recommendations of AWS Welding Handbook, Volume 2, Chapter 12 - Soldering. Use only for filling or sealing joints and not for mechanical strength. Where exposed to view, soldered joints shall be finished to match adjoining finish metal and made as unnoticeable as practicable.

G.

3.4

INSTALLATION OF SPECIFIC METAL ITEMS A. Setting Loose Plates: 1. Clean concrete and masonry bearing surfaces of any bond-reducing materials, and roughen to improve bond to surfaces. Clean the bottom surface of bearing plates. Set loose leveling and bearing plates on wedges or other adjustable devices. After the bearing members have been positioned and plumbed,
05500-20 Metal Fabrications

2.
ITCC in Riyadh Residential Complex J10-13300

tighten the anchor bolts, do not remove wedges or shims, but if protruding, cut-off flush with the edge of the bearing plate before packing with grout. 3. 3.5 PAINTING A. Touch-up Painting: Immediately after erection, clean field welds, bolted connections and abraded areas in shop applied paint. Paint damaged areas with the same paint used for shop prime painting. Apply by brush or spray to provide a minimum dry film thickness conforming to that specified in Section 09900 Painting. Finish Painting: Painting of unfinished and prime coated metal fabrications required to be field painted shall conform to Section 09900 - PAINTING. END OF SECTION Pack grout solidly between bearing surfaces and plates to ensure that no voids remain.

B.

ITCC in Riyadh Residential Complex J10-13300

05500-21

Metal Fabrications