Federal Electricity & Water Authority Water Directorate ...Metal wor… · of joinery works shall...

WAM

Client: FEDERAL ELECTRICITY AND WATER AUTHORITY (FEWA) Project: STANDARD SPECIFICATIONS FOR WATER WORKS

Engineer WATER DIRECTORATE - ASSET MANAGEMENT DEPARTMENT

Title: Technical Terms / Chapter-4 / Engineering Specifications / Civil Engineering Works Specification

CS13-JOINERY / METAL WORKS

Office:

DUBAI Order:

Document:

MWA_PRO_07/WAM-04-CS13 Rev: OCT/2014 sheet: 1 of: 22

Federal Electricity & Water Authority

Water Directorate

Asset Management Department

STANDARD SPECIFICATIONS

FOR WATER WORKS

TECHNICAL TERMS

Chapter – 4

Engineering Specifications

[C-Civil Engineering Works Specifications]

CS13-Joinery/Metal Work

WAM





Office: DUBAI Order: Document: MWA_PRO_07/WAM-04-SC13 Rev: OCT/2014 sheet:

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TABLE OF CONTENT

A) JOINERY

1. GENERAL

2. STANDARDS AND CODES (To include all latest amendments)

3. MATERIALS

3.1 General

3.2 Timber (Solid Timber)

3.3 Plywood and Veneers

3.4 Adhesives (Glues)

3.5 Coating Materials

3.6 Wood Preservatives

3.7 Fire Protection

3.8 Screws, Nails, Bolts, etc.

3.9 Fittings

4. EXECUTION OF WORK

4.1 General

4.2 Execution of Solid Timbers

4.3 Sealing, Veneering and Coating

4.4 Glueing

4.5 Installation

4.6 Chemical Preservation of Timbers

4.7 Doors

4.7.1 Interior Flush Doors

4.7.2 Door Frames

4.7.3 Hardware

B) METALWORK(STEEL AND ALUMINIUM WORKS)

1. GENERAL

2. STANDARDS AND CODES (to include all latest amendments)

3. SAMPLES

4. STEEL WORK

4.1 General

4.2 Shop Finish

4.3 Storage and Protection

4.4 Welding

4.5 Requirements for Fire Separation Openings

4.6 Steel Doors and Frames

4.7 Fire Rated Steel Doors

4.8 Rolling Steel Doors

4.8.1 General

4.8. 2 Materials

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4.8.3 Operation

4.8.4 Paint

4.8.5 Steel Frames and Lintels for Rolling Doors

4.9 Special Features

4.10 Shop drawings

4.11 Metal Frames for Doors

4.12 Iron Mongery

4.13 Open type Steel Flooring

4.14 Handrails and Balustrades

4.15 Cable Trench Covers

4.16 Removable Bollards

4.17 Painting

4.18 Ancillary Steelwork

4.19 Ladders

4.20 Gratings

4.21 Submittals

4.22 Delivery, Storage and Handling

4.23 Fabrication

4.23.1 General

4.23.2 Finished Hardware Preparation

4.24 Installation

4.25 Adjustment and Cleaning

5. ALUMINIUM WORKS

5.1 General

5.2 Marking

5.3 Submittals

5.4 Materials

5.5 Aluminium Windows

5.6 Execution

5.7 Aluminium Coping

5.8 Sandwich Panel Construction

6. CAST/EXTRUDED ALUMINIUM AND FABRICATED STEEL ACESSORIES FOR CONCRETE

CHAMBERS/BOXES AND CONCRETE RESERVOIRS.

6.1 Locally Manufactured Aluminium and Steel Fabricated Items

6.2 Cast Aluminium Items

6.3 Aluminium Ladders

6.4 Aluminium Walkway Grating

7. MISCELLANEOUS METAL WORKS

7.1 Chain Link Fencing

7.2 Fencing Gate

7.3 Mechanical Level Indicator

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A) JOINERY

1. GENERAL

These Specifications shall apply to all parts of the work in which joinery (carpentry for permanent

features, i.e., excluding formwork or shuttering, wood scaffolding, etc.) will be used. All services shall comprise labour, equipment and the supply of the appurtenant materials and structural components including transport, loading, off-loading and storage at the Site unless otherwise specified.

2. STANDARDS AND CODES (To include all latest amendments) B.S. 459 Doors B.S. 1186 Quality of timber and workmanship for joinery B.S. 1202 Specification for nails B.S. 1204 Synthetic resin adhesives for wood B.S. 1210 Specification for wood screws B.S. 1282 Guide to the choice, use and application of wood preservatives. B.S. 1455 Plywood manufactured from tropical hardwoods B.S. 3444 Specification for blockboard and laminboard B.S. 4978 Timber grades for structural use B.S. 5268 Code of practice for the structural use of timber B.S. 1455 Plywood B.S. 8000 Code of Practice for carpentry, joinery and general fittings

3. MATERIALS 3.1 General

All materials and structural components to be supplied, erected or installed by the Contractor and, therefore, ultimately incorporated in the structure shall be new and unused. They shall be suitable for their intended purpose and appropriately match each other.

Joinery work shall be executed in first grade teak, maranti or hardwood of an approved standard

according to the Appendices of BS 1186. Joinery content at the time of application or installation of joinery works shall conform to BS 1186 part 3.

All materials and structural components covered by standards shall meet the quality and

dimensional requirements thereof.All materials and structural components not standardized shall be used only with the approval of the Authority/ Engineer.

3.2 Timber (Solid Timber)

The timber shall at least have the quality features required for structural components to be painted with an adequate opaque colour unless otherwise specified.

Timber and other wood material shall be straight, sound, of mature growth, well seasoned and

conditioned to suit the particular purpose for which it is to be used. The material shall be cleanly sawn, square edged, and free from injurious shakes, splits, warps, wanes and knots, soft spots and rot, incipient decay and all other defects.

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The timber shall be in a suitable condition so that the components of it will neither crack nor warp nor twist.The moisture content of timber assemblies when leaving the manufacturer’s works shall be as follows (referred to the over-dry weight)

8 to 12% for interior finish components 10 to 15% for structural parts in permanent connection with the outside air.

Proof of this moisture content shall be furnished to FEWA/ Engineer.Timber for carpentry shall be free from excessive knots, splits or irregularities of grain which will adversely affect strength, and shall have a moisture content not exceeding 18%.All timber shall be sound and free from any fungal or insect attack.No timber is to be incorporated in the Works which has been used for formwork, planking,strutting, scaffolding, or any other form of plant work.

3.3 Plywood and Veneers Plywood shall conform to BS 1455. All surfaces to be veneered with plywood or seal-coated shall be adequately closed.Face veneers

shall be of selected wood and of standard thickness from flitches specially selected and approved by the Engineer for architectural adaptation with respect to cutting lengths, uniformity of colour, figure, grain character or other special requirements. Faces shall be of one or more pieces of veneer and shall be matched for colour and grain at the joint to produce balance and continuity of character.

Faces shall be selected for figure and colour; however, mineral streaks and discolourations,

wormholes, ruptured grain, loose texture, close or shake shall not be allowed. Pieced veneers shall be parallel clipped, jointed and edge glued by a tapeless splicer. Faces shall be balanced and sequence matched with all panels including door faces numbered and indicated on shop drawings for Engineer’s approval. Faces shall not contain open joints, depressions, glue, stain or other manufacturing irregularities. Plywood shall be sanded both sides and fine belt sanded on face to provide suitable surface for finishing.

3.4 Adhesives (Glues) Plywood adhesives shall be BS 1203, WBP grade. Surfaces treated by adhesives (glues) must

not cause any discoloration or other damage.Sealing compounds shall be resistant to atmospheric influences, shall not harden and shall not be aggressive.

3.5 Coating Materials All coating materials shall form a good bond with the base.Their surface shall be readily brushable and insensitive to wiping contact.

3.6 Wood Preservatives Wood preservatives shall be of an officially approved type. Where subsequent painting of the timbers is proposed, the wood preservative shall be compatible with the paint. In interior applications the wood preservative shall be odourless.Treated lumber shall be accompanied by a certificate from a recognized lumber treating company certifying the amount of treatment and the percentage of moisture after drying.

3.7 Fire Protection

Fire retardant treatment of timber shall be applied by vacuum/ pressure impregnation and shall comply with the requirements of BS 476 part 7, Class 1 and local fire requirements. Minimum fire rating shall be 30 minutes.

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3.8 Screws, Nails, Bolts, etc.

Screws shall comply with BS 1210 and nails with BS 1202. Bolts shall generally be square with large washers and nuts. Other fixing accessories shall comply with BS 1494.

3.9 Fittings

Samples of all fittings such as hinges, hooks, anchors, locks, handles, key plates, keys, etc. shall be submitted in good time by the Contractor.All fittings shall be of stainless steel unless otherwise specified.

4. EXECUTION OF WORK 4.1 General

Prior to the start of his operations under this Specification, the Contractor shall verify that all conditions are suitable for the timely and effective carrying out of his work. The Contractor shall verify that such conditions as the following do not exist undue humidity of the structure; inadequate painting of the structural components intended to be installed; lack of possibilities for fixing the structural components to and sealing them against the respective part or parts of the structure.

The timber dimensions specified in the Contract Documents shall apply to the finished timber.All

structural components shall be made so that when properly treated and used they will not warp or crack under any circumstances including stresses due to temperature and humidity that will have to be expected.

Mouldings and frames shall be of hardwood. All timber connections and mitre shall be accurately

fitted. The surfaces exposed to view shall be finished by planing and sanding in order to remove any marks or blemishes before priming.

4.2 Execution of Solid Timbers Solid timbers shall be joined in such a way that in the event of variations in air humidity, the wood

is free to swell and shrink without affecting the joint. Framing timbers shall not be butted.Dovetailing may be used subject to the Engineer’s consent.

4.3 Sealing, Veneering and Coating

All edge surfaces of plywood remaining exposed to view shall be veneered or provided with bandings (insets or strips).On sealed, veneered and coated surfaces the joints and irregularities of the base shall not show even after final drying.All finish paintings or coatings shall tightly seal in the joints and shall not have any unglued points.

4.4 Glueing

The type and strength of glueing shall suit the installation and the intended application of the structural component, and shall not be affected by the climatical conditions existing in the project area.

4.5 Installation

Structural components such as panel frames, linings and the like shall be installed and fixed in true alignment, at accurate angles and at the specified level. They shall be designed to permit any sealing arrangement required.

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Where the frames are sealed against their stops or rebates by sprayed compounds, these shall firmly bond to the frames and adjacent parts of the structure at the range of temperatures prevailing on Site so that they will absorb all movements, expansions and shrinkages of the structural component without developing cracks or breaking off.

All nails on surfaces exposed to view shall have flush heads. They shall be countersunk. The use

of nails with notched heads and screw nails in lieu of wood screws shall not be allowed. Structural components that can be unhinged from their frames shall be durably marked as

correlated parts at unobtrusive points. The markings shall still be visible after painting.

4.6 Chemical Preservation of Timbers All timbers ultimately in contact with the outside air or permanently with particularly humid air or

connecting to masonry or concrete, e.g., windows and doors, including lining and casing, shall before being inserted be treated on all sides with a suitable wood preservative.The manufacturer’s instructions shall be complied with.The Contractor shall in the choice and use of the wood preservative exercise the care required in the handling of poisonous substances. If FEWA/ Engineer has not specified the wood preservatives to be used, the Contractor may make his own choice of a suitable preservative, subject to the Engineer’s approval.Before leaving the workshop, the timber components shall receive a coat of paint. 4.7 Doors

For framing timbers core only shall be used (not sapwood). The frame timbers shall be jointed by mortise and tenon or by dowelling.The tenons must not be wider than 60 mm and shall have grooved tenons of 15 mm length.In jointing the rails or grooves, they shall be glued and wedged across the full section, also on the parapets of the timber connections.

All panelling shall be free to move in the grooves of the framing. In doors with opaque painting,

panels exceeding 30 cm width shall be made of plywood.

Solid wood panels over 30 cm wide shall be glued up of several sections. All rabbet ledges shall be screwed to the frame timber, outer rabbet ledges shall in addition be glued.Linings with or without sills as well as trim frames shall at all corners be rabbeted, dovetailed, morticed, dowelled or finger-jointed. Unless otherwise specified, hardwood shall be used for the sills.Casings on doors, windows, etc., shall at the corners be butted or mitred by mortise and tenon or scarfed or dowelled and glued.

4.7.1 Interior Flush Doors Interior flush doors shall be of solid construction and generally in accordance with BS 459. Sizes

and types as shown on the approved drawings and indicated in the door schedule. Thickness of doors shall not be less than 44 mm and may be of greater thickness where higher grades of fire resistance or special finishes are required. Face veneer shall be of 1.2 mm thickness, properly dried selected wood or as specified, laid with grain at right angles to the grain of 3-ply panel, each of 1.4 mm thickness. All doors shall have a painted finish as defined in the painting section of the Specification.

All doors shall have 150 mm high hardwood rails the full thickness and width of the cores, to

provide housing for closers and floor spring fittings. The core shall be of kiln-dried wood block joints well staggered and in random lengths. Only adhesives may be used, which are of material compositions withstanding the extreme climatical conditions, waterproof and heat-resistant.

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A manufacturer’s certificate shall be provided for all fire rated doors showing that the doors have been independently tested to BS 476 part 8 or other approved equivalent standard.An integral intumescent sealing strip shall be provided on all floor edges to stop flame and smoke spread.All wooden parts, prior to use, have to be treated with wood preservation as specified.Clearance between doors and frames shall be not more than 3 mm at jambs and heads.

Sound insulation 35-40 dB(A)

4.7.2 Door Frames Wooden doorframes and linings shall be constructed from hardwood following the general

requirements of BS 1567 and BS 4787 part 1. Frames shall have a minimum overall thickness of 40 mm and the minimum width shall be the total thickness of the wall including finishes. A minimum of 3 galvanized steel cramps shall be used to fix each side of the frame.

4.7.3 Hardware

All hardware for doors shall meet the following requirements and match each other. Only heavy solid hardware of non-corroding materials will be accepted (stainless steel).

Each door leaf shall be furnished as follows:

3 hinges 140 mm high pivoted with ball bearings; 1 mortised heavy door lock with profile cylinder for master-key system, backsets 65 mm; 2 stainless steel lever handles of 125 mm; 2 stainless steel door handle plates or roses; 2 stainless steel kicking plates; 1 door stop;

Automatic door closers where indicated on the Door Schedule; Where indicated on the drawings or in the door schedule, they shall be furnished with top hung

door closers. All doorstops shall be sealed with PVC or rubber strips to reduce impact sound.

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B) METALWORK(STEEL AND ALUMINIUM WORKS)

1 GENERAL

This work shall consist of the design and fabrication, supply, fixing and hanging of all metal doors and windows, complete in accordance with Drawings and Specifications.

This work shall also consist of supply, design, fabrication and installation of items not specified in

other Sections or not shown on drawings but which are required to complete the work, including but not limited to, cladding, miscellaneous angles, channels, plates, platforms, ladders, railings, gratings, anchors, bars and similar shapes, etc.

2. STANDARDS AND CODES (to include all latest amendments)

B.S. 476 Fire tests on building materials and structures B.S. 729 Hot dipped galvanized coatings on iron and steel articles B.S. 1161 Aluminium alloy sections for structural purposes B.S. 1245 Metal door frames steel B.S. 1449 Steel plate, sheet and strip

B.S. 1474 wrought aluminium and aluminium alloys for general engineering purposs, bars, extruded round tube and sections.

B.S. 4951 Builders hardware lock and latch furniture B.S. 5368 Method of testing windows

3. SAMPLES

The Contractor shall submit representative samples for metal sections etc., he proposes to supply and use along with manufacturers Product Specification, quality certification and installation instructions, if any, to the Engineer for approval.

4. STEEL WORK 4.1 General

Mild steel shall comply with BS 4360. Steel components shall be of rolled sections wherever possible. Galvanized sections used shall be hot-dipped galvanized in accordance with BS 729, Part 2: 1971, after cutting and holding.

Surfaces of such items, which come into contact with dissimilar metals shall have isolators placed

between connecting surfaces.

Unless otherwise specified the choice of the steel quality shall be submitted for the Engineer’s approval. That choice shall take into account the importance of the work, the particular conditions and the kind of connections used.All work shall be executed to the highest quality.

All joints shall be tightly fitted; exposed welds shall be executed neatly and ground and finished

smooth without pits and blemishes. All work shall be fitted together at the fabricating shop insofar as is possible, and delivered complete and ready for erection.Handling and delivery: Proper care shall be exercised in handling all work in order to protect the finished surfaces. All work shall be in first class condition upon completion of the Project.

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The shop drawings shall indicate all hardware applications and no fabrication shall commence until approval of the shop drawings is received from the Engineer. The Contractor shall furnish one set of approved shop drawings to the hardware suppliers. 4.2 Shop Finish All exposed surfaces shall be ground or sanded smooth.All surfaces shall be phosphate-treated and cleaned to ensure maximum paint adherence.The shop finish shall include primer, undercoat and topcoat. Finished surface shall be smooth, uniform and free from drips and brush marks.

4.3 Storage and Protection

Steel works shall be installed in accordance with the manufacturer’s instructions and shall be properly protected during installation to avoid distortion.

Storage on Site prior to installation shall be effected in a protected area inaccessible to workmen.

Items damaged before, during or after installation shall be replaced as directed by the Engineer. 4.4 Welding Welding shall be by an electric arc process. The procedure to be followed, plant and equipment to be used, and the testing and inspection to be applied shall all be to the satisfaction of the FEWA/Engineer and shall conform generally with the relevant British Standard Specification and specified requirements of BS 4871 or BS 4872.Welding shall be carried out in workshops under suitable conditions of temperature and where continuous supervision is exercised. Welding should be as per approved welding procedure, inline with ANSI/AWS D1.1, by qualified welders with certificates not older than 6 months all as per ASME IX standard. Site welding will not be permitted without the special approval of FEWA/Engineer.

All fillet welds are to be neatly formed and finished at a 45 degree splay and all welding is to be ground flat and smooth. 4.5 Requirements for Fire Separation Openings

a) Construct fire rated doors and frames with a minimum fire rating of 3 hours in conformance with BS 476, part 8, or of NFPA 80 as tested in conformance to ASTM E152 (to include latest amendments).

b) Validate that doors and frames meet local authority fire rating requirements. 4.6 Steel Doors and Frames

Steel doors and frames shall be standard factory manufactured doors from reputed door manufacturing company to the approval of Authority. Coating for doors and frames shall be applied at the factory and shall be suitable for prevailing climatic conditions and plant environment. Coating is of prime importance and only high class coating shall be proposed. Coating shall be applied on galvanised steel.

Preferred coating is Polyvinyl Chloride - PVC - Plastisol coating about 175 micron thickness,

applied to galvanized substrate with about 25 micron primer. This coating shall be applied to exterior side of both steel sheets (skins). The tenderer may propose powder coating or alternate coating, which is equivalent to or better than the specified coating.

Door leaves shall be approximately 45 mm thick with steel sheets (skins) on both sides. The steel

sheets shall be 1.2 to 1.5 mm thick. Door leaves shall be manufactured to form an interlocking box construction with internal bracings, stiffeners, etc. The inside of steel sheets shall be coated

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with suitable corrosion resistant coating suitable for climatic condition. The infill shall either be mineral wool or other suitable insulating material.

Door frames shall be profiled or Z - section manufactured from 1.6 to 2.0 mm thick steel

sheets.Doors shall be complete with handle, heavy-duty lock/ latch, heavy-duty welded hinges (minimum 3 nos.) with bronze/ stainless steel pins, doorstops, rubber sealing strips, escutcheon plate, etc.

4.7 Fire Rated Steel Doors

Fire-rated steel doors and frames shall comply with ASTM E152, B.S. 476, part 8 and BS 1245.The fire rating shall be 2 Hours.

The door leaves shall be constructed from zinc-coated steel sheet 1.2mm to 1.5mm thick, double skin with internal “z” section stiffeners vertically at 25 cm intervals. The total thickness of the door shall be 45 mm including fire-resisting mineral wool.

An integral intumescent sealing strip shall be provided on all door edges to stop flame and smoke

spread.

Frames shall be produced from zinc-coated steel with four wall fixing ties per jamb. The frame shall be backfilled with mortar and built into the blockwork or concrete.

Continuous steel integral hinge reinforcement with provision for full mortise template type hinges

shall be provided.Continuous steel integral mortise lock reinforcement for lock front shall be provided.

4.8 Rolling Steel Doors 4.8.1 General This specification covers the furnishing of all labor supervision, materials, tools, equipment and services necessary for or incidental to the fabrication and installation of Rolling Steel Doors.

Rolling Steel Doors shall be of types specified below and manufactured by a manufacturer actively engaged in the production of such rolling steel doors. Manufacturer’s catalog cuts containing sufficient technical information must be submitted for approval prior to submission of shop drawings. 4.8. 2 Materials Curtains shall be constructed of interlocking roll-formed galvanized steel slats to provide a curtain stiffness to withstand wind pressure of 125 kg per square meter. Galvanized steel slats shall be tight-coat galvanized with a coating of 0.40 kg/sq. meter of flat metal, free from flaking or peeling.

Curtains shall be equipped with a rolled steel bottom bar consisting of two angles of equal weight, one or each side, securely fastened to the bottom of curtain for reinforcement and to provide contact against the sill when closed. The ends of the alternate interlocking slats shall be fitted with malleable iron end locks, which shall act as a wearing surface in the guides and prevent lateral movement of individual curtain slats. Curtains shall also be equipped with wind locks. Guides shall be formed of standard rolled steel angles not lighter than 5 mm thick and of sufficient depth to retain curtains in place under design wind pressure. They shall be attached to jambs, plumb and true, by bolts of not less than 10 mm diameter, spaced not more than 65 mm on centers. Guides shall be fitted at top into slots cast in the mouth of the roller shaft brackets.

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Roller shaft shall be steel pipe of sufficient diameter to reduce deflection do not exceed 2.5 mm per meter of span. Ends of roller shaft shall be completely closed by cast-iron plugs machined to fit I.D. of pipe and secured by cap screws. Roller shaft shall house all counterbalancing mechanism including an oil-tempered helical steel spring capable of producing sufficient torque to assure easy operation of the door curtain from any position. Spring tension shall be adjustable by means of adjusting wheel on the outside of the end bracket. Brackets shall be of heavy cast iron or steel, designed to form an end enclosure support for the hood. Ends of roller shaft shall be journal led into bracket hubs of sufficient thickness to provide ample bearing surface to load of roller shaft and curtain.

Operator bracket hub and plug in spring end of shaft shall be fitted with self-lubricating bronze bearing of permanently lubricated sealed bar bearings.

Hoods shall be of not less than 24 gauge bonderized-hot-galvanized steel formed to fit contour of end brackets in a neat manner and reinforced with stiffening rolls at top and bottom edges.

4.8.3 Operation Motorized rolling shutter doors shall be electrically operated. 415 volt, 3 phase, 50 Hertz electric motor and worm reducing gears shall be separate units coupled together and so designed and constructed that in case of failure in the electrical system the door can be operated by means of an auxiliary operating mechanism. A control lever shall be located within easy reach from the floor, which will instantly engage the auxiliary chain-gear operating mechanism. Power unit shall be self-locking and capable of holding the door in any position in case of failure of the counter balancing spring.

Motor unit shall be so designed that the motor can be completely removed without interfering with the operation of the door by the auxiliary chain-gear operator.

Electric Motor shall be fitted with ball bearings and be of sufficient capacity to move the door curtain in either direction from any position at a speed of 200 mm/second. Electric controls shall include the following :

Molded case circuit breaker, reversing across-the-line type automatic starter with overload relays, solenoid brake interlock switch, limit switch, and three button “open”, “Close” and “Stop” push button control switch.

Manually operated doors shall be operated mechanically by means of a chain-gear operator. Hand chain is to be galvanized. Gears shall be of high-grade gray iron cast from machine cast patterns. Gear reduction shall be calculated to reduce pull on hand chain to not over 15.75 kg. 4.8.4 Paint Galvanized steel for curtain slats shall have 0.40 kg of zinc per square meter and shall be chemically cleaned and Bonderized for paint-bond, and shall be given one dip coat of rust-inhibiting synthetic enamel which shall be baked on at 175 degrees C. prior to roll forming.

All other surfaces of door parts shall be given one shop coat of rust-inhibiting paint.

4.8.5 Steel Frames and Lintels for Rolling Doors Steel lintels shall be provided for all opening dimensions for rolling steel doors. Provide a minimum of three adjustable anchors per frame jambs as required when built into masonry.

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Anchors shall be fabricated from 6 mm x 100 mm steel flats extending 300 mm into mortar joints to floor by steel angle clips. All frames shall be neatly metered at corners, securely full welded and ground flush. Provide all necessary filed bolts, clips etc., for frames and lintels. 4.9 Special Features A compressible rubber seal shall be attached to the standard double-angle bottom bar to provide additional weathering at the sill.A rubber weathering seal at the hood shall be provided to prevent air flow around coil. Weathering at the jambs shall be furnished along with a continuous flat end lock which will operate between two closely fitting metal slide bars attached to the inside of the guide channels for curved slats. Combination end locks and wind locks with locking bars shall be furnished. Automatic bottom bar shall be provided on the door curtain which shall be capable of stopping the downward movement of the curtain instantly upon contact with any obstruction in the door opening and designed so that door may not be energized in downward direction until obstruction has been removed. 4.10 Shop drawings Shop drawings shall be submitted for approval prior to fabrication and delivery of doors. Shop drawings shall indicate the following minimum information : Type, location and elevation of each door Details of Construction Gauges of Materials. Identification of surface preparation. Approval of shop drawings will be for arrangement only and shall not relieve the fabricator of the responsibility for errors, omissions or the accuracy of his own dimensions.

4.11 Metal Frames for Doors

All necessary shop drawings shall be submitted and approvals obtained from Engineer. Frames shall be manufactured to comply with B.S. No. 1245 for 3 hour fire rated doors. Frames shall be cold-formed with head and jamb members mitred to smooth hairline joints

continuously welded and ground smooth. Frame shall be rigid, neat in appearance, free from defects, warp or buckle.

Forming shall be to profiled or ‘Z’ section manufactured from 1.6mm to 2.0mm thick steel sheets.

All angles, moulds and returns shall be straight, true to line and neatly formed. Corner joints shall be mitred.

Frames shall be neatly mortised and reinforced with 5 mm steel plate welded to the inner surfaces

of frames at all hardware. Mortising, drilling and tapping for mortised hardware shall be done by the frame manufacturer. Drilling and tapping for surface hardware shall be done by the installer. Foreign matter shall be kept from tapped holes. Frames not properly prepared to receive hardware shall be rejected.

Frames shall be thoroughly cleaned of grease, oil and other impurities, filled flush to conceal all seams, welds, etc. and given two coats of zinc chromate primer.

Frames shall be delivered to the Job Site properly braced and crated in a manner to prevent

damage. Frames with warps, bends or fault workmanship shall be rejected.

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Anchors for frames shall be provided. Unless otherwise shown on Drawings, a minimum of three anchors of an approved type shall be provided plus a floor anchor on each side of the frame. Anchors shall be of the adjustable type.

The anchors shall be built into the mortar joints between blocks or chased into the concrete.

4.12 Iron Mongery

The Contractor shall provide and fix the ironmongery complete, including all necessary screws, bolts, plugs and other fixings. The use of nails for fixing shall not be allowed.

All ironmongery shall be of first quality and according to British Standards as quoted below (To

include all latest amendments): BS 455 : Locks and latches for doors Schedule for sizes and dimensions BS 1227 : Hinges BS 1128 : Door bolts-iron, steel and non-ferrous

Doors shall be complete with a minimum of 3 heavy duty hinges, cylinder locks, stainless steel handles and door plates, door stops, closers, holders and panic bars, where doors provide emergency escape.

The Contractor shall be required to submit for approval samples of all items of ironmongery he proposes to use. 4.13 Open type Steel Flooring Open type steel flooring shall be rectangular pattern open floor grating. The minimum thickness of load bearing bars shall be 3 mm and the load bearing bars shall have a minimum depth of 1/40 x span, but not less than 25 mm. They shall span in the shortest direction and, where practical, the pattern shall be continuous at the meeting point of separate pieces of flooring.

Each panel shall have an edge bar on the bearing edges which shall have a thickness not less than the load bearing bars. Panels shall be clipped down to the supporting steelwork so that each individual panel is held by a minimum of four clips.Studs shall be welded to the supporting steelwork.

All components shall be fabricated from mild steel grade 5275 JR to BS EN 10025 as aminimum. All panels shall be removable and fixing shall be such that when a panel is removed, the remaining panels will remain firm and replaced panels are safe against displacement and dropping through before the fastenings have been made.Panels shall be formed as necessary to take account of pipes and valves which pass through the floor. The maximum clearance between floor plates and pipes shall be 25 mm.All panels of open type steel flooring together with accessories and fixings shall be galvanised to BS 729. 4.14 Handrails and Balustrades

These shall be provided to staircases, balconies, ramps, terraces, and any other such areas, as shown on drawings or instructed by FEWA/ Engineer.

The handrails shall consist of steel tubing to BS 6323 having an internal diameter of 35 mm. Each length shall be jointed with internal ferrules. The handrails and knee rails shall be at 1100mm and 600mm respectively above floor or platform levels.

a) In pumphouse, workshop shed, chlorination building etc.

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Generally, these shall be standard tube and ball type, heavy duty to BS 5395 as approved by the FEWA/ Engineer. Handrails 38Ø, 1000mm high above finished floor level are to be of galvanized steel sections in double row securely fixed to solid forged stanchions at intervals not exceeding 1.2 m. A 100 x 6 mm galvanized steel kicking plate is to be continuously fixed to the stanchions. All such handrails, stanchions and kicking plates are to be galvanised to BS 729, or otherwise painted in accordance with the instructions of the FEWA/ Engineer. Where shown on drawings decorative stainless steel handrailing shall be provided in lieu of the above & in accordance with detail drawings to be submitted to the FEWA/ Engineer for approval.

b) Offices, service buildings, accommodation building etc. Handrails/balustrades shall have clean lines, pleasant feel and permanent colour of nylon creating a lasting visual appeal and interest. The system shall include a unique lift off top rail facility which enables the top rail on balustrades to be replaced, should it become damaged, without having to refit the whole system. The thickness of nylon sleeve shall be 4 mm minimum. The nylon sleeve shall be coloured throughout. The steel core handrails and posts shall be 38Ø hollow core with minimum wall thickness of 2 mm. Infill panels of balustrades shall be 10 mm minimum toughened glass. Glass infill panels shall be provided to BS 6206 class A.

4.15 Cable Trench Covers Covers to internal cable trenches shall be galvanized non-slip chequer plate complying with the loading requirements of Clause 6.4. The plates shall be secured by means ofcountersunk set screws at approved spacing to mild steel angles cast leg-down at the top edges of trenches, with metal tangs at suitable centres. A mild steel flat 25 mm wide and of the same thickness as the plates shall be continuously welded to the top outer edge of the angles. The top surface of the plates shall be flush with the adjoining floor.Maximum clearance between adjacent plates and trench edges shall be 3 mm.All items shall be hot dipped galvanized after fabrication to BS 729 or equal.

4.16 Removable Bollards Removable Bollards shall be provided to protect the frames of vehicle garage doors, isolated columns and equipment, and at other locations as directed by the FEWA/Engineer.

Bollards shall comprise galvanized mild steel seamless tubes of minimum diameter 100 mm and wall thickness 4 mm set vertically into suitable concrete pockets. Tubes may be installed in tubular sockets.

Bollards shall have a minimum height of 1000 mm above ground level. The bollards shall be painted with red and white colours in alternating bands of 200 mm approximately. Top of the bollards shall be capped and connected by a removable chain.

4.17 Painting

All metalwork, with the exception of metal decking ladder rungs shall, unless agreed otherwise with the FEWA/Engineer, be painted in accordance with the Specification for Painting.

4.18 Ancillary Steelwork

Flooring, stairways, ladders, handrailing and the like shall comply with the requirements of BS 5395 and as per the detail drawing submitted by Contractor upto satisfaction of FEWA/Engineer.

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4.19 Ladders Ladders shall be made of galvanized mild steel. Rungs shall be constituted of minimum dia 22

mm round bars. Maximum rung spacing 300 mm. Minimum ladder width 400 mm.

4.20 Gratings Metallic gratings may be provided in non-corrosive areas only and shall be made of galvanized

steel, nominal 40 mm thick. Grating sections shall be of the size to allow removal by hand, and provided with hold down clips and shall be included with frames and support items.

4.21 Submittals The Contractor shall submit manufacturer’s Specifications for fabrication and installation, including

data substantiating that products comply with requirements.

4.22 Delivery, Storage and Handling Delivery hollow metal work cartoned or crated to provide protection during transit and job storage.

Provide additional sealed plastic wrapping for factory-finished doors.

Inspect hollow metal work upon delivery for damage. Minor damages may be repaired provided finish items are equal in all respects to new work and acceptable to the Engineer; otherwise, remove and replace damaged items as directed.

Store doors and frames at Building Site under cover. Place units on wood sills at least 10 cm high, or otherwise store on floors in manner that will prevent rust and damage. Avoid use of non-vented plastic or canvas shelters, which could create humidity chamber.

If cardboard wrapper on door becomes wet, remove carton immediately. Provide 6 mm spaces

between stacked doors to promote air circulation.

4.23 Fabrication 4.23.1 General

Fabricate steel door and frame units to be rigid, neat in appearance and free from defects, wrap or buckle. Wherever practicable, 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.

Fabricate exposed face of doors and panels, including stiles and rails of nonflush units, from only

cold-rolled steel. Fabricate frames, concealed stiffeners, reinforcement edge channels louvers and moldings from

either cold-rolled or hot-rolled steel (at fabricator’s option). Fabricate exterior doors, panels and frames from galvanized sheet steel. Close top and bottom

edges of exterior doors as integral part of door construction or by addition of inverted steel channels.

Exposed Fasteners : unless otherwise indicated, provide countersunk flat heads for exposed

screws and bolts.

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4.23.2 Finished Hardware Preparation a) Prepare doors and frames to receive mortised and concealed finish hardware in

accordance with final Finish Hardware Schedule and templates provided by hardware supplier. Comply with applicable requirements of ANSI A 115 series Specifications for door and frame preparation for hardware.

b) Reinforce doors and frames to receive surface-applied hardware. Drilling and tapping for surface applied finish hardware may be done at Project Site.

c) Locate finish hardware as shown on final shop drawings or if not shown, in

accordance with “Recommended Locations for Builder’s Hardware” published by Door and Hardware Institute.

4.24 Installation

a) General : Install standard steel doors, frames and accessories in accordance with final shop drawings and manufacturer’s data and as herein specified.

b) Placing Frames : Comply with provisions of SDI-105 “Recommended Erection

Instructions for Steel Frames”, unless otherwise indicated.Set frames accurately in position, plumbed, aligned and braced securely until permanent anchors are set. After wall construction is completed, remove temporary braces and spreaders leaving surfaces smooth and undamaged.

c) In masonry construction, locate 3 wall anchors per jamb at hinge and strike levels.

d) At in-plate concrete construction, set frames and secure to adjacent construction

with machine screws and masonry anchorage devices.

e) Install fire-rated frames in accordance with ASTM Specifications.

4.25 Adjustment and Cleaning a) Protection Removal Immediately prior to final inspection, remove protective plastic wrapping from

prefinished doors. b) Final Adjustments Check and readjust operating finish hardware items, leaving steel doors and

frames undamaged and in complete and proper operating condition.

5. ALUMINIUM WORKS 5.1 General

All extruded aluminium shall be salt resistant aluminium alloy with a built-in full width architrave and powder coated finish. Doors and large windows shall be fabricated from heavy sections and other items from medium sections. Screws and internal components shall be aluminium of sufficient strength to perform the specific function for which they are used.The Contractor shall submit samples of components to FEWA/Engineer for approval. Dry glazing materials shall be of resilient architectural quality neoprene and butyl tape.

All windows and doors shall be constructed by approved specialist suppliers of light, medium or

heavy section to suit the location, local building regulations and particular requirements noted on the Drawings or in Window Schedules, or requested by FEWA/ Engineer as to weight and profile.

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All frames shall be made to fit the actual openings with a 5 mm clearance all round. Discrepancies in overall width or height exceeding 5 mm shall not be allowed, and the frames shall be rejected in such cases. Any small discrepancies shall have the gaps suitably backed and then filled with gun applied sealant.

All nuts, bolts, washers and screws used for assembly and fixing shall be of adequate strength for

their purpose within the design and shall be of aluminium.

All sealants used in the assembly and the fixing of cladding and window framing shall be non-setting to allow thermal movement without detriment to those joints sealants used for peripheral caulking, and shall be in one part silicone sealant and conforming to BS 4245. All spliced joints between mullions shall be sealed with an approved silicone product compatible with other sealants and packings used.

Corner cleats must have a cross-section which corresponds to the interior profile contours. At the mitres a perfect sealing and glueing is required. In T-joints the seeping of water into the construction must be prevented by corresponding packing and permanently elastic sealing. The insulation effect of thermally insulated profiles if any must also be fully secured in the corner and T-cleat connections.

The system shall be designed to suffer no permanent distortion or other damage. Deflections are not to exceed 1/250 for double glazed units and 1/200 for single glazing, when subjected to positive and negative pressures as determined by and in accordance with BS CP3 Chapter 5 part 2.

The aluminium works and glazing assemblies shall be constructed and installed in the prepared

locations with sufficient tolerance and, where necessary, expansion joints incorporated within the couplings, to provide for expansion and contraction as will be caused by the climatic conditions and temperature changes, winter to summer, day to night, without buckling, distortion of joints, damage to the sealants or other detrimental effects. Details shall be prepared based upon the dimensions at 20°C and take account of the ambient temperatures at the time of assembly and installation.

All profile rebates where rain water or condensate could seep in are to be drained off and

ventilated by wind-protected slots or through cavities to the outside.The system shall incorporate an integral and internal condensate collection drainage channel to remove condensate from within the assembly to the external drainage system.

All internal section junctions are to be adequately sealed.The tone of colour is to be defined, according to colour samples, by FEWA/ Engineer.The Contractor shall protect the aluminium materials during plastering, etc. to avoid attacks on finished metal surface.All visible fittings must suit the profile colour if available.The Contractor must submit working drawings for specific positions and details as requested by the Engineer.

The aluminium oxide shall be of 25 microns minimum thickness. The colour wet or powder

coating of the aluminium profiles and/or sheets must be produced by the two-component lacquers on polyester resin or polyurethane basis with a layer thickness of more than 0.6 mm.

FEWA/ Engineer reserves the right to check the quality of coating. The Contractor is responsible

for materials and finishes of his performance till takeover, i.e. against damage of coating.

All ironmongery, which is to have the same finish as the frames, shall be approved by the Engineer.

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5.2 Marking

Where necessary to prevent contamination or marking surface of adjacent materials, mask the area with masking tape or other convenient mean. After the work has been completed immediately remove the protective tape.

5.3 Submittals a) The Contractor shall submit manufacturer’s Specifications, recommendations and standard

details for aluminium door and window units, including fabrication, finishing, hardware and other components of the work, included certified test laboratory reports as necessary to show compliance with requirements.

b) Shop drawings, aluminium windows and doors : The Contractor shall submit shop drawings including wall elevation and full size detail sections of every typical composite member. Show anchors, hardware and other components not included in manufacturer’s standard data. Include glazing details.

c) Samples aluminium windows and doors : The Engineer reserves the right to require additional samples, which will show fabrication techniques and workmanship or component parts, and design of hardware and other exposed auxiliary items for window and door units.

d) Warranty, aluminium windows and doors : submit two copies of written warranty signed by the manufacturer, installer and contractor, agreeing to replace aluminium window and door units which fail in materials or workmanship within the warranty period. Failure of materials or workmanship shall include (but not be limited to) excessive leakage or air infiltration, excessive deflections, faulty operation of sash, deterioration of finish or metal in excess of normal weathering and defects in hardware, weatherstripping, and other components of the work.

5.4 Materials a) Aluminium Extrusions : alloy and temper recommended by manufacturer for strength,

corrosion resistance and application of required finish, but not less than 22,000 psi ultimate tensile strength and not less than 2 mm thickness at any location for main frame and sash members.

b) Fasteners : aluminium, non-magnetic stainless steel or other metallic or non-metallic materials warranted by the manufacturer to be non-corrosive and compatible with the aluminium members, trim, hardware, anchors and other components of the units.

Reinforcements : Where fasteners screw-anchor into aluminium less than 4 mm thick, reinforce interior with aluminium or non-magnetic stainless steel to receive screw threads, or provide standard non-corrosive pressed-in splined grommet nuts.

Do not use exposed fasteners except where unavoidable for application of hardware. Match finish of metal surrounding fastener, unless otherwise indicated.

Provide flat-head machine screws for exposed fasteners, unless otherwise indicated. c) Anchors, Clips and Accessories : depending on strength and corrosion-inhibiting

requirements fabricate units of aluminium, non-magnetic stainless steel, or hot-dipped zinc coated steel or iron complying with ASTM A 386.

d) Compression Glazing Strips and Weather-stripping : unless otherwise indicated, and at manufacturer’s option, provide molded neoprene gaskets complying with AAMA SG-1 or with ASTM D 2000 Designation 28C415 to 38C620, or molded PVC gaskets complying with ASTM C 5096, Grade 4.

e) Weather-stripping : unless otherwise indicated, provide woven pile weather-stripping of wool polypropylene or nylon pile and resin impregnated backing fabric, and aluminium backing strip; comply with AAMA 701.2

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f) Sealant : unless otherwise indicated for sealants required within fabricated units, provide type recommended by manufacturer for joint size and movement, to remain in permanently elastic, non-shrinking and non-migrating. Comply with 7T-Series sections for installation of sealants.

5.5 Aluminium Windows

Windows shall be pre-assembled units. Corners of windows and frames are to be mitred, reinforced with a solid internal aluminium corner bracket and then cold-forged to form tight hairline joints. All critical joints shall be pre-sealed with a suitable non-hardening material.

The locking assembly shall comprise a forged anodized aluminium handle with keep. Hinges shall

be balance type friction arms of heavy duty aluminium which shall allow the window to be set in any open position. Sliding units shall also be fitted in designated locations. Weather seals shall be architectural grade neoprene, double sealed around the window between frame and operating section except on the exterior of the sill.

Glazing beads shall be of the lock-in type requiring no screws. Glazing materials shall be butyl

tape and a continuous neoprene wedge. All external windows shall be double-glazed. Sections shall not be less than 2 mm in thickness.

5.6 Execution a) Installation : comply with manufacturer’s Specifications and Recommendations for the

installation of window units, hardware, operators, and other components of the work. b) Set units plumb, level and true to line, without warp or rack of frames or sash. Anchor

securely in place. Separate aluminium and other sensitive surfaces from sources of corrosion or electrolytic action at points of contact with other materials.

c) Adjust operating sash and hardware to provide a tight fit a contact points and at weather-stripping (if any), for smooth operation and weather tight closure.

d) Clean aluminium surfaces promptly after installation of units exercising care to avoid damage of protective coatings and finishes. Remove excess glazing and sealant compounds, dirt and other substances. Lubricate hardware and moving parts.

e) After installation and completion of glazing and operating hardware, the hardware shall be adjusted to provide free operation and a watertight condition when closed and locked. Hardware and operating parts shall be lubricated or waxed as required.

5.7 Aluminium Coping Roof trims shall be turned in, extruded aluminium alloy with mill finish to the patterns shown on the Drawings, and meeting the requirements of B.S. 1470.Fixing straps and fastening clips shall be of extruded aluminium alloy to BS 1474, with an extruded neoprene channel seal bonded to the top. Straps shall have a coat of zinc chromate primer.Corners, stop ends, up stands, T-junctions, column caps, joggle clips for expansion joints, and all incidentals shall be approved by the Engineer.

5.8 Sandwich Panel Construction Where so shown on the drawings and schedules cladding shall be as proprietry fabricated sandwich panels comprising an inner skin of 0.5 mm aluminium sheet, 40 mm of suitable insulation material and 0.7 mm aluminium sheet as described above.

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6. CAST/EXTRUDED ALUMINIUM AND FABRICATED STEEL ACESSORIES FOR CONCRETECHAMBERS/BOXES AND CONCRETE RESERVOIRS.

6.1 Locally Manufactured Aluminium and Steel Fabricated Items FEWA/Engineer reserve the right to conduct spot checking visits to the manufacturing / fabrication facilities with full right of immediate access and reserve the right to select sample be tested by an independent laboratory. The cost of such tests shall be borne by the Contractor.

Should FEWA/Engineer conclude that all or either of the material used, manufacturing,fabrication or coating process is/are not in accordance with tender specifications, the manufacturer/fabricator may be black listed and an alternative manufacturer/fabricator shall be proposed by the Contractor.

6.2 Cast Aluminium Items Surface boxes, covers and frames, ventilation pipes etc shall be manufactured of aluminium alloy LM-6 in accordance to BS-1490 with chemical composition as follows.

Chemical Composition Copper 0.1% Magnesium 0.1% Silicon 5 to 13% Iron 0.6% Manganese 0.5% Nickel 0.1% Zinc 0.1% Lead 0.1% Tin 0.05% Titanium 0.2% Other elements 0.2% Aluminium Remaider

6.3 Aluminium Ladders Ladders shall be fabricated out of extruded aluminium according to BS 1474 alloy 6063, T-5.The width of the ladders shall not be less than 300 mm between the centrelines of the stringers.Stringers shall be extruded aluminium with 30 mm diameter minimum with wall thickness of4mm.Rungs shall be solid serrated, non slip surface, extruded aluminium.All joints shall be of welded construction by (TIG) Tungsten Inert Gas.

Ladders shall be designed for the following loads: Rungs For a single load of 2000 N applied at the centre or at the

ends. Uprights For vertical load of 5000 N applied on a 1.00 m long piece

(safety against buckling). When exposed to a deflection test under a load of 1000 N, applied at the centre of a 1.00 m span, the deflection shall not exceed 15 mm at the point of load and no permanent deflection shall remain after the load has been removed.

Stainless steel expansion bolts shall be used for fixing the ladders to the Concrete wall and/ or floor.Coating for ladders shall be hot cured polyester powder coating. The Contractor shall forward his proposal for the subject ladders including typical test details for FEWA/Engineer approval. FEWA/Engineer reserves the right to carry out additional tests on the ladders supplied and the costs of these tests shall be deemed to be allowed for by the Contractor in his respective rates.

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6.4 Aluminium Walkway Grating Aluminium walkway grating shall be fabricated out of silver anodised extruded aluminium to BS 1474, alloy 6063, T-5 with non-skid surface and adequate dirt/sand disposalarrangements.The grating shall have adequate kicker plates and aluminium supports bolted to the bottom concrete slab of the chamber with stainless steel expansion bolts. No riveted joint shall be allowed. The stainless steel fixtures shall be insulated from the aluminium.

The grating shall be subjected to load test in accordance to the following procedure : - 3000 N shall be applied on 1.00 m span x 0.5 wide sample simply supported at the span

ends. The load shall be evenly distributed. - The load shall be applied at 0.8 m (0.1 m from the supports at each end). - The deflection measured at the center of the span shall not exceed 1.40 mm. - The load shall be applied for a period of not less than 10 minutes. - Permanent deflection after the load is removed shall not exceed 0.2 mm measured at the

center of the span. The load test shall be executed at the manufacturer/fabricator workshop and witnessed by FEWA/Engineer. The cost of all necessary materials and equipments to perform the above test shall be borne by the Contractor.

7. MISCELLANEOUS METAL WORKS 7.1 Chain Link Fencing

The fencing should conform to BS : 1722. Fencing mesh should be 2000 mm high, 50x50 mm. mesh size with galvanized iron wire 3/4 mm, dia. Plastic coated to 3.2 mm. in dark green colour.

The fencing should have at least 3 line wires of plastic coated wire 3.0/4.0 mm. The fence should be tied to the line wires and posts using plastic coated 1.8/2.6 mm. tie wires at equal spacing. Top and bottom line should be tied at 150 mm centres and the remaining at 300 mm centers.

Intermediate posts shall be of dia. 60.0 mm. O.D., 2.6mm. thick GI tube, powder coated in dark green colour (RAL 6005) at 3M centres. Corner/end post shall be of dia. 76.2 mm OD., 2.9mm. thick. The post should be 700 mm. below ground level embedded in concrete footing.

Standard braces at corner posts terminal posts and gate posts shall be provided.3 strands of barbed wire should be provided on the upper part of the fencing. Barbed wire should be galvanized iron double strand 4 points barbs spaced at 100 mm.

7.2 Fencing Gate Gates shall have pipe frame, rod brace and chain link fabric. The prefabricated gate shall be sand blasted and galvanized in accordance with BS : 729 or equivalent and finished with approved quality powder coating. The gate shall be fitted with drop-bolts, back latches, locking bar, cat bar, lock plates, etc.

7.3 Mechanical Level Indicator Mechanical float and board type tank level indicator with float (316 L) and pointer cradle, signal red, mild steel having 6 nylon rollers for frictionless gliding on board graduated both (volume) in imperial gallons (and level) in meters. Board shall be manufactured from extra thick epoxy painted Aluminium sheet with minimum 100 mm unit length. Pulleys shall be of stainless steel with stainless steel bush bearing and stainless steel shaft for free rotation.

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