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SECTION 05500 METAL FABRICATIONS

PART 1 - GENERAL 1.1 A. B. DESCRIPTION OF WORK The extent of metal fabrications work is shown on the drawings. The work of this Section includes items fabricated from iron and steel shapes, plates, bars strips, tubes, pipes, and castings which are not directly a part of structural steel or other metal systems in these specifications. Related Work: 1. 2. 1.2 A. Section 03300 : Cast-in-place Concrete Section 09875 : Corrosion Resistant Coatings

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QUALITY ASSURANCE Codes and Standards: Comply with the applicable provisions of the following codes, standards, and specifications, except as otherwise shown and specified. 1. AISC "Specification for the Design, Fabrication, and Erection of Structural Steel for Buildings," including "Commentary of the AISC Specifications." AISC "Specification for the Design of Cold-formed Steel Structural Members." AWS D1.1 "Structural Welding Code" and "Welding Handbook." NAAMM "Metal Bar Grating Manual."

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Qualification of Welding Work: Qualify welding processes and welding operators in accordance with AWS "Standard Qualification Procedure." Field Measurements: Take field measurements prior to fabrication to ensure proper fitting of the work. However, do not delay job progress; allow for trimming and fitting whenever the taking of field measurements before fabrication might delay the work. Shop Assembly: Preassemble items in the shop to the greatest extent possible to minimize field splicing, welding, and assembly. SUBMITTALS Product Data: Submit manufacturer's specifications, load tables, dimension diagrams, anchor details and installation instructions for products to be used in

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the fabrication of metal work, including paint products. Indicate by transmittal that copy of instructions has been distributed to the installer. B. Shop Drawings: 1. Submit shop drawings for fabrication and erection of assemblies of metal fabrications. Include plans, elevations, and details of sections and connections. Show anchorage and accessory items. Include setting drawings and templates for location and installation of metal fabrications and anchorage devices.

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Samples: Submit sets of representative samples of materials and finishes for products exposed to view. MARAFIQ review will be for color, textures, style, and finish of metal fabrications. Material compliance certification with standard designated. DELIVERY, HANDLING, AND STORAGE Deliver all items to be set in concrete or masonry including frames, plates, treads, thresholds, railings, handrails, grating, angles, sleeves, anchor bolts, and inserts in sufficient time to be set and checked prior to concrete placement. Store products clear of ground and covered to avoid damage to inclement weather and construction activities. Handle items so as to protect surfaces from damage during erection and construction operations. Disassemble units only to extent necessary for shipping and handling limitations. Clearly mark units for reassembly and coordinated installation.

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PART 2 - PRODUCTS 2.1 A. B. C. MATERIALS Steel Plates, Shapes and Bars: ASTM A36. Steel plates to be Bent or Cold-formed: ASTM A283, Grade C. Steel Tubing: ASTM A501, Hot-formed, welded or seamless, including square, rectangular, round, and special shapes. Steel Pipe: ASTM A53; type as selected; Grade A; Black finish unless galvanized is required; standard weight (Schedule 40), unless otherwise indicated. Solder Metals: Comply ASTM B32. Flux materials shall comply with AWS "American Welding Handbook" for the type of metal and solder material at each location.
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F. 2.2 A.

Nonshrink Grout: See Section 03300. ANCHORS Threaded-type Concrete Inserts: Galvanized ferrous castings, internally threaded to receive 19 mm diameter machine bolts; either malleable iron complying with ASTM A47 or cast steel complying with ASTM A27. Provide bolts, washers, and shims as required, hot-dip galvanized. Wedge-type Concrete Inserts: 1. Galvanized box-type ferrous castings, designed to accept 19 mm diameter bolts having special wedge-shaped heads; either malleable iron complying with ASTM A47 or cast steel complying with ASTM A27; hotdip galvanized. Provide carbon steel bolts having special wedge-shaped heads, nuts, washers, and shims; all hot-dip galvanized.

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Slotted-type Concrete Inserts: Galvanized 3 mm thick pressed steel plate complying with ASTM A283; box-type welded construction with slot designed to receive 19 mm diameter square head bolt and with knockout cover; hot-dip galvanized. FASTENERS General: Provide zinc-coated fasteners, with galvanizing complying with ASTM A153 and this section for exterior applications or where built into exterior walls. Select fasteners for the type, grade, and class required. Bolts and Nuts: ASTM A307, Grade A, regular hexagon head. Lag Bolts: Square head type. Machine Screws: Cadmium plated steel. Wood Screws: Flat head carbon steel. Plain Washers: Round, general assembly grade carbon steel. Lock Washers: Helical spring type carbon steel. Masonry Anchorage Devices: Expansion shields. Toggle Bolts: Tumble-wing type; class and style as required. FABRICATED METAL ITEMS Exposed Metal Surfaces:

2.3 A.

B. C. D. E. F. G. H. I. 2.4 a.

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For metal fabrications which will be exposed to view, surfaces of metal shall be smooth and free of blemishes including pitting, seam marks, roller marks, rolled trade names, and roughness. Remove such blemishes by grinding or welding prior to cleaning, treating, and application of surface finishes including zinc coatings per section 09875.

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Rough Hardware: 1. Furnish bent or otherwise custom fabricated bolts, plates, anchors, hangers, dowels and other miscellaneous steel and iron shapes as required for framing and supporting metalwork, and for anchoring or securing metalwork to concrete or other structures, hot-dip galvanized. Manufacture or fabricate items of sizes, shapes, and dimensions required. Furnish malleable iron washers for heads and nuts which bear on temporary wood structural connections; elsewhere furnish steel washers, all hot-dip galvanized.

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Rung Ladders: 1. Fabricate ladders for the locations shown, with dimensions, spacings, details, and anchorages as indicated. Comply with the requirements of ANSI A14.3, except as otherwise indicated. a. Unless otherwise shown, provide 13 mm x 60 mm continuous structural steel flat bar side rails with eased edges, spaced 450 mm apart. Provide 25 mm diameter solid structural steel bar rung, spaced 300 mm on center.

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Fit rungs in centerline of side rails, plug weld and grind smooth on outer rail faces. Support each ladder at top and bottom and at intermediate points spaced not more than 1500 mm on center. Use welders or bolted steel brackets, designed for adequate support and anchorage, and to hold the ladder clear of the wall surface with a minimum of 175 mm clearance from wall to centerline of rungs. Extend rails 1000 mm above top rung, and return rails to wall or structure unless other secure handholds are provided. If the adjacent structure does not extend above the top rung, gooseneck the extended rails back to the structure to provide secure ladder access. Provide non-slip surface on the top of each rung, either by coating the rung with aluminum oxide granules set in epoxy resin adhesive, or by using a type of manufactured rung which has a slip resistant surface. Hot-dip galvanize and paint all ladders, brackets, and fasteners.

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Sloping Ladders (Ship's Ladders): 1. Provide sloping ladders designed and constructed to support a live load of 5 kPa. Fabricate of open type construction with structural steel channel or plate stringers, supporting brackets, toe guards, carrying angles, treads, platforms, and railings of the size and dimensions shown. Treads shall have abrasive non-slip surfaces. Assembly shall be fully welded and bolted construction. Hot-dip galvanize and paint ladders, brackets, railings, and fasteners.

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Loose Bearing and Leveling Plates: Provide loose bearing and leveling plates for steel items bearing on masonry or concrete construction. Fabricate flat, free from warp or twist, and of required thickness and bearing area. Drill plates to receive anchor bolts. Hot-dip galvanize and paint after fabrication. Loose Steel Lintels: Provide loose structural steel lintels for openings and recesses in masonry walls and partitions as shown. Weld adjoining members together to form a single unit where indicated. Provide not less than 200 mm bearing at each side of openings, unless otherwise indicated. Hot-dip galvanize and paint loose steel lintels installed in exterior walls. Miscellaneous Framing and Supports: 1. Provide miscellaneous steel framing and supports which are not a part of the structural steel frame work and are required to complete the work. Fabricate miscellaneous assemblies to the sizes, shapes, and profiles shown or, if not shown, of the required dimensions to receive adjacent grating, plates, doors, or other work to be retained by the framing. Except as otherwise shown, fabricate from structural steel shapes, plates and steel bars, of welded construction using mitered corners, welded brackets, splice plates, and a minimum number of joints for field connection. Cut, drill, and tap units to receive hardware and similar items. Equip assemblies with integrally welded anchors for casting into concrete or building into masonry. Furnish inserts for placement into concrete or masonry. a. Except as otherwise shown, space anchors, 600 mm on center, and provide assemblies 25 mm x 6 mm x 200 mm steel strips. Miscellaneous frames and supports to be hot-dip galvanized and painted per section 09875 include exterior assemblies at soffits, assemblies in wet areas such as showers, and where indicated or instructed by the MARAFIQ.

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Nosings: Provide nosings fabricated of structural steel shapes as shown with fully welded construction having mitered corners and continuously welded joints.
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Provide anchors welded to nosings for embedding in concrete or masonry construction; space anchors not more than 150 mm from each end, 150 mm from corners, and 600 mm on-center, unless otherwise shown. Hot-dip galvanize and paint nosings per section 09875. I. Miscellaneous Steel Trim: Provide shapes and sizes as required for the profiles shown. Fabricate units from structural steel shapes, plates, and bars, with continuously welded joints and smooth exposed edges. Use concealed field splices wherever possible. Provide cutouts, fittings, and anchorages as required for coordination of assembly and installation with other work. Hot-dip galvanize and paint exterior miscellaneous steel trim. Shelf Angles: 1. Provide structural steel shelf angles of sizes shown for attachment to concrete or masonry framing. Provide slotted holes to receive 19 mm bolts, spaced not more than 150 mm from ends and not more than 600mm on center, unless otherwise indicated. Hot-dip galvanize and paint shelf angles per section 09875. Furnish wedge-type concrete inserts, complete with fasteners, for attachment of shelf angles to cast-in-place concrete.

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Steel Grating: 1. Use materials of the size and thickness shown, or if not shown, of the size recommended from the Load Table in NAAMM "Metal Bar Grating Manual." Work to the dimensions shown or accepted on shop drawings, using proven details of fabrication and support. Use the type of materials shown or specified for the various components of the work. Metal Bar Grating: Comply with NAAMM "Metal Bar Grating Manual" and as herein specified. a. Traffic Surface: Plain or knurled or serrated or having applied abrasive finish, consisting of aluminum oxide aggregate in an epoxy resin adhesive. Steel Finish: Hot-dip galvanized after fabrication.

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Provide removable grating sections with end-banding bars for each panel, 4 saddle clip anchors designed to fit over 2 bearing bars, and 4 stud bolts with washers and nuts, unless otherwise indicated. a. Notch gratings for penetrations as indicated. Layout units to allow grating removal without disturbing items penetrating grating. Provide banding for openings in grating separated by more than 4 bearing bars, of same material and size as bearing bars, unless otherwise indicated.

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Notching of bearing bars at supports to maintain elevations will not be permitted. Weld stud bolts to receive saddle clip anchors to supporting steel members.

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Expanded Metal Grating: 1. Provide expanded metal grating as shown on the drawings and herein specified. Provide style, size, thickness and type of grating as shown, or as recommended by the manufacturer for the loads imposed if not shown. Include non-slip serrated edges, unless otherwise shown. Finish: Hot-dip galvanized and painted after fabrication. Cut, drill and fit as required for installation. Set grating accurately in location, alignment and elevation, plumb, level, true, and free of rack. Wherever gratings are pierced by pipes, ducts, and structural members, cut openings neatly and accurately to size and weld a strap steel collar not less than 3 mm thick to the cut ends. Divide panels into sections only to extent required for installation wherever grating platforms, runways, etc., are to be placed around previously installed pipe, ducts, and structural members. Fit exposed connections accurately together to form tight hairline joints. Weld non-removable units to supporting members or framework. Secure removable units to supporting members or framework with galvanized machine screws, or manufacturer's standard saddle or clip units.

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Steel Pipe Railings: 1. Fabricate pipe railings to dimensions and details shown, with smooth bends and welded joints ground smooth and flush. Where details are not shown, use 38 mm steel pipe. Adjust railings prior to anchoring to ensure matching alignment at butting joints. Space posts not more than 2400 mm on centers, unless otherwise shown. Plumb posts in each direction. Secure posts and rail ends to building construction as follows: a. Anchor posts in concrete by means of pipe sleeves set and anchored into concrete. Provide sleeves of galvanized steel pipe, not less than 150 mm long and having an inside diameter not less than 13 mm greater than outside diameter of the inserted pipe. Provide steel plate closure secured to the bottom of sleeve and of width and length not less than 25 mm greater than outside diameter of sleeve. After posts have been inserted into sleeves, fill annular space between post and sleeve solid with non-shrink,
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nonferrous grout. Cover anchorage joint with a round steel flange welded to post. b. Anchor posts to steel with steel oval flanges, angle type or floor type as required by conditions, welded to posts and bolted to steel supporting members. Anchor rail ends into concrete and masonry with steel round flanges welded to rail ends and anchored into wall construction with expansion shields and bolts. Anchor rail ends to steel with steel oval or round flanges welded to rail ends and bolted to structural steel members, unless otherwise indicated. Provide removable railing sections as indicated. Furnish slip-fit metal socket or sleeve for casting into concrete. Accurately locate sleeves to match post spacing.

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Secure handrails to walls with wall brackets and end fittings. Provide brackets with not less than 75 mm clearance from inside face to handrill to the finish wall surface. Drill wall plate portion of bracket to receive bolt, unless indicated for or, if not indicated, at not more than 2400 mm on center. Provide flush-type wall return fittings with same projection as that specified for wall brackets. Secure wall brackets and wall return fittings to building construction as follows: a. For concrete and solid masonry anchorage, use bolt anchor expansion shields and lag bolts. For hollow masonry anchorage, use toggle bolts having square heads. For stud portions use lag bolts set into wood backing between studs. Coordinate with stud installation for accurate location of backing members.

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Hot-dip galvanize and paint all steel railings, including pipe, fittings, brackets, fasteners, and other ferrous metal components per section 09875.

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PAINT & GALVANIZING Galvanizing: Provide zinc coating for all steel items using the hot-dip process after fabrication in accordance with section 09875 and this section to a thickness not less than 80 micrometers. Paint: Galvanized surfaces shall be painted with the exception of items to be embedded in concrete. 1. Etch primer, as approved by the MARAFIQ.

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Organic Zinc primer equal to Interzinc 72 (manufactured by International Paints) to be used in the repair of damaged galvanized surfaces and in the areas of field welding, as approved by the MARAFIQ. Epoxy paint specifically to be used on galvanized surface (500 micron thickness -3 coats), as approved by the MARAFIQ.

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FABRICATION Shop fabricate metal fabrication units so far as practicable. Use materials of the size and thicknesses shown, or if not shown, of the required size and thicknesses to produce adequate strength and durability in the finished product for the intended use. Work to the dimensions shown or accepted on shop drawings, using proven details of fabrication and support. Use the type of materials shown or specified for the various components of work. 1. Form exposed work true to line and level with accurate angles and surfaces and straight sharp edges. Ease exposed edges to a radius of approximately 1 mm unless otherwise shown. Form bent-metal corners to the smallest radius possible without causing grain separation of otherwise impairing the work.

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Weld corners and seams continuously and in accordance with the recommendations of AWS. At exposed connections, grind exposed welds smooth and flush to match and blend with adjoining surfaces. Form exposed connections with hairline joints which are flush and smooth, using concealed fasteners wherever possible. Use exposed fasteners of the type shown or, if not shown, use Phillips flathead (countersunk) screws or bolts. Provide for anchorage of the type shown, coordinated with the supporting structure and the progress schedule. Fabricate and space anchoring devices to provide adequate support for the intended use of the work. Cut, reinforce, drill, and tap metal fabrications indicated to receive finish hardware and similar items of work. Galvanizing: 1. 2. ASTM A153, for galvanizing of iron and steel hard-ware. ASTM A123, for galvanizing of rolled, pressed, and forged steel shapes, plates, bars, and strip, 3 mm thick and heavier. ASTM A386, for galvanizing of assembled steel products. Thickness of zinc layer to be not less than 80 micrometers.

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Painting: 1. Surface preparation and painting over steel, other metal and galvanized surfaces shall be in accordance with paint manufacturer's written instructions and Chapter 22 of Steel Structures Painting Council (SSPC) Manual and section 09875, whichever is the more stringent.

PART 3 - EXECUTION 3.1 A. INSPECTION Examine the areas and conditions under which metal fabrication items are to be installed. Do not proceed with the work until unsatisfactory conditions have been corrected. PREPARATION Coordinate setting drawings, diagrams, templates, instructions, and directions for installation of anchorage such as concrete inserts, anchor bolts, and miscellaneous items having integral anchors, which are to be embedded in concrete or masonry construction. Coordinate the delivery of such items to the affected trades for installation. Take field measurements prior to fabrication and delivery of metal fabrications to ensure proper fit of work. INSTALLATION, GENERAL Install units to allow for expansion and contraction from a minimum ambient temperature range of 0 to 49 degree C without causing deformation of units, and overstress of welds and fasteners. Set metal fabrications accurately, in locations, alignments, and elevations shown; plumb, level, true, and free of rack, measured from established lines and levels. Fastening to In-place Construction: Provide anchorage devices and fasteners where necessary for securing metal fabrication items to in-place construction including threaded fasteners for concrete and masonry inserts, toggle bolts, through-bolts, wood screws, and other connectors as required. Provide temporary bracing or anchors in formwork for items which are to be built into concrete, masonry, or similar construction. Cutting and Fitting: 1. Perform cutting, drilling, welding, and fitting required for the installation of the metal fabrications.

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Fit exposed connections accurately together to form tight hairline joints. Weld connections which are not to be left as exposed joints, but cannot be shop welded because of shipping size limitations. Grind joints smooth and touch-up shop paint coats. Do not weld, cut, or abrade exposed surfaces which cannot be completely restored in the field. Drill holes for bolts and screws. Conceal fasteners where possible. Mill exposed ends and edges smooth, with corners slightly rounded.

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Field Welding: Comply with AWS Code for procedures of arc welding, appearance and quality of welds made, and methods used in correcting welding work. Soldering: 1. Comply with the recommendations of AWS "Welding Handbook," Volume 2, Chapter 12 "Soldering." Use only for filling or sealing joints and not for mechanical strength. Where exposed to view, soldered and brazed joints shall be finished to match adjoining finish metal and made as unnoticeable as practicable. Use brazing if necessary to finish steel or iron. Conceal brazing metal. Comply with AWS "Welding Handbook" for brazing.

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3.4 A.

INSTALLATION OF SPECIFIC METAL ITEMS Setting Loose Plates: 1. Clean concrete and masonry bearing surfaces of any bond-reducing materials, and roughen to improve bond to surfaces. Clean the bottom surface of bearing plates. Set loose leveling and bearing plates on wedges, or other adjustable devices. After the bearing members have been positioned and plumbed, tighten the anchor bolts. Do not remove wedges or shims, but if protruding, cut-off flush with the edge of the bearing plate before packing with grout. Pack grout solidly between bearing surfaces and plates to ensure that no voids remain.

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Setting Treads, Thresholds, and Nosing: Install cast-in threads, thresholds, and nosing with anchorage system shown or in accordance with manufacturer's recommendations. Seat exterior units in bituminous mastic to provide a corrosion resistant and watertight installation.

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3.5 A.

PAINTING Repair: 1. Immediately after erection, clean field welds, bolted connections, and abraded areas of painted surfaces. Repair damaged galvanized surfaces and field welded areas with organic zinc primer and paint with the same paint and thickness used in shop painting per repair procedure approved by the MARAFIQ and meeting the minimum requirements of section 09875. + + END OF SECTION 05500 + +

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P.O. Number : 7200018725