U.S EMBASSY COMPOUND EMERGENCY … EMBASSY COMPOUND EMERGENCY SANCTUARY (CES) May 15 ... ACI 336.1-01, “Specifications for Construction of Drilled ... “Design and Construction

U.S EMBASSYCOMPOUND EMERGENCY

SANCTUARY (CES)

May 15 2017

DESIGN

Division 3 - Division 9

UNITED STATES DEPARTMENT OF STATE MARCH 2008 OVERSEAS BUILDINGS OPERATIONS OBO STANDARD SPECIFICATIONS

CAST-IN-PLACE CONCRETE SECTION 03300 - 1

SECTION 03300 - CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1 SUMMARY

A. This Section specifies cast-in-place concrete for all building types (including parking structures) and sitework. Work includes formwork, reinforcement, concrete materials, mixture design, placement procedures, and finishes.

B. Cast-in-place concrete includes the following:

1. Footings and Foundations. 2. Foundation walls. 3. Slabs-on-grade. 4. Suspended slabs. 5. Concrete toppings. 6. Building frame members. 7. Building walls. 8. Equipment pads and bases. 9. Site perimeter walls, concrete filled bollards, and site structures. 10. Topping slabs 11. Garage slab on grade

C. Related Sections:

1. Division 3 Section "Unbonded Post-Tensioned Concrete for Parking Structures" where Contractor selects the use of post-tensioned concrete for some of the structural components of parking structures.

2. Division 3 Section "Plant-Precast Structural Concrete for Parking Structures" where Contractor selects the use of precast concrete for some of the structural components of parking structures.

1.2 DEFINITIONS

A. Cementitious Materials: Portland cement alone or in combination with one of blended hydraulic cement, fly ash and other pozzolans, ground granulated blast-furnace slag, or silica fume; subject to compliance with requirements.

1.3 SUBMITTALS

A. General: Submit the following according to Conditions of the Contract and Division 1 Specification Sections.

B. Product Data: For each type of manufactured material and product indicated.



C. Design Mixtures: For each concrete mixture. Include alternate mixtures designs when characteristics of materials, project conditions, weather, test results, or other circumstances warrant adjustments.

1. Indicate amounts of mix water to be withheld for later addition at Project site.

D. Steel Reinforcement Shop Drawings: Placing drawings that detail fabrication, bending, and placement. Include bar sizes, lengths, material, grade, bar schedules, stirrup spacing, bent bar diagrams, bar arrangement, splices and laps, mechanical connections, tie spacing, hoop spacing, and supports for concrete reinforcement.

E. Formwork Shop Drawings: Prepared, signed and sealed by a professional engineer indicating fabrication and erection of forms of specific finished concrete surfaces. Show form construction including jointing, special form joints or reveals, location and pattern of form tie placement, and other items that affect exposed concrete visually. Show locations and detail construction joints for concrete work.

1. Shoring and Reshoring: Indicate proposed schedule and sequence of stripping formwork, shoring removal, and installing and removing reshoring.

2. Review is for general applications and features only. Designing formwork and shoring sequence for structural stability and efficiency is Contractor’s responsibility.

F. Welding Certificates: Copies of certificates for welding procedures and personnel.

G. Material Test Reports: For the following, from a qualified testing agency, indicating compliance with requirements:

1. Aggregates. [Include service record data indicating absence of deleterious expansion of concrete due to alkali aggregate reactivity].

H. Steel Reinforcement. [Include requirements of section 1903.5.1.2 of the OBO IBC Code Supplement when applicable].

I. Material Certificates: Signed by manufacturers certifying that each of the following items complies with requirements, including where applicable, compatibility with other subsequent materials and finishes:

1. Cementitious materials. 2. Admixtures. 3. Form materials and form-release agents. 4. Steel reinforcement and accessories. 5. Fiber reinforcement. 6. Waterstops. 7. Curing and sealing compounds. 8. Floor and slab treatments. 9. Bonding agents. 10. Adhesives. 11. Vapor retarders. 12. Semirigid joint filler.



13. Epoxy joint filler. 14. Joint-filler strips. 15. Repair materials.

J. Minutes of preinstallation conference.

1.4 QUALITY ASSURANCE

A. Installer Qualifications: An experienced installer who has completed concrete Work similar in material, design, and extent to that indicated for this Project and whose work has resulted in construction with a record of successful in-service performance.

B. Professional Engineer Qualifications: A professional engineer who is experienced in providing engineering services of the kind indicated. Engineering services are defined as those performed for formwork and shoring and reshoring installations that are similar to those indicated for this Project in material, design, and extent.

C. Manufacturer Qualifications: A firm experienced in manufacturing ready-mixed concrete products complying with ASTM C 94 requirements for production facilities and equipment.

D. Source Limitations: Obtain each type or class of cementitious material of the same brand from the same manufacturer's plant, each aggregate from one source, and each admixture from the same manufacturer.

E. Welding: Qualify procedures and personnel according to AWS D1.4, "Structural Welding Code--Reinforcing Steel."

F. Codes and Standards: Comply with provisions of the latest editions of the following codes, specifications, and standards, except where more stringent requirements are shown or specified.

1. American Concrete Institute (ACI) 301-99, “Specifications for Structural Concrete for Buildings.”

2. ACI 117-90, “Specification for Tolerances for Concrete Construction and Materials”.

3. ACI 211.1-91, “Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass Concrete.”

4. ACI 304R-00, “Guide for Measuring, Mixing, Transporting, and Placing Concrete.”

5. ACI 305R-99, “Hot Weather Concrete.”

6. ACI 306R-88, “Cold Weather Concrete.”

7. ACI 309R-96, “Guide for Consolidation of Concrete.”

8. ACI 318M-02, “Building Code Requirements for Reinforced Concrete.”



9. ACI 347-01, “Guide to Formwork for Concrete.”

10. Concrete Reinforcing Steel Institute (CRSI) “Manual of Standard Practice, 2001, 27th Edition”.

11. ACI 362.1R-99, “Guide for the Design of Durable Parking Structures”.

12. ACI 362.2R-00, “Guide for Structural Maintainance of Parking Structures”.

13. ACI 336.1-01, “Specifications for Construction of Drilled Piers”.

14. ACI 336.3R, “Design and Construction of Drilled Piers”.

G. Preinstallation Conference: Conduct conference at the Project site to comply with requirements of Division 1 Section “Project Meetings” and the following:

1. At least 35 days prior to submitting design mixes, conduct a meeting to review detailed requirements for preparing concrete design mixes and to determine procedures for satisfactory concrete operations. Review requirements for submittals, status of coordinating work, and availability of materials. Establish preliminary work progress schedule and procedures for materials inspection, testing, and certifications. Require representatives of each entity directly concerned with cast-in-place concrete to attend conference, including, but not limited to, the following:

a. Contractor’s superintendent. b. Agency responsible for concrete design mixes. c. Agency responsible for field quality control. d. Ready-mix concrete producer. e. Primary admixture manufacturers. f. Concrete subcontractor. g. Formwork subcontractor. h. Steel reinforcing installer subcontractor. i. Quality Control Manager. j. Contracting Officer’s Representative (COR).

H. Place concrete after the placement of all forms, reinforcement, inserts, sleeves, and other embedments have been inspected and approved by the Contractor’s superintendent and the Quality Control Manager and reviewed by the COR.

I. Place concrete only under the supervision of the Contractor’s superintendent and the Quality Control Manager.

J. The Contractor is responsible for the establishment of a quality control program to manage forming, reinforcement, production, delivery, placement, compaction, finishing, curing, protection and patching of all concrete. Comply with the requirements specified in Section 01401.



K. Provide the Quality Control Manager and the COR with access to the site or to the plant to facilitate inspection of the reinforcement. Submit a schedule, showing the beginning and the duration of the shop fabrication, in sufficient time to allow for the proper inspection.

L. Provide the Quality Control Manager and the COR, with access to the concrete plant to facilitate inspection of concrete. Notify the Quality Control Manager when production of concrete is to commence and the plant location in sufficient time to allow for the proper inspection.

M. Inspection and testing will be performed by the Quality Control Manager in accordance with the requirements of this Section and Section 01401, Contractor’s Quality Control.

N. Provide free access to the Work and cooperate with the appointed Quality Control Manager.

O. Tests of the proposed cement, aggregates and other concrete ingredients will be performed to ensure conformance with the specified requirements.

P. The Quality Control Manager will make the concrete compressive test specimens and perform all the tests specified in this Section and Section 01401.

Q. The Quality Control Manager shall be the only entity authorized to allow the addition of any water to a concrete mix after batching.

R. The Quality Control Manger shall have the authority to reject concrete prior to or during placement for reasons of non-compliance with the Contract Documents.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Store cement, aggregate, admixture, water, embedded items and reinforcing in a manner to prevent deterioration or intrusion of any foreign matter. Do not use damaged or deteriorated materials.

B. Deliver, store, and handle steel reinforcement to prevent bending and damage.

1. Avoid damaging coatings on steel reinforcement. 2. Repair damaged epoxy coatings on steel reinforcement according to

ASTM D 3963/D 3963M.

PART 2 - PRODUCTS

2.1 FORM MATERIALS

A. Forms for Exposed Finish Concrete: Plywood, metal-framed plywood faced, or other acceptable panel-type materials to provide continuous, straight, smooth, exposed surfaces. Furnish in largest practicable sizes to minimize number of joints or as shown on drawings.



B. Forms for Unexposed Finish Concrete: Plywood, lumber, metal, or another acceptable material. Provide lumber dressed on at least two edges and one side for tight fit.

C. Chamfer Strips: Wood, metal, PVC or rubber strips, 20 mm by 20 mm.

D. Form Release Agent: Provide commercially formulated form release agent with a maximum of 450 mg/l volatile organic compounds (VOCs) that will not bond with, stain, or adversely affect concrete surfaces and will not impair subsequent treatments of concrete surfaces.

E. Form Ties: Factory-fabricated, adjustable-length, removable or snap-off metal form ties designed to prevent form deflection and to prevent spalling of concrete upon removal. Provide units that will leave no metal closer than 40 mm to the plane of the exposed concrete surface.

1. Provide ties that, when removed, will leave holes not larger than 25 mm in diameter in the concrete surface.

2.2 STEEL REINFORCEMENT

A. Reinforcing Bars: ASTM A 615/A 615M, Grade 420 (Grade 60), deformed. Reinforcing as indicated on the structural drawings to comply with the special ductility requirements of ACI-318M, paragraph 21.2.5, parts (a) and (b).

B. Low-Alloy-Steel Reinforcing Bars: ASTM A 706/A 706M, deformed.

C. Reinforcing bars shall be manufactured by an OBO prequalified manufacturer. Refer to Tables at the end of this Section.

D. Epoxy-Coated Reinforcing Bars: ASTM A 775/A 775M.

E. Plain-Steel Wire: ASTM A 82, as drawn.

F. Deformed-Steel Wire: ASTM A 496.

G. Plain-Steel Welded Wire Reinforcement: ASTM A 185, fabricated from as-drawn steel wire into flat sheets.

H. Deformed-Steel Welded Wire Reinforcement: ASTM A 497, flat sheet.

2.3 REINFORCEMENT ACCESSORIES

A. Bar Supports: Bolsters, chairs, spacers, and other devices for spacing, supporting, and fastening reinforcing bars and welded wire reinforcement in place. Manufacture bar supports according to CRSI's "Manual of Standard Practice" from steel wire, plastic, or precast concrete or fiber-reinforced concrete of greater compressive strength than concrete, and as follows:

1. For concrete surfaces exposed to view where legs of wire bar supports contact forms, use CRSI Class 1 plastic-protected or CRSI Class 2 stainless-steel bar supports.



2. For slabs-on-grade, use supports with sand plates or horizontal runners where base material will not support chair legs.

3. For epoxy-coated reinforcement, use epoxy-coated or other dielectric-polymer-coated wire bar supports.

B. Joint Dowel Bars: Plain-Steel bars, ASTM A615M, Grade 420, cut bars true to length with ends square and free of burs.

C. Mechanical Splices and Connections: As indicated on Drawings.

2.4 CONCRETE MATERIALS

A. Portland Cement: ASTM C 150, Type Type [I] [II] [I/II] [III] [V], [gray] [white].[ Supplement with the following:]

1. Use one brand of cement throughout Project unless otherwise acceptable to Project Director.

B. Fly Ash: ASTM C 618, Class F.

C. Ground Granulated Blast-Furnace Slag (GGBF): ASTM C 989, Grade 100 or 120.

D. Silica Fume: ASTM C 1240.

E. Normal-Weight Aggregate: ASTM C 33, uniformly graded, and as follows: 1. Coarse aggregate size for concrete in walls, columns, beams, and structural slabs shall not

exceed 20 mm. 2. Coarse Aggregates:

a. General Use: 25 mm to 4.75 mm. b. Walls, Columns, Beams, and Structural Slabs: 20 mm to 4.75 mm. c. Tight Placement: 12.5 mm to 4.75 mm.

3. Fine Aggregates: Fineness modulus shall not be less than 2.3 nor more than 3.1. 4. Combined Aggregate Gradation: Well graded from coarsest to finest with not more than

18 percent and not less than 8 percent retained on an individual sieve, except that less than 8 percent may be retained on coarsest sieve, on the No. 50 (0.300 mm) sieve, and the No. 100 (0.150 mm) sieve.

5. Materials that contain particles that will discolor the surface shall not be used for any exposed concrete.

6. Provide aggregates from a single source for exposed concrete. 7. Do not use aggregates containing chloride ions in excess to the requirements of ACI for

concrete construction in corrosive environments.

F. Lightweight Aggregate: ASTM C 330.

1. Nominal Maximum Aggregate Size: 20 mm.



G. Water: Potable and complying with ASTM C 94.

2.5 ADMIXTURES

A. General: Admixtures certified by manufacturer to contain not more than 0.1 percent water-soluble chloride ions by mass of cementitious material and to be compatible with other admixtures and cementitious materials. Do not use admixtures containing calcium chloride. Accelerating admixtures shall not be used unless approved by the Quality Control Manager.

B. Air-Entraining Admixture: ASTM C 260, Type C.

C. Water-Reducing Admixture: ASTM C 494, Type A.

D. Retarding Admixture: ASTM C 494, Type B.

E. Accelerating (Non-Corrosive) Admixture: ASTM C 494, Type C.

F. Water-Reducing and Retarding Admixture: ASTM C 494, Type D.

G. Water-Reducing and Accelerating Admixture: ASTM C 494, Type E.

H. High Range, Water-Reducing Admixture (Superplasticizer): ASTM C 494, Type F.

I. High Range, Water-Reducing and Retarding Admixture: ASTM C 494, Type G.

J. Corrosion-Inhibiting Admixture: Commercially formulated, calcium nitrite, anodic inhibitor or mixed cathodic and anodic inhibitor; capable of forming a protective barrier and minimizing chloride reactions with steel reinforcement in concrete.

1. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, the following:

a. DCI or DCI-S; W. R. Grace & Co., Construction Products Div. b. Rheocrete CNI; Master Builders, Inc.

2.6 FIBER REINFORCEMENT

A. Synthetic Fiber: Fibrillated or monofilament polypropylene fibers engineered and designed for use in concrete, complying with ASTM C 1116, Type III, 12 to 25 mm long.

B. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, the following:

1. Fibrillated Fibers:

a. Fibrasol F; Axim Concrete Technologies. b. Fibermesh; Fibermesh, Div. of Synthetic Industries.



c. Forta; Forta Corporation. d. Grace Fibers; W. R. Grace & Co., Construction Products Div.

2. Monofilament Fibers:

a. Fibrasol IIP; Axim Concrete Technologies. b. Fiberstrand 100; Euclid Chemical Co. c. Fibermix Stealth; Fibermesh, Div. of Synthetic Industries. d. Forta Mono; Forta Corporation. e. Grace MicroFiber; W. R. Grace & Co., Construction Products Div.

2.7 WATERSTOPS

A. Flexible Rubber Waterstops: CE CRD-C 513, for embedding in concrete to prevent passage of fluids through joints. Factory fabricated corners, intersections, and directional changes.

1. Profile: Flat, dumbbell with center bulb. 2. Dimensions: 150 mm by 10 mm thick.

B. Flexible PVC Waterstops: CE CRD-C 572, for embedding in concrete to prevent passage of fluids through joints. Factory fabricated corners, intersections, and directional changes.

1. Profile: Flat, dumbbell with center bulb. 2. Dimensions: 150 mm by 10 mm thick.

C. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

1. Rubber Waterstops:

a. Greenstreak. b. Progress Unlimited Inc. c. Westec Barrier Technologies; Div. of Western Textile Products, Inc.

2. PVC Waterstops:

a. Greenstreak. b. Meadows: W. R. Meadows, Inc. c. Murphy: Paul Murphy Plastics Co. d. Progress Unlimited Inc. e. Vinylex Corporation. f. Sika Corporation.

D. Self-Expanding Strip Waterstops: Manufactured rectangular or trapezoidal strip, sodium bentonite or other hydrophylic material for adhesive bonding to concrete.

1. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, the following:



a. Volclay Waterstop-RX; Colloid Environmental Technologies Co. b. Conseal CS-231; Concrete Sealants Inc. c. Swellseal Joint; De Neef Construction Chemicals (U.S.) Inc. d. Superseal; Tremco Incorporated. e. Hydrotite; Greenstreak.

2.8 VAPOR RETARDERS

A. Vapor Retarder: Polyethylene sheet, ASTM D 4397, not less than 0.20 mm (8 mils) thick.

B. Granular Fill: Clean mixture of crushed stone or crushed or uncrushed gravel; ASTM D 448, Size 57, with 100 percent passing a 38-mm sieve and 0 to 5 percent passing a 2.36-mm (No. 8) sieve.

2.9 FLOOR AND SLAB TREATMENTS

A. Slip-Resistive Aggregate Finish: Factory-graded, packaged, rustproof, non-glazing, abrasive aggregate of fused aluminum-oxide granules or crushed emery with emery aggregate containing not less than 50 percent aluminum oxide and not less than 25 percent ferric oxide; unaffected by freezing, moisture, and cleaning materials.

B. Penetrating Liquid Floor Treatment (Liquid Densifer/Sealer): For warehouses and garages. Chemically reactive, waterborne solution of inorganic silicate or siliconate materials and proprietary components; odorless; colorless; that penetrates, hardens, and densifies concrete surfaces, increases abrasion resistance, and provides a low sheen surface that is easy to clean and reduces the problem of tire mark removal.

C. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, the following:

1. Penetrating Liquid Floor Treatment:

a. Chemisil Plus; ChemMasters. b. “Ashford Formula”, Curecrete Chemical Co. c. “Euco Diamond Hard”, The Euclid Chemical Co.

2.10 CURING MATERIALS

A. Evaporation Retarder: Waterborne, monomolecular film forming, manufactured for application to fresh concrete and exposed concrete slab surfaces for temporary protection from rapid moisture loss.

B. Absorptive Cover: AASHTO M 182, Class 2, burlap cloth made from jute or kenaf, weighing approximately 300 g/sq. m (9 oz./sq. yd.) dry.



C. Moisture-Retaining Cover: ASTM C 171, polyethylene film or white burlap-polyethylene sheet.

D. Water: Potable.

E. Clear, Solvent-Borne, Membrane-Forming Curing Compound: ASTM C 309, Type1, Class B.

F. Clear, Waterborne, Membrane-Forming Curing Compound: ASTM C 309, Type 1 Class B.

G. Clear, Solvent-Borne, Membrane-Forming Curing and Sealing Compound: ASTM C 1315, Type 1, Class A.

H. Clear, Waterborne, Membrane-Forming Curing and Sealing Compound: ASTM C 1315, Type 1, Class A.

I. Available Products: Subject to compliance with requirements, products that may be incorporated into the Work include, but are not limited to, the following:

1. Evaporation Retarder:

a. Spray-Film; ChemMasters. b. Sure Film (J-74); Dayton Superior. c. Confilm; Degussa Construction Chemicals. d. Eucobar; Euclid Chemical Co. e. E-Con; L&M Construction Chemicals, Inc.

2. Clear, Solvent-Borne, Membrane-Forming Curing Compound:

a. Spray-Cure Clear; ChemMasters. b. General Purpose Cure & Seal (J-20UV); Dayton Superior. c. MasterKure N-Seal-HS; Degussa Construction Chemicals d. Diamond Clear; Euclid Chemical Co. e. Dress & Seal 30; L&M Construction Chemicals, Inc.

3. Clear, Waterborne, Membrane-Forming Curing Compound:

a. Safe Cure Clear; ChemMasters. b. Day-Chem Rez Cure (J-11-W); Dayton Superior. c. Kure-N-Seal W; Degussa Construction Chemicals. d. Diamond Clear VOX; Euclid Chemical Co. e. Dress & Seal WB 30; L&M Construction Chemicals, Inc.

4. Clear, Solvent-Borne, Membrane-Forming Curing and Sealing Compound:

a. Spray-Cure & Seal 25; ChemMasters. b. Super Diamond Clear; Euclid Chemical Co. c. Lumiseal Plus; L&M Construction Chemicals, Inc. d.



5. Clear, Waterborne, Membrane-Forming Curing and Sealing Compound:

a. Polyseal WB; ChemMasters. b. Super Diamond Clear VOX; Euclid Chemical Co. c. Lumiseal WB Plus; L&M Construction Chemicals, Inc..

2.11 RELATED MATERIALS

A. Bonding Agent: ASTM C 1059, Type II, non-redispersible, acrylic emulsion or styrene butadiene.

B. Epoxy Bonding Adhesive: ASTM C 881, two-component epoxy resin, capable of humid curing and bonding to damp surfaces, of type, class, and grade to suit requirements.

C. Dovetail Anchor Slots: Hot-dip galvanized steel sheet, not less than 0.85 mm (22 gage) thick, with bent tab anchors. Temporarily fill or cover face opening of slots to prevent intrusion of concrete or debris.

D. Reglets: Fabricate reglets of not less than 0.55 mm (26 gage) thick galvanized steel sheet. Temporarily fill or cover face opening of reglet to prevent intrusion of concrete or debris.

E. Epoxy Joint Filler: For control and construction joints of slab-on-grade in warehouses, a two component, 100 percent solids, low-range tensile strength semi-rigid epoxy with a minimum shore D hardness 50 (ASTM D676) and elongation of 6 percent (ASTM D 2240). The epoxy joint filler shall be mixed and installed in strict accordance with the direction of manufacturer. The joint filler shall not be filled sooner than 90 days after slab placement.

F. Joint Sealant for Isolation Joint at Slab-on-Grade:

1. Eucolastic I (Urethane sealant): Use closed cell polyethylene backer rod.

2.12 REPAIR MATERIALS

A. Repair Underlayment: Cement-based, polymer-modified, self-leveling product that can be applied in thicknesses from 3 mm and that can be feathered at edges to match adjacent floor elevations.

1. Cement Binder: ASTM C 150, Portland cement or hydraulic or blended hydraulic cement as defined in ASTM C 219.

2. Primer: Product of underlayment manufacturer recommended for substrate, conditions, and application.

3. Aggregate: Well-graded, washed gravel, 3 to 6 mm or coarse sand as recommended by underlayment manufacturer.

4. Compressive Strength: Not less than 30 MPa at 28 days when tested according to ASTM C 109/C 109M.



B. Repair Topping: Traffic-bearing, cement-based, polymer-modified, self-leveling product that can be applied in thicknesses from 6 mm.

1. Cement Binder: ASTM C 150, Portland cement or hydraulic or blended hydraulic cement as defined in ASTM C 219.

2. Primer: Product of topping manufacturer recommended for substrate, conditions, and application.

3. Aggregate: Well-graded, washed gravel, 3 to 6 mm or coarse sand as recommended by topping manufacturer.

4. Compressive Strength: Not less than 40 MPa at 28 days when tested according to ASTM C 109/C 109M.

C. Epoxy Crack Injection Adhesive: ASTM C 881/C 881M, Type [I,] [IV,] [Grade 1,] [except for gel time,] [solvent free].

2.13 CONCRETE MIXES

A. Prepare design mixes for each type and strength of concrete determined by laboratory trial batch method as specified ACI 211.1, ACI 301 and ACI 318M. Use an independent testing agency acceptable to the Project Director for preparing and reporting proposed mix designs. Do not use the same testing agency for field quality control testing.

B. Submit written reports to the Project Director of each proposed mix prepared and sealed by a professional engineer for each class of concrete at least 15 days prior to start of Work. Do not begin concrete production until the Project Director has approved proposed mix designs.

C. Cementitious Materials: Limit percentage, by weight, of cementitious materials other than portland cement in concrete as follows:

1. Limit use of fly ash and ground granulated blast furnace (GGBF) slag to not exceed 20 percent of cementitious content by weight.

2. Limit use of silica fume to not exceed 10 percent of cementitious content by weight.

D. Design mixes to provide normal weight concrete with properties as indicated herein unless indicated otherwise on the Structural Drawings.

1. Civil/Site and Perimeter Walls. Proportion normal-weight concrete mix as follows:

a. Compressive Strength (28 Days): 25 MPa minimum. b. Maximum Slump: 125 mm2.

2. Slab-on-Grade and Footings. Proportion normal-weight concrete mix as follows:

a. Compressive Strength (28 Days): 25 MPa minimum. b. Maximum Slump: 125 mm3.

3. Suspended Slabs and Building Frame Members: Proportion normal-weight concrete mix as follows:



a. Maximum Slump: 125 mm. b. Maximum Slump for Concrete Containing High-Range, Water-Reducing

Admixture: 200 mm after admixture is added to concrete with 50 mm to 75 mm slump.

c. Compressive Strength (28 Days): 30 MPa minimum.

4. Slab on Grade for Garages. Proportion normal-weight concrete mix as follows

a. Compressive Strength (28 Days): 30 MPa minimum b. Air Entrainment of 5 to 6% c. Water/Cement Ratio of 0.45.

5. Garage Suspended Slabs and Building Frame Members. Proportion normal-weight concrete mix as follows

a. Compressive Strength (28 Days): 35 MPa minimum b. Air Entrainment of 5 to 6% c. Water/Cement Ratio of 0.45.

E. Water-Cementitious Materials Ratio: Provide concrete for following conditions with maximum water-cementitious materials (W/C) ratios as follows:

1. Unless noted otherwise: Maximum W/C = 0.50. 2. Maximum Water-Cementitious Materials Ratio: 0.45 for concrete subject moderate

sulfate exposure (per ACI 318M Table 4.3.1) or required to have low water permeability or subject to freezing and thawing while moist.

3. Maximum Water-Cementitious Materials Ratio: 0.40 for concrete subject to severe or very severe sulfate exposure (per ACI 318M Table 4.3.1) or for corrosion protection of steel reinforcement in concrete exposed to chlorides from deicing chemicals, salt, saltwater, brackish water, seawater, or spray from these sources.

F. Minimum Cementitious Content: For concrete subject sulfate exposure (per ACI 318M Table 4.3.1) including foundations protected with two layers of bituminous dampproofing:

1. Moderate Sulfate Exposure: 334 kg/m3 minimum cementitious content. 2. Severe Sulfate Exposure: 362 kg/m3 minimum cementitious content. 3. Very Severe Sulfate Exposure: 390 kg/m3 minimum cementitious content.

G. Limit water-soluble, chloride ion content in hardened concrete to 0.15 percent by weight of cement.

H. Synthetic Fiber: Uniformly disperse in concrete mix at manufacturer’s recommended rate, but not less than 0.90 kg/m3 (1.5 lb./cu. yd.).

I. Air Content: Use air-entraining admixtures in exterior exposed concrete unless otherwise indicated. Add air-entraining admixture at manufacturer’s prescribed rate to result in concrete at point of placement having total air content of 6 percent with a tolerance of plus or minus 1½ percent.



1. Do not air entrain concrete for trowel finished interior floors and suspended slabs. 2. Do not allow entrapped air content to exceed 3 percent. 3. Concrete exposed to sulfates shall be air-entrained.

J. Admixtures: Use admixtures according to manufacturers written instructions.

1. Use water-reducing admixture or high-range water-reducing admixture (superplasticizer) in concrete, as required, for placement and workability.

2. Use water-reducing and retarding admixtures when required by high temperatures, low humidity, or other adverse placement conditions.

3. Use high range water-reducing admixture in pumped concrete as required for pumpability and workability and concrete required to be watertight, and concrete with a water-cementitious materials ratio below 0.50.

4. Use corrosion-inhibiting admixture in concrete mixes where indicated. Corrosion inhibiting admixture is to be added at the Project site.

2.14 FABRICATING REINFORCEMENT

A. Fabricate steel reinforcement according to CRSI's "Manual of Standard Practice."

2.15 CONCRETE MIXING

A. Ready-Mixed Concrete: Measure, batch, mix, and deliver concrete according to ASTM C 94, and furnish batch ticket information.

1. When air temperature is between 30 deg C and 32 deg C, reduce mixing and delivery time from 90 minutes to 75 minutes, and when air temperature is above 32 deg C, reduce mixing and delivery time to 60 minutes.

PART 3 - EXECUTION

3.1 FORMWORK

A. Design, erect, shore, brace, and maintain formwork, according to ACI 301 and as shown on formwork shop drawings which have been reviewed by the Project Director, to support vertical, lateral, static, and dynamic loads, and construction loads that might be applied, until concrete structure can support such loads.

B. Construct formwork so concrete members and structures are of size, shape, alignment, elevation, and position indicated, within tolerance limits of ACI 117.

C. Limit concrete surface irregularities, designated by ACI 347R as abrupt or gradual, as follows:

1. Class A, 3 mm. 2. Class B, 6 mm; Parking Garages are Class B



3. Class C, 13 mm. 4. Class D, 25 mm.

D. Construct forms tight enough to prevent loss of concrete mortar.

E. Fabricate forms for easy removal without hammering or prying against concrete surfaces. Provide crush or wrecking plates where stripping may damage cast concrete surfaces. Provide top forms for inclined surfaces steeper than 1.5 horizontal to 1 vertical. Kerf wood inserts for forming keyways, reglets, recesses, and the like, for easy removal.

1. Do not use rust-stained steel form-facing material.

F. Set edge forms, bulkheads, and intermediate screed strips for slabs to achieve required elevations and slopes in finished concrete surfaces. Provide and secure units to support screed strips; use strike-off templates or compacting-type screeds.

G. Provide temporary openings for cleanouts and inspection ports where interior area of formwork is inaccessible. Close openings with panels tightly fitted to forms and securely braced to prevent loss of concrete mortar. Locate temporary openings in forms at inconspicuous locations.

H. Chamfer exterior corners and edges of permanently exposed concrete.

I. Form openings, chases, offsets, sinkages, keyways, reglets, blocking, screeds, and bulkheads required in the Work. Determine sizes and locations from trades providing such items.

J. Clean forms and adjacent surfaces to receive concrete. Remove chips, wood, sawdust, dirt, and other debris just before placing concrete.

K. Retighten forms and bracing before placing concrete, as required, to prevent mortar leaks and maintain proper alignment.

L. Coat contact surfaces of forms with form-release agent, according to manufacturer's written instructions, before placing reinforcement.

M. Camber forms for horizontal members with spans over 9 meters for 125% of the deflection due to the weight of the structure.

3.2 EMBEDDED ITEMS

A. Place and secure anchorage devices and other embedded items required for adjoining work that are attached to or supported by cast-in-place concrete. Use setting drawings, templates, diagrams, instructions, and directions furnished with items to be embedded.

1. Install anchor bolts, accurately located, to elevations required. 2. Install reglets to receive top edge of foundation sheet waterproofing and to receive

through-wall flashing in outer face of concrete frame at exterior walls, where flashing is shown at lintels, shelf angles, and other conditions.



3. Install dovetail anchor slots in concrete structures as indicated. 4. Install FE/BR window and door embeds. 5. Install blast resistant window embeds. 6. Install Corner guards on the parking garage columns.

3.3 REMOVING AND REUSING FORMS

A. General: Formwork, for sides of beams, walls, columns, and similar parts of the Work, that does not support weight of concrete may be removed after cumulatively curing at not less than 10 deg C for 24 hours after placing concrete provided concrete is hard enough to not be damaged by form-removal operations and provided curing and protection operations are maintained.

B. Leave formwork for beam soffits, joists, slabs, and other structural element, that supports weight of concrete in place until concrete has achieved the following:

1. At least 70 percent of 28-day design compressive strength, but not less than four days. 2. Determine compressive strength of in-place concrete by testing representative field- or

laboratory-cured test specimens according to ACI 301. 3. Remove forms only if shores have been arranged to permit removal of forms without

loosening or disturbing shores.

C. Clean and repair surfaces of forms to be reused in the Work. Split, frayed, delaminated, or otherwise damaged form-facing material will not be acceptable for exposed surfaces. Apply new form-release agent.

D. When forms are reused, clean surfaces, remove fins and Latinate, and tighten to close joints. Align and secure joints to avoid offsets. Do not use patched forms for exposed concrete surfaces unless approved by COR.

3.4 SHORES AND RESHORES

A. Comply with ACI 318M, ACI 301, and recommendations in ACI 347R for design, installation, and removal of shoring and reshoring.

B. In multistory construction, extend shoring or reshoring over a sufficient number of stories to distribute loads in such a manner that no floor or member will be excessively loaded or will induce tensile stress in concrete members without sufficient steel reinforcement.

C. Plan sequence of removal of shores and reshore to avoid damage to concrete. Locate and provide adequate reshoring to support construction without excessive stress or deflection.

3.5 VAPOR RETARDERS

A. Vapor Retarder: Place, protect, and repair vapor-retarder sheets according to ASTM E 1643 and manufacturer's written instructions.



1. Place vapor retarder sheeting in position with longest dimension parallel the direction of pour.

2. Lap joints: 150 mm and seal with manufacturer’s recommended mastic or pressure-sensitive tape.

3.6 STEEL REINFORCEMENT

A. General: Comply with CRSI's "Manual of Standard Practice" for placing reinforcement.

1. Do not cut or puncture vapor retarder. Repair damage and reseal vapor retarder before placing concrete.

B. Install in accordance with steel reinforcement placement shop drawings that have been reviewed by the Project Director.

C. Clean reinforcement of loose rust and mill scale, earth, ice, and other foreign materials.

D. Accurately position, support, and secure reinforcement against displacement. Locate and support reinforcement with bar supports to maintain minimum concrete cover as approved by the Project Director. Do not tack weld crossing reinforcing bars.

1. Shop- or field-weld reinforcement according to AWS D1.4, where indicated. 2. Welding of reinforcing bars is not permitted unless indicated on the structural drawings.

E. Set wire ties with ends directed into concrete, not toward exposed concrete surfaces.

F. Install welded wire reinforcement in longest practicable lengths on bar supports spaced to minimize sagging. Lap edges and ends of adjoining sheets at least one mesh spacing. Offset laps of adjoining sheet widths to prevent continuous laps in either direction. Secure overlaps with wire.

G. Epoxy-Coated Reinforcement: Use epoxy-coated steel wire ties to fasten epoxy-coated reinforcement. Repair cuts and damaged epoxy coatings with epoxy repair coating according to ASTM D 3963/D 3963M.

3.7 JOINTS

A. General: Construct joints true to line with faces perpendicular to surface plane of concrete.

B. Construction Joints: Install so strength and appearance of concrete are not impaired, at locations indicated or as approved by COR. Indicate locations and show details on shop drawing submittals.

1. Place joints perpendicular to main reinforcement. Continue reinforcement across construction joints, unless otherwise indicated. Do not continue reinforcement through sides of strip placements of floors and slabs.



2. Form from preformed galvanized steel, plastic keyway-section forms, or bulkhead forms with keys, unless otherwise indicated. Embed keys at least 40 mm into concrete.

3. Locate joints for beams, slabs, joists, and girders in the middle third of spans. Offset joints in girders a minimum distance of twice the beam width from a beam-girder intersection.

4. Locate horizontal joints in walls and columns at underside of floors, slabs, beams, and girders and at the top of footings or floor slabs.

5. Space vertical joints in walls as indicated. Locate joints beside piers integral with walls, near corners, and in concealed locations where possible.

6. Use a bonding agent at locations where fresh concrete is placed against hardened or partially hardened concrete surfaces.

C. Contraction (Control) Joints in Slabs-on Grade: Construct contraction joints in slabs-on-grade to form panels of patterns as shown. Use saw cuts 3 mm wide by one-fourth of the slab depth or inserts 6 mm wide by one-fourth of slab depth, unless otherwise indicated.

1. Form contraction joints by inserting premolded plastic, hardboard, or fiberboard strip into fresh concrete until top surface of strip is flush with slab surface. Tool slab edges round on each side of insert. After concrete has cured, remove inserts and clean groove of loose debris.

2. Contraction joints in unexposed floor slabs may be formed by saw cuts as soon as possible after slab finishing as may be safely done without dislodging aggregate.

3. If joint pattern is not shown, provide joints not exceeding 4.5 meters in either direction and located to be conform to bay spacing wherever possible (at column centerlines, half bays, third bays).

4. Discontinue reinforcing through joint only as shown on the drawings.

D. Isolation Joints in Slabs-on-Grade: After removing formwork, install joint-filler strips at slab junctions with vertical surfaces, such as column pedestals, foundation walls, grade beams, and other locations, as indicated.

1. Extend joint-filler strips full width and depth of joint, terminating flush with finished concrete surface, unless otherwise indicated.

2. Terminate full-width joint-filler strips not less than 12 mm or more than 25 mm below finished concrete surface where joint sealants, specified in Division 7 Section "Joint Sealants," are indicated.

3. Install joint-filler strips in lengths as long as practicable. Where more than one length is required, lace or clip sections together.

E. Dowel Joints: Install dowel sleeves and dowels or dowel bar and support assemblies at joints where indicated.

1. Use dowel sleeves or lubricate or asphalt-coat one-half of dowel length to prevent concrete bonding to one side of joint, unless indicated otherwise on the drawings.



3.8 WATERSTOPS

A. Flexible Waterstops: Install in construction joints as indicated to form a continuous diaphragm. Install in longest lengths practicable. Support and protect exposed waterstops during progress of Work. Field-fabricate joints in waterstops according to manufacturer's written instructions.

B. Self-Expanding Strip Waterstops: Install in construction joints and at other locations indicated, according to manufacturer's written instructions, bonding or mechanically fastening and firmly pressing into place. Install in longest lengths practicable.

3.9 CONCRETE PLACEMENT

A. General: Comply with ACI 304, “ Guide for Measuring, Mixing, Transporting, and Placing Concrete,” and as specified.

B. Before placing concrete, verify that installation of formwork, reinforcement, and embedded items is complete and that required inspections have been performed.

C. Do not add water to concrete during delivery, at Project site, or during placement, unless approved by Project Director.

D. Deposit concrete continuously or in layers of such thickness that no new concrete will be placed on concrete that has hardened enough to cause seams or planes of weakness. If a section cannot be placed continuously, provide construction joints as specified. Deposit concrete to avoid segregation and at such a rate of placement not to exceed the maximum shown on the formwork shop drawings.

E. Deposit concrete in forms in horizontal layers no deeper than 600 mm and in a manner to avoid inclined construction joints. Place each layer while preceding layer is still plastic, to avoid cold joints.

1. Consolidate placed concrete with mechanical vibrating equipment supplemented by hand spading, rodding, or tamping. Use equipment and procedures for consolidating concrete recommended by ACI 309R.

2. Do not use vibrators to transport concrete inside forms. Insert and withdraw vibrators vertically at uniformly spaced locations no farther than the visible effectiveness of the vibrator. Place vibrators to rapidly penetrate placed layer and at least 150 mm into preceding layer. Do not insert vibrators into lower layers of concrete that have begun to lose plasticity. At each insertion, limit duration of vibration to time necessary to consolidate concrete and complete embedment of reinforcement and other embedded items without causing mix constituents to segregate.

F. Deposit and consolidate concrete for floors and slabs in a continuous operation, within limits of construction joints, until placement of a panel or section is complete.

1. Consolidate concrete during placement operations so concrete is thoroughly worked around reinforcement and other embedded items and into corners.

2. Maintain reinforcement in position on chairs during concrete placement.



3. Screed slab surfaces with a straightedge and strike off to correct elevations. 4. Slope surfaces uniformly to drains where required. 5. Begin initial floating using bull floats or darbies to form a uniform and open-textured

surface plane, free of humps or hollows, before excess moisture or bleedwater appears on the surface. Do not further disturb slab surfaces before starting finishing operations.

G. Cold-Weather Placement: Comply with ACI 306.1 and as follows. Protect concrete work from physical damage or reduced strength that could be caused by frost, freezing actions, or low temperatures.

1. When air temperature has fallen to or is expected to fall below 4 deg C, uniformly heat water and aggregates before mixing to obtain a concrete mixture temperature of not less than 10 deg C and not more than 27 deg C at point of placement.

2. Do not use frozen materials or materials containing ice or snow. Do not place concrete on frozen subgrade or on subgrade containing frozen materials.

3. Do not use calcium chloride, salt, or other materials containing antifreeze agents or chemical accelerators, unless otherwise specified and approved in mix designs.

H. Hot-Weather Placement: Place concrete according to recommendations in ACI 305R and as follows, when hot-weather conditions exist:

1. Cool ingredients before mixing to maintain concrete temperature below 32 deg C at time of placement. Chilled mixing water or chopped ice may be used to control temperature, provided water equivalent of ice is calculated to total amount of mixing water. Using liquid nitrogen to cool concrete is Contractor's option.

2. Cover steel reinforcement with water-soaked burlap so steel temperature will not exceed ambient air temperature immediately before embedding in concrete.

3. Fog-spray forms, steel reinforcement, and subgrade just before placing concrete. Keep subgrade moisture uniform without standing water, soft spots, or dry areas.

4. Concrete placement shall not be started if the temperature is 40 deg. C and rising or until it is 43 deg. C and falling. All concrete placement shall be completed at ambient air temperature of less than 45 deg. C.

3.10 FINISHING FORMED SURFACES

A. Rough-Formed Finish: As-cast concrete texture imparted by form-facing material with tie holes and defective areas repaired and patched. Remove fins and other projections exceeding ACI 347R limits for class of surface specified.

B. Smooth-Formed Finish: As-cast concrete texture imparted by form-facing material, arranged in an orderly and symmetrical manner with a minimum of seams. Repair and patch tie holes and defective areas. Remove fins and other projections exceeding 3 mm in height.

1. Apply to concrete surfaces exposed to public view or to be covered with a coating or covering material applied directly to concrete, such as waterproofing, dampproofing, veneer plaster, or painting.

C. Rubbed Finish: Apply the following to smooth-formed finished concrete:



1. Smooth-Rubbed Finish: No later than one day after form removal, moisten concrete surfaces and rub with carborundum brick or another abrasive until producing a uniform color and texture. Do not apply cement grout other than that created by the rubbing process.

2. Grout-Cleaned Finish: Wet concrete surfaces and apply grout of a consistency of thick paint to coat surfaces and fill small holes. Mix one part portland cement to one and one-half parts fine sand with a 1:1 mixture of bonding admixture and water. Add white Portland cement in amounts determined by trial patches so color of dry grout will match adjacent surfaces. Scrub grout into voids and remove excess grout. When grout whitens, rub surface with clean burlap and keep surface damp by fog spray for at least 36 hours.

D. Related Unformed Surfaces: At tops of walls, horizontal offsets, and similar unformed surfaces adjacent to formed surfaces, strike off smooth and finish with a texture matching adjacent formed surfaces. Continue final surface treatment of formed surfaces uniformly across adjacent unformed surfaces, unless otherwise indicated.

3.11 FINISHING FLOORS AND SLABS

A. General: Comply with recommendations in ACI 302.1R for screeding, restraightening, and finishing operations for concrete surfaces. Do not wet concrete surfaces. Specified Overall Values (SOV) for flatness and Minimum Local Values (MLV) for both FF (flatness) and FL (levelness) are measured according to ASTM E 1155, Standard Test Method for Determining Floor Flatness and Levelness Using the F-Number System. FL (levelness) shall be calculated for suspended slabs before slab shoring is removed.

B. Scratch Finish: While still plastic, texture concrete surface that has been screeded and bull-floated or darbied. to a tolerance of Specified Overall Value (SOV) FF18 / FL15 and Minimum Local Value (MLV) FF13 / FL10. Use stiff brushes, brooms, or rakes.

1. Apply scratch finish to surfaces indicated and to surfaces to receive concrete floor topping or mortar setting beds for ceramic or quarry tile, portland cement terrazzo, and other bonded cementitious floor finishes and where indicated.

2. Finish surface to a tolerance of Specified Overall Value (SOV) FF18 / FL15 and Minimum Local Value (MLV) FF13 / FL10.

C. Float Finish: Consolidate surface with power-driven floats or by hand floating if area is small or inaccessible to power driven floats. Restraighten, cut down high spots, and fill low spots. Repeat float passes and restraightening until surface is left with a uniform, smooth, granular texture. Grind smooth any surface defects that would telegraph through applied floor covering system.

1. Apply float finish to surfaces indicated on the Architectural Drawings, to surfaces to receive trowel finish, and to floor and slab surfaces to be covered with fluid-applied or sheet waterproofing, built-up or membrane roofing, or sand-bed terrazzo.




D. Trowel Finish: After applying float finish, apply first trowel finish and consolidate concrete by hand or power-driven trowel. Continue troweling passes and restraighten until surface is free of trowel marks and uniform in texture and appearance. Grind smooth any surface defects that would telegraph through applied coatings or floor coverings.

1. Apply a trowel finish to surfaces indicated on Architectural Drawings and to floor and slab surfaces exposed to view or to be covered with resilient flooring, carpet, ceramic or quarry tile set over a cleavage membrane, paint, or another thin film-finish coating system.


E. Trowel and Fine-Broom Finish: Apply a partial trowel finish, stopping after second troweling, to surfaces indicated on Architectural Drawings and to surfaces where ceramic or quarry tile is to be installed by either thickset or thin-set method. Immediately after second troweling, and when concrete is still plastic, slightly scarify surface with a fine broom.

F. Broom Finish: Apply a broom finish to parking garage floors, exterior concrete platforms, steps, and ramps, and elsewhere as indicated on Architectural Drawings.

1. Immediately after float finishing, slightly roughen trafficked surface by brooming with fiber-bristle broom perpendicular to main traffic route. Coordinate required final finish with Project Director before application.

G. Slip-Resistive Aggregate Finish: Before final floating, apply slip-resistive aggregate finish where indicated on Architectural Drawings and to concrete stair treads, platforms, and ramps. Apply according to manufacturer's written instructions and as follows:

1. Uniformly spread 1.2 kg/m2 (0.25 lbs/ft2) of dampened slip-resistive aggregate over surface in one or two applications. Tamp aggregate flush with surface, but do not force below surface.

2. After broadcasting and tamping, apply float finish. 3. After curing, lightly work surface with a steel wire brush or an abrasive stone, and water

to expose slip-resistive aggregate.

3.12 MISCELLANEOUS CONCRETE ITEMS

A. Filling In: Fill in holes and openings left in concrete structures, unless otherwise indicated, after work of other trades is in place. Mix, place, and cure concrete, as specified, to blend with in-place construction. Provide other miscellaneous concrete filling indicated or required to complete Work.

B. Curbs: Provide monolithic finish to interior curbs by stripping forms while concrete is still green and by steel-troweling surfaces to a hard, dense finish with corners, intersections, and terminations slightly rounded.



C. Equipment Bases and Foundations: Provide machine and equipment bases and foundations as shown on Drawings. Set anchor bolts for machines and equipment at correct elevations, complying with diagrams or templates of manufacturer furnishing machines and equipment.

D. Steel Pan Stairs: Provide concrete fill for steel pan stair treads, landings, and associated items. Cast-in inserts and accessories as shown on Drawings. Screed, tamp, and trowel-finish concrete surfaces.

3.13 CONCRETE PROTECTION AND CURING

A. General: Protect freshly placed concrete from premature drying and excessive cold or hot temperatures. Comply with ACI 306.1 for cold-weather protection and with recommendations in ACI 305R for hot-weather protection during curing.

B. Evaporation Retarder: Apply evaporation retarder to unformed concrete surfaces if hot, dry, or windy conditions cause moisture loss approaching 1 kg/m2 x hour (0.20 lbs./ft.2 x hour) before and during finishing operations. Apply according to manufacturer's written instructions after placing, screeding, and bull floating or darbying concrete, but before float finishing.

C. Formed Surfaces: Cure formed concrete surfaces, including underside of beams, supported slabs, and other similar surfaces. If forms remain during curing period, moist cure after loosening forms. If removing forms before end of curing period, continue curing by one or a combination of the following methods:

1. Moisture Curing: Keep surfaces continuously moist for not less than seven days with the following materials:

a. Water. b. Continuous water-fog spray. c. Absorptive cover, water saturated, and kept continuously wet. Cover concrete

surfaces and edges with 300-mm lap over adjacent absorptive covers.

2. Moisture-Retaining-Cover Curing: Cover concrete surfaces with moisture-retaining cover for curing concrete, placed in widest practicable width, with sides and ends lapped at least 300 mm, and sealed by waterproof tape or adhesive. Cure for not less than seven days. Immediately repair any holes or tears during curing period using cover material and waterproof tape.

a. Moisture cure or use moisture-retaining covers to cure concrete surfaces to receive penetrating liquid floor treatments.

b. Cure concrete surfaces to receive floor coverings by moisture cure or with either a moisture-retaining cover or a curing compound that the manufacturer recommends for use with floor coverings.

3. Curing Compound: Apply uniformly in continuous operation by power spray or roller according to manufacturer's written instructions. Recoat areas subjected to heavy rainfall within three hours after initial application. Maintain continuity of coating and repair damage during curing period.



4. Curing and Sealing Compound: Apply uniformly to floors and slabs indicated on Architectural Drawings in a continuous operation by power spray or roller according to manufacturer's written instructions. Recoat areas subjected to heavy rainfall within three hours after initial application. Repeat process 24 hours later and apply a second coat. Maintain continuity of coating and repair damage during curing period.

D. Unformed Surfaces: Begin curing immediately after finishing concrete. Cure unformed surfaces, including floors and slabs, concrete floor toppings, and other surfaces, by one or a combination of the following methods:

1. Moisture Curing: Keep surfaces continuously moist for not less than seven days with the following materials:

a. Water. b. Continuous water-fog spray. c. Absorptive cover, water saturated, and kept continuously wet. Cover concrete

surfaces and edges with 300-mm lap over adjacent absorptive covers.

2. Moisture-Retaining-Cover Curing: Cover concrete surfaces with moisture-retaining cover for curing concrete, placed in widest practicable width, with sides and ends lapped at least 300 mm, and sealed by waterproof tape or adhesive. Cure for not less than seven days. Immediately repair any holes or tears during curing period using cover material and waterproof tape.

a. Moisture cure or use moisture-retaining covers to cure concrete.

3. Curing Compound: Apply curing compound to concrete slabs as soon as final finishing operations are complete (within 2 hours and after surface water sheen has disappeared. Apply uniformly in continuous operation by power spray or roller according to manufacturer's written instructions. Recoat areas subjected to heavy rainfall within three hours after initial application. Maintain continuity of coating and repair damage during curing period.

4. Curing and Sealing Compound: Apply uniformly to floors and slabs indicated in a continuous operation by power spray or roller according to manufacturer's written instructions. Recoat areas subjected to heavy rainfall within three hours after initial application. Repeat process 24 hours later and apply a second coat. Maintain continuity of coating and repair damage during curing period.

5. Hot-Weather Curing: Cure concrete according to recommendations in ACI 305R and as follows, when hot-weather conditions exist:

a. When ambient air temperature is expected to be greater or equal to 36 deg. C in the following seven days after flatwork is poured it shall be moist-cured for a minimum of seven days.

3.14 LIQUID FLOOR TREATMENTS

A. Penetrating Liquid Floor Treatment: Prepare, apply, and finish penetrating liquid floor treatment according to manufacturer's written instructions.



1. Remove curing compounds, sealers, oil, dirt, laitance, and other contaminants and complete surface repairs.

2. Do not apply to concrete that is less than 14 days old. 3. Apply liquid until surface is saturated, scrubbing into surface until a gel forms; rewet;

and repeat brooming or scrubbing. Rinse with water; remove excess material until surface is dry. Apply a second coat in a similar manner if surface is rough or porous. Comply with manufacturer’s written instructions.

B. Sealing Coat: Uniformly apply a continuous sealing coat of curing and sealing compound to hardened concrete by power spray or roller according to manufacturer's written instructions.

3.15 JOINT FILLING

A. Prepare, clean, and install joint filler according to manufacturer's written instructions.

1. Defer joint filling until concrete has aged at least six months. Do not fill joints until construction traffic has permanently ceased.

B. Remove dirt, debris, saw cuttings, curing compounds, and sealers from joints; leave contact faces of joint clean and dry.

C. Install semi-rigid epoxy joint filler the full depth in saw-cut joints and at least 50 mm deep in formed joints. Overfill joint and trim joint filler flush with top of joint after hardening.

3.16 CONCRETE SURFACE REPAIRS

A. Patching Defective Areas: Repair and patch defective areas with cement mortar immediately after removing forms, when acceptable to the Project Director. Remove and replace concrete that cannot be repaired and patched to the Project Directors approval.

B. Patching Mortar: Mix dry-pack mortar, consisting of one part Portland cement to 2-1/2 parts fine aggregate passing a 1.2 mm (No. 16) sieve, using only enough water as required for handling and placing.

C. Repairing Formed Surfaces: Remove and replace concrete having defective surfaces if defects cannot be repaired to satisfaction of the Project Director. Surface defects include color and texture irregularities, cracks, spalls, air bubbles, honeycomb, rock pockets, fins and other projections on the surface, and stains and other discoloration that cannot be removed by cleaning.

1. Immediately after form removal, cut out honeycombs, rock pockets, and voids more than 12 mm in any dimension in solid concrete but not less than 25 mm in depth. Make edges of cuts perpendicular to concrete surface. Clean, dampen with water, and brush-coat holes and voids with bonding agent. Fill and compact with patching mortar before bonding agent has dried. Fill form-tie voids with patching mortar or cork cone plugs secured in place with bonding agent.



2. Repair defects on surfaces exposed to view by blending white Portland cement and standard Portland cement so that, when dry, patching mortar will match surrounding color. Patch a test area at inconspicuous locations to verify mixture and color match before proceeding with patching. Compact mortar in place and strike off slightly higher than surrounding surface.

3. Repair defects on concealed formed surfaces that affect concrete's durability and structural performance as determined by COR.

D. Repairing Unformed Surfaces: Test unformed surfaces, such as floors and slabs, for finish and verify surface tolerances specified for each surface. Correct low and high areas. Test surfaces sloped to drain for trueness of slope and smoothness; use a sloped template.

1. Repair finished surfaces containing defects. Surface defects include spalls, popouts, honeycombs, rock pockets, crazing and cracks in excess of 0.25 mm wide or that penetrate to reinforcement or completely through unreinforced sections regardless of width, and other objectionable conditions.

2. After concrete has cured at least 14 days, correct high areas by grinding. 3. Correct localized low areas during or immediately after completing surface finishing

operations by cutting out low areas and replacing with patching mortar. Finish repaired areas to blend into adjacent concrete. Proprietary underlayment compounds may be used when acceptable to the COR.

4. Correct other low areas scheduled to receive floor coverings with a repair underlayment when acceptable to the COR. Prepare, mix, and apply repair underlayment and primer according to manufacturer's written instructions to produce a smooth, uniform, plane, and level surface. Feather edges to match adjacent floor elevations.

5. Correct other low areas scheduled to remain exposed with a repair topping when acceptable to the COR. Cut out low areas to ensure a minimum repair topping depth of 6 mm to match adjacent floor elevations. Prepare, mix, and apply repair topping and primer according to manufacturer's written instructions to produce a smooth, uniform, plane, and level surface.

6. Repair defective areas, except random cracks and single holes 25 mm or less in diameter, by cutting out and replacing with fresh concrete. Remove defective areas with clean, square cuts and expose steel reinforcement with at least 20 mm clearance all around. Dampen concrete surfaces in contact with patching concrete and apply bonding agent. Mix patching concrete of same materials and mix as original concrete except without coarse aggregate. Place, compact, and finish to blend with adjacent finished concrete. Cure in same manner as adjacent concrete.

7. Repair random cracks and single holes 25 mm or less in diameter with patching mortar. Groove top of cracks and cut out holes to sound concrete and clean off dust, dirt, and loose particles. Dampen cleaned concrete surfaces and apply bonding agent. Place patching mortar before bonding agent has dried. Compact patching mortar and finish to match adjacent concrete. Keep patched area continuously moist for at least 72 hours.

E. Perform structural repairs of concrete, subject to COR approval, using epoxy adhesive and patching mortar.

F. Repair materials and installation not specified above may be used, subject to acceptance of the COR.



3.17 CONCRETE CRACK REPAIRS

A. Epoxy Crack Injection: Comply with manufacturer's written instructions and the following:

1. Clean areas to receive capping adhesive of oil, dirt, and other substances that would interfere with bond, and clean cracks with oil-free compressed air or low-pressure water to remove loose particles.

2. Place injection ports as recommended by epoxy manufacturer, spacing no farther apart than thickness of member being injected. Seal injection ports in place with capping adhesive.

3. Seal cracks at exposed surfaces with a ribbon of capping adhesive at least 6 mm (1/4 inch) thick by 25 mm (1 inch) wider than crack.

4. Inject cracks wider than 0.075 mm (0.003 inch) to a depth of 200 mm (8 inches) or to a width of less than 0.075 mm (0.003 inch), whichever is less.

5. Inject epoxy adhesive, beginning at widest part of crack and working toward narrower parts. Inject adhesive into ports to refusal, capping adjacent ports when they extrude epoxy. Cap injected ports and inject through adjacent ports until crack is filled.

6. After epoxy adhesive has set, remove injection ports and grind surfaces smooth.

3.18 QUALITY CONTROL TESTING DURING CONSTRUCTION

A. General: The Contractor shall employ a qualified independent testing and inspecting agency, approved by the COR, to sample materials, perform tests, and submit test reports according to the requirements specified in this Article.

B. Testing Services: Testing of composite samples of fresh concrete obtained according to ASTM C 172 shall be performed according to the following requirements:

1. Testing Frequency: Obtain at least one composite sample for each 50 m2 or fraction thereof of each concrete mix placed each day unless directed otherwise by the Project Director. When frequency of testing will provide fewer than five compressive-strength tests for each concrete mix, testing shall be conducted from at least five randomly selected batches or from each batch if fewer than five are used.

2. Slump: ASTM C 143; one test at point of discharge for each composite sample. Perform additional tests when concrete consistency appears to change.

3. Air Content: ASTM C 231; pressure method, for normal-weight concrete; ASTM C 173, volumetric method, for structural lightweight concrete; one test for each composite sample.

4. Concrete Temperature: ASTM C 1064; one test hourly when air temperature is 4 deg C and below, when 27 deg C and above, and one test for each set of composite sample.

5. Unit Weight: ASTM C567; one test for each composite sample. 6. Compressive Test Specimens: ASTM C31/C31M; cast and laboratory cure one set of

four standard cylinders specimens for each composite sample. 7. Compressive-Strength Tests: ASTM C39; one specimen tested at 7 days, two specimens

tested at 28 days, and one specimen tested at 56 days (reserve).



C. When strength of field-cured cylinders is less than 85 percent of companion laboratory-cured cylinders, Contractor shall evaluate operations and provide corrective procedures for protecting and curing in-place concrete as approved by the Project Director.

D. Test results shall be reported in writing to COR, ready-mix producer, and the Contractor within 24 hours after testing. Reports of compressive-strength tests shall contain Project identification name and number, date of concrete placement, name of concrete testing and inspection agency, concrete type and class, location of concrete batch in structure, design compressive strength at 28 days, concrete mix proportions and materials, compressive breaking strength, and type of break for both 7-day, 28-day, and 56 day (reserve) tests.

E. Nondestructive Testing: Impact hammer, sonoscope, or other nondestructive device may be permitted by the COR but shall not be used as the sole basis for acceptance or rejection of concrete.

F. Additional Tests: The testing and inspecting agency shall make additional test of in-place concrete when test results indicate specified concrete strengths and other characteristics have not been attained in the structure, as directed by the COR. Testing agency may conduct tests to determine adequacy of concrete by cored cylinders complying with ASTM C 42, or by other methods as directed by the COR. Any concrete that does not comply with this specification will not be accepted. Concrete found to be deficient shall be corrected in a manner satisfactory to the COR. All investigations, testing, load tests, and correction of deficiencies shall be performed at the expense of the Contractor and approved by the COR.

G. Quality Control Testing of Reinforcing Steel: an OBO approved independent testing lab shall test Reinforcing steel as required. Approved OBO independent testing labs are those labs accredited by International Accreditation Services, Inc. (IAS), or inspected by Cement and Concrete Reference Laboratory (CCRL), or labs at OBO prequilified reinforcing steel mills, or labs at approved State Department of Transportation labs. See Table 03300-3.18.

END OF SECTION 03300



CONCRETE MIX DESIGN SUBMITTAL FORM

Project: City: General Contractor: Concrete Contractor: Concrete Strength (Class): Use (Describe):

Design Mix Information (Check One)

Based on Std. Deviation Analysis Trial Mix Text Data

Design Characteristics Density kg/m3 Strength MPa (28 day) Air % specified If trial mixes are used the Mix Design is proportioned to achieve f´cr = f´c + 8.3MPa (9.7 MPa for 35MPa strength and higher strength at 28 days)

MATERIALS

Type/ Source

Specific Gravity

Weight (kg)

Absolute Volume (m3)

Cement Fly Ash

Silica Fume GGBF Slag

Fine Aggregate Course Aggregate

Water Air

Other Total m3

Water/Cementitious Material Ratio (kg water/kg cementitious material) = _____________

ADMIXTURES

Manufacturer Dosage (Metric)

Water Reducer Air Entraining Agent

High Range Water Reducer Non-Corrosive Accelerator

Other



Slump before HRWR mm Slump after HRWR mm Standard Deviation Analysis (from experience records):

# of Test Cylinders Evaluated: Standard Deviation:

The larger of: f’cr = f’c + 1.34s or f’cr = f’c + 2.33s-3.5 (MPa) (Refer to ACI 301 for increased deviation factor when less than 30 tests are available. Refer to ACI 318M Section 5.3 – Proportioning on the basis of field experience or trial mixtures, or both.)

LABORATORY TESTS DATA

Compressive strength Age (days) Mix #1 Mix #2 Mix #3 7 MPa MPa MPa 7 MPa MPa MPa 28 MPa MPa MPa 28 MPa MPa MPa 28 average MPa MPa MPa

REQUIRED ATTACHMENTS: Combined Aggregate Gradation Report Standard Deviation Analysis Summary or Trial Mixture Test Data Admixture Compatibility Certification Letter Note: 8% - 18% aggregate required to be retained on each sieve except the top size and the #100 Submitted by :

Name: Address: Phone #: Main Plant Location: Kilometers to Project: Secondary Plant Location: Kilometers to Project: Date:



Table 03300-2.2: The following are prequalified to supply reinforcing steel on OBO projects subject to the conditions of the specifications and established policy and procedures.

Steel Mill Location & Contact Info

A.B. Steel Mill, Inc. 204 W North Bend Road Cincinnati, OH 45216 (513) 679-4499

Bayou Steel - Tennessee 2404 South Roane Street Harriman, TN 37748 (865) 882-5100 www.bayousteel.com

Border Steel, Inc I-10 And Vinton Road El Paso, Texas 79385 (915) 886-2000 www.bordersteel.com

Cascade Rolling Mill, Inc.

3200 N. Highway 99W P.O. Box 687 McMinnville, OR 97128-9399 (503) 472-4181 www.csrm.com

Connecticut Steel Corporation 35 Toelles Road Wallingford, CT 06492 (203) 265-0615 www.connecticutsteel.com

Gerdau Ameristeel - Beau-mont

100 Old Highway 90 West Vidor, TX 77662 (409) 768-1211 www.gerdauameristeel.com

Gerdau Ameristeel – Charlotte

6601 Lakeview Road Charlotte, NC 28269 (704) 596-0361 www.gerdauameristeel.com

Gerdau AmeriSteel – Jackson

801 Gerdau Ameristeel Road Jackson, Tennessee 38305 (731) 424-5600 www.gerdauameristeel.com

Gerdau AmeriSteel - Jackson-ville

Hwy. 217 Yellow Water Road Baldwin, FL 32234 (904) 266-4261 www.gerdauameristeel.com

Gerdau Ameristeel – Knox-ville

1919 Tennessee Ave N. W. Knoxville, TN 37921-2696 (865) 546-5472 www.gerdauameristeel.com

Gerdau Ameristeel – Perth Amboy

225 Elm Street Perth Amboy, NJ 08862 (732) 442-1600 www.gerdauameristeel.com

Gerdau Ameristeel - Sayre-ville

North Crossman Road Sayreville, New Jersey 08871-0249 (732) 721-6600 www.gerdauameristeel.com




Gerdau Ameristeel – St. Paul, MN

1678 Red Rock Road St. Paul, MN 55119 (651) 731-5600 www.gerdauameristeel.com

Gerdau Ameristeel – Wilton, IA

1500-2500 West 3rd Street Wilton, IA 52778 (563) 732-3231 www.gerdauameristeel.com

Marion Steel Company 912 Cheney Avenue Marion, Ohio 43302 (800) 333-4011 www.marionsteel.com

MMFX Steel Corporation of America

8800 Corporate Center, Suite 207 Charlotte, NC 28266 (704) 752-9155 www.mmfxsteel.com

Nucor Steel - Auburn, Inc. 25 Quarry Road PO Box 2008 Auburn, NY 13021 (315) 253-4561 www.nucorauburn.com

Nucor Steel - Birmingham PO Box 2764 Birmingham, AL 35202 (866) 862-4796 www.nucorbar.com

Nucor Steel - Jackson 3630 Fourth Street Jackson, MS 39232 (800) 723-1623 www.nucorbar.com

Nucor Steel - Kankakee 972 East 4500 North Road Bourbonnais, Il 60914-4127 (815) 937-3131 www.nucorbar.com

Nucor Steel - Seattle 2424 SW Andover Seattle, WA 98106-1100 (206) 933-2222 www.nucorbar.com

Nucor Steel – South Carolina 300 Steel Mill Rd. Darlington, SC 29540 (800) 999-7461 www.nucorbar.com

Nucor Steel - Texas P.O. Box 126 Jewett, TX 75846 (800) 527-6445 www.nucorbar.com

Nucor Steel – Utah Nucor Steel - Utah PO Box 100 Plymouth, UT 84330 (800) 453-2886 www.nucorbar.com




Rocky Mountain Steel Mills P.O. Box 316, Pueblo, CO 81002 (719) 561-6000 www.oregonsteel.com

Sheffield Steel 2300 South Hwy 97 Sandy Springs, OK 74063 (916) 245-1335 www.sheffieldsteel.com

SMI - Texas P.O. Box 911 Seguin, Texas 78156-0911 (830) 372-8200 www.smi-texas.com

SMI Steel – South Carolina 310 New State Road Cayce, SC 29033 (800) 637-3227 www.smi-sc.com

TAMCO Steel

P.O. Box 325 12459-B Arrow Rte. Rancho Cucamonga, CA 91739 909-899-0660 www.tamcosteel.com

TXI Chaparral Steel 300 Ward Road Midlothian, Texas 76065 (800) 527-7979 (972) 299-5212 www.chaparralsteel.com



Table 03300-3.18: The following are OBO approved independent testing labs for the evaluation of rein-forcing steel for compliance with ASTM A 615/A 615M and ASTM A 706/A 706M.

I. Labs accredited by International Accreditation Services, Inc. (IAS) (www.iasonline.org), a subsidiary corporation of the International Code Council (ICC):

Applied Materials & Engineering, Inc. (TL-188) 980 41st Street Oakland, California 94608 Wilson Dean, Manager (510) 420-8190 Construction Technology Laboratories, Inc. (TL-200) 5400 Old Orchard Road Skokie, Illinois 60077 Charles H Walden, Quality Manager Jeff Gilmore (847) 965-7500

Metals & Materials Engineering (TL-236) 1039 Industrial Court Suwanee, Georgia 30024 Scott Lowrie, Vice President (678) 730-2000 Smith-Emery Laboratories (TL-191) 781 East Washington Boulevard Los Angeles, California 90021 John Latiolait, Laboratory Director (213) 749-3411 Testing Engineers, Inc. (TL-168) 2811 Teagarden Street San Leandro, California 94577 Dan Wantanbe, Materials Science Division Manager (510) 835-3142 Western Technologies, Inc. (TL-107) 3737 East Broadway Road Phoenix, Arizona 85040-2966 Randolf Marwig, P.E., Managing Director (602) 437-3737 Wiss, Janney, Elstner Associates, Inc. (TL-165) 330 Pfingsten Road Northbrook, Illinois 66062 F. Dirk Heidbrink, Laboratory QA Manager Todd Nelson (x 4283) (847) 272-7400



II. Labs inspected by Cement and Concrete Reference Laboratory (CCRL) (www.ccrl.us).

LAB LOCATION EMAIL PHONE

MACTEC Engr & Consult. Atlanta, GA [email protected] (404) 873-4761 MACTEC Engr. & Consult. Jacksonville, FL [email protected] (904) 396-5173 Soil & Materials Engineers, Inc. Plymouth, MI [email protected] (734) 454-9900 Soil Consultants, Inc. Charleston, SC [email protected] (843) 723-4539 Stork Twin City Testing Corp. St. Paul, MN [email protected] (651) 645-3601 Testwell Laboratories, Inc. Ossining, NY [email protected] (914) 944-2555 Wright Padgett Christopher Mt. Pleasant, SC [email protected] (843) 884-1234

III. Labs at OBO prequalified reinforcing steel mills. IV. Labs at Sate Department of Transportations capable of testing ASTM reinforcing steel for

compliance.

UNITED STATES DEPARTMENT OF STATE 28 FEBRUARY 2006 OVERSEAS BUILDINGS OPERATIONS OBO STANDARD SPECIFICATIONS

METAL FABRICATIONS SECTION 05500 - 1

SECTION 05500 - METAL FABRICATIONS

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes the following:

1. Loose bearing and leveling plates. 2. Loose steel lintels. 3. Shelf angles. 4. Support angles for elevator door sills. 5. Elevator machine beams. 6. Steel framing and supports for overhead doors. 7. Steel framing and supports for operable partitions and ceiling hung toilet partitions. 8. Steel framing and supports for countertops. 9. Metal angle corner guards for columns, walls and bading deck edge subject to vehicular

impact. 10. Metal edgings. 11. Bicycle Racks. 12. Flack Jacket Hanger Racks in the Marine Security Guard React Room. 13. Pipe bollards.

1.2 PERFORMANCE REQUIREMENTS

A. Structural Performance of Ladders: Provide ladders capable of withstanding the effects of loads and stresses within limits and under conditions specified in ANSI A14.3.

B. Thermal Movements: Provide exterior metal fabrications that allow for thermal movements resulting from the following maximum change (range) in ambient and surface temperatures by preventing buckling, opening of joints, overstressing of components, failure of connections, and other detrimental effects. Base engineering calculation on surface temperatures of materials due to both solar heat gain and nighttime-sky heat loss.

1. Temperature Change (Range): 67 deg C, ambient; 100 deg C, material surfaces.

1.3 SUBMITTALS

A. Product Data: For the following: 1. Metal nosings and treads. 2. Paint products. 3. Grout.

B. Shop Drawings: Show fabrication and installation details for metal fabrications.



1. Include plans, elevations, sections, and details of metal fabrications and their connections. Show anchorage and accessory items.

2. Provide templates for anchors and bolts specified for installation under other Sections. 3. For installed products indicated to comply with design loads, include structural analysis

data signed and sealed by the qualified professional engineer responsible for their preparation.

C. Mill Certificates: Signed by manufacturers of stainless-steel sheet certifying that products furnished comply with requirements.

D. Welding certificates.

E. Qualification Data: For professional engineer.


A. Fabricator Qualifications: A firm experienced in producing metal fabrications similar to those indicated for this Project and with a record of successful in-service performance, as well as sufficient production capacity to produce required units.

B. Welding: Qualify procedures and personnel according to the following:

1. AWS D1.1, "Structural Welding Code--Steel." 2. AWS D1.2, "Structural Welding Code--Aluminum." 3. AWS D1.3, "Structural Welding Code--Sheet Steel." 4. Certify that each welder has satisfactorily passed AWS qualification tests for welding

processes involved and, if pertinent, has undergone recertification.

PART 2 - PRODUCTS

2.1 METALS, GENERAL

A. Metal Surfaces, General: For metal fabrications exposed to view in the completed Work, provide materials with smooth, flat surfaces without blemishes. Do not use materials with exposed pitting, seam marks, roller marks, rolled trade names, or roughness.

2.2 FERROUS METALS

A. Steel Plates, Shapes, and Bars: ASTM A 36/A 36M.

B. Stainless-Steel Sheet, Strip, Plate, and Flat Bars: ASTM A 666, Type 304.

C. Stainless-Steel Bars and Shapes: ASTM A 276, Type 304.

D. Steel Tubing: Cold-formed steel tubing complying with ASTM A 500.



E. Steel Pipe: ASTM A 53, standard weight (Schedule 40), unless another weight is indicated or required by structural loads.

F. Cast-in-Place Anchors in Concrete: Anchors of type indicated below, fabricated from corrosion-resistant materials capable of sustaining, without failure, the load imposed within a safety factor of 4, as determined by testing per ASTM E 488, conducted by a qualified independent testing agency.

1. Threaded or wedge type; galvanized ferrous castings, either ASTM A 47M malleable iron or ASTM A 27/A 27M cast steel. Provide bolts, washers, and shims as needed, hot-dip galvanized per ASTM A 153/A 153M.

G. Galvanized Pipe and Sleeves: Galvanized steel complying with ASTM A 653/A 653M, commercial steel, Type B, with Z275 coating; 2.8-mm nominal thickness.

H. Welding Rods and Bare Electrodes: Select according to AWS specifications for metal alloy welded.

2.3 NONFERROUS METALS

A. Aluminum Plate and Sheet: ASTM B 209M , Alloy 6061-T6.

B. Aluminum Extrusions: ASTM B 221M , Alloy 6063-T6.

C. Aluminum-Alloy Rolled Tread Plate: ASTM B 632/B 632M, Alloy 6061-T6.

D. Aluminum Castings: ASTM B 26/B 26M, Alloy 443.0-F.

E. Bronze Plate, Sheet, Strip, and Bars: ASTM B 36/B 36M, Alloy UNS No. C28000 (muntz metal, 60 percent copper).

F. Bronze Extrusions: ASTM B 455, Alloy UNS No. C38500 (extruded Architectural bronze).

G. Bronze Castings: ASTM B 584, Alloy UNS No. C83600 (leaded red brass) or No. C84400 (leaded semired brass).

2.4 FASTENERS

A. General: Provide Type 304 or 316 stainless-steel fasteners for exterior use and zinc-plated fasteners with coating complying with ASTM B 633, Class Fe/Zn 5, where built into exterior walls. Select fasteners for type, grade, and class required.

B. 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.

C. Anchor Bolts: ASTM F 1554, Grade 36.

D. Machine Screws: ASME B18.6.7M.



E. Lag Bolts: ASME B18.2.3.8M.

F. Wood Screws: Flat head, carbon steel, ASME B18.6.1.

G. Plain Washers: Round, carbon steel, ASME B18.22M.

H. Lock Washers: Helical, spring type, carbon steel, ASME B18.21.2M.

I. Expansion Anchors: Anchor bolt and sleeve assembly of material indicated below 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.

1. Material: Carbon-steel components zinc-plated to comply with ASTM B 633, Class Fe/Zn 5.

2. Material: Alloy Group 1 or 2 stainless-steel bolts complying with ASTM F 738M and nuts complying with ASTM F 836M.

J. Toggle Bolts: FS FF-B-588, tumble-wing type, class and style as needed.

2.5 MISCELLANEOUS MATERIALS

A. Welding Rods and Bare Electrodes: Select according to AWS specifications for metal alloy welded.

B. Shop Primers: Provide primers that comply with Division 9 painting Sections.

C. Universal Shop Primer: Fast-curing, lead- and chromate-free, universal modified-alkyd primer complying with MPI#79.

1. Use primer with a VOC content of 420 g/L (3.5 lb/gal.) or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

2. Use primer containing pigments that make it easily distinguishable from zinc-rich primer.

D. Zinc-Rich Primer: Complying with SSPC-Paint 20 or SSPC-Paint 29 and compatible with topcoat.

1. Use primer with a VOC content of 420 g/L (3.5 lb/gal.) or less when calculated according to 40 CFR 59, Subpart D (EPA Method 24).

E. Galvanizing Repair Paint: High-zinc-dust-content paint for regalvanizing welds in steel, complying with SSPC-Paint 20.

F. Bituminous Paint: Cold-applied asphalt emulsion complying with ASTM D 1187.

G. Nonshrink, Metallic Grout: Factory-packaged, ferrous-aggregate grout complying with ASTM C 1107, specifically recommended by manufacturer for heavy-duty loading applications.



H. Nonshrink, Nonmetallic Grout: Factory-packaged, nonstaining, noncorrosive, nongaseous grout complying with ASTM C 1107. Provide grout specifically recommended by manufacturer for interior and exterior applications.

I. Concrete Materials and Properties: Comply with requirements in Division 3 Section "Cast-in-Place Concrete" for normal-weight, air-entrained, ready-mix concrete with a minimum 28-day compressive strength of 20 MPa , unless otherwise indicated.

2.6 FABRICATION, GENERAL

A. Shop Assembly: Preassemble items in shop to greatest extent possible to minimize field splicing and assembly. Disassemble units only as necessary for shipping and handling limitations. Use connections that maintain structural value of joined pieces. Clearly mark units for reassembly and coordinated installation.

B. Shear and punch metals cleanly and accurately. Remove burrs.

C. Ease exposed edges to a radius of approximately 1 mm, unless otherwise indicated. Form bent-metal corners to smallest radius possible without causing grain separation or otherwise impairing work.

D. Weld corners and seams continuously to comply with the following:

1. Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals.

2. Obtain fusion without undercut or overlap. 3. Remove welding flux immediately. 4. 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.

E. Provide for anchorage of type indicated; coordinate with supporting structure. Fabricate and space anchoring devices to secure metal fabrications rigidly in place and to support indicated loads.

F. Cut, reinforce, drill, and tap metal fabrications as indicated to receive finish hardware, screws, and similar items.

G. Fabricate joints that will be exposed to weather in a manner to exclude water, or provide weep holes where water may accumulate.

H. Allow for thermal movement resulting from the following maximum change (range) in ambient and surface temperatures by preventing buckling, opening up of joints, overstressing of components, failure of connections, and other detrimental effects. Base engineering calculation on surface temperatures of materials due to both solar heat gain and nighttime-sky heat loss.

1. Temperature Change (Range): 67 deg C, ambient; 100 deg C, material surfaces.



I. Form exposed work true to line and level with accurate angles and surfaces and straight sharp edges.

J. Remove sharp or rough areas on exposed traffic surfaces.

K. Form exposed connections with hairline joints, flush and smooth, using concealed fasteners where possible. Use exposed fasteners of type indicated or, if not indicated, Phillips flat-head (countersunk) screws or bolts. Locate joints where least conspicuous.

2.7 LOOSE BEARING AND LEVELING PLATES

A. Provide loose bearing and leveling plates for steel items bearing on masonry or concrete construction. Drill plates to receive anchor bolts and for grouting.

B. Galvanize plates after fabrication.

2.8 LOOSE STEEL LINTELS

A. Fabricate loose structural-steel lintels from steel angles and shapes of size indicated for openings and recesses in masonry walls and partitions at locations indicated.

B. Weld adjoining members together to form a single unit where indicated.

C. Size loose lintels to provide bearing length at each side of openings equal to one-twelfth of clear span, but not less than 200 mm, unless otherwise indicated.

D. Galvanize loose steel lintels located in exterior walls.

2.9 MISCELLANEOUS FRAMING AND SUPPORTS

A. General: Provide steel framing and supports indicated and as necessary to complete the Work.

B. Fabricate units from structural-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 retained by framing and supports. Cut, drill, and tap units to receive hardware, hangers, and similar items.

1. Fabricate units from slotted channel framing where indicated. 2. Where units are indicated to be cast into concrete or built into masonry, equip with

integrally welded steel strap anchors 32 mm wide by 6 mm thick by 200 mm long at 600 mm o.c., unless otherwise indicated.

3. Furnish inserts if units must be installed after concrete is placed.

C. Fabricate supports for operable partitions as follows:



1. Beams: Continuous steel shapes of sizes indicated with attached bearing plates, anchors, and braces as indicated. Drill bottom flanges of beams to receive partition track hanger rods; locate holes where indicated on operable partition Shop Drawings.

D. Galvanize miscellaneous framing and supports where indicated.

2.10 MISCELLANEOUS STEEL TRIM

A. Unless otherwise indicated, fabricate units from structural-steel shapes, plates, and bars of profiles shown with continuously welded joints, and smooth exposed edges. Miter corners and use concealed field splices where possible.

B. Provide cutouts, fittings, and anchorages as needed to coordinate assembly and installation with other work. Provide anchors, welded to trim, for embedding in concrete or masonry construction, spaced not more than 150 mm from each end, 150 mm from corners, and 600 mm o.c., unless otherwise indicated.

C. Galvanize miscellaneous steel trim in the following locations:

1. Exterior. 2. Interior, where indicated.

2.11 STEEL PIPE BOLLARDS

A. Type: Standard schedule 40 steel pipe.

1. Fill with standard weight concrete; set in concrete foundations. 2. Continuously weld steel plate to top; grind smooth.

B. Finish: Paint.

2.12 FLACK JACKET HANGER RACKS

A. Fabricate racks from metal material specified in this Section according to drawings.

1. Fasteners for attachment to walls specified in this Section according to drawings. 2. Steel Plate: 6 mm thick. 3. Steel Rods: 6 mm. 4. Pipe Sleeve: From similar material for fabrication of pipes.

B. Helmet Shelf: Fabricate from wire fabric.

2.13 BICYCLE RACKS

A. Fabricate from Schedule 40 steel pipe, fully welded together, to lengths indicated.



B. Fabricate with DN 80 top rails and end posts, DN 40 bottom rails and intermediate posts not more than 1800 mm o.c., and DN 20 vertical separators at approximately 200 mm o.c.

C. Make top rails 900 mm above pavement/floor and bottom rails 100 mm above pavement/floor.

D. Fabricate end posts and intermediate posts with 6.4-mm ( thick steel baseplates for bolting to concrete slab. Drill end post baseplates at all 4 corners and intermediate-post baseplates at 2 opposite sides for 12.7-mm ( anchor bolts.

E. Galvanize bicycle racks after fabrication.

F. Prime bicycle racks with zinc-rich primer.

2.14 FINISHES, GENERAL

A. Comply with NAAMM's "Metal Finishes Manual for Architectural and Metal Products" for recommendations for applying and designating finishes.

B. Finish metal fabrications after assembly.

2.15 STEEL AND IRON FINISHES

A. Galvanizing: Hot-dip galvanize items as indicated to comply with applicable standard listed below:

1. ASTM A 123, for galvanizing steel and iron products. 2. ASTM A 153/A 153M, for galvanizing steel and iron hardware.

B. Preparation for Shop Priming: Prepare uncoated ferrous-metal surfaces to comply with minimum requirements indicated below for SSPC surface-preparation specifications and environmental exposure conditions of installed metal fabrications:

1. Exteriors (SSPC Zone 1B): SSPC-SP 6/NACE No. 3, "Commercial Blast Cleaning." 2. Interiors (SSPC Zone 1A): SSPC-SP 3, "Power Tool Cleaning."

C. Apply shop primer to uncoated surfaces of metal fabrications, except those with galvanized finishes and those to be embedded in concrete, sprayed-on fireproofing, or masonry, unless otherwise indicated. Comply with SSPC-PA 1, "Paint Application Specification No. 1," for shop painting.

2.16 STAINLESS-STEEL FINISHES

A. Remove tool and die marks and stretch lines or blend into finish.

B. Grind and polish surfaces to produce uniform, directionally textured, polished finish indicated, free of cross scratches. Run grain with long dimension of each piece.



C. Bright, Directional Polish: No. 4 finish.

D. When polishing is completed, passivate and rinse surfaces. Remove embedded foreign matter and leave surfaces chemically clean.

2.17 ALUMINUM FINISHES

A. Finish designations prefixed by AA comply with the system established by the Aluminum Association for designating aluminum finishes.

B. As-Fabricated Finish: AA-M10 (Mechanical Finish: as fabricated, unspecified).

C. Class I, Clear Anodic Finish: AA-M12C22A41 (Mechanical Finish: nonspecular as fabricated; Chemical Finish: etched, medium matte; Anodic Coating: Architectural Class I, clear coating 0.018 mm or thicker) complying with AAMA 607.1.

PART 3 - EXECUTION

3.1 INSTALLATION, GENERAL

A. Fastening to In-Place Construction: Provide anchorage devices and fasteners where necessary for securing metal fabrications to in-place construction. Include threaded fasteners for concrete and masonry inserts, toggle bolts, through-bolts, lag bolts, wood screws, and other connectors.

B. Cutting, Fitting, and Placement: Perform cutting, drilling, and fitting required for installing metal fabrications. Set metal fabrications accurately in location, alignment, and elevation; with edges and surfaces level, plumb, true, and free of rack; and measured from established lines and levels.

C. Provide temporary bracing or anchors in formwork for items that are to be built into concrete or similar construction.

D. Fit exposed connections accurately together to form hairline joints. Weld connections that are not to be left as exposed joints but cannot be shop welded because of shipping size limitations. Do not weld, cut, or abrade surfaces of exterior units that have been hot-dip galvanized after fabrication and are for bolted or screwed field connections.

E. Field Welding: Comply with the following requirements:

1. Use materials and methods that minimize distortion and develop strength and corrosion resistance of base metals.

2. Obtain fusion without undercut or overlap. 3. Remove welding flux immediately. 4. 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.



F. Corrosion Protection: Coat concealed surfaces of aluminum that will come into contact with grout, concrete, masonry, wood, or dissimilar metals with a heavy coat of bituminous paint.

3.2 INSTALLING BICYCLE RACKS

A. Anchor bicycle racks to existing construction with expansion anchors. Provide four 12.7-mm bolts at each end post and 2 at each intermediate post.

3.3 SETTING BEARING AND LEVELING PLATES

A. Clean concrete and masonry bearing surfaces of bond-reducing materials, and roughen to improve bond to surfaces. Clean bottom surface of plates.

B. Set bearing and leveling plates on wedges, shims, or leveling nuts. After bearing members have been positioned and plumbed, tighten anchor bolts. Do not remove wedges or shims but, if protruding, cut off flush with edge of bearing plate before packing with grout.

1. Use nonshrink grout, either metallic or nonmetallic, in concealed locations where not exposed to moisture; use nonshrink, nonmetallic grout in exposed locations, unless otherwise indicated.

2. Pack grout solidly between bearing surfaces and plates to ensure that no voids remain.

3.4 INSTALLING MISCELLANEOUS FRAMING AND SUPPORTS

A. General: Install framing and supports to comply with requirements of items being supported, including manufacturers' written instructions and requirements indicated on Shop Drawings, if any.

B. Anchor supports for operable partitions securely to and rigidly brace from building structure.

3.5 ADJUSTING AND CLEANING

A. Touchup Painting: Immediately after erection, clean field welds, bolted connections, and abraded areas of shop paint, and paint exposed areas with the same material as used for shop painting to comply with SSPC-PA 1 for touching up shop-painted surfaces.

1. Apply by brush or spray to provide a minimum 0.05-mm dry film thickness.

B. Touchup Painting: Cleaning and touchup painting of field welds, bolted connections, and abraded areas of shop paint are specified in Division 9 Section "Painting."

C. Galvanized Surfaces: Clean field welds, bolted connections, and abraded areas and repair galvanizing to comply with ASTM A 780.


UNITED STATES DEPARTMENT OF STATE JANUARY 2008 OVERSEAS BUILDINGS OPERATIONS OBO STANDARD SPECIFICATIONS

THROUGH-PENETRATION FIRESTOP SYSTEMS SECTION 07841 - 1

SECTION 07841 - THROUGH-PENETRATION FIRESTOP SYSTEMS

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes through-penetration firestop systems for penetrations through the following fire-resistance-rated assemblies, including both empty openings and openings containing penetrating items:

1. Walls and partitions. 2. Smoke barriers. 3. Construction enclosing compartmentalized areas.


A. General: For penetrations through the following fire-resistance-rated constructions, including both empty openings and openings containing penetrating items, provide through-penetration firestop systems that are produced and installed to resist spread of fire according to requirements indicated, resist passage of smoke and other gases, and maintain original fire-resistance rating of construction penetrated.

1. Fire-resistance-rated load-bearing walls, including partitions, with fire-protection-rated

openings. 2. Fire-resistance-rated non-load-bearing walls, including partitions, with fire-protection-

rated openings. 3. Fire-resistance-rated floor assemblies. 4. Fire-resistance-rated roof assemblies.

B. Rated Systems: Provide through-penetration firestop systems with the following ratings determined per ASTM E 814 :

1. F-Rated Systems: Provide through-penetration firestop systems with F-ratings indicated, but not less than that equaling or exceeding fire-resistance rating of constructions penetrated.

2. T-Rated Systems: For the following conditions, provide through-penetration firestop systems with T-ratings indicated, as well as F-ratings, where systems protect penetrating items exposed to potential contact with adjacent materials in occupiable floor areas:

a. Penetrations located outside wall cavities. b. Penetrations located outside fire-resistance-rated shaft enclosures. c. Penetrations located in construction containing fire-protection-rated openings. d. Penetrating items larger than 100-mm-diameter nominal pipe or 100 sq. cm in

overall cross-sectional area.



C. For through-penetration firestop systems exposed to view, traffic, moisture, and physical damage, provide products that, after curing, do not deteriorate when exposed to these conditions both during and after construction.

1. For piping penetrations for plumbing and wet-pipe sprinkler systems, provide moisture-resistant through-penetration firestop systems.

2. For floor penetrations with annular spaces exceeding 100 mm (4 inches) 3. in width and exposed to possible loading and traffic, provide firestop systems capable of

supporting floor loads involved, either by installing floor plates or by other means. 4. For penetrations involving insulated piping, provide through-penetration firestop systems

not requiring removal of insulation.

D. For through-penetration firestop systems exposed to view, provide products with flame-spread and smoke-developed indexes of less than 25 and 450, respectively, as determined per ASTM E 84.

1.3 SUBMITTAL

A. Product Data: For each type of product indicated.

B. Shop Drawings: For each through-penetration firestop system, show each type of construction condition penetrated, relationships to adjoining construction, and type of penetrating item. Include firestop designation of qualified testing and inspecting agency that evidences compliance with requirements for each condition indicated.

1. Submit documentation, including illustrations, from a qualified testing and inspecting agency that is applicable to each through-penetration firestop system configuration for construction and penetrating items.

2. Where Project conditions required modification to a qualified testing and inspecting agency’s illustration for a particular through-penetration firestop condition, submit illustration, with modifications marked, approved by through-penetration firestop system manufacturer’s fire-protection engineer as an engineering judgment or equivalent fire-resistance-rated assembly.

C. Through-Penetration Firestop System Schedule: Indicate locations of each through-penetration firestop system, along with the following information.

1. Types of penetrating items. 2. Types of constructions penetrated, including fire-resistant ratings, and where applicable,

thicknesses of construction penetrated. 3. Through-penetration firestop systems for each location identified by firestop design

designation of qualified testing and inspecting agency.

D. Qualification Data: For Installer.

E. Product Certificates: For through-penetration firestop system products, signed by product manufacturer.



F. Product Test Reports: From a qualified testing agency indicating through-penetration firestop system complies with requirements, based on comprehensive testing of current products.


A. Installer Qualifications: A firm that has been approved by FMG according to FMG 4991, "Approval of Firestop Contractors."

B. Installer Qualifications: A firm experienced in installing through-penetration firestop systems similar in material, design, and extent to that indicated for this Project, whose work has resulted in construction with a record of successful performance. Qualifications include having the necessary experience, staff, and training to install manufacturer's products per specified requirements. Manufacturer's willingness to sell its through-penetration firestop system products to Contractor or to Installer engaged by Contractor does not in itself confer qualification on buyer.

C. Installation Responsibility: Assign installation of through-penetration firestop systems and fire-resistive joint systems in Project to a single qualified installer.

D. Source Limitations: Obtain through-penetration firestop systems, for each kind of penetration and construction condition indicated, through one source from a single manufacturer.

E. Fire-Test-Response Characteristics: Provide through-penetration firestop systems that comply with the following requirements and those specified in Part 1 "Performance Requirements" Article:

1. Firestopping tests are performed by a qualified testing and inspecting agency. A qualified testing and inspecting agency is UL, or another agency performing testing and follow-up inspection services for firestop systems acceptable to authorities having jurisdiction.

2. Through-penetration firestop systems are identical to those tested per testing standard referenced in "Part 1 Performance Requirements" Article. Provide rated systems complying with the following requirements:

a. Through-penetration firestop system products bear classification marking of qualified testing and inspecting agency.

b. Through-penetration firestop systems correspond to those indicated by reference to through-penetration firestop system designations listed by the following:

1) UL in its "Fire Resistance Directory."

F. Preinstallation Conference: Conduct conference at Project site to comply with requirements in Division 1 Section "Project Management and Coordination."




A. Deliver through-penetration firestop system products to Project site in original, unopened containers or packages with intact and legible manufacturers' labels identifying product and manufacturer; date of manufacture; lot number; shelf life, if applicable; qualified testing and inspecting agency's classification marking applicable to Project; curing time; and mixing instructions for multicomponent materials.

B. Store and handle materials for through-penetration firestop systems to prevent their deterioration or damage due to moisture, temperature changes, contaminants, or other causes.

1.6 PROJECT CONDITIONS

A. Environmental Limitations: Do not install through-penetration firestop systems when ambient or substrate temperatures are outside limits permitted by through-penetration firestop system manufacturers or when substrates are wet due to rain, frost, condensation, or other causes.

B. Ventilate through-penetration firestop systems per manufacturer's written instructions by natural means or, where this is inadequate, forced-air circulation.

1.7 COORDINATION

A. Coordinate construction of openings and penetrating items to ensure that through-penetration firestop systems are installed according to specified requirements.

B. Coordinate sizing of sleeves, openings, core-drilled holes, or cut openings to accommodate through-penetration firestop systems.

C. Notify Government's inspecting agency at least seven days in advance of through-penetration firestop system installations; confirm dates and times on days preceding each series of installations.

D. Do not cover up through-penetration firestop system installations that will become concealed behind other construction until Government's inspecting agency and building inspector, if required by authorities having jurisdiction, have examined each installation.

PART 2 - PRODUCTS

2.1 FIRESTOPPING, GENERAL

A. Compatibility: Provide through-penetration firestop systems that are compatible with one another, with the substrates forming openings, and with the items, if any, penetrating through-penetration firestop systems, under conditions of service and application, as demonstrated by through-penetration firestop system manufacturer based on testing and field experience.



B. Accessories: Provide components for each through-penetration firestop system that are needed to install fill materials and to comply with "Performance Requirements" Article. Use only components specified by through-penetration firestop system manufacturer and approved by the qualified testing and inspecting agency for firestop systems indicated. Accessories include, but are not limited to, the following items:

1. Permanent forming/damming/backing materials, including the following:

a. Slag/rock-wool-fiber insulation. b. Sealants used in combination with other forming/damming/backing materials to

prevent leakage of fill materials in liquid state. c. Fire-rated form board. d. Fillers for sealants.

2. Temporary forming materials. 3. Substrate primers. 4. Collars. 5. Steel sleeves.

2.2 FILL MATERIALS

A. General: Provide through-penetration firestop systems containing the types of fill materials indicated in the Through-Penetration Firestop System Schedule at the end of Part 3 by reference to the types of materials described in this Article. Fill materials are those referred to in directories of the referenced testing and inspecting agencies as fill, void, or cavity materials.

B. Cast-in-Place Firestop Devices: Factory-assembled devices for use in cast-in-place concrete floors and consisting of an outer metallic sleeve lined with an intumescent strip, a radial extended flange attached to one end of the sleeve for fastening to concrete formwork, and a neoprene gasket.

C. Latex Sealants: Single-component latex formulations that after cure do not re-emulsify during exposure to moisture.

D. Firestop Devices: Factory-assembled collars formed from galvanized steel and lined with intumescent material sized to fit specific diameter of penetrant.

E. Intumescent Composite Sheets: Rigid panels consisting of aluminum-foil-faced elastomeric sheet bonded to galvanized steel sheet.

F. Intumescent Putties: Nonhardening dielectric, water-resistant putties containing no solvents, inorganic fibers, or silicone compounds.

G. Intumescent Wrap Strips: Single-component intumescent elastomeric sheets with aluminum foil on one side.



H. Mortars: Prepackaged, dry mixes consisting of a blend of inorganic binders, hydraulic cement, fillers, and lightweight aggregate formulated for mixing with water at Project site to form a nonshrinking, homogeneous mortar.

I. Pillows/Bags: Reusable, heat-expanding pillows/bags consisting of glass-fiber cloth cases filled with a combination of mineral-fiber, water-insoluble expansion agents, and fire-retardant additives.

J. Silicone Foams: Multicomponent, silicone-based liquid elastomers that, when mixed, expand and cure in place to produce a flexible, nonshrinking foam.

K. Silicone Sealants: Moisture-curing, single-component, silicone-based, neutral-curing elastomeric sealants of grade indicated below:

1. Grade: Pourable (self-leveling) formulation for openings in floors and other horizontal surfaces and nonsag formulation for openings in vertical and other surfaces requiring a nonslumping, gunnable sealant, unless indicated firestop system limits use to nonsag grade for both opening conditions.

2. Grade for Horizontal Surfaces: Pourable (self-leveling) formulation for openings in floors and other horizontal surfaces.

3. Grade for Vertical Surfaces: Nonsag formulation for openings in vertical and other surfaces.

2.3 MIXING

A. For those products requiring mixing before application, comply with through-penetration firestop system manufacturer's written instructions for accurate proportioning of materials, water (if required), type of mixing equipment, selection of mixer speeds, mixing containers, mixing time, and other items or procedures needed to produce products of uniform quality with optimum performance characteristics for application indicated.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine substrates and conditions, with Installer present, for compliance with requirements for opening configurations, penetrating items, substrates, and other conditions affecting performance.

B. Proceed with installation only after unsatisfactory conditions have been corrected.



3.2 PREPARATION

A. Surface Cleaning: Clean out openings immediately before installing through-penetration firestop systems to comply with written recommendations of firestop system manufacturer and the following requirements:

1. Remove from surfaces of opening substrates and from penetrating items foreign materials that could interfere with adhesion of through-penetration firestop systems.

2. Clean opening substrates and penetrating items to produce clean, sound surfaces capable of developing optimum bond with through-penetration firestop systems. Remove loose particles remaining from cleaning operation.

3. Remove laitance and form-release agents from concrete.

B. Priming: Prime substrates where recommended in writing by through-penetration firestop system manufacturer using that manufacturer's recommended products and methods. Confine primers to areas of bond; do not allow spillage and migration onto exposed surfaces.

C. Masking Tape: Use masking tape to prevent through-penetration firestop systems from contacting adjoining surfaces that will remain exposed on completion of Work and that would otherwise be permanently stained or damaged by such contact or by cleaning methods used to remove smears from firestop system materials. Remove tape as soon as possible without disturbing firestop system's seal with substrates.

3.3 THROUGH-PENETRATION FIRESTOP SYSTEM INSTALLATION

A. General: Install through-penetration firestop systems to comply with "Performance Requirements" Article and firestop system manufacturer's written installation instructions and published drawings for products and applications indicated.

B. Install forming/damming/backing materials and other accessories of types required to support fill materials during their application and in the position needed to produce cross-sectional shapes and depths required to achieve fire ratings indicated.

1. After installing fill materials, remove combustible forming materials and other accessories not indicated as permanent components of firestop systems.

C. Install fill materials for firestop systems by proven techniques to produce the following results:

1. Fill voids and cavities formed by openings, forming materials, accessories, and penetrating items as required to achieve fire-resistance ratings indicated.

2. Apply materials so they contact and adhere to substrates formed by openings and penetrating items.

3. For fill materials that will remain exposed after completing Work, finish to produce smooth, uniform surfaces that are flush with adjoining finishes.



3.4 IDENTIFICATION

A. Identify through-penetration firestop systems with preprinted metal or plastic labels. Attach labels permanently to surfaces adjacent to and within 150 mm (6 inches) of edge of the firestop systems so that labels will be visible to anyone seeking to remove penetrating items or firestop systems. Use mechanical fasteners for metal labels. For plastic labels, use self-adhering type with adhesives capable of permanently bonding labels to surfaces on which labels are placed and, in combination with label material, will result in partial destruction of label if removal is attempted. Include the following information on labels:

1. The words "Warning - Through-Penetration Firestop System - Do Not Disturb. Notify Building Management of Any Damage."

2. Contractor's name, address, and phone number. 3. Through-penetration firestop system designation of applicable testing and inspecting

agency. 4. Date of installation. 5. Through-penetration firestop system manufacturer's name. 6. Installer's name.

3.5 CLEANING AND PROTECTION

A. Clean off excess fill materials adjacent to openings as Work progresses by methods and with cleaning materials that are approved in writing by through-penetration firestop system manufacturers and that do not damage materials in which openings occur.

B. Provide final protection and maintain conditions during and after installation that ensure through-penetration firestop systems are without damage or deterioration at time of Substantial Completion. If, despite such protection, damage or deterioration occurs, cut out and remove damaged or deteriorated through-penetration firestop systems immediately and install new materials to produce through-penetration firestop systems complying with specified requirements.



JOINT SEALANTS SECTION 07920 - 1

SECTION 07920 - JOINT SEALANTS

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes joint sealants for the following applications:

1. Exterior joints in the following vertical surfaces and horizontal nontraffic surfaces:

a. Control and expansion joints in unit masonry. b. Joints in dimension stone cladding. c. Joints between metal panels. d. Joints between different materials listed above. e. Perimeter joints between materials listed above and frames of doors, windows and

louvers. f. Control and expansion joints in ceilings and other overhead surfaces.

2. Exterior joints in the following horizontal traffic surfaces:

a. Joints in stone paving units. b. Tile control and expansion joints. c. Joints between different materials listed above.

3. Interior joints in the following vertical surfaces and horizontal nontraffic surfaces:

a. Control and expansion joints on exposed interior surfaces of exterior walls. b. Tile control and expansion joints. c. Vertical joints on exposed surfaces of walls and partitions. d. Perimeter joints between interior wall surfaces and frames of interior doors

windows and elevator entrances. e. Joints between plumbing fixtures and adjoining walls, floors, and counters.

4. Interior joints in the following horizontal traffic surfaces:

a. Control and expansion joints in tile flooring.


A. Provide elastomeric joint sealants that establish and maintain watertight and airtight continuous joint seals without staining or deteriorating joint substrates.

B. Provide joint sealants for interior applications that establish and maintain airtight and water-resistant continuous joint seals without staining or deteriorating joint substrates.



1.3 SUBMITTALS

A. Product Data: For each joint-sealant product indicated.

B. Samples for Initial Selection: Manufacturer's color charts consisting of strips of cured sealants showing the full range of colors available for each product exposed to view.

C. Samples for Verification: For each type and color of joint sealant required, provide Samples with joint sealants in 13-mm (1/2-inch) wide joints formed between two 150-mm (6-inch) long strips of material matching the appearance of exposed surfaces adjacent to joint sealants.

D. LEED Submittals:

1. Credit EQ 4.1: Manufacturers' product data for interior sealants, including printed statement of VOC content.

E. Product Certificates: For each type of joint sealant and accessory, signed by product manufacturer.

F. SWRI Validation Certificate: For each elastomeric sealant specified to be validated by SWRI's Sealant Validation Program.

G. Qualification Data: For Installer and testing agency.

H. Preconstruction Field Test Reports: Indicate which sealants and joint preparation methods resulted in optimum adhesion to joint substrates based on preconstruction testing specified in "Quality Assurance" Article.

I. Compatibility and Adhesion Test Reports: From sealant manufacturer, indicating the following:

1. Materials forming joint substrates and joint-sealant backings have been tested for compatibility and adhesion with joint sealants.

2. Interpretation of test results and written recommendations for primers and substrate preparation needed for adhesion.

J. Field Test Report Log: For each elastomeric sealant application.

K. Product Test Reports: Based on comprehensive testing of product formulations performed by a qualified testing agency, indicating that sealants comply with requirements.


A. Preconstruction Compatibility and Adhesion Testing: Submit samples of materials that will contact or affect joint sealants to joint-sealant manufacturers for testing according to ASTM C 1087 to determine whether priming and other specific joint preparation techniques are required to obtain rapid, optimum adhesion of joint sealants to joint substrates.



B. Preconstruction Field-Adhesion Testing: Before installing elastomeric sealants, field test their adhesion to Project joint substrates according to the method in ASTM C 1193 that is appropriate for the types of Project joints.

PART 2 - PRODUCTS

2.1 MATERIALS, GENERAL

A. Compatibility: Provide joint sealants, backings, and other related materials that are compatible with one another and with joint substrates under conditions of service and application, as demonstrated by sealant manufacturer, based on testing and field experience.

B. Colors of Exposed Joint Sealants: As indicated.

2.2 ELASTOMERIC JOINT SEALANTS

A. Elastomeric Sealants: Comply with ASTM C 920 and other requirements indicated for each liquid-applied chemically curing sealant specified, including those referencing ASTM C 920 classifications for type, grade, class, and uses related to exposure and joint substrates.

B. Stain-Test-Response Characteristics: Where elastomeric sealants are specified to be nonstaining to porous substrates, provide products that have undergone testing according to ASTM C 1248 and have not stained porous joint substrates indicated for Project.

C. Suitability for Immersion in Liquids. Where elastomeric sealants are indicated for Use I for joints that will be continuously immersed in liquids, provide products that have undergone testing according to ASTM C 1247 and qualify for the length of exposure indicated by reference to ASTM C 920 for Class 1 or 2. Liquid used for testing sealants is deionized water, unless otherwise indicated.

D. Suitability for Contact with Food: Where elastomeric sealants are indicated for joints that will come in repeated contact with food, provide products that comply with 21 CFR 177.2600.

E. Single-Component Nonsag Polysulfide Sealant :

1. Type and Grade: S (single component) and NS (nonsag). 2. Class: 25. 3. Use Related to Exposure: NT (nontraffic). 4. Uses Related to Joint Substrates: M, G, A, and, as applicable to joint substrates

indicated, O.

F. Multicomponent Nonsag Neutral-Curing Silicone Sealant :

1. Type and Grade: M (multicomponent) and P (pourable). 2. Class: 50.



3. Use Related to Exposure: NT (nontraffic). 4. Uses Related to Joint Substrates: M, G, A, and, as applicable to joint substrates

indicated, O.

G. Single-Component Pourable Neutral-Curing Silicone Sealant :

1. Type and Grade: S (single component) and P (pourable). 2. Class: 100/50. 3. Uses Related to Exposure: NT and T (traffic). 4. Uses Related to Joint Substrates: M A and O, as applicable to joint substrates indicated.

H. Single-Component Neutral- and Basic-Curing Silicone Sealant:

1. Type and Grade: S (single component) and NS (nonsag). 2. Class: 100/50. 3. Use Related to Exposure: NT (nontraffic). 4. Uses Related to Joint Substrates: M, G, A, and, as applicable to joint substrates

indicated, O. 5. Stain-Test-Response Characteristics: Nonstaining to porous substrates per

ASTM C 1248.

I. Single-Component Neutral-Curing Silicone Sealant :


indicated, O.

J. Single-Component Mildew-Resistant Neutral-Curing Silicone Sealant :


indicated, O.

K. Single-Component Nonsag Urethane Sealant :

1. Type and Grade: S (single component) and NS (nonsag). 2. Class: 50. 3. Use Related to Exposure: NT (nontraffic). 4. Uses Related to Joint Substrates: M, A, and, as applicable to joint substrates indicated,

O.



2.3 SOLVENT-RELEASE JOINT SEALANTS

A. Acrylic-Based Solvent-Release Joint Sealant : Comply with ASTM C 1311 or FS TT-S-00230.

B. Butyl-Rubber-Based Solvent-Release Joint Sealant: Comply with ASTM C 1085.

C. Pigmented Narrow-Joint Sealant: Manufacturer's standard, solvent-release-curing, pigmented, synthetic-rubber sealant complying with AAMA 803.3 and formulated for sealing joints 5 mm or smaller in width.

2.4 LATEX JOINT SEALANTS

A. Latex Sealant : Comply with ASTM C 834, Type P, Grade NF.

2.5 ACOUSTICAL JOINT SEALANTS

A. Acoustical Sealant for Exposed and Concealed Joints: Manufacturer's standard nonsag, paintable, nonstaining latex sealant complying with ASTM C 834 that effectively reduces airborne sound transmission through perimeter joints and openings in building construction as demonstrated by testing representative assemblies according to ASTM E 90.

B. Acoustical Sealant for Concealed Joints: Manufacturer's standard, nondrying, nonhardening, nonskinning, nonstaining, gunnable, synthetic-rubber sealant recommended for sealing interior concealed joints to reduce airborne sound transmission.

2.6 JOINT-SEALANT BACKING

A. General: Provide sealant backings of material and type that are nonstaining; are compatible with joint substrates, sealants, primers, and other joint fillers; and are approved for applications indicated by sealant manufacturer based on field experience and laboratory testing.

B. Cylindrical Sealant Backings: ASTM C 1330, Type C (closed-cell material with a surface skin) O (open-cell material), B (bicellular material with a surface skin), and of size and density to control sealant depth and otherwise contribute to producing optimum sealant performance:

C. Elastomeric Tubing Sealant Backings: Neoprene, butyl, EPDM, or silicone tubing complying with ASTM D 1056, nonabsorbent to water and gas, and capable of remaining resilient at temperatures down to minus 32 deg C. Provide products with low compression set and of size and shape to provide a secondary seal, to control sealant depth, and to otherwise contribute to optimum sealant performance.

D. Bond-Breaker Tape: Polyethylene tape or other plastic tape recommended by sealant manufacturer for preventing sealant from adhering to rigid, inflexible joint-filler materials or joint surfaces at back of joint where such adhesion would result in sealant failure. Provide self-adhesive tape where applicable.



2.7 MISCELLANEOUS MATERIALS

A. Primer: Material recommended by joint-sealant manufacturer where required for adhesion of sealant to joint substrates indicated, as determined from preconstruction joint-sealant-substrate tests and field tests.

B. Cleaners for Nonporous Surfaces: Chemical cleaners acceptable to manufacturers of sealants and sealant backing materials, free of oily residues or other substances capable of staining or harming joint substrates and adjacent nonporous surfaces in any way, and formulated to promote optimum adhesion of sealants to joint substrates.

C. Masking Tape: Nonstaining, nonabsorbent material compatible with joint sealants and surfaces adjacent to joints.

PART 3 - EXECUTION

3.1 PREPARATION

A. Surface Cleaning of Joints: Clean out joints immediately before installing joint sealants.

1. Remove all foreign material from joint substrates that could interfere with adhesion of joint sealant.

a. Clean porous joint substrate surfaces by brushing, grinding, blast cleaning, mechanical abrading, or a combination of these methods to produce a clean, sound substrate capable of developing optimum bond with joint sealants. Remove loose particles remaining after cleaning operations above by vacuuming or blowing out joints with oil-free compressed air.

2. Remove laitance and form-release agents from concrete.

a. Clean nonporous surfaces with chemical cleaners or other means that do not stain, harm substrates, or leave residues capable of interfering with adhesion of joint sealants.

B. Joint Priming: Prime joint substrates, where recommended in writing by joint-sealant manufacturer, based on preconstruction joint-sealant-substrate tests or prior experience. Apply primer to comply with joint-sealant manufacturer's written instructions. Confine primers to areas of joint-sealant bond; do not allow spillage or migration onto adjoining surfaces.

C. Masking Tape: Use masking tape where required to prevent contact of sealant with adjoining surfaces that otherwise would be permanently stained or damaged by such contact or by cleaning methods required to remove sealant smears. Remove tape immediately after tooling without disturbing joint seal.



3.2 INSTALLATION

A. Sealant Installation Standard: Comply with recommendations in ASTM C 1193 for use of joint sealants as applicable to materials, applications, and conditions indicated.

B. Acoustical Sealant Application Standard: Comply with recommendations in ASTM C 919 for use of joint sealants in acoustical applications as applicable to materials, applications, and conditions indicated.

C. Install sealant backings of type indicated to support sealants during application and at position required to produce cross-sectional shapes and depths of installed sealants relative to joint widths that allow optimum sealant movement capability.

1. Do not leave gaps between ends of sealant backings. 2. Do not stretch, twist, puncture, or tear sealant backings. 3. Remove absorbent sealant backings that have become wet before sealant application and

replace them with dry materials.

D. Install bond-breaker tape behind sealants where sealant backings are not used between sealants and backs of joints.

E. Install sealants using proven techniques that comply with the following and at the same time backings are installed:

1. Place sealants so they directly contact and fully wet joint substrates. 2. Completely fill recesses in each joint configuration. 3. Produce uniform, cross-sectional shapes and depths relative to joint widths that allow

optimum sealant movement capability.

F. Tooling of Nonsag Sealants: Immediately after sealant application and before skinning or curing begins, tool sealants according to requirements specified below to form smooth, uniform beads of configuration indicated; to eliminate air pockets; and to ensure contact and adhesion of sealant with sides of joint.

1. Remove excess sealant from surfaces adjacent to joints. 2. Use tooling agents that are approved in writing by sealant manufacturer and that do not

discolor sealants or adjacent surfaces. 3. Provide concave joint configuration per Figure 5A in ASTM C 1193, unless otherwise

indicated.

G. Installation of Preformed Silicone-Sealant System: Comply with manufacturer's written instructions.



H. Installation of Preformed Foam Sealants: Install each length of sealant immediately after removing protective wrapping, taking care not to pull or stretch material, producing seal continuity at ends, turns, and intersections of joints. For applications at low ambient temperatures where expansion of sealant requires acceleration to produce seal, apply heat to sealant in compliance with sealant manufacturer's written instructions.

I. Clean off excess sealant or sealant smears adjacent to joints as the Work progresses by methods and with cleaning materials approved in writing by manufacturers of joint sealants and of products in which joints occur.



STEEL DOORS AND FRAMES SECTION 08110 - 1

SECTION 08110 - STEEL DOORS AND FRAMES

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes the following:

1. Steel doors. 2. Steel door frames. 3. Stainless-steel doors and frames. 4. Sidelight or borrowed-light frames. 5. Hollow-metal panels and frames. 6. Fire-rated door and frame assemblies. 7. Louvers in doors.

B. Related Sections include the following:

1. Division 4 Section “Unit Masonry Assemblies” for building anchors into and grouting frames in masonry construction.

2. Division 5 Section “Formed-Metal Fabrications” for customized hollow-metal work other than doors, panels, and frames.

3. Division 8 Section “Flush Wood Doors” for wood doors installed in steel frames. 4. Division 8 Section “Sound Control Doors” for acoustical doors with an STC rating of 43

to 52. 5. Division 8 Sections for door hardware and weather stripping. 6. Division 8 Section “Glazing” for glass in doors and sidelights or borrowed lights. 7. Division 9 Section “Gypsum Board Assemblies” for steel stud and gypsum board

partitions. 8. Division 9 Section “Painting” for field painting primed doors and frames.

1.2 DEFINITIONS

A. Uncoated steel sheet thickness is indicated as the minimum thickness according to HMMA 803, Steel Tables.

B. Metallic-coated steel sheet thickness is indicated as the minimum thickness of the uncoated base metal.

C. Stainless-steel sheet thicknesses are indicated as the specified thickness for which over and under thickness tolerances apply according to ASTM A 480/A 480M.



1.3 SUBMITTALS

A. Product Data: Include construction details, material descriptions, core descriptions, label compliance, sound and fire-resistance ratings, and finishes for each type of door and frame specified.

B. Shop Drawings: Show fabrication and installation of doors and frames. Include details of each frame type, elevations of door design types, conditions at openings, details of construction, dimensions of profiles and hardware preparation, location and installation requirements of door and frame hardware and reinforcements, location and thickness of lead lining, and details of joints and connections. Show anchorage and accessories.

1. Electric Hardware Devices: Indicated routing of electrical conduit for electric hardware devices.

2. Security System Components: Indicate all cutouts required to metal door and frame components to accept security system components.

C. Door Schedule: Submit schedule of doors and frames using same reference numbers for details and openings as those on Drawings.

1. Coordinate glazing frames and stops with glass and glazing requirements.

D. Product Certificates: Signed by manufacturers of doors certifying that products furnished comply with or exceed the acceptance criteria of ANSI A250.4 for Level A doors.

E. Oversize Construction Certification: For door assemblies required to be fire rated and exceeding limitations of labeled assemblies, submit certification of a testing agency acceptable to authorities having jurisdiction that each door and frame assembly has been constructed to comply with design, materials, and construction equivalent to requirements for labeled construction.


A. Manufacturer Qualifications: A firm experienced in manufacturing custom steel doors and frames similar to those indicated for this Project and with a record of successful in-service performance, as well as sufficient production capacity to produce required units.

B. Fire-Rated Door Assemblies: Assemblies complying with NFPA 80 that are listed and labeled by a testing and inspecting agency acceptable to authorities having jurisdiction, for fire ratings indicated, based on testing according to NFPA 252.

1. Test Pressure: Test at atmospheric pressure. 2. Oversize Fire-Rated Door Assemblies: For units exceeding sizes of tested assemblies,

provide certification by a testing agency acceptable to authorities having jurisdiction that doors comply with standard construction requirements for tested and labeled fire-rated door assemblies except for size.

3. Temperature-Rise Rating: If indicated, provide doors that have a temperature-rise rating of 250 deg C maximum in 30 minutes of fire exposure.




A. Deliver doors and frames palleted, wrapped, or crated to provide protection during transit and Project site storage. Do not use nonvented plastic.

B. Inspect doors and frames, on delivery, for damage. Minor damage may be repaired provided refinished items match new work and are approved by COR; otherwise, remove and replace damaged items as directed.

C. Store doors and frames under cover at building site. Place units on minimum 100-mm-high wood blocking. Avoid using nonvented plastic or canvas shelters that could create a humidity chamber. If wrappers on doors become wet, remove cartons immediately. Provide minimum 6-mm spaces between stacked doors to permit air circulation.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, provide doors and frame by one of the following:

1. Steel Doors and Frames:

a. Amweld Building Products, Inc. b. Ceco Door Products. c. Curries Company. d. Deronde Products, Inc. e. Firedoor Corporation of Florida. f. Fleming: S. W. Fleming Limited. g. Steelcraft; a division of Ingersoll-Rand. h. Tex-Steel Corporation.

2. Stainless-Steel Doors and Frames:

a. Curries Company. b. Deronde Products, Inc. c. Fleming: S. W. Fleming Limited. d. Next Door Company. e. Steelcraft; a division of Ingersoll-Rand. f. Tex-Steel Corporation.

2.2 MATERIALS

A. Hot-Rolled Steel Sheets: ASTM A 569/A 569M, CS (commercial steel), Type B; free of scale, pitting, or surface defects; pickled and oiled.

B. Cold-Rolled Steel Sheets: ASTM A 366/A 366M, CS (commercial steel), Type B.



C. Metallic-Coated Steel Sheets: ASTM A 653/A 653M, CS (commercial steel), Type B; with Z180 zinc (galvanized) or ZF180 zinc-iron-alloy (galvannealed) coating.

D. Stainless-Steel Sheets Where Required for Finish: AISI Type 302/304, complying with ASTM A 167, commercial quality, No. 4 directional polish. Finish is intended to match that of those Forced Entry/Ballistic Resistant (FE/BR) doors in Section 08318 which have stainless steel finish in cases where comparable FE/BR and non-FE/BR doors are seen in relation to each other. (#73738, D. Hammes, 1/20/06)

E. Inserts, Bolts, and Fasteners: Manufacturer’s standard units. Where items are to be built to exterior walls, zinc coat according to ASTM A 153/A 153M, Class C or D as applicable.

F. Filler: Sound deadening and heat-retarding mineral fiber insulating material. At doors required to have temperature rise rating provide mineral fiberboard core.

G. Glazing and Glazing Felt: Clear Wire Glass: Type II, Class 1, Form 1, with pattern M1 (diamond) wire mesh where shown.

1. Fire Resistance Rated Wire Glass: Provide wire glass products that are identical to those tested per ASTM E163 (UL 9) and are labeled and listed by UL or other testing and inspecting agency acceptable to authorities having jurisdiction.

H. Lead Lining: Rolled sheet lead conforming to requirements of FS QQ-L-201, Grade C (Chemical Lead) in sizes and thicknesses indicated.

2.3 DOORS

A. General: Provide flush-design doors, 44 mm thick, of seamless hollow construction, unless otherwise indicated. Construct doors with smooth, flush surfaces without visible joints or seams on exposed faces or stile edges. Exterior doors to be IGGA (1.5mm) galvanized interior doors 18 GA (1.2mm).

1. Visible joints or seams around glazed or louvered panel inserts are permitted. 2. For single-acting swing doors, bevel both vertical edges 3 mm in 50 mm. 3. For double-acting swing doors, round vertical edges with 54-mm radius. 4. Exterior doors to have flush tops.

B. Metallic Core Construction: Provide the following core construction welded to both door faces:

1. Continuous Truss-Form Inner Core: 0.33-mm- thick steel reinforcement spot welded to face sheets a maximum of 75 mm o.c. vertically and horizontally.

C. Fire Door Cores: As required to provide fire-protection and temperature-rise ratings indicated.

D. Astragals: As required by NFPA 80 to provide fire ratings indicated.

E. Top and Bottom Channels: Spot weld metal channel not less than thickness of face sheet to face sheets not more than 150 mm o.c.



1. Reinforce tops and bottoms of doors with inverted horizontal channels of same material as face sheet so flanges of channels are even with bottom and top edges of face sheets.

2. For exterior doors, close bottom edge with metallic-coated steel closing channel and top edge with filler channel of same material, so webs of channels are flush with bottom and top door edges.

F. Hardware Reinforcement: Fabricate reinforcing plates from the same material as door to comply with the following:

1. Hinges and Pivots: 4.2 mm thick by 38 mm wide by 150 mm longer than hinge, secured by not less than six spot welds.

2. Lock Face, Flush Bolts, Closers, and Concealed Holders: 2.3 mm thick. 3. All Other Surface-Mounted Hardware: 1.3 mm thick.

G. Interior Doors: Fabricate face sheets of doors from two 1.06-mm- thick, cold-rolled, stretcher-leveled steel sheets and other metal components from hot- or cold-rolled steel sheets.

H. Exterior Steel Doors: Fabricate face sheets of doors from two 1.3-mm-thick, stretcher - leveled, metallic-coated steel sheets. Provide weep-hole openings in bottom of doors to permit entrapped moisture to escape. Seal joints in top edges of doors against water penetration.

I. Stainless-Steel Doors: Fabricate face sheets of doors from two 1.3-mm-thick, stainless-steel sheets permanently and continuously bonded to nonmetallic cores or welded to rigid, internal stainless-steel core.

1. Internal Construction: Vertically reinforced with 1.3-mm-thick, stainless-steel sheet sections, spaced not more than 150 mm o.c., extended full-door height, and spot welded to both face sheets at not more than 125 mm o.c.

2. Reinforce tops and bottoms of doors with 1.3-mm-thick, stainless-steel horizontal channels spot welded a maximum of 150 mm o.c. to door faces.

a. For exterior doors, close bottom edge with minimum 1.3-mm-thick, stainless-steel closing channel and top edge with same thickness of stainless-steel filler channel, so webs of channels are flush with bottom and top door edges. Provide weep-hole openings in bottom of doors to permit entrapped moisture to escape. Seal joints in top edges of doors against water penetration.

J. Electrical Requirements: Provisions for installation of electrical items specified elsewhere; arrange so that wiring can be readily removed and replaced.

1. Security System Components: Provide all cutouts and reinforcements required for metal doors to accept security system components.

K. Doors With Electric Hinges: General: Provide with metal conduit raceway to permit wiring from electric hinge to other electric door hardware.

1. Hinge Location: Center for doors less than 2286 mm or 2nd hinge from door bottom for doors greater than 2286 mm; top or bottom electric hinge locations shall not be permitted.



2.4 PANELS

A. Provide panels of same materials, construction, and finish as specified for doors.

2.5 FRAMES

A. Fabricate frames of full-welded unit construction, with corners mitered, reinforced, and continuously welded full width of mitre. Knockdown frames are acceptable for drywall construction only.

1. For exterior use, form frames from 1.9-mm-thick, metallic-coated steel sheets galvanized. 2. For interior use, form frames from cold- or hot-rolled steel sheet of the following

thicknesses:

a. Openings up to and Including 1200 mm Wide: 1.5 mm. b. Openings More than 1200 mm Wide: 1.9 mm.

3. For stainless-steel doors, form frames from 1.6-mm-thick, stainless-steel sheets with No. 4 finish.

4. Lead Lined Frames: 1.519 mm thick steel.

B. Hardware Reinforcement: Fabricate from same material as frame. Minimum thickness of steel reinforcing plates for the following hardware:

1. Hinges and Pivots: 4.2 mm thick by 38 mm wide by 150 mm longer than hinge, secured by not less than six spot welds.

2. Strikes, Flush Bolts, and Closers: 2.3 mm. 3. Surface-Mounted Hold-Open Arms and Panic Devices: 2.3 mm.

C. Mullions and Transom Bars: Provide closed or tubular mullions and transom bars where indicated. Fasten mullions and transom bars at crossings and to jambs by butt welding. Reinforce joints between frame members with concealed clip angles or sleeves of same metal and thickness as frame.

1. Provide false head member to receive lower ceiling where frames extend to finish ceilings of different heights.

D. Head Reinforcement: Where installed in masonry, leave vertical mullions in frames open top for grouting.

E. Supports and Anchors: After fabricating, galvanize units to be built into exterior walls according to ASTM A 153/A 153M, Class B.

F. Jamb Anchors: Weld jamb anchors to frames near hinges and directly opposite on strike jamb as required to secure frames to adjacent construction.



1. Masonry Construction: Adjustable, flat, corrugated, or perforated T-shaped anchors to suit frame size; formed of same material as frame; not less than 1.3 mm thick; with leg not less than 50 mm wide by 250 mm long. Furnish at least the number of anchors per jamb according to the following frame heights:

a. Two anchors per jamb up to 1500 mm in height. b. Three anchors per jamb from 1500 to 2250 mm in height. c. Four anchors per jamb from 2250 to 2400 mm in height. d. One additional anchor per jamb for each 600 mm or fraction thereof more than

2400 mm in height.

2. Metal-Stud Partitions: Insert type with notched clip to engage metal stud, welded to back of frames, formed of same material as frame, not less than 1.0 mm thick. Provide at least the number of anchors for each jamb according to the following heights:

a. Three anchors per jamb up to 1500 mm in height. b. Four anchors per jamb from 1500 to 2250 mm in height. c. Five anchors per jamb from 2250 to 2400 mm in height. d. One additional anchor per jamb for each 600 mm or fraction thereof more than

2400 mm in height.

3. In-Place Concrete or Masonry: Anchor frame jambs with minimum 9-mm-diameter concealed bolts into expansion shields or inserts 150 mm from top and bottom and 650 mm o.c., unless otherwise indicated. Reinforce frames at anchor locations. Except for fire-rated openings, apply removable stop to cover anchor bolts, unless otherwise indicated.

G. Floor Anchors: Provide floor anchors for each jamb and mullion that extends to floor, formed of same material as frame, 1.7 mm thick, as follows:

1. Monolithic Concrete Slabs: Clip-type anchors, with two holes to receive fasteners, welded to bottom of jambs and mullions.

2. Separate Topping Concrete Slabs: Adjustable type with extension clips, allowing not less than 50-mm height adjustment. Terminate bottom of frames at finish floor surface.

H. Head Anchors: Provide two head anchors for frames more than 1066 mm wide and mounted in steel-stud walls.

I. Head Strut Supports: Provide 9-by-50-mm vertical steel struts extending from top of frame at each jamb to supporting construction above, unless frame is anchored to masonry or to other structural support at each jamb. Bend top of struts to provide flush contact for securing to supporting construction above. Provide adjustable wedged or bolted anchorage to frame jamb members.

J. Structural Reinforcing Metals: Provide as part of frame assembly, where indicated at mullions, transoms, or other locations to be built into frame.

K. Head Reinforcement: For frames more than 1200 mm wide in masonry wall openings, provide continuous steel channel or angle stiffener, 2.3 mm thick for full width of opening, welded to back of frame at head.



L. Spreader Bars: Provide removable spreader bar across bottom of frames, tack welded to jambs and mullions.

M. Rubber Door Silencers: Except on weather-stripped doors, drill stop in strike jamb to receive three silencers on single-door frames and drill head jamb stop to receive two silencers on double-door frames. Install plastic plugs to keep holes clear during construction.

N. Plaster Guards: Provide 0.4-mm-thick plaster guards or dust-cover boxes of same material as frame, welded to frame at back of hardware cutouts to close off interior of openings and prevent mortar or other materials from obstructing hardware operation.

O. X-Ray Door Frame Struts and Lead Linings:

1. Struts: Provide vertical steel struts, 9.525 mm x 50 mm extended from top of frame at each jamb to supporting structural construction above, unless frame is set in masonry or attached directly to concrete. Bend top of struts at a right angle and attach to supporting structural construction above by bolting. Use inserts or expansion anchors into supporting structural construction above. Provide bolted attachment of struts to frame at jambs to permit height adjustment during installation. Adapt jamb anchor clips at struts to permit adjustment.

2. Lead Lining: All X-ray door frames shall be provided with a minimum 25 mm x 50 mm x 4.76 mm continuous structural angle welded to the full length of the hinge, head, and strike jambs. The door frame and structural angle shall then receive a single 1.5 mm thickness of lead sheet having a width to provide an effective lead lap with the lead of the adjoining wall construction lead shielding materials. Lead sheet shall be factory installed as a continuous lining formed to the contour of the door frame and structural angle and around areas prepared to receive hardware. Lead lining shall be held in place with retaining clip devises.

2.6 LOUVERS

A. Door Louvers: Fabricate louvers and mount flush into doors without overlapping moldings on surface of door face sheets. Provide internal support as recommended by louver manufacturer. Prime paint steel louvers after fabrication.

1. Interior Louvers: Sightproof, stationary type, constructed of inverted Y-shaped blades formed of same material as door.

a. Steel: 0.8 mm thick. b. Stainless Steel: 0.95 mm thick.

2.7 STOPS AND MOULDINGS

A. Provide stops and moldings around solid, glazed, and louvered panels where indicated.

B. Form fixed stops and moldings integral with frame, unless otherwise indicated.



C. Provide removable stops and moldings where indicated or required, formed of 0.8-mm-thick steel sheets matching steel frames. Secure with countersunk flat or oval head machine screws spaced uniformly not more than 300 mm o.c. Form corners with butted hairline joints.

D. Coordinate rabbet width between fixed and removable stops with type of glass or panel and type of installation indicated.

2.8 FABRICATION

A. Fabricate doors and frames rigid, neat in appearance, and free of defects, warp, or buckle. Accurately form metal to required sizes and profiles. Weld exposed joints continuously; grind, fill, dress, and make smooth, flush, and invisible. Where practical, fit and assemble units in manufacturer’s plant. Clearly identify work that cannot be permanently factory assembled before shipment, to assure proper assembly at Project site.

1. Fabricate doors to comply with acceptance criteria of ANSI A250.4 for a Level A door.

B. For doors with metallic core constructions, weld cores to both door face sheets.

C. Exposed Fasteners: Provide countersunk flat or oval heads for exposed screws and bolts, unless otherwise indicated.

D. Thermal-Rated (insulating) Assemblies: At exterior locations and elsewhere as shown or scheduled, provide doors and frames fabricated as thermal-insulating assemblies and tested according to STM C 236 or ASTM C 976.

1. Provide thermal-rated assemblies with U-factor of 1.7 W/sq. m x K, unless otherwise indicated.

E. Sound-Rated (Acoustical) Assemblies: Where shown or scheduled, provide door and frame assemblies fabricated as sound-reducing type, tested according to ASTM E 1408, and classified according to ASTM E 413.

1. Provide acoustical assemblies with STC sound ratings of 33 or better, unless otherwise indicated.

F. Hardware Preparation: Prepare doors and frames to receive hardware, including cutouts, reinforcement, mortising, drilling, and tapping, according to final hardware schedule and templates provided by hardware supplier. Comply with applicable requirements of ANSIA115 Series specifications for door and frame preparation for hardware.

1. Reinforce doors and frames to receive surface-applied hardware. Drilling and tapping for surface-applied hardware may be done at Project site.

2. Locate hardware as indicated or, if not indicated, according to HMMA 831, “Recommended Hardware Locations for Custom Hollow Metal Doors and Frames.”



2.9 GLAZED LIGHT FRAMES

A. Form glazed light frames to the profiles shown. Provide anchors at jambs same as for door frames. Provide closed mullion sections same as for door frames. Fabricate from 1.519 mm thick steel for interior work.

B. Miter, fit, and weld corners of panel moldings for glass panels in sidelights and borrowed lights to form continuous frame around panels. Provide non-removable panel moldings on the exterior. Secure removable moldings with not less than No. 6 x 32 Phillips oval-head countersunk machine screws at 300 mm on center.

C. Provide continuous felt strips cemented in place, on all bed and stop surfaces for interior light frames to be glazed so that at no time does metal touch glass.

1. Glaze light frames with wire glass.

2.10 BULLET RESISTANT ACOUSTICAL DOORS

A. Provide special bullet resistant acoustical doors fabricated from sheet steel where shown with Z180 zinc (galvanized) or ZF180 zinc-iron-alloy (galvannealed) coating or scheduled, compete with frames. Provide a Sound Transmission Class of 49, as determined in accordance with ASTM E413, for each door, threshold and frame assembly when installed. The door and frame assembly shall be designed to withstand a commercially loaded handgun or rifle ammunition, including armor piercing ammunition, having a muzzle velocity not to exceed 3,500 feet per second and maximum energy of 5,250 foot pounds. The assembly shall be complete with necessary gasketing, thresholds and sound seals to achieve the specified STC rating and bullet resistance. Doors shall be designed for use with standard builder’s hardware as scheduled.

B. Basis of Design: Moduline APR Type Single Leaf Personnel Doors Modified to comply with the requirements; Industrial Acoustics Company, or equal.

2.11 FINISHES, GENERAL

A. Comply with NAAMM’s “Metal Finishes Manual for Architectural and Metal Products” for recommendations for cleaning, treating, priming, and when specified, finishing.

B. Finish products specified in this Section after fabrication.

2.12 METALLIC-COATED STEEL FINISHES

A. Surface Preparation: Clean surfaces with nonpetroleum solvent so surfaces are free of oil and other contaminants. After cleaning, apply a conversion coating suited to the organic coating to be applied over it. Clean welds, mechanical connections, and abraded areas, and apply galvanizing repair paint specified below to comply with ASTM A 780.

1. Galvanizing Repair Paint: High-zinc-dust-content paint for regalvanizing welds in steel, complying with SSPC-Paint 20.



B. Factory Priming for Field-Painted Finish: Apply shop primer specified below immediately after surface preparation and pretreatment. Apply a smooth coat of even consistency to provide a uniform dry film thickness of not less than 0.02 mm.

1. Shop Primer: Manufacturer’s of fabricator’s standard, fast-curing, lead- and chromate-free, primer complying with ANSI A 224.1 acceptance criteria; recommended by primer manufacturer for zinc-coated steel; compatible with substrate and field-applied finish paint system indicated; and providing a sound foundation for field-applied topcoats despite prolonged exposure.

2.13 STEEL SHEET FINISHES

A. Surface Preparation: Clean surfaces to comply with SSPC-SP 1, “Solvent Cleaning”; remove dirt, oil, grease, or other contaminants that could impair paint bond. Remove mill scale and rust, if present, from uncoated steel, complying with SSPC-SP 3, “Power Tool Cleaning,” or SSPC-SP 6/NACE No. 3, “Commercial Blast Cleaning.”

B. Factory Priming for Field-Painted Finish: Apply shop primer specified below immediately after surface preparation and pretreatment. Apply a smooth coat of even consistency to provide a uniform dry film thickness of not less than 0.02 mm.

1. Shop Primer: Manufacturer’s or fabricator’s standard, fast-curing, corrosion-inhibiting, lead- and chromate-free, universal primer complying with ANSI A 224.1 acceptance criteria; compatible with substrate and field-applied finish paint system indicated; and providing a sound foundation for field-applied topcoats despite prolonged exposure.

2.14 STAINLESS-STEEL FINISHES

A. Remove tool and die marks and stretch lines or blend into finish. Grind and polish surfaces to produce uniform, directionally textured polished finish indicated, free cross scratches. Run gain with long dimension of each piece.

1. Bright, Directional Polish: No. 4 finish. 2. When polishing is completed, passivate and rinse surfaces. Remove embedded foreign

matter and leave surfaces chemically clean.

PART 3 - EXECUTION

3.1 INSTALLATION

A. General: Install doors and frames according to DHI A115.IG and manufacturer’s written instructions.

B. Frames: Install frames for doors, transoms, sidelights, borrowed lights, and other openings, of size and profile indicated.



1. Set masonry anchorage devices where required for securing frames to in-place concrete or masonry construction.

a. Set anchorage devices opposite each anchor location according to details on Shop Drawings and anchorage device manufacturer’s written instructions. Leave drilled holes rough, not reamed, and free of dust and debris.

2. Floor anchors may be set with powder-actuated fasteners instead of masonry anchorage devices and machine screws, if so indicated on Shop Drawings.

3. Placing Frames: Set frames accurately in position; plumb; align, and brace securely until permanent anchors are set. After wall construction is complete, remove temporary braces and spreaders, leaving surfaces smooth and undamaged.

a. At existing concrete or masonry construction, set frames and secure in place with machine screws and masonry anchorage devices.

b. At fire-rated openings, install frames according to NFPA 80. c. Field splice only at approved locations. Weld, grind, and finish as required to

conceal evidence of splicing on exposed faces. d. Remove spreader bars from each frame only after frame is properly set and

secured.

C. Doors: Fit non-fire-rated doors accurately in their respective frames, with the following clearances:

1. Jambs and Head: 2 mm. 2. Meeting Edges, Pairs of Doors: 3 mm. 3. Bottom: 9 mm, if no threshold or carpet. 4. Bottom: 3 mm, at threshold or carpet.

D. Fire-Rated Doors: Install with clearances as specified in NFPA 80.

E. Smoke Control Doors: Install according to NFPA 105.

3.2 ADJUSTING AND CLEANING

A. Final Adjustments: Check and readjust operating hardware items just before final inspection. leave work in complete and proper operating condition. Remove and replace defective work, including doors or frames that are warped, bowed, or otherwise unacceptable.

B. Prime-Coat Touchup: Immediately after erection, sand smooth any rusted or damaged areas of prime coat and apply touchup of compatible air-drying primer.

C. Stainless-Steel Touchup: Immediately after erection, smooth any abraded areas of stainless steel and polish to match undamaged finish.



FORCED ENTRY (FE) / BALLISTIC RESISTANT (BR) DOOR ASSEMBLIES SECTION 08318 - 1

SECTION 08318 - FORCED ENTRY (FE) / BALLISTIC RESISTANT (BR) DOOR ASSEMBLIES

PART 1 - GENERAL

1.1 SUMMARY

A. The extent of forced-entry resistant (FE) and ballistic resistant (BR) door assemblies required for the Project is indicated on Construction Drawings, and in Door/Frame/Hardware schedules, including construction, profiles, swing, sizes, hardware, accessories, devices, and locations.

B. The applicability of administrative, product, and installation requirements in this section for projects involving OBO’s Government Procured Equipment (GPE) program for FE/BR and blast resistant products is identified in Section 08010, “GPE Door and Window Requirements.” Section 08010 is only included in projects which use the GPE program. If the GPE Program is applicable for a project, that will be identified in the project Statement of Work or elsewhere in the project contract.

C. Related Sections include the following:

1. List below only products, construction, and equipment that the reader might expect to find in this Section but are specified elsewhere.

2. Division 5 Sections "Metal Fabrications" for steel supports. 3. Division 8 Sections for doors not designated for special security performances. 4. Division 8 Section "Security Hardware" for hardware to be installed as work of this Section. 5. Division 8 Section "Glazing." 6. Division 8 Section "Security Glazing." 7. Other sections of these specifications for interface of door hardware and device units, with

alarm/security/safety/access/monitoring systems; not work of this section.


A. General: Fabricate and install FE/BR door assemblies to achieve indicated levels of resistance. Extend resistance to include anchorages, interfaces with adjoining substrates, and hardware. For each performance identified below, provide specific performance ratings, also referred to as Government Code numbers, as indicated in Table 1.2.

1. Door Composition.

2. Fire-rated assemblies: Where indicated for fire resistance, provide flush steel doors-and-frame units; comply with NFPA 80, Standard for Fire Doors and Windows. Provide units that have been tested by recognized testing agency in accordance with NFPA No. 252 and ASTM E 152.



3. Forced-Entry (FE) resistant assemblies: Where door assembly is shown or scheduled as FE, provide door manufacturer's material and fabrication for panels, inserts, hardware, devices, and framing of units for rating categories established by Physical Security Division of Bureau of Diplomatic Security (DS/PSP/PSD):

4. Ballistic resistant (BR) assemblies: Where door assembly is shown or scheduled as BR, provide door manufacturer's materials and fabrication for panel, inserts, and framing of unit for rating categories established by DS/PSP/PSD:

TABLE 1.2 – DOOR CODES

DOS CODE 1st DIGIT 2nd DIGIT 3rd DIGIT 4th DIGIT (Door Composition) (Fire Rating) (Forced En-

try Rating) (Ballistic Re-sistance Rating)

1 Transparent (various sized lites)

None None None

2 Steel or Hollow Metal

1.5 hours (Class B, Class D at exterior) with 30- min. temp. rise limited to 121 deg. C (250 deg. F)

15 minutes Submachine gun (9mm)

3 Solid Core Wood (Stave or Particle)

3 hours (Class A) with 30-min. temp. rise limited to 121 deg. C (250 deg. F)

60 minutes Rifle 5.56 & 7.62 NATO

4 Hollow Metal with Mineral Core

45 minutes (Class C) with 30-min. temp. rise limited to 121 deg. C (250 deg. F)

5 minutes Armor-Piercing (.30-06)

5 Various Non-metal Skins with Mineral Core

20 minutes NOT USED NOT USED

6 NOT USED 1 hour NOT USED NOT USED

1.3 SUBMITTALS

A. Product data for each element of work, whether purchased from other manufacturers or provided as door Fabricator's standard production. Include data substantiating that products comply with requirements of these specifications.

B. Manufacturer's standard color chart.



C. Manufacturer’s Certifications:

1. Certification of Inspection and Shipment: Use form available at end of this Section.

2. Letter Indicating Use of Certified Products: Letter from manufacturer indicating the products have been certified by Bureau of Diplomatic Security (DS) or by ASTM and UL in accordance with article on "Manufacturers" in this Section.

3. Letter Indicating Coordination of Automatic Door Operators: Letter from manufacturer indicating that automatic door operators for handicap compliance have been fully designed by and coordinated with the hardware supplier for the width and weight of each applicable door, that the operator controls and equipment are sized adequately given the location of the control box and its relationship to the door, and is fully compliant with OBO International Codes Supplement (OBO-ICS) IBC accessibility and fire resistance construction related to egress.

D. Manufacturer’s Inspection Reports: Use forms are available at end of this Section.

E. Certificates of Compliance: Completed certificates of compliance documenting that all FE/BR door assemblies have been installed per the contract requirements and construction documents.

F. Shop drawings showing each dimensioned detail of each door assembly, including performance rating, swing, hardware set, and adjacent construction. Provide drawings on B-size (297 mm x 420 mm) sheets. After final modifications and corrections have been incorporated into the drawings, submit drawings as AutoCAD files with .DWG extension. Show the following:

1. Cover sheet: Include manufacturer's name, address, telephone, and facsimile numbers; customer and address; project location; contract or purchase order number; and submittal release record.

2. Unit information:

a. Manufacturer's model number. b. Government code. c. Mark (door no.). d. Door/frame finish. e. Door type. f. Government or ASTM/UL certification number. g. Government or ASTM/UL certification number for glazing, if different from door

certification. h. Government certification number for deal tray, if different from door certification.

3. Elevation Drawings: Show typical door exterior elevations at not less than 1:20 scale.

a. Rough opening dimensions. b. Door opening dimensions. c. Frame opening dimensions. d. Vision opening dimensions. e. Substrate/rough opening material. f. Finished floor. g. Sill condition.



h. Undercut for carpet. i. Weatherstripping. j. Manufacturer's name and reference numbers for primer and finish paint, including

number of coats applied. k. Door class (fire) rating: rated or non-rated. l. Door and frame gauge thickness. m. Separate steel sub-frames/embeds (number and list). n. Detail symbols. o. Hardware and hardware symbols. p. Electrical access, including terminal strips.

4. Plan Drawings:

a. Relate to elevation on drawing. b. Identify "Attack" and "Protected" sides. c. Identify door swing (i.e., RH, LH, RHRB, LHRB). d. Provide key on drawings. e. Indicate room space numbers taken from Construction Drawings.

5. Details: Show section at 1:5 scale of members indicating construction, size, and thickness of components, frame profile, anchorage, steel sub-frames/embeds, continuous shim plates (where applicable), location of conduit entry into both sub-frame and door frame, threshold configuration, thumbturn lock guards, vision panel together with connections, fasteners, shims, sealant, backer rods, and means of separating dissimilar metals. Details shall be on separate sheets from plan and elevation drawings.

6. General Product Information: Include notes sheet, miscellaneous materials specifications, abbreviations, finish/paint system, legend, and glazing specifications.

7. Breakdown of Product Line Items:

a. If Manufacturer produces one contract line item as several parts (e.g., door with transom and sidelights), they shall break out items on drawings. Each item shall be a subdivision of that product line item number.

8. Installation instructions shall cite all anchorage components, including complete description of anchors, as well as installation criteria such as drilling specifications into concrete or masonry, torque requirements, minimum edge distance, spacing, etc. For sub-frame attachment to concrete, instructions shall include alert to installers to avoid cutting rebar during anchor installation.

9. Installation instructions shall be customized for each type of application.




A. Quality Control for Forced-Entry/Ballistic Resistant (FE/BR) Products: Certificates for fabricated and assembled FE/BR products specified in this Section shall follow quality control procedures established by the Government. Forms for compliance are found at the end of this Section.

B. Testing Laboratory Qualifications: For compliance with non-security performance requirements on security door assemblies of this Section, use only those testing laboratories, which have successfully demonstrated to COR that they have experience and capabilities needed to satisfactorily conduct required tests.

C. Installer Qualification Data: Submit resumes of all installers documenting the installers have installed FE/BR door assemblies for a DOS project within the last 5 years. The resume must include at least 3 references (including contract information) that can provide verification that the installer has the expertise required to perform a successful installation. The installer's qualifications must be approved COR with input from OBO/CFSM/SM physical security engineer. Each installer or installation team must be certified by the manufacturer as being capable of properly installing the FE/BR products. The installer must provide written documentation to the COR that the installation team is certified in their products installation.

D. Manufacturer's Technical Representative: For new construction and renovation projects with FE/BR products, the FE/BR supplier shall appoint a manufacturer's technical representative to the project. The manufacturer's technical representative shall have the following responsibilities:

1. Pre-Installation Conference: Before beginning installation of the FE/BR assemblies, the manufacturer's technical representative shall conduct a pre-installation conference at the Project site with the installation sub-contractor, the electrical sub-contractor, the COR, and other interested parties to review installation procedures and manuals, schedules, and coordination of the FE/BR-assembly installation with other elements of the Work.

2. Training: The manufacturer's technical representative shall provide the crew, which is to actually perform the installations of the FE/BR assemblies with a minimum of 16 hours of on-site, hands-on training before the installation of the first FE/BR door. The manufacturer's technical representative shall also instruct the crew on preventive measures which must be taken to protect the FE/BR assemblies from damage during construction.

3. Inspection: The manufacturer's technical representative shall observe and advise the crew during their installation of the first three FE/BR doors. Upon completion of the installation of each of the three initial FE/BR doors, the manufacturer's technical representative shall inspect the work and direct the crew in any correction or modifications required for acceptable performance of the units. For unique site conditions, the manufacturer's technical representative shall also be responsible for observing and inspecting the installation of FE/BR doors, beyond the initial three doors, as necessary to ensure that the installation crew is adequately prepared for installation.

4. Additional Assistance: The manufacturer's technical representative shall provide the General Contractor any additional advice, instruction, training, supervision, or inspection required to enable the General Contractor to complete the installation certification described below, and to fully train the Embassy staff in the proper operation and maintenance of the FE/BR assemblies.



E. Certification by General Contractor: Prior to final completion, the General Contractor shall provide to the COR a certification that the FE/BR materials have been installed in accordance with the manufacturer's instructions, these specifications and are operational. Use Certificates of Compliance forms at end of this Section. Deviation from these requirements identified in this form is only permitted with the written approval of COR with input from OBO/CFSM/SM physical security engineer. Specifically, the General Contractor's certification shall include verification that:

1. The manufacturer's technical representative was on site during the initial stages of installation and for site-specific unique conditions as required.

2. The manufacturer's technical representative was on site during the initial stages of installation and for site-specific unique conditions as required.

3. Each embed plate or sub-frame has been installed level, plumb and square.

4. All embed plate assemblies must have been factory welded together.

5. All units with glazing have been pre-glazed at the factory.

6. Employees performing the installation meet the specified training and experience qualifications.

7. No part of the forced entry lock (FEL) has been altered including but not limited to grinding, cutting or re-welding any part of the FEL strike, strike plate (steel couple with vertical slot welded to the frame) and strike plate receiver (vertical slot in door leaf). No part of the FE/BR door has been altered. The only acceptable fix for defective or altered parts is to unbolt the altered piece and replace altered piece in its entirety.

8. Door frame bolt/screw horizontal slotted holes are 16 mm x 35 mm (5/8” x 1-1/4”) round access holes. Washer diameters are 27 mm so that 4mm of the slotted hole will be visible on each side of the washer. This configuration has been inspected and it has been confirmed that the bolts are centered in the slotted holes.

9. All temporary bolts have been replaced with permanent bolts.

10. All frame bolts have been torqued to exactly 47.5 Nm (35 ft./lbs.). Shims have been inserted at all bolt locations.

11. Frame bolts/screws are 12 mm x 40 mm socket head cap screws with 3mm x 27 mm (1/8” x 1-1/6”) diameter grade 8 or equivalent class 10.9 or 12.9 washers.

12. All FE/BR product bolts, screws and anchors are metric products.

13. No finish materials overlap the door frame/sub-frame and ballistic trim bars unless the finish materials can be easily removed and reinstalled. Any overlapping finish work (i.e. metal, wood, stone, etc.) must be capable of removal without damaging the door frame and surrounding finishes. Door and frame are installed such that removal of the door and frame is possible without demolishing the finishes and trim and must the door is capable of future adjustments of 6-mm in or out of the opening.



14. Any cladding that covers the door frame bolt/screw access holes has either access holes with cap plugs or is attached with screws for easy removal. Cap plugs and cladding for each door have been bagged and won't be installed until after the final QA inspection has been conducted by the OBO/CFSM/SM physical security engineer.

15. The manufacturer and installer must ensure any decorative cladding around the electro magnetic lock on the door frame will allow the lock position to be adjusted in both directions.

16. At each door assembly, there is a continuous minimum gap between the door leaf and the door frames.

17. All access plates for each door have been installed as indicated in the approved shop drawings.

18. Any continuous hinges with squeaks have been replaced. Field lubrication of the hinge as a solution for eliminating squeaks is not acceptable.

19. Each door frame head has been installed level and the non-hinge side jamb has been installed plumb and square.

20. Each lockset, deadbolt and panic exit device is able to fully engage and freely operate.

21. On doors with panic hardware, the panic exit device strike plate has been installed in a location that will eliminate any door leaf bounce on the frame.

22. All door assembly frames, in large multi-unit elevations, have been separated from other FE or FE/BR product frames with a structural steel tube, which will allow for future door frame adjustments.

23. Thresholds do not exceed specified limits, as indicated in the approved shop drawings.

24. Each door closer has been installed and adjusted in accordance with the manufacturer's instructions.

25. Automatic door operators have been adjusted as appropriate in accordance with the manufacturer's instructions to meet ADA-ABA and appropriate fire codes.

26. Adjustable strike plates have been provided for all locksets, both key and push-button combination type (if available and as indicated on the shop drawings).

27. Separate pieces of ballistic trim have been installed, as indicated in the approved shop drawings.

28. Ballistic trim bars have been secured/screwed to the sub-frame and not the door frame.

29. A 6 mm (¼”) gap between the back of the ballistic trim bar and door frame has been maintained.

30. Uneven shimming of FE/BR products that utilize a continuous type hinge has not been permitted.



31. The manufacturer has provided two metal ID plates for each product that has machine applied letters and numbers. One ID plate should be located on the door frame and one ID plate should be located under the door leaf edge scalp plate just below the top FEL.

32. That completed Certificates of Compliance have been submitted for each individual FE and FE/BR product (sample template is attached to the end of this specification)

1.5 IDENTIFICATION SYSTEMS

A. Identify each assembly to provide Government with ready reference to original manufacturer to facilitate reorders, replacement parts, service, resolution of complaints, and inventory. The label shall be an embossed/printed metal plate or metallic foil with adhesive backing for permanent identification. Locate label on the door frame header so that it is not exposed when the door is closed and is clearly visible and not obscured by hardware when the door is open. The label shall be approximately 40 x 75 mm and shall cite:

1. Manufacturer's name/city/state. 2. Contract number. 3. Month/year of manufacture. 4. Mark number. 5. Government or ASTM/UL certification model number. 6. Government code number.

B. Provide steel stamped ID codes. Locate one ID plate on door frame and one ID plate under door leaf edge scalp plate just below top FEL. Place ID plates directly beneath the upper FEL under the door leaf non-hinge jamb trim plate, which will consist of the manufacturer name abbreviation, fabrication date (mm/yy) and mark number.


A. Deliver each assembly to project site with fabrication, finishing, and assembly of primary panels, embeds/sub-frames, and frames completed and prepared for installation and connection with security systems. Disassemble hardware for shipping only to extent hardware interferes with shipping.

B. Deliver door assemblies with glazing panels as factory glazed unless otherwise directed by Government.

C. Pack door assemblies and accessories in two crates: one crate for the door and frame, and one crate for the embed/sub-frame and ballistic trim. Provide two wood cross braces on both sides of the crates. In each crate, provide a separate compartment for installation hardware.

D. Provide removable spreader bar between jambs during fabrication, delivery, and installation and to include mullions of each frame assembly, except where integral threshold is required and serves same purpose. Do not mar finishes of assembly with installation or removal of spreader bars.

E. Provide protection of pre-finished units, such as pre-finished with baked enamel or stainless steel, using self-adhesive paper.



F. Treat security door assemblies as fragile merchandise packaged and shipped in export wood crates with width end in upright position and blocked together in a mass. Comply with manufacturer's directions for storage and handling to prevent edge damage or other damage to assembly resulting from effects of moisture, condensation, temperature changes, direct exposure to sun, and contact with chemical solvents. Provide at least one wood cross-brace for the door assembly. Clearly mark crates to indicate which side should be opened first.

G. Clearly mark sub-frames/embeds with door mark number and identify head and left and right jambs. Package sub-frames/embeds separately and ship in export wood crates separate from the door assemblies. Protect each sub-frame/embed piece to minimize damage to finished surfaces.

H. Package and ship installation hardware (anchors, bolts, screws, shims, ballistic trim, shop drawings, etc.) for each door in the same crate as the door assembly.

I. Package and ship shop drawings for each door in the same crate as the door assembly.

J. Manufacturer shall ship embed plate sub frames factory welded together with adequate temporary bracing for installation on site for new concrete wall construction.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Certified Units: Provide units, including frames and sub-frames which meet the requirements in either Subparagraph 1 or Subparagraph 2 below:

1. Have been certified by Bureau of Diplomatic Security (DS) in accordance with DS/PSP/PSD SD-STD-01.01, latest revision.

2. Meet ASTM and UL standards for FE/BR identified below. These assemblies must conform to other requirements of this Section regarding installation, operation, maintenance, hardware, finishes, and weather protection. These assemblies must also be able to accept scheduled hardware without compromising performance of either the door assembly or the hardware.

a. 15 Minute FE/BR Doors: Certified to ASTM F 1450-97, Grade 1 and to UL 752, Level 8. Door glazing to be certified to ASTM F 1915-98, Grade 1 and to UL 752, Level 8. Door Installation must be in accordance with reverse bevel configuration required of Government certified doors.

b. 5 Minute FE Doors: Certified to ASTM F 1450-97, Grade 4. Door glazing to be certified to ASTM F 1915-98, Grade 4. Door Installation must be in accordance with reverse bevel configuration required of Government certified doors.



B. Clarifications and additional OBO requirements for products tested under the ASTM and UL standards:

1. Glazing in doors to be tested shall not be limited by the 100mm x 635mm vision panel specified in ASTM F-1450-97. It shall be sized to reflect Government’s project requirements such as two large vision panels or one large single vision panel for transparent doors.

2. Door pairs have to be tested. ASTM's single door test results can't be extrapolated to cover door pairs.

3. Door frames are to be bolted to the sub-frames instead of being welded as shown in the ASTM test specifications. The door frames are to have horizontally slotted holes, not to exceed 300mm on center.

4. Manufacturer shall provide two copies of all applicable ASTM and UL test reports for each product.

5. Manufacturer shall provide two copies of the installation instruction manuals for each product.

6. Door frame and sub-frame head are to have access ports to support 25mm conduit. 7. Provide at least two bolt holes in the door head sill frame to facilitate proper installation. 8. Insert shims at every frame bolt. Provide 1.5mm (1/16-inch) thick plastic shims or stainless

steel shims with break off tabs for rough opening (R.O.) frame clearance.

C. Selection of fabricator/manufacturer for each type of security door assembly, and selection of manufactured elements, which are used in make up of that assembly, are Contractor's options subject to the following requirements and limitations, and subject to general provisions of Construction Contract:

1. Pre-certified fabricators (by DS) of ballistic-resistant and forced-entry-resistant assemblies are identified in a separate Contract Attachment labeled "Government Certified FE/BR Products and Designs".

2.2 MATERIALS, GENERAL

A. Hot-Rolled Steel Sheets and Strips: ASTM A 569, commercial quality, pickled and oiled, except as otherwise indicated.

B. Cold-Rolled Steel Sheets: ASTM A 366, commercial quality, except as otherwise indicated.

C. Galvanized Steel Sheets: ASTM A 526, with ASTM A 525, G90 zinc coating, mill phosphatized; commercial quality, except as otherwise indicated.

D. Stainless Steel Sheets where required for finish: AISI Type 302/304, complying with ASTM A 167; commercial quality, No. 4 directional polish.

E. Supports and Anchors: Fabricate to endure required performances, but of not less than 1.5 mm sheet steel. For exterior wall assemblies, hot-dip zinc coat support/anchor units after fabrication in compliance with ASTM A 153, Class B.



F. Inserts, Bolts Fasteners: Standard units of strengths required to endure performances; hot-dip zinc coated where used in exterior wall assemblies in compliance with ASTM A 153, Class C/D.

1. Frame bolts/screws are 12 mm x 40 mm socket head cap screws with 3mm x 27 mm (1/8” x 1-1/6”) diameter grade 8 or equivalent class 10.9 or 12.9 washers.

G. Paint for Shop Application: Rust-inhibitive enamel for baking suitable as base for finish coats, which are specified as work of other sections.

H. Vision Panels, General: Fabricate vision panels of sizes shown and scheduled with same performance capabilities as specified/shown for door assembly where installed. Where applicable, achieve performances and combined performances through lamination of transparent sheets, films, and screens of standard manufactured/tested products. Comply with applicable provisions of Division 8 glazing section and Section 08845, "Security Glazing."

1. Forced-Entry (FE) Resistance: Where assembly is indicated for forced-entry resistance rating (FE), provide light of size shown or scheduled in accordance with Bureau of Diplomatic Security (DS) certification.

2. Ballistic Resistance (BR): Where assembly is indicated for ballistic-resistance rating (BR), provide light of size shown or scheduled in accordance with DS certification.

I. Hot-Dip Galvanizing: All exterior doors must be hot-dip galvanized in accordance with ASTM standards.

2.3 HARDWARE

A. General: Provide special units of door hardware to achieve performances, and as shown and scheduled. Standard units for each security door assembly are specified to be furnished as work of "Door Hardware" Section; see Project "Finish Hardware Schedule" and "Data Sheets," and provisions of this Section, as well as notes on door-and-frame schedule.

2.4 FABRICATION AND ASSEMBLY

A. General: Fabricate, test, and pre-assemble security door assemblies with hardware at factory; disassemble hardware only to extent necessary for handling, packaging, shipment, and installation at Project. Fabricate metal work to comply with performance requirements. Fabrications shall be rigid, neat, and free from warp/buckle/similar defects, with eased edges and continuously-welded joints, ground where exposed, to produce smooth, flush, invisible joints. Weld in accordance with AWS D1.1, Structural Welding Code for Steel.

1. Prepare door leafs and frames of each assembly to receive hardware, devices, and accessory units as shown and scheduled. Reinforce work for hardware and devices, and cut work for mortised or concealed units; comply with ANSI A115 series specifications, working from templates supplied by unit manufacturers and suppliers.



a. Locate hardware, devices, and accessories as shown and scheduled (including on approved shop drawings) or, if not otherwise indicated: 1) in accordance with DHI Recommended Locations for Builder's Hardware or, 2) in accordance with security device manufacturer's recommendation for optimum responses, but 3) in any case, as required to achieve required assembly performances. Do not cut or otherwise alter hardware in order to install on door.

b. Except where assembly is equipped with door-seal stripping at jambs and head, provide neoprene door silencers on stops; three at strike jamb for single door, and four at head for double door.

c. Except as otherwise indicated, pre-fabricate and pre--assemble security door assemblies to include full extent of required conduit-protected electrical/electronic power and control wiring placed and supported to avoid conflicts with other elements and subsequent drilling/cutting-in of work during installation of units. Provide access ports as required to support 25 mm conduit in door frames and sub-frames/embeds.

d. Clearances: Not more than 3 mm at jambs and head, except not more than 6 mm between fire-rated pair of doors. Not more than 6 mm at bottom. Undercut for carpets are not permitted where doors are used in corridors.

e. Fabricate frames with horizontally slotted bolt holes to allow for future frame adjustment.

2. Provide the removable glazing stops and similar moldings on interior or "protected" side of assemblies. Glazing shall be removable without removing door from frame, through the top of the door or removing any surface steel panel. Select and size stops, moldings, and anchors to conform to Bureau of Diplomatic Security (DS) certified design.

3. Shop painting: Provide base-coat, factory-applied painting of ferrous metal elements of assemblies excluding other specified exposed-finish surfaces of stainless steel, aluminum, bronze, and similar metals not intended for painting. Provide touch-up paint with each painted door.

a. Clean steel and zinc-coated steel surfaces of mill scale, rust, oil, grease, dirt, and other substances, immediately before finish application.

b. Apply pretreatment of cold phosphate solution (SSPC--PT2), hot phosphate solution (SSPC-PT4), or basic zinc -chromate/vinyl-butryal solution (SSPC-PT3).

c. Apply paint coat specified for shop application, and bake on within time limits recommended by manufacturer of pretreatment. Apply in a uniform, smooth coat to result in dry film thickness of not less than 0.05 mm.

4. Vision panels:

a. The transparencies shall be enclosed and cushioned within core of door for continuous perimeter bite of not less than 20 mm on each side and 6 mm cushion clearance to fixed metal stop on glazing edges. Glazings shall be factory installed with no raw metal edges evident or in contact with glass in door vision openings. Vision opening edges shall be cushioned and trimmed neatly to provide acceptable appearance.



b. If external frames are used to either side or to both faces of door, frame(s) shall not exceed 40 mm in width and shall be configured internally to cushion all perimeter edges and faces of glazing and provide minimum bite of 20 mm and 6 mm cushion clearance to fixed metal stop on glazing edges. Frame shall not produce pinch point with hardware. All external bolts to attach frame shall be flush mounted. Alternatively, protruding bolt heads shall be covered with additional trim frame and flush mounted screws.

5. Sub-frames/Embeds: Provide steel sub-frames or embed plates for all FE or FE/BR doors for installation at concrete, masonry, and other non-steel rough openings and for structural steel openings where the depth is less than the door frame depth. For individual openings, sub-frames or embeds shall be provided by the door supplier. For larger, multi-panel openings, sub-frames or embeds may be provided by either the door supplier or the Contractor; in either case they shall be designed by the door supplier and shown with the door shop drawings. Sub-frames shall be 6 mm thick minimum and embeds a minimum of 6 mm for interior applications and a minimum of 10 mm for exterior applications, with a minimum depth equal to or greater than the door frame depth. Coordinate the sub-frame or embed anchor locations with the door frame bolt hole locations. The steel sub-frame/embed shall be assembled and braced by the manufacturer prior to shipping, in order to avoid out of plane deformation during transportation, installation and concrete pouring. The steel sub-frame/embed shall be installed plumb and square. The maximum allowable tolerances are 5 mm out of square within the opening, per opening (see Figure 2.4-1), and 7 mm out of plumb parallel to the wall per opening (see Figure 2.4-2). Bi-axial allowable maximum tolerances are 5 mm (see Figure 2.4-3). The sum of all discrepancies in plumb and square for all three axes cannot exceed 17 mm.



FIGURE 2.4-1 - OUT OF SQUARE TOLERANCES

FIGURE 2.4-2 - OUT OF PLUMB TOLERANCES



FIGURE 2.4-3 - BI-AXIAL TOLERANCES

a. For New Concrete -Exterior embeds shall be constructed of A36 mild steel 10-mm (3/8 inch) thick steel plate or greater as required to comply with engineer's report for blast resistance, if applicable, and shall be hot dip galvanized for corrosion resistance per section 8318-12/2.2. Attach steel embed plate per the blast report or with a minimum 12 mm x 150 mm steel studs, spaced 150 mm on center. All embeds shall be factory drilled and tapped with an anchor design to allow minimum 10-mm (3/8 inch) adjustment 360 degrees from the centerline of the center of the drilled and tapped hole. All fasteners for doors or windows shall be ASTM grade 8 or other appropriate high strength bolt as identified in the blast report and complying with standard OBO specifications for FE/BR and Blast resistant products. All door embeds shall be pre-punched for the technical security conduit. Embeds without adjustment features or blank plates for field drilling and tapping shall not be permitted. Final embed design; construction and features shall be accepted by COR based on input from OBO/CFSM/SM physical security engineer prior to fabrication and shipment.

b. Interior embeds shall be A36 mild steel 6-mm (1/4 inch) minimum thickness and shall be prime painted with a high-grade metal primer. All embeds shall be factory drilled and tapped with an anchor design to allow minimum 10-mm (3/8 inch) adjustment 360 degrees from the centerline of the center of the drilled and tapped hole. All fasteners for doors or windows shall be ASTM grade 8 or other appropriate high strength bolt as identified in the blast report and complying with standard OBO specifications for FE/BR and Blast resistant products. All door embeds shall be pre-punched for the technical security conduit. Embeds without adjustment features or blank plates for field drilling and tapping shall not be permitted. Final embed design; construction and features shall be accepted by COR based on input from OBO/CFSM/SM physical security engineer prior to fabrication and shipment.



c. For Existing Concrete: Provide a steel sub-frame, typically a 50 mm x 150 mm x 6 mm steel tube. Anchor the sub-frame with either 12 mm diameter x 90 mm long drop-in type expansion anchors or with Hilti HY150 injection or equivalent strength anchoring system with 12 mm diameter x 200 mm long Hilti HIT threaded rods spaced at 300 mm on center.

d. For Solid Masonry: Provide a steel sub-frame, typically a 50mm x 150mm x 6mm steel tube. Anchor the sub-frame with a Hilti HY150 or equivalent strength injection anchoring system with 12 mm diameter x 200 mm long Hilti HIT threaded rods spaced at 300 mm on center.

e. For Hollow Masonry: Provide a steel sub-frame, typically a 50 mm x 150 mm x 6 mm steel tube. Anchor the sub-frame to the masonry with a Hilti HY20 or equivalent strength injection anchoring system with 12 mm diameter x 200 mm long Hilti HIT threaded rods and screen tubes spaced at 300 mm on center.

6. Protect the bottom forced entry lock thumbturn with a "U" shaped metal guard, with the opening at the bottom that has been approved by the OBO/CFSM/SM FE/BR Program. Attach the guard to the door surface with counter-sunk screws on the inside of the "U." The finish of the guard shall match the finish of the door.

7. Doors, windows and glazed panels in multi-unit elevations shall be designed and fabricated with minimum 50mm x 150mm x 6mm steel tubes or as required by blast loading to separate the head and jambs of each door frame from other door, window frames and glazed panels.

8. All embed plate assemblies must have been factory welded together.

9. Door frame bolt/screw horizontal slotted holes are 16 mm x 35 mm (5/8” x 1-1/4”) round access holes. Washer diameters are 27 mm so that 4mm of the slotted hole will be visible on each side of the washer. This configuration has been inspected and it has been confirmed that the bolts are centered in the slotted holes.

10. All FE/BR product bolts, screws and anchors shall be metric products.

11. Cladding that covers door frame bolt/screw access holes shall have either access holes with cap plugs or shall be attached with screws for easy removal. Cap plugs and cladding for each door shall be placed in bags for installation until after the final QA inspection.

12. Manufacturer shall ensure any decorative cladding around the electro magnetic lock on door frame allows lock position to be adjusted in both directions.

13. At each door assembly, provide continuous minimum gap between door leaf and door frame.

14. In large multi-unit elevations, fabricate door assembly frames so that frames have been separated from other FE or FE/BR product frames with structural steel tube to allow for future door frame adjustments.



15. Ensure that thresholds do not exceed specified limits, as indicated in the approved shop drawings.

16. Provide adjustable strike plates for locksets, both key and push-button combination type (if available and as indicated on the shop drawings).

PART 3 - EXECUTION

3.1 INSTALLATION

A. General:

1. Install FE/BR door assemblies only into a steel substrate and in such a manner that allows for future frame adjustment. This may be either a structural steel wall or other structural steel assembly, steel embed in concrete, or a steel sub-frame attached to concrete or masonry.

2. Install security door assemblies in accordance with approved shop drawings, manufacturer's data and instructions, and requirements of these specifications.

3. Install the assemblies in compliance with recommendations and instructions of SDI-100 and SDI-105.

a. At fire-rated door openings, comply with NFPA Standard No. 80.

4. Install each embed plate or sub-frame level, plumb and square.

5. No part of the forced entry lock (FEL) may be altered including but not limited to grinding, cutting or re-welding any part of the FEL strike, strike plate (steel couple with vertical slot welded to the frame) and strike plate receiver (vertical slot in door leaf). No part of the FE/BR door may be altered. The only acceptable fix for defective or altered parts is to unbolt the altered piece and replace altered piece in its entirety.

6. Replace temporary bolts with permanent bolts.

7. Torque frame bolts to exactly 47.5 Nm (35 ft./lbs.). Insert shims at bolt locations.

8. Finish materials shall not overlap door frame/sub-frame and ballistic trim bars unless finish materials can be easily removed and reinstalled. Any overlapping finish work (e.g. metal, wood, stone) shall be capable of removal without damaging the door frame and surrounding finishes. Install door and frame such that removal of the door and frame is possible without demolishing the finishes and trim, and such that door is capable of future adjustments of 6-mm in or out of opening.

9. Installer in coordination with manufacturer shall ensure any decorative cladding around electro magnetic lock on door frame allows lock position to be adjusted in both directions.

10. Install access plates for doors as indicated in the approved shop drawings.



11. Install door frame head level and non-hinge side jamb plumb and square.

12. Ensure each lockset, deadbolt and panic exit device is able to fully engage and freely operate.

13. For doors with panic hardware, install panic exit device strike plate in location that will eliminate any door leaf bounce on frame.

14. Install each door closer in accordance with the manufacturer's instructions.

15. Install separate pieces of ballistic trim as indicated in the approved shop drawings.

16. Secure ballistic trim bars to sub-frame and not door frame.

17. Maintain 6 mm (¼”) gap between back of ballistic trim bar and door frame.

18. Evenly install shimming of FE/BR products that utilize a continuous type hinge; uneven shimming is not acceptable.

B. Anchorage: The door manufacturer shall provide anchors appropriate for substrate to which door frame and sub-frame is to be fastened. Door frames shall have pre-drilled horizontally slotted bolt hole patterns not to exceed 300 mm on center. The manufacturer shall verify substrates involved, and supply any special fastening tools (e.g., special drill, bit, tap) required by anchoring system. The anchor shall be acceptable for shock/short duration loading, and have potential for removal and re-installation during life of building.

1. Avoid cutting rebar during concrete sub-frame installation.

2. Provide 1.5 mm (1/16 inch) thick plastic shims with break-off tabs for rough opening (RO) frame clearance.

3. Match finish of cap plugs used in frame with frame finish to the maximum extent possible. Do not install cap plugs until after the final QA inspection of doors, conducted by OBO/CFSM/SM physical security engineer, has been completed.

3.2 ADJUST AND CLEAN

A. General: Upon request of COR, remove protective coverings and clean exposed surfaces. Repair damaged elements, restore abraded surfaces, touch-up base-coat paint finish with air-drying primer, and remove imperfections from exposed natural metal finishes.

1. Check and readjust hardware, devices, and accessories with door-to-frame-and-sill/ threshold clearances set for proper operation of locks, door seals, and other operational units. Do not remove permanently applied performance labels.

2. Comply with "Door Hardware" section requirements for protection and handling of keys, locking devices, and associated information.

3. Exercise extreme care in cleaning exposed surfaces of polycarbonate; comply with manufacturer's directions.



4. Replace Any continuous hinges with squeaks. Field lubrication of the hinge as a solution for eliminating squeaks is not acceptable.

5. Adjust each door closer in accordance with the manufacturer's instructions.

6. Adjust automatic door operators in accordance with the manufacturer's instructions to meet accessibility requirements of OBO-ICS IBC Chapter 11.




MANUFACTURER’S CERTIFICATION OF INSPECTION AND SHIPMENT

Manufacturer:

Contract Number:

Job Number:

I certify that the shipment of the items listed below and consigned to ______________________________ was in-spected and found to comply with all the requirements of the contract.

Crate No. Contract Item No.

Mark No. Unit Description Shipment

Quantity Date Shipped Weight and Cube (LxWxH)

/ / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /

Total number of containers: Total weight and cube:

Bill of Lading Number(s):

Shipped via USDA: Final Destination:

Signed: Certifying Official Title:

Typed Name: Date: / /

Distribution: 1 – Enclose in a waterproof envelope with the Master Packing List and firmly attach envelope to a marked shipping container.

1 – Project Director as COR. 1 – Retained by Manufacturer.


FORCED ENTRY (FE) / BALLISTIC RESISTANT (BR) DOOR ASSEMBLIES SECTION 08318-21

MANUFACTURER’S FINAL INSPECTION REPORT Page 1 of 4

Manufacturer:

Contract Number:

Job/Mark Number(s):

Shop Drawing Number: Final Acceptance of

Product:

Inspector: Date: / /

Inspection Criteria Findings Acceptance N/A NO YES

1. APPEARANCE

1.A SURFACES OF DOORS, WINDOWS, MODULAR PANELS, LOURVERS, AND FRAMES

No sharp edges or safety hazards Weldments ground and sanded Depressions filled and sanded Surfaces flush, flat and smooth Hardware cutouts, edges smooth, straight

and sanded

1.B PRE-TREATMENT AND PAINT FINISH

Coverage, uniform w/o runs or sags. Thickness:

Prime: 1.0 + .25 mil Cite: Finish: 2.0 + .50 mil Cite:

Hardness: F minimum scratch H minimum gouge

Color Cite: No overspray Smooth

1.C ASSEMBLIES

Square tight fitted components Paint and hardware finish compatible

1.D IDENTIFICATION

Proper labels & Bar codes Located as specified

Acceptance:

Rejection:

Comments/Notes: (Attach additional sheets as necessary)

Quality Control Inspector: Date: / /





2. GENERAL

2.A GLAZING

No crazing or delaminating Flatness within specification tolerance Glazing trim properly installed:

Vinyl Other Cite:

Proper glazing blocks No silicone caulk No scratches

2.B WIRING

Diagram provided on interior cover of ter-minal block cavity

Conduits provided as cited Holes drilled for wiring Properly secured Code of wires correct

2.C MISCELLANEOUS

Cover and scalp plates: Properly applied No interference w/hardware Correct screws used Flush with mating surfaces

Weather strip on exterior doors Silencers applied to jamb Door doesn't hit jamb Locking angles clear jamb Threshold properly protected and mounted

to check fit

Pull doesn't exceed 10 lbs for armored or 7 lbs for non-armored to open door

Finish per SHW schedule Quantity per SHW schedule

Acceptance:

Rejection:







3. HARDWARE

3.A FORCED ENTRY LOCK

Bolt throw, ease, clearance in locking angle and fit to scalp

Secure inside door Cylinder tight, flush to door Key removes when lock is thrown Shutter is operable (and is) Operable with

electric current

3.B FORCED ENTRY HINGE

Fitted and attached per appropriate Figure (13-D)

3.C LOCKSET

Proper space in jamb for deadbolt Latch and deadbolt align w/strike Latch and deadbolt operable (ea. side if

applicable) , w/ and w/o key)

Trim flush & true w/door surface Strike plate flush & true w/jamb Stem correct for use in lock Latch not tight or loose in strike

3.D CLOSER

Latch time, normal: 3-4 seconds Latch time, fast close: 2-3 seconds Latch time, slow close: 5-7 seconds Mount bracket secured flush to jamb Mounting screws do not protrude Arm parallel to door surface

3.E PANIC EXIT DEVICE

Cut to correct length Solenoid works properly @ 24V DC

3.F ELECTRONIC HARDWARE

All function when power applied Magnetic Sensors indicate ON/OFF

Acceptance:

Rejection:







4. PACKAGING AND PACKING

Packaging complies with Section 140 Wood case complies with Figure 14B 2x4 brace ins3erts to protect hardware, etc. Unit plumb and level in case Unit properly secured in case Trim properly secured in case Packing list/Inspection certificate Master Packing list and shop drawings All items on packing list verified

5. MARKING ON CASE

Marking complies w/Section 140 Weight –Dimension -Cube Crate Number, of Total in shipment Job number and Mark number "THIS END UP" "OPEN FIRST"

"FRAGILE" warning signage applied

Origin, USDA & final destination shown Bot tom/Top arrow indicators shown

6. SHIPPING

"Tip-N-Tell" applied/documented TNT Inside/Outside/Pins pulled Load properly secured in truck All applicable data on Shipping Docs. Representative pictures of door, window,

modular unit, and louver

Acceptance:

Rejection:





MANUFACTURER’S GLAZING INSPECTION REPORT

Manufacturer:

Contract Number:

Job/Mark Number(s):


Product:


FE/BR Glazing Inspection Criteria Findings Acceptance N/A NO YES

A. VISION OPENINGS

Verify glazing to specification requirements Confirm glazing ID to Label, Bar Code Flatness to spec. tolerance 0.030"/ft. No crazing, cracks, chips, scratches No delaminating or un-lamination Bite minimum 3/4" sides, metal stop edges Tape trim fitted, to glazing and stop Vinyl trim proper size and type Proper glazing blocks (cite type, size) No scratches Painted/Anodized Surfaces Clean, w/o Fingerprints, dirt, scratches, etc.

Paper protection applied to polycarbonate "Attack Side" label on glass face

B. OPTICAL DEFECTS

1. The defects shall not be of a size, or frequency in the assembly, to cause focusing of the viewer’s eye on such defects when viewing through the assembly.

2. Occlusions (spherical and cylindrical combined) shall not appear at a frequency exceeding three per square foot in the major viewing area of the assembly.

Inspect for defects, open or entrapped: Bubbles, seeds, lint, dirt, etc. Spherical occlusion exceeding 1/16" . Cylindrical occlusion exceeding 1/16" Cylindrical occlusion exceeding 1/2" length. No crazing, cracks, chips, scratches. No delaminating or un-lamination. No distortions. No hazed conditions. Any condition affecting light transmission.

Acceptance:

Rejection:





MANUFACTURER’S PREPARATION FOR ASSEMBLIES INSPECTION REPORT DRILLED, PUNCHED HOLES & CUT-OUTS (LOCATION, TEMPLATES & TOLERANCES)

Page 1 of 2

Manufacturer:

Contract Number:

Job/Mark Number(s):


Product:



A. FORCED ENTRY HINGE (Continuous types):

Proper cutouts, around angles, etc. Countersink screw heads 1/64" minimum below

plane of hinge leaf.

Fitted and attached per Figure 13-D. Located 1/8" from top of door Back of hinge properly protected Finish compatible to SHW Schedule Precise hole layout per specified template. Identify leaf for door side to jamb.

B. DOOR:

Holes in hinge and door aligned Threads in door not stripped Flange on hinge flush w/ door surface Hinge placed for proper swing of door ID Label on hinge side w/Mark Number.

C. JAMB:

Holes in hinge and jamb bar align. Access holes in hinge and bar align. Threads in jamb not stripped. Hinge flange flush w/back-up bar.

D. MULLION (per elevation):

Line-up + 1/32" (front to back). Alignment of holes + 1/32". Dimensional + 1/32” each unit.

Acceptance:

Rejection:





MANUFACTURER’S PREPARATION FOR ASSEMBLIES INSPECTION REPORT DRILLED, PUNCHED HOLES & CUT-OUTS (LOCATION, TEMPLATES & TOLERANCES)

Page 2 of 2

Manufacturer:

Contract Number:

Job/Mark Number(s):


Product:



E. HARDWARE CUTOUT DIMENSIONS:

Von Duprin (33 & 99) strike, 3/16" back-up plate.

Russwin-strike + 1/32", tabs, recess as specified Simplex-strike + 1/32", tabs, recess as specified 310 strike + 1/32", tabs, recess as specified Sentrol + 1/32". E.P.T + 1/32". Bolt access holes. Electric Access Panel + 1/32".

F. MISCELLANEOUS:

Wire holes, location clear. Glazing bar(s), (if used) tolerances + 1/32"

square, overall dimensions

Trim ( fit to glazing stop) Welds: placement, sized as specified penetration

with no splatter

Threshold bar location to be 1/32" back from jamb stop.

G. OVERALL DIMENSIONS:

Height (outside + 1/32" RH/LH side) Width (outside + 1/32" top/bottom) Square inside frame + 1/16". Straightness + 1/16" each direction. Strike receiver square with jamb + 1/32" all

dimensional locations.

Acceptance:

Rejection:





MANUFACTURER’S WELDING REPORT

Manufacturer:

Contract Number:

Job/Mark Number(s):


Product:



A. WELDING PRACTICE AND PROCEDURES:

Only specified and properly qualified welding proce-dures are used for the work.

Joint preparation and fit-up meet the requirements of the welding procedure and drawings.

Specified filler metals are used and maintained in proper condition for use as specified.

Technique and performance of each welder, welder operator and tacker are as specified.

The work conforms to requirements of the applicable code, standard, specification and drawing.

The work inspected is identified with specified mark-ing methods and/or appropriate records.

Base material, consumable welding material con-form.

Specified welding filler materials are used on each base metal or combination of base metals.

The welding equipment to be used is appropriate for use with the welding procedure and can produce the specified welds.

B. PRODUCTION WELDS – ACCEPTANCE CRITERIA:

A weld shall be acceptable by visual inspection provided all four of the following criteria are met: The weld has no cracks. Minimum reinforcement of 1/32" (1 mm) for all

square groove, arc spot, and arc seam welds.

No undercut exceeds 10% thickness of the steel which has the undercut.

Filet weld faces shall be flat or slightly convex.

Acceptance:

Rejection:





MANUFACTURER’S PRETREATMENT AND FINISH INSPECTION REPORT

Manufacturer:

Contract Number:

Job/Mark Number(s):


Product:



A. SURFACES OF DOORS, WINDOWS, MODULAR OPAQUE PANELS, LOUVERS & FRAMES:

No sharp edges or safety hazards No weld splatter, burn marks, etc. "Sight Lines" aligned within the designed system

of products

Weldments ground and sanded smooth Exposed fillet welds radiused And ground smooth

Depressions filled and sanded Surfaces flush, flat and smooth Hardware cutouts, edges smooth, straight and

swiped.

B. PRETREATMENT AND PAINTING:

All metal surfaces cleansed of dirt, grime, oils, rust, etc.

All exterior and interior surfaces treated as per Specification FS-TT-C 490.

C. PAINT FINISH:

Coverage, uniform w/o runs or sags. Thickness:

Prime: 1.0 + .25 mil. Cite: Finish: 2.0 + .50 mil. Cite:

Hardness: F minimum scratch H minimum gouge

Accepted color, no discoloration. Good adhesion. No foreign matter in coating.

Acceptance:

Rejection:





Certificate of Compliance

Manufacturers and Contract Specifications for FE/BR Products FE/BR Door Assemblies

Door Number__________

(Per Construction Documents) Each of these items indicated below must be inspected by the contractor prior to acceptance of the

FE/BR products by DoS. A completed Certificate of Compliance is required for each individual product.

1 The manufacturer's technical representative was on site dur-

ing the initial stages of installation and for site-specific unique conditions as required.

Representatives Name Dates on site

2 Each embed plate or sub-frame has been installed level, plumb and square.

Inspecting Official Date

3 All embed plate assemblies must have been factory welded together.


4 All units with glazing have been pre-glazed at the factory.


5 Employees performing the installation meet the specified training and experience qualifications.

Certifying Official Date

6 No part of the forced entry lock (FEL) has been altered in-cluding but not limited to grinding, cutting or re-welding any part of the FEL strike, strike plate (steel couple with vertical slot welded to the frame) and strike plate receiver (vertical slot in door leaf). No part of the FE/BR door has been al-tered. The only acceptable fix for defective or altered parts is to unbolt the altered piece and replace altered piece in its en-tirety.


7 Door frame bolt/screw horizontal slotted holes are 16 mm x 35 mm (5/8” x 1-1/4”) round access holes. Washer diameters are 27 mm so that 4mm of the slotted hole will be visible on each side of the washer. This configuration has been inspect-ed and it has been confirmed that the bolts are centered in the slotted holes.




8 All temporary bolts have been replaced with permanent bolts.


9 All frame bolts have been torqued to exactly 47.5 Nm (35 ft./lbs.). Shims have been inserted at all bolt locations.


10 Frame bolts/screws are 12 mm x 40 mm socket head cap screws with 3mm x 27 mm (1/8” x 1-1/6”) diameter grade 8 or equivalent class 10.9 or 12.9 washers.


11 All FE/BR product bolts, screws and anchors are metric products.


12 No finish materials overlap the door frame/sub-frame shim space and ballistic trim bars unless the finish materials can be easily removed and reinstalled. Any overlapping finish work (i.e. metal, wood, stone, etc.) must be capable of removal without damaging the door frame and finish to allow future adjustments of 6-mm in or out of the opening.


13 Any cladding that covers the door frame bolt/screw access holes has either access holes with cap plugs or is attached with screws for easy removal. Cap plugs and cladding for each door have been bagged and won't be installed until after the final QA inspection has been conducted by the OBO/CFSM/SM physical security engineer.

Certifying Official

Date

14 The manufacturer and installer must ensure any decorative cladding around the electro magnetic lock on the door frame will allow the lock position to be adjusted in both directions.

Certifying Official

Date

15 At each door assembly, there is a continuous minimum gap between the door leaf and the door frames.

Certifying Official

Date

16 All access plates for each door have been installed as indicat-ed in the approved shop drawings.

Certifying Official

Date

17 Any continuous hinges with squeaks have been replaced. Field lubrication of the hinge as a solution for eliminating squeaks is not acceptable.


18 Each door frame head has been installed level and the non-hinge side jamb has been installed plumb and square.

Certifying Official

Date

19 Each lockset, deadbolt and panic exit device is able to fully engage and freely operate.

Certifying Official

Date

20 On doors with panic hardware, the panic exit device strike plate has been installed in a location that will eliminate any door leaf bounce on the frame.


21 All door assembly frames, in large multi-unit elevations, have been separated from other FE or FE/BR product frames with a structural steel tube, which will allow for future door frame adjustments.

Certifying Official

Date

22 Thresholds do not exceed specified limits, as indicated in the approved shop drawings.

Certifying Official

Date



23 Each door closer has been installed and adjusted in accord-ance with the manufacturer's instructions.

Certifying Official

Date

24 Automatic door operators have been adjusted as appropriate in accordance with the manufacturer's instructions to meet ADA-ABA and appropriate fire codes.

Certifying Official

Date

25 Adjustable strike plates have been provided for all locksets, both key and push-button combination type (if available and as indicated on the shop drawings).

Certifying Official

Date

26 Separate pieces of ballistic trim have been installed, as indi-cated in the approved shop drawings.

Certifying Official

Date

27 Ballistic trim bars have been secured/screwed to the sub-frame and not the door frame.

Certifying Official

Date

28 A 6 mm (¼”) gap between the back of the ballistic trim bar and door frame has been maintained.

Certifying Official

Date

29 Uneven shimming of FE/BR products that utilize a continu-ous type hinge has not been permitted.

Certifying Official

Date

30 The manufacturer has provided two metal ID plates for each product that has machine applied letters and numbers. One ID plate should be located on the door frame and one ID plate should be located under the door leaf edge scalp plate just below the top FEL.

Certifying Official

Date

UNITED STATES DEPARTMENT OF STATE JANUARY 2009

OVERSEAS BUILDINGS OPERATIONS

OBO STANDARD SPECIFICATIONS

SECURITY DOOR HARDWARE UNCLASSIFIED 1

SECTION 08714 - SECURITY DOOR HARDWARE

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Contract Drawings and general provisions of the Contract, including Contract Clauses and Conditions (CC&C), Supplemental Contract

Clauses and Conditions, and Division 1 Sections of these Contract Specifications, apply to this Section.

1.2 SUMMARY

A. Related Sections

1. Division 8 Section for metal doors and frames.

2. Division 8 Section for wood doors.

3. Division 8 Section for FE/BR door assemblies.

4. Division 16 for electronic security and power for electrically operated hardware devices.

5. Classified Section 08715, “Security Door Hardware for PCC.”

1.3 SUBMITTALS

A. General: Submit in accordance with Division 1 requirements.

B. Product Data: Submit three copies of catalog cuts of all items used in the supplier's schedule.

1. Include construction and installation details, material descriptions, dimensions of individual components and profiles, and finishes.

C. Shop Drawings: For power-assist operators. Include plans, elevations, sections, details, and attachments to other work.





1. Indicate required clearances, method of field assembly, components, and location and size of each field connection.

2. Include locations and elevations of entrances showing activation and safety devices.

D. Hardware Schedules: Based on hardware indicated, organize hardware schedule into groups or sets showing complete designations of every

item required for each door opening. Schedule shall be vertical layout similar to the format used herein. Lines shall be double-spaced with

pages numbered and dated; Security Hardware Sets shall be listed as SHW-1, SHW-2, etc.

1. For doors of different sizes or where hinges, locks or closers are different, a separate heading shall be used. No labeled openings shall be

combined with non-labeled openings. Horizontal hardware schedules are not acceptable. Include the following:

a. Number, location, hand, fire rating, DOS Code, size and material of each door opening (hands and swings to be determined in

relation to key side of opening).

b. Type, style, function, size, finish and quantity of each hardware item.

c. Name and manufacturer of each item.

d. Fastening requirements.

e. Explanation of abbreviations used.

f. Keying information.

g. Wiring diagrams (after each corresponding hardware group).

E. Hardware Schedule Index: Furnish an index cross referencing Contract Document door number and hardware group, and supplier's hardware

set.

F. Keying Schedule: Submit separate detailed schedule, indicating the Government's approved master key system, for Government review and

approval after Hardware Schedule has been approved.

G. Wiring Diagrams: Furnish wiring diagrams illustrating point-to-point hook-up of all electrical hardware specified herein. Include fire alarm

and/or access control system interface where applicable. Diagrams shall be complete by opening and shall indicate connections between all

components affected. Manufacturers’ standard line diagrams are not acceptable.

H. Samples: If requested by COR, submit one sample of each requested item tagged with full description for coordination with the hardware

schedule. These items will remain on file in the COR's office until all other similar items have been installed in the project. At that time, items

on file will be released for installation in pre-determined Project locations.





I. Operating Instructions: Furnish the Government with one complete set of installation instructions, including special adjusting tools and

maintenance instructions listing routine maintenance procedures, possible breakdowns and repairs, and troubleshooting guides. One complete

catalog shall be furnished for each manufacturer listed in the approved hardware schedule.

J. Templates: Furnish templates and approved hardware schedule to door and frame fabricators. Where fabricator cannot work to paper

templates, ship templates and or physical hardware to factories of respective manufacturers. Prepay cost for shipping and delivery.

K. Informational Submittals: Submit the following:

1. Certifications specified in Quality Assurance article.

2. Qualifications Data: Hardware Suppliers Qualification data.

L. Closeout Submittals: Submit specified warranty in accordance with Division 1 requirements.

M. Certification: After completion of hardware installation, submit written certification attesting that hardware has been installed in accordance

with manufacturer's templates and instructions and that hardware has not been altered.


A. General Requirements: Hardware has been specified by manufacturer's name, brand and catalog numbers for purpose of establishing basis for

quality, design and operational function.

1. Provide designated product, or where more than one product or manufacturer is listed, provide equivalent product of one of other listed

manufacturers.

2. Obtain each type of hardware from single manufacturer.

3. Hardware Sets within this Section are not complete with respect to thickness of doors, hand, backset, method of fastening, and other

detail requirements.

4. Review Drawings and Door Schedules thoroughly and provide required hardware for all openings, including openings that may have

been inadvertently omitted from Door Schedules.

5. Should opening be omitted or opening not indicated with hardware set, provide hardware of same quality, design and function as

specified for similar openings.





6. Sequence of Operation: Provide electrified door hardware function, sequence of operation, and interface with other building control

systems indicated.

7. Furnish hardware complete with brackets, plates, fittings, fastenings and other accessories required for installation.

B. Regulatory Requirements:

1. Comply with OBO International Codes Supplement (OBO-ICS) IBC Section 1101 to accommodate barrier free design except where

specifically indicated by the Government.

2. Provide knurled tactile warning on door hardware to hazardous areas; abrasive coating not acceptable.

3. Comply with NFPA 80 for hardware at fire-rated assemblies.

4. Provide hardware that has been tested and listed by UL or FM for fire-rated assemblies of types that comply with requirements of door

and frame labels.

5. Comply with National Electrical Code requirements for personnel doors to protect workers in applicable electrical spaces.

6. Latches and Locks for Means of Egress Doors (Except where Specifically Indicated Otherwise): Comply with NFPA 101. Latches

shall not require more than 67 N (15 lbf) to release the latch. Locks shall not require use of a key, tool, or special knowledge for

operation.

7. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, by a testing agency, and marked for

intended location and application.

C. Hardware Supplier Qualifications: Door hardware supplier who has been furnishing hardware for a period of not less than two years, and who

is, or who employs an Architectural Hardware Consultant (AHC) who will be available at reasonable times during the course of Work for

consultation about Project's hardware requirements.


A. Comply with Division 1 requirements.

1. Pack each hardware item separately. Include manufacturer's printed installation instructions, trim, fasteners accessories, and special

tools necessary for installation.

2. Legibly mark and adequately label each package indicating opening for which intended. Provide markings corresponding with approved

Hardware Schedule.





3. Deliver permanent security cores and keys as indicated in Keying section, not less than two months prior to scheduled substantial

completion.

PART 2 - PRODUCTS

2.1 APPROVED PRODUCTS

A. See door hardware sets at end of this Section for approved products.

2.2 HINGES

A. FE/BR Hinges: For FE/BR doors that utilize a continuous Hager Roton hinge, provide Hager Roton 1200 Series or equivalent extra-heavy

duty hinge.

B. Electrified Functions for Hinges: Comply with the following:

1. Power Transfer: Concealed PTFE-jacketed wires, secured at each leaf and continuous through hinge knuckle.

2. Monitoring: Concealed electrical monitoring switch.

3. Power Transfer and Monitoring: Concealed PTFE-jacketed wires, secured at each leaf and continuous through hinge knuckle, and with

concealed electrical monitoring switch.

2.3 CYLINDERS AND CORES

A. Provide cylinders for locks, deadlocks, and other control and locking devices indicated in the Hardware Sets.

B. Security Doors:

1. Acceptable Manufacturers:

a. Medeco Security Locks, Inc. an ASSA ABLOY Group company.





b. No substitutions.

2. Description:

a. Original high security cylinder with interchangeable core. Provide six-pin commercial keyway.

b. All cylinders shall be equipped with temporary construction core for use during construction. The contractor is responsible for the

purchase of the final cores and coordination of their secure shipment to the project site through DS.

2.4 KEY CONTROL SYSTEM (DELETED for this Project)

2.5 POWER-ASSIST OPERATORS

A. Acceptable Manufacturers:

1. LCN Closers; an Ingersoll-Rand company.

2. No Substitutions.

B. Standard: BHMA A156.19.

C. Description: Units shall be pneumatically powered; surface mounted to frame head, and shall operate as manual door closers unless power-

assist is activated and when power is lost.

1. Activation of power-assist shall open doors to 90-degrees.

2. Furnish actuators with satin stainless steel dress plates embossed with the universal handicap symbol. Refer to OBO–ICS Chapter 11

for the power assist operators requirements.

3. Opening Force:

a. If Power Fails: Not more than 67 N (15 lbf) required to release a latch if provided, not more than 133 N (30 lbf) required to

manually set door in motion, and not more than 67 N (15 lbf) required to fully open door.

b. Accessible Interior Doors: Not more than 22 N (5 lbf) to fully open door.

4. Entrapment Protection: Not more than 67 N (15 lbf) required to prevent stopped door from closing or opening.

D. Required Features: Manufacturer's standard cast iron construction.





1. Rack and pinion construction with compression spring, fully hydraulic.

2. Closing speed and latching speed controlled by independently operated valves.

3. Adjustable spring power allowing adjustment up to 50 percent in field to suit individual door conditions.

4. Adjustable hydraulic backcheck.

2.6 AUXILIARY HARDWARE


1. Hager Companies.

2. *Ives Hardware; an Ingersoll-Rand Company.

3. *Rockwood Manufacturing Co., Inc.

4. Triangle Brass Manufacturing Co., Inc. (“Trimco” – see www.trimcobbw.com)

5. * Manufacturer used in Hardware Sets at end of section.

B. Manual Flush Bolts: Top manual flush bolt shall not exceed 1880 mm (74-inches) from floor to centerline.

C. Door Stops: Furnish wall stops equal to Ives 407CVX or Rockwood 400 wherever trim strikes wall. Where wall stops are not suitable, furnish

surface mounted overhead stops equal to Glynn-Johnson 450 Series. Where door closers are specified in the Hardware Sets and wall stops are

not suitable, provide closer arms with built-in stops (LCN No.3077-CNS).

D. Silencers: Furnish rubber silencers equal to Ives SR64 or Rockwood 608 for hollow metal frames; three per single door and four per pair.

Silencers are not required at doors specified to receive continuous weather-stripping or seals.

2.7 OVERHEAD STOPS AND HOLDERS


1. Architectural Builders Hardware.

2. *Glynn-Johnson; an Ingersoll-Rand Company.





3. Rixson, an ASSA ABLOY Group company.


B. Where wall stops are not suitable, furnish surface overhead stops equal to Glynn-Johnson 450 Series. In Hardware Sets where door closers are

specified, provide closer arms with built-in stops (LCN No.3077-CNS).

2.8 THERESHOLDS, WEATHER-STRIPPING AND SEALS


1. Hager Companies.

2. National Guard Products.

3. *Pemko Manufacturing Co.

4. Reese Enterprises, Inc.

5. Zero International, Inc.


B. Description: Refer to the Hardware Sets for grade and style. Where required, field modify thresholds to accept strikes for flush bolts and exit

device rods.

C. Smoke Seals: Where required by applicable code, at doors located in Smoke Barrier Partitions, provide smoke seals equal to Pemko S88 at the

head and jambs; and at pairs of doors, one Pemko 375CR or two Pemko 303AS astragal seals as appropriate; coordinate with Drawings and

schedules.

D. Astragals: Where indicated in the Hardware Sets, provide overlapping astragals equal to Pemko 357SP. Astragals shall be full height, installed

on the "threat" side of the opening.

2.9 ACOUSTICAL TREATMENT

A. Provide full door gasketing/acoustical seals with flat threshold installed to maintain STC rating of surrounding walls.





B. Certification: Provide certification that the door construction utilized has been tested at an independent laboratory in accordance with ASTM

E90-90, and that the STC determined in accordance with ASTM E413-87 is not less than that specified. The laboratory referenced in the

certification must be qualified under the National Voluntary Laboratory Accreditation Program (NAVLAP) of the U.S. Bureau of Standards.

Certification must reference laboratory name, test report number, and date of test; substitution of test data not in accordance with ASTM E90-

04 and E413-87 will not be acceptable.

C. Sound-Rated Gasketing: Assemblies that are listed and labeled by a testing and inspecting agency, for sound ratings indicated, based on

testing according to ASTM E 1408.

D. Secondary Requirements: If fire resistance is required, certify that assemblies have been tested in accordance with UL 10B for labeled fire

doors and frames and meets the requirements of NFPA 80. If seismic stability is required, submit calculations showing ability of door systems

to withstand pertinent seismic forces.

2.10 ELECTROMAGNETIC DOOR HOLDERS(DELETED for this project)


1. Corbin Russwin Architectural Hardware; an ASSA ABLOY Group company.

2. *LCN Closers; an Ingersoll-Rand company.

3. Rixson, an ASSA ABLOY Group company.


B. Description: Refer to the Hardware Sets for size and style. Install wall holders with shims as required for a complete installation; coordinate

with Drawings and details.

1. Wall Actuators: Schlage, an Ingersoll-Rand company.

2. Post Actuators: MS Sedco.

2.11 KEYING

A. The following is the DOS required keying plan for SECURITY DOOR OPENINGS:





1. Key locksets and cylinders to factory established and recorded system.

a. All key operated locks on individual doors shall be keyed alike.

b. Grand Master and Great Grand Master systems are not permitted.

c. All exterior FE and FE/BR doors shall have an interior cylinder with a non-removable thumb turn.

d. Security doors shall be keyed different and master keyed by building within the following categories: Exterior FE and FE/BR

doors; interior hard-line doors; Telecommunications Room doors; and EC Room doors.

e. Security doors shall be keyed different and master keyed by floor within the Controlled Access Area, except for the PCC and

Secure Conference or Processing rooms.

f. Security doors shall be keyed alike with no master key within the following categories: Pharmacy, Safe Haven or Safe Area, and

LAA Lock and Leave doors.

g. Security doors shall be keyed different with no master key within the following categories: Telephone Equipment Rooms; Secure

Generator Room; React Room; PCC; Secure Conference or Processing rooms; and Primary Lock and Leave doors.

B. The Project Director, a representative of the Post, the General Contractor's representative, and either the RSO or the PSO shall meet to

determine if there are any special keying conditions required so they may be incorporated into the keying schedule.

C. Key Quantities : Furnish plain bow keys of nickel silver material in the following quantities:

1. For each master key system, provide:

a. Two master keys.

b. Two control keys (pinned to the master).

c. Two operating keys per cylinder change.

2. For each individually keyed cylinder, provide:

a. Two control keys.

b. Two operating keys per keyed cylinder.

3. For each construction key system, provide:

a. Two control keys.

b. Eight master keys.





D. Identification and Control

1. Identify master keys with registry number; do not stamp with master key, letter M, or similar identification; manufacturer's trademark or

identification not allowed.

2. Stamp master keys with DO NOT DUPLICATE.

3. Furnish visual controls system; coordinate provisions with the Government. Stamp or emboss keys and cylinders with identification

code. Code should not be stamped on the face of the cylinders, only on the barrel.

E. Delivery

1. Deliver construction cores, construction master keys, and construction keys to the Project Site.

2. Permanent cores, operating keys and permanent control keys shall be individually packaged by the door, identified by the lock and OBO

PROJECT NUMBER ONLY (not Post name), and shipped by the supplier, via prepaid freight to:

U.S. Department of State

DS Lock Support

State Annex #24 (SA-24)

5800 Barclay Drive

Suite 3

Alexandria, Virginia 22315-5700

3. After removal of temporary construction cores, ship construction cores, construction keys, and construction control keys to the above-

mentioned address.

2.12 FINISHES

A. Base Metals: Produce hardware units of basic metal and forming method indicated, using manufacturers' standard metal alloy of composition,

temper and hardness, but in no case of lesser quality than specified or inferred by use of a particular manufacturer's number, style or grade or

as established by appropriate referenced specification listed herein.

B. Finishes: Finishes shall conform to the quality of finish including thickness of plating or coating (if any), composition, hardness and other

qualities complying with manufacturers' standards, but in no case less than the standards established by ANSI/BHMA A156.18.





1. All exposed hardware except door closers shall be satin stainless steel, ANSI/BHMA 630/US32D. Closers shall be painted to match

satin stainless steel. Hinges shall be satin stainless steel. Items not available in stainless steel shall be furnished with satin chrome

finish, ANSI/BHMA 626/US26D.

2. Security hardware finish shall match finish of non-security hardware to the maximum extent possible.

C. Prime Coated Items: Field painted under Division 9 painting section.

2.13 FASTENERS

A. Manufacture hardware to conform to published templates, generally prepare for machine screw installation. Do not provide hardware that has

been prepared for self-tapping or sheet metal screws except as specifically indicated.

1. Furnish screws for installation with each hardware item. Provide Phillips flat head or oval head screws except as otherwise indicated.

Finish exposed (exposed under any condition) screws to match the hardware finish or, if exposed in surfaces of other work, to match the

finish of such work as closely as possible, except as otherwise indicated.

2. Provide concealed fasteners for hardware units that are exposed when the door is closed, except to the extent no standard manufactured

units of the type specified are available with concealed fasteners.

3. Do not use through bolts for installation except where it is not possible to adequately reinforce the work, to accept machine screws or

concealed fasteners or other standard type, to satisfactory avoid the use of through bolts. Grommet nuts and cealnuts are not acceptable.

B. Furnish fasteners that are compatible with both the units fastened and the substrates, and which will not cause corrosion or deterioration of

hardware, base material reinforcement, or fastener. Furnish wall stops with expansion anchors and machine screws. Furnish thresholds with

lead anchors and 1/4-20 stainless steel machine screws.

2.14 ACCESSORIES

A. Door Coat and Hat Hook: Provide cast aluminum, double prong hooks on inside face of all private office doors and toilet rooms; Ives Model

No. 405 wide body design (ANSI/BHMA A156.16, L33113).

PART 3 - EXECUTION





3.1 EXAMINATION

A. Examine conditions and proceed with work in accordance with Division 1 requirements.

3.2 INSTALLATION

A. Install hardware plumb, level, and true to line in accordance with manufacturer's templates, Section 01600, and Project conditions.

1. Install fire rated hardware in accordance with NFPA 80.

2. Where cutting and fitting is required on substrates to be field painted or similarly finished, install, fit, remove and store hardware prior to

finishing. Reinstall hardware after finishing operations are completed.

3. Do not install surface mounted items until finishes have been completed on the substrate.

4. Reinforce attachment substrates as necessary for installation and operation.

5. Mortise work to correct size and location without gouging, splintering or causing irregularities in exposed finish work.

6. Fit faces of mortised components snug and flush without excessive clearance.

7. Set thresholds at exterior doors in bed of sealant. Remove excess sealant.

B. Hardware Mounting Heights: Mount hardware units at heights recommended by DHI (see "Recommended Locations for Builders Hardware")

on custom doors except as otherwise indicated or required to comply with governing regulations, and except as may be otherwise indicated.

C. Cylinder Cores: When instructed, Contractor shall remove temporary construction cores. Permanent cores will be installed by the

Government. After installation of the permanent cores, ship construction cores, operating keys, and control keys via pre-paid freight to the

DS/PEL/SEM address noted in Paragraph on "Keying."

D. Power-Assist Operators: Where post mounted actuator buttons are indicated, run signal wire below grade in conduit complying with Division

16. Elsewhere, run signal wire concealed in Technical Security System conduit. Run pneumatic lines between pumps and door operators

concealed. At curtain walls, run pneumatic lines concealed in metal trays finished to match curtain wall.

3.3 ADJUSTING





A. Check and adjust each operating hardware item to ensure correct operation and function.

1. Adjust sweep period so that, from an open position of 70 degrees, the door will take at least 3 seconds to move to a point 75 mm (3

inches) from the latch, measured to the leading edge of the door.

2. Ensure weather-stripping and seals do not inhibit closing and positive latching of door.

3. Lubricate moving or operating components as recommended by hardware manufacturer. Use graphite type lubrication if none other is

recommended.

4. Replace defective materials or units that cannot be adjusted to operate as intended. Reinstall items found improperly installed.

5. Prior to date of Substantial Completion, readjust and reapply lubricant to hardware items as necessary.

3.4 DEMONSTRATION

A. Instruct Government's designated personnel in proper adjustment and maintenance of hardware at time of Substantial Completion.

1. In the presence of the Government's representative, demonstrate that the keys operate freely in designated unit.

2. Hardware supplier: Completely set-up key control system with keys tagged and placed in cabinet. Cross index system executed with

appropriate information typed in on index cards and instruct Government's designated personnel in the proper use of the system.





3.5 HARDWARE SETS – SECURE DOORS

SHW-4A

QUAN. ITEM MODEL & NOTES MFR.

Certified Forced Entry Hinge Model and quantity to match

certified/rated door.

1 Lockset ML2067 x NSM x 32D Corbin Russwin

1 Interchangeable Core & Mortise

Cylinder

32-0200-26D x CT-Z00 Medeco

Certified Forced Entry Lock Model and quantity to match

certified/rated door.

1 Closer 4041 x Cush-n-Stop – AL LCN

1 Manual kick stand hold open

1 Door Viewer (peep)

1 Set Weather Stripping 332CR Pemko

1 Sill Sweep 315CN Pemko


PORTLAND CEMENT PLASTER SECTION 09220 - 1

SECTION 09220 - PORTLAND CEMENT PLASTER

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes:

1. Three coat Portland cement plaster for application to metal lath. 2. Direct applied plaster finish coat system over primer to perimeter concrete walls.

B. Related Sections:

1. Section 09205, “Furring and Lathing.”

1.2 SUBMITTALS

A. Sample Panel: Submit sample panels of each finish not less than 600 mm square, on movable frames for preliminary review of color and texture prior to preparation of field samples.


A. Single Source Responsibility: Except where specified otherwise, obtain plaster materials from a single manufacturer or from manufacturers recommended by prime manufacturer of portland cement plaster.

B. Installer Qualifications: Company specializing in portland cement plaster work having minimum of five years successful documented experience with work comparable to that indicated and specified.

1.4 FIELD SAMPLES

A. Sample Installation:

1. For final review of each finish, construct sample panel of approximately 30,000 sq. mm as directed.

2. Install one full size unit in location as directed by COR. 3. Show finish and construction techniques.

B. Record tools and techniques used in accepted sample for application of final work.




A. Comply with Division 1 and the following.

1. Deliver materials in manufacturer's unopened containers, fully identified with name, brand, type and grade.

2. Protect plaster materials from contamination and dampness until used. Store in dry, ventilated space, off ground.

1.6 ENVIRONMENTAL REQUIREMENTS

A. Comply with requirements of referenced plaster application standards and recommendations of plaster manufacturer for environmental conditions before, during, and after application of plaster.

B. Cold Weather Requirements: Do not use frozen materials in plaster mixes.

1. Do not apply plaster to base that is wet, frozen or which contains frost. 2. When ambient temperature is 4 deg. C and falling, heat materials and furnish heated

enclosure for at least 24 hours after plastering in accordance with Portland Cement Association (PCA) recommendations.

C. Hot Weather Requirements: Comply with PCA recommendations.

1. Protect plaster from uneven and excessive evaporation during hot, dry weather.

D. Interior Plaster Requirements: Maintain continuous and uniform building temperatures of not less than 12 degrees C and not more than 26 degrees C for minimum period of one week prior to and during plastering operations and one week after plaster has set.

1. Ventilate building spaces to remove water in excess of that amount required for proper hydration of plaster, immediately after its application and during set.


A. Protect fixtures, frames, inserts and other contiguous work from rusting, soiling or clogging due to plastering.

PART 2 - PRODUCTS

2.1 PLASTER MATERIALS

A. Portland Cement: ASTM C150, Type I, II or III, or air-entrained equivalents as required.

B. Hydrated Lime: ASTM C206, Type S.



C. Aggregates:

1. ASTM C897 for base and finish coats.

D. Fiber for Base Coat: Alkaline-resistant (AR) glass or polypropylene fibers, 13 mm long, free of contaminates, manufactured for use in portland cement plaster.

E. Plaster Finish Coat Material:

1. System manufacturer's factory mixed formulation of acrylic polymer, aggregate, and color-fast pigments producing finish resistant to dirt pick-up.

2. Provide primer where necessary for adhesion to concrete perimeter walls and to plaster substrates.

3. Use single color batches for individual colors to avoid color changes from differently mixed batches.

4. Colors: Selected from full range of manufacturer's standard colors

a. PFC-1: As selected.

b. PFC-2: As selected.

F. Water: Suitable for domestic consumption, free of harmful soluble salts, acids, alkalis and other deleterious matter which would impair the work.

2.2 PLASTER MIXES

A. General: Mix proportions are by volume, unless otherwise specified. Measurement by shovel method not permitted. Mixes and mix proportions are suggestive only; variations to meet local conditions, manufacturer's requirements, application requirements, or to achieve the desired finish are permitted within limits specified in ASTM C926.

1. Make lime putty from hydrated lime; machine mix with water to putty form; allow to stand at least 15 minutes before using.

2. Provide either neat or ready-mixed materials, at Contractor's option, for finish coat as required to match accepted sample.

3. Fiber Content: Add fiber to following mixes after ingredients have mixed at least two minutes. Comply with fiber manufacturer's directions but do not to exceed 9.7 kg/m2 of cementitious materials. Reduce aggregate quantities accordingly to maintain workability.

B. Scratch Coat Mix:

1. One part Portland cement. 2. Three to four parts aggregate. 3. 1/4 part lime. 4. Fiber.



C. Brown Coat Mix:

1. One part Portland cement. 2. Three to five parts aggregate. 3. 1/4 part lime.

D. Integral Color Finish Coat: Factory prepared mix requiring addition of water only in accordance with manufacturer's instructions.

E. Mixing: Use mechanical mixers for mixing plaster, small batches may be hand mixed.

1. Do not use frozen, caked, or lumped material. 2. Clean mechanical mixers, mixing boxes and tools after mixing each batch; keep free of

plaster from previous mixes. 3. Thoroughly mix plaster with proper amount of water until uniform in color and

consistency. 4. Retempering not permitted; discard plaster that has begun to stiffen.

PART 3 - - EXECUTION

3.1 EXAMINATION

A. Examine conditions and proceed with work in accordance with Section Z01701.

1. Carefully examine lathing and accessories which are to receive plaster before plaster is applied. Do not apply plaster until unsatisfactory conditions are rectified and made suitable for application of plaster.

2. Carefully examine metal grounds such as corner beads, screeds and other accessories to see that they are straight, curved, plumb, level, square, or true to required angles before plaster is applied.

3.2 PREPARATION

A. Prepare concrete perimeter walls to receive direct applied plaster finish.

B. Ensure form oils and other bond breaker items have been completely removed.

C. Prepare concrete as required by plaster finish material manufacturer to ensure complete adhesion of materials.

3.3 PLASTER INSTALLATION, GENERAL

A. Plaster: Install in accordance with ASTM C926 and PCA recommendations, except for more stringent requirements of manufacturer or these specifications.



B. Apply uniform thickness measured in mm from back face of lath as follows:

Soffits Walls Columns First coat: 10 13 13 Second coat: 6 10 6 Third coat: 3 3 3 Fourth coat: 3

C. Do not exceed more than 3 mm in 3000 mm variation from true plumb or level plane in any exposed line of surface, as measured by 3000 mm straightedge placed on any location on surface.

D. Machine Applied Plaster: At Contractor's option, plaster base coats may be machine applied.

1. Comply with PCA recommendations. 2. Apply finish coat in method to achieve specified finish. 3. Determine proper consistency by slump test as follows:

a. Take slump test samples from nozzle of plastering machine hose using a 50 by 100 by 300 mm slump cone.

b. 63 mm, maximum slump, unless otherwise recommended by plaster manufacturer.

E. Unless otherwise indicated, make interior angles square and external corners square.

F. Solidly grout hollow metal frames occurring in plaster walls with plaster specified for scratch or brown coat.

G. Where casing beads do not occur at juncture of plaster and hollow metal frames, cut a groove in base coat and later in finish coat to minimize appearance of cracks at these joints.

H. To avoid abrupt changes in uniform appearance of succeeding coat, apply each plaster coat to an entire surface plane without interruption.

1. Joining of wet plaster to set plaster should be made at naturally occurring interruptions in plane of plaster, such as corners or openings in plaster work. Stoppage of plaster within a panel is not permitted.

2. Space control joints in accordance with Section 09205.

3.4 PLASTER APPLICATION

A. Scratch Coat: Apply first coat with sufficient material and pressure to form full keys through, and to embed into, metal lath.

1. Provide sufficient depth of material over metal lath to allow for scratching of surface. 2. Bring surface to true even plane by rodding; fill surface defects and scratches.



3. As soon as first coat has become firm, scratch entire surface in one direction only to provide mechanical bond with second coat.

4. On vertical surfaces, scratch horizontally.

B. Brown Coat: Immediately begin second coat application as soon as first coat is sufficiently rigid to resist pressures of second coat application without cracking.

1. Apply second coat with sufficient material and pressure to ensure tight contact with scratch coat.

2. Bring surface to true even plane by rodding; fill surface defects and scratches. 3. Pause and allow plaster to achieve proper moisture content so that necessary

reconsolidation of plaster can be achieved. Determine correct time for floating by placing a finishing trowel against surface; trowel should not stick to unworked plaster.

4. Float surface and leave uniformly rough to provide bond for finish coat.

C. Finish Coat: Provide tools and techniques as required to achieve specified finish.

1. Apply primer if necessary to perimeter concrete walls and to plaster substrates. 2. Apply finish coat with sufficient pressure and material to ensure tight contact with, and

complete coverage of, brown coat or concrete walls. 3. Bring to required plaster thickness; Finish coat not less than 1.6 mm; 2 mm at concrete

perimeter walls. 4. Ensure substrate imperfections do no transfer to finish surface.

5. Finish surface finish to match accepted sample.

D. Moist Curing: Follow procedures for each coat as recommended by ASTM C926 and PCA and as required based on environmental conditions.

1. Prevent premature dry-out.

3.5 PATCHING

A. Work containing cracks, blisters, pits, checks, or discolorations will be rejected. Remove such work, and replace with new. Patching of defective work permitted only with approval of COR.

1. Neatly perform cutting, patching, repairing and pointing-up operations. Repair cracks and indented surfaces by moistening plaster and filling with new material, troweled or tamped flush with adjoining surfaces.

2. Point-up and finish surfaces to match adjacent plaster.

B. Where new plaster adjoins plaster that has been installed more than 48 hours, cut existing plaster at an angle of approximately 0.78 rad with surface before installing new plaster.

3.6 CLEANING

A. Remove plaster spillage promptly from adjoining work.



B. Remove protective coverings used to protect other work. Repair or replace surfaces that have been damaged by plastering work.

3.7 PROTECTION

A. Protect plaster from weather, freezing, premature drying, marking, dirt, dust, marring or other damage throughout construction period so that it will be without any indication of damage at time of acceptance.



PAINTING SECTION 09912 - 1

SECTION 09912 - PAINTING

PART 1 - GENERAL

1.1 Products and materials in this Section have been selected for one or more of the following: recycled material content; resource reuse; rapidly renewable materials; certified wood; regionally manufactured materials; regionally extracted materials; water use reduction; innovative wastewater technologies; stormwater management; light pollution reduction; exterior heat island reduction; energy efficiency; indoor chemical and pollutant source control; CFC reduction; elimination of HCFC’s and halons; and/ or low-VOC emitting characteristics.

1.2 SUMMARY

A. This Section includes surface preparation and field painting of exposed exterior and interior items and surfaces.

1. Surface preparation, priming, and finish coats specified in this Section are in addition to shop priming and surface treatment specified in other Sections.

B. Paint exposed surfaces, except where these Specifications indicate that the surface or material is not to be painted or is to remain natural. If an item or a surface is not specifically mentioned, paint the item or surface the same as similar adjacent materials or surfaces. If a color of finish is not indicated, COR will select from standard colors and finishes available.

1. Painting includes field painting of exposed bare and covered pipes and ducts (including color coding), hangers, exposed steel and iron supports, and surfaces of mechanical and electrical equipment that do not have a factory-applied final finish.

C. Do not paint prefinished items, concealed surfaces, finished metal surfaces, operating parts, and labels.

1. Prefinished items include the following factory-finished components:

a. Architectural woodwork. b. Acoustical wall panels. c. Metal lockers. d. Unit kitchens. e. Elevator equipment. f. Finished mechanical and electrical equipment. g. Light fixtures.

2. Concealed surfaces include walls or ceilings in the following generally inaccessible spaces:

a. Foundation spaces. b. Furred areas.



c. Ceiling plenums. d. Utility tunnels. e. Pipe spaces. f. Duct shafts. g. Elevator shafts.

3. Finished metal surfaces include the following:

a. Anodized aluminum. b. Stainless steel. c. Chromium plate. d. Copper and copper alloys. e. Bronze and brass.

4. Operating parts include moving parts of operating equipment and the following:

a. Valve and damper operators. b. Linkages. c. Sensing devices. d. Motor and fan shafts.

5. Labels: Do not paint over UL, FMG, or other code-required labels or equipment name, identification, performance rating, or nomenclature plates.

1.3 REFERENCES

1. Code of Federal Regulations (CFR), Title 40, Chapter I, Part 51.100.

2. U.S. Environmental Protection Agency (EPA), Test Method 24 – Determination of Volatile Matter Content, Water Content, Density, Volume Solids, And Weight Solids of Surface Coat-ings.

3. Green Seal Environmental Standard GS-11, Paints.

4. Green Seal Environmental Standard GC-03, Anti-Corrosive Paints.

5. State of California Air Resources Board (CARB), Suggested Control Measure for Architec-tural Coatings.

6. South Coast Air Quality Management District, Rule 1113: Architectural Coatings.

1.4 DEFINITIONS

1. Volatile Organic Compounds (VOCs): Compounds as defined by the U.S. Environmental Protection Agency (EPA) in 40 CFR § 51.100 (s), (1).

2. Anti-Corrosive Paints: Coatings formulated and recommended for use in preventing the cor-rosion of ferrous metal substrates.



1.5 SUBMITTALS

A. Product Data: For each type of product indicated.

B. Samples for Initial Selection: For each type of topcoat product indicated.

C. Samples for Verification: For each type of paint system and in each color and gloss of topcoat indicated.

1. Submit Samples on rigid backing, 200 mm square. 2. Step coats on Samples to show each coat required for system. 3. Label each coat of each Sample. 4. Label each Sample for location and application area.

D. Product List: For each product indicated, include the following:

1. Cross-reference to paint system and locations of application areas. Use same designations indicated on Drawings and in schedules.

2. Printout of current "MPI Approved Products List" for each product category specified in Part 2, with the proposed product highlighted.

E. LEED Submittals: For Credit EQ 4.2, manufacturers' product data for paints, including printed statement of VOC content and chemical components.

F. Flat and Non-Flat Interior Coatings: Provide a certification by the manufacturer that products supplied comply with the Volatile Organic Compound (VOC) and chemical component restrictions of the Green Seal Environmental Standard GS-11, if the product is a flat or non-flat interior coating applied indoors and on-site.

G. Anti-Corrosive Coatings: Provide a certification by the manufacturer that products supplied comply with the Volatile Organic Compound (VOC) and chemical component restrictions of Green Seal Environmental Standard GC-03, if the product is an anti-corrosive coating applied indoors and on-site.

H. Other Interior Coatings: If the product is applied indoors and on-site, and not covered by both the Green Seal Environmental Standard GS-11 and Standard GC-03, provide a certification by the manufacturer that products supplied comply with the chemical component restrictions of the Green Seal Environmental Standard GS-11, Paints, and comply with the Volatile Organic Compound (VOC) restrictions of the State of California Air Resources Board (CARB) Suggested Control Measure for Architectural Coatings, and the South Coast Air Quality Management District Rule 1113: Architectural Coatings


A. Store materials not in use in tightly covered containers in a well-ventilated area at a minimum ambient temperature of 7 deg C. Maintain storage containers in a clean condition, free of foreign materials and residue.



B. Apply waterborne paints only when temperatures of surfaces to be painted and surrounding air are between 10 and 32 deg C.

C. Apply solvent-thinned paints only when temperatures of surfaces to be painted and surrounding air are between 7 and 35 deg C.

D. Do not apply paint in snow, rain, fog, or mist; or when relative humidity exceeds 85 percent; or at temperatures less than 3 deg C above the dew point; or to damp or wet surfaces.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Provide paint products by one of the following manufacturers:

1. Benjamin Moore 2. PPG Industries 3. Sherwin-Williams

2.2 PAINT MATERIALS, GENERAL

A. Material Compatibility: Provide block fillers, primers, and finish-coat materials that are compatible with one another and with the substrates indicated under conditions of service and application, as demonstrated by manufacturer based on testing and field experience.

B. Material Quality: Provide manufacturer's best-quality paint material of the various coating types specified that are factory formulated and recommended by manufacturer for application indicated. Paint-material containers not displaying manufacturer's product identification will not be acceptable.

C. Chemical Components of Interior Paints and Coatings: Provide products that comply with the following limits for VOC content when calculated according to 40 CFR 59, Subpart D (EPA Method 24) and the following chemical restrictions. 1. The following chemicals shall not be used as an ingredient in any of the paints or

coatings applied indoors and on-site: a. Aromatic Compounds: The product must contain no more than 1.0% by weight of

the sum total of aromatic compounds. b. Halomethanes: Methylene Chloride. c. Chlorinated Ethanes: 1,1,1-trichloroethane.

Aromatic Solvents: Benzene, Toluene (methylbenzene), Ethylbenzene.

d. Chlorinated Ethylenes: Vinyl Chloride. e. Polynuclear Aromatics: Naphthalene. f. Chlorobenzenes: 1,2-dichlorobenzene. g. Phthalate Esters: di (2-ethylhexyl) phthalate, butyl benzyl phthalate, di-n-butyl

phthalate, di-n-octyl phthalate, diethyl phthalate, dimethyl phthalate.



h. Miscellaneous Semi-Volatile Organics: Isophorone.Metals and their compounds: Antimony, Cadmium, Hexavalent Chromium, Lead, Mercury.

i. Preservatives (Anti-Fouling Agents): Formaldehyde. j. Ketones: Methyl ethyl ketone, Methyl isobutyl Ketone. k. Miscellaneous Volatile Organics: Acrolein, Acrylonitrile.

2. Volatile Organic Compounds: The volatile organic compound (VOC) concentrations (in grams per liter) of the paint or coating shall not exceed those listed below if the paint or coating is applied indoors, on-site. VOCs shall be tested in accordance with the U.S. Environmental Protection Agency (EPA) Test Method 24. The calculation of VOC shall exclude water, exempt solvents, and tinting color added at the point of sale.

NOTE: EDIT THE TEXT BELOW TO MATCH PAINTS AND COATINGS SPECIFIED FOR PROJECT.

1. Flat Interior Coatings: 50 g/L.

2. Non-Flat Interior Coatings: 150 g/L.

3. Gloss Anti-Corrosive Interior Coatings: 250 g/L.

4. Semi-Gloss Anti-Corrosive Interior Coatings: 250 g/L.

5. Flat Anti-Corrosive Interior Coatings: 250 g/L.

6. Anti-Fouling Coatings: 400 g/L.

7. Bond Breaker Coatings: 350 g/L.

8. Concrete Curing Compounds: 350 g/L.

9. Faux Finishing/Glazing (Japans) Coatings: 350 g/L.

10. Fire Resistive Coatings: 350 g/L.

11. Fire Retardant, Clear Coatings: 650 g/L.

12. Fire Retardant, Opaque (Pigmented) Coatings: 350 g/L.

13. Floor Coatings: 250 g/L.

14. Flow Coatings: 420 g/L.

15. Form Release Compounds: 250 g/L.

16. Graphic Arts (Sign Paints): 500 g/L.

17. High Temperature Coatings: 420 g/L.

18. Industrial Maintenance Coatings: 250 g/L.

19. Lacquers (including lacquer sanding sealers): 550 g/L.

20. Lacquers, Clear Brushing: 680 g/L.

21. Low Solids Coatings: 120 g/L.

22. Magnesite Cement: 450 g/L.



23. Mastic Texture: 300 g/L.

24. Metallic Pigmented Coatings: 500 g/L.

25. Multi-Color Coatings: 250 g/L.

26. Pre-Treatment Wash Primers Coatings: 420 g/L.

27. Recycled Coatings: 250 g/L.

28. Sanding Sealers (Non-Lacquer): 350 g/L.

29. Shellacs, Clear: 730 g/L.

30. Shellacs, Opaque: 550 g/L.

31. Specialty Primers, Sealers, and Undercoaters: 350 g/L.

32. Stains: 250 g/L.

33. Swimming Pool Coatings: 340 g/L.

34. Swimming Pool Repair and Maintenance Coatings: 340 g/L.

35. Temperature-Indicator Safety Coatings: 550 g/L.

36. Varnishes: 350 g/L.

37. Waterproofing Sealers: 250 g/L.

38. Waterproofing Sealers, Concrete/Masonry: 400 g/L.

39. Wood Preservatives: 350 g/L.

2.3 PREPARATORY COATS

A. Concrete Unit Masonry Block Filler: High-performance latex block filler of finish coat manufacturer and recommended in writing by manufacturer for use with finish coat and on substrate indicated.

B. Exterior Primer: Exterior alkyd or latex-based primer of finish coat manufacturer and recommended in writing by manufacturer for use with finish coat and on substrate indicated.

1. Ferrous-Metal and Aluminum Substrates: Rust-inhibitive metal primer. 2. Zinc-Coated Metal Substrates: Galvanized metal primer. 3. Where manufacturer does not recommend a separate primer formulation on substrate

indicated, use paint specified for finish coat.

C. Interior Primer: Interior latex-based or alkyd primer of finish coat manufacturer and recommended in writing by manufacturer for use with finish coat and on substrate indicated.

1. Ferrous-Metal Substrates: Quick drying, rust-inhibitive metal primer. 2. Zinc-Coated Metal Substrates: Galvanized metal primer. 3. Where manufacturer does not recommend a separate primer formulation on substrate

indicated, use paint specified for finish coat.



2.4 EXTERIOR FINISH COATS

A. Exterior Flat Acrylic Paint.

B. Exterior Semigloss Acrylic Enamel.

C. Exterior Full-Gloss Acrylic Enamel for Concrete, and Masonry.

D. Exterior Full-Gloss Acrylic Enamel for Ferrous and Other Metals.

E. Exterior Full-Gloss Alkyd Enamel.

2.5 INTERIOR FINISH COATS

A. Interior Flat Acrylic Paint.

B. Interior Flat Latex-Emulsion Size.

C. Interior Semigloss Acrylic Enamel.

D. Interior Full-Gloss Acrylic Enamel.

E. Interior Full-Gloss Alkyd Enamel for Gypsum Board.

F. Interior Full-Gloss Alkyd Enamel for Wood and Metal Surfaces.

2.6 INTERIOR WOOD STAINS AND VARNISHES

A. Open-Grain Wood Filler.

B. Interior Wood Stain: Alkyd based.

C. Interior Alkyd- or Polyurethane-Based Clear Satin Varnish.

D. Interior Waterborne Clear Satin Varnish: Acrylic-based polyurethane.

E. Interior Waterborne Clear Gloss Varnish: Acrylic-based polyurethane.

F. Paste Wax: As recommended by manufacturer.

PART 3 - EXECUTION

3.1 APPLICATION

A. Comply with procedures specified in PDCA P4 for inspection and acceptance of surfaces to be painted.



B. Coordination of Work: Review other Sections in which primers are provided to ensure compatibility of the total system for various substrates. On request, furnish information on characteristics of finish materials to ensure use of compatible primers.

C. Remove hardware and hardware accessories, plates, machined surfaces, lighting fixtures, and similar items already installed that are not to be painted. If removal is impractical or impossible because of size or weight of the item, provide surface-applied protection before surface preparation and painting.

1. After completing painting operations in each space or area, reinstall items removed using workers skilled in the trades involved.

D. Surface Preparation: Clean and prepare surfaces to be painted according to manufacturer's written instructions for each particular substrate condition and as specified.

1. Provide barrier coats over incompatible primers or remove and reprime. 2. Cementitious Materials: Remove efflorescence, chalk, dust, dirt, grease, oils, and release

agents. Roughen as required to remove glaze. If hardeners or sealers have been used to improve curing, use mechanical methods of surface preparation.

3. Wood: Clean surfaces of dirt, oil, and other foreign substances with scrapers, mineral spirits, and sandpaper, as required. Sand surfaces exposed to view smooth and dust off.

a. Scrape and clean small, dry, seasoned knots, and apply a thin coat of white shellac or other recommended knot sealer before applying primer. After priming, fill holes and imperfections in finish surfaces with putty or plastic wood filler. Sand smooth when dried.

b. Prime, stain, or seal wood to be painted immediately on delivery. Prime edges, ends, faces, undersides, and back sides of wood, including cabinets, counters, cases, and paneling.

c. If transparent finish is required, backprime with spar varnish. d. Backprime paneling on interior partitions where masonry, plaster, or other wet

wall construction occurs on back side. e. Seal tops, bottoms, and cutouts of unprimed wood doors with a heavy coat of

varnish or sealer immediately on delivery.

4. Ferrous Metals: Clean ungalvanized ferrous-metal surfaces that have not been shop coated; remove oil, grease, dirt, loose mill scale, and other foreign substances. Use solvent or mechanical cleaning methods that comply with SSPC's recommendations.

a. Blast steel surfaces clean as recommended by paint system manufacturer and according to SSPC-SP 6/NACE No. 3, SSPC-SP 10/NACE No. 2.

b. Treat bare and sandblasted or pickled clean metal with a metal treatment wash coat before priming.

c. Touch up bare areas and shop-applied prime coats that have been damaged. Wire-brush, clean with solvents recommended by paint manufacturer, and touch up with same primer as the shop coat.

5. Galvanized Surfaces: Clean galvanized surfaces with nonpetroleum-based solvents so surface is free of oil and surface contaminants. Remove pretreatment from galvanized sheet metal fabricated from coil stock by mechanical methods.



E. Material Preparation:

1. Maintain containers used in mixing and applying paint in a clean condition, free of foreign materials and residue.

2. Stir material before application to produce a mixture of uniform density. Stir as required during application. Do not stir surface film into material. If necessary, remove surface film and strain material before using.

F. Exposed Surfaces: Include areas visible when permanent or built-in fixtures, grilles, convector covers, covers for finned-tube radiation, and similar components are in place. Extend coatings in these areas, as required, to maintain system integrity and provide desired protection.

1. Paint surfaces behind movable equipment and furniture the same as similar exposed surfaces. Before final installation of equipment, paint surfaces behind permanently fixed equipment or furniture with prime coat only.

2. Paint interior surfaces of ducts with a flat, nonspecular black paint where visible through registers or grilles.

3. Paint back sides of access panels and removable or hinged covers to match exposed surfaces.

4. Finish exterior doors on tops, bottoms, and side edges the same as exterior faces. 5. Finish interior of wall and base cabinets and similar field-finished casework to match

exterior.

G. Sand lightly between each succeeding enamel or varnish coat.

H. Scheduling Painting: Apply first coat to surfaces that have been cleaned, pretreated, or otherwise prepared for painting as soon as practicable after preparation and before subsequent surface deterioration.

1. Omit primer over metal surfaces that have been shop primed and touchup painted. 2. If undercoats, stains, or other conditions show through final coat of paint, apply

additional coats until paint film is of uniform finish, color, and appearance.

I. Application Procedures: Apply paints and coatings by brush, roller, spray, or other applicators according to manufacturer's written instructions.

J. Minimum Coating Thickness: Apply paint materials no thinner than manufacturer's recommended spreading rate. Provide total dry film thickness of the entire system as recommended by manufacturer.

K. Mechanical and Electrical Work: Painting of mechanical and electrical work is limited to items exposed in equipment rooms and occupied spaces.

L. Block Fillers: Apply block fillers to concrete masonry block at a rate to ensure complete coverage with pores filled.

M. Prime Coats: Before applying finish coats, apply a prime coat, as recommended by manufacturer, to material that is required to be painted or finished and that has not been prime coated by others. Recoat primed and sealed surfaces where evidence of suction spots or



unsealed areas in first coat appears, to ensure a finish coat with no burn-through or other defects due to insufficient sealing.

N. Pigmented (Opaque) Finishes: Completely cover surfaces as necessary to provide a smooth, opaque surface of uniform finish, color, appearance, and coverage. Cloudiness, spotting, holidays, laps, brush marks, runs, sags, ropiness, or other surface imperfections will not be acceptable.

O. Transparent (Clear) Finishes: Use multiple coats to produce a glass-smooth surface film of even luster. Provide a finish free of laps, runs, cloudiness, color irregularity, brush marks, orange peel, nail holes, or other surface imperfections.

P. Stipple Enamel Finish: Roll and redistribute paint to an even and fine texture. Leave no evidence of rolling, such as laps, irregularity in texture, skid marks, or other surface imperfections.

3.2 CLEANING AND PROTECTING

A. At the end of each workday, remove empty cans, rags, rubbish, and other discarded paint materials from Project site.

B. Protect work of other trades, whether being painted or not, against damage from painting. Correct damage by cleaning, repairing or replacing, and repainting, as approved by COR.

C. Provide "Wet Paint" signs to protect newly painted finishes. After completing painting operations, remove temporary protective wrappings provided by others to protect their work.

1. After work of other trades is complete, touch up and restore damaged or defaced painted surfaces. Comply with procedures specified in PDCA P1.
