SECTION 05500 PAGE 1

METAL FABRICATIONS

PART 1 GENERAL

1.01 WORK INCLUDED

(A) Furnish labor and materials necessary to complete metal fabrications as indicated,
specified or both. This section shall include the following metal fabrications:
rough hardware and fasteners misc. steel trim
loose bearing and leveling plates loose steel lintels and angles

1.02 QUALITY ASSURANCE

(A) The publications listed below form a part of this specification to the extent referenced.
The publications are referenced in the text by the basic designation only.
American Society of Testing and Materials (ASTM):
A6/A6M-07 Standard Specification for General Requirements for Rolled
Structural Steel Bars, Plates, Shapes, and Sheet Piling
A27/A27M-05 Standard Specification for Steel Castings, Carbon, for General
Application
A36/A36M-05 Standard Specification for Carbon Structural Steel
A47/A47M-99(2004) Standard Specification for Ferritic Malleable Iron Castings
A48/A48M-03 Standard Specification for Gray Iron Castings
A53/A53M-07 Standard Specification for Pipe, Steel, Black and Hot-Dipped,
Zinc-Coated, Welded and Seamless
A123/A123M-02 Standard Specification for Zinc (Hot-Dip Galvanized)) Coatings on
Iron and Steel Products
A153/A153M-05 Standard Specification for Zinc Coating (Hot-Dip) on Iron and
Steel Hardware
A307-07b Standard Specification for Carbon Steel Bolts and Studs, 60,000
PSI Tensile Strength
A536-84(2004) Standard Specification for Ductile Iron Castings
A563-07a Standard Specification for Carbon and Alloy Steel Nuts
A563M-07 Standard Specification for Carbon and Alloy Steel Nuts [Metric]
B633-07 Standard Specification for Electrodeposited Coatings of Zinc on
Iron and Steel
C1107/C1107-07a Standard Specification for Packaged Dry, Hydraulic-Cement
Grout (Nonshrink)
E488-96(2003) Standard Test Methods for Strength of Anchors in Concrete and
Masonry Elements
F568M-04 Standard Specification for Carbon and Alloy Steel Externally
Threaded Metric Fasteners
F593-02e2 Standard Specification for Stainless Steel Bolts, Hex Cap Screws,
and Studs
F594-02 Standard Specification for Stainless Steel Nuts
F738M-02 Standard Specification for Stainless Steel Metric Bolts, Screws,
and Studs
F836M-02 Standard Specification for Style 1 Stainless Steel Metric Nuts
American Welding Society (AWS):
D1.1 Structural Welding Code - Steel

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D1.2 Structural Welding Code - Aluminum

D1.3 Structural Welding Code-Sheet Steel
Steel Structures Painting Council (SSPC):
SSPC Painting Manual, Volume 2, 8th Edition
(B) Cast iron shall conform to ASTM A48 and unless designated otherwise, shall be Class No.
30 with a minimum tensile strength of 30,000 psi.
(C) Nodular or Ductile Iron Castings shall conform to ASTM A536. This material may be used
in place of cast iron for items and locations as hereinafter specifically designated.
(D) Steel shall conform to ASTM A6/A 6M. Steel plates, shapes and bars shall conform to
ASTM A36/A 36M. Steel pipe shall conform to ASTM A53, standard weight (schedule 40)
unless otherwise indicated, or another weight required by structural loads.
(E) Aluminum shall be of the alloy as specified under the particular item. Comply with NAAMM
"Metal Finishes Manual" for recommendations relative to applying and designing
finishes.
(F) Welding Standards: Comply with applicable provisions of AWS D1.1, D1.2, and D1.3.
(G) Where steel items indicated under this specification are located on the building exterior, or
where they are specifically noted as ‘galvanized’ the fabrication shall comply with
standards for G90, hot dipped galvanized.

1.03 SUBMITTALS
(A) Shop Drawings: Shop drawings (2 prints and 1 sepia) for all miscellaneous items shall be
submitted for approval. Shop drawings shall show plans, elevations, sections and details
of metal fabrications and their connections. Show anchorage and accessory items.
(B) Field Measurements: Check actual locations of walls and other construction to which
metal fabrications must fit by accurate field measurements before fabrication. Show
recorded measurements on final shop drawings. Coordinate fabrication schedule with
construction progress to avoid delaying the Work. Where field measurements cannot be
made without delaying the project, guarantee dimensions with contractor and proceed
with fabricating products without field measurements. Coordinate construction to ensure
that actual dimensions correspond to guaranteed dimensions. Allow for trimming and
fitting.
(C) Welder Certification: Certify that each welder has satisfactorily passed AWS qualification
tests for welding processes involved (see standards above) and, if pertinent, has
undergone recertifications.

1.04 PRODUCT HANDLING

(A) Job Site Storage: All ferrous metal shall be properly stored on the project site to protect the
material from exposure to the elements that could produce rust or corrosion.
(B) Remediation: Material that is damaged by rust or corrosion may be deemed unsuitable for
installation. In such cases, the general contractor will either replace the unsuitable
material or restore the material to a suitable condition - at the discretion of the architect.

PART 2 PRODUCTS

2.01 FABRICATION, GENERAL

(A) Form metal fabrications from materials of size, thickness, and shapes indicated but not
less than that needed to comply with performance requirements indicated. Work to
dimensions indicated or accepted on shop drawings, using proven details of fabrication

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and support. Form exposed work true to line and level with accurate angles and surfaces
and straight sharp edges. Use type of materials indicated or specified for various
components of each metal fabrication.
(B) Allow for thermal movement resulting from the following maximum change (range) in
ambient temperature in the design, fabrication, and installation of installed metal
assemblies to prevent buckling, opening up of joints, and overstressing of welds and
fasteners. Base design calculations on actual surface temperatures of metals due to
both solar heat gain and nighttime sky heat loss. Temperature Change (Range): 120
deg F.
(C) Shear and punch metals cleanly and accurately. Remove burrs.
(D) Ease exposed edges to a radius of approximately 1/32 inch (1 mm), unless otherwise
indicated. Form bent-metal corners to smallest radius possible without causing grain
separation or otherwise impairing work. Remove sharp or rough areas on exposed
traffic surfaces.
(E) 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 that
no roughness shows after finishing, and contour of welded surface matches those
adjacent.
(F) Form exposed connections with hairline joints, flush and smooth, using concealed
fasteners wherever possible. Use exposed fasteners of type indicated or, if not
indicated, Phillips flat-head (countersunk) screws or bolts. Locate joints where least
conspicuous.
(G) 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.
(H) 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. Cut, reinforce, drill, and tap
metal fabrications as indicated to receive finish hardware, screws, and similar items.
(I) Fabricate joints that will be exposed to weather in a manner to exclude water, or provide
weep holes where water may accumulate.
(J) Galvanizing: For those items indicated for exterior application or where noted to receive
galvanizing, apply zinc coating by the hot-dip process complying with ASTM A153 for
galvanizing iron and steel hardware, and ASTM A123 for galvanizing both fabricated and
unfabricated iron and steel products made of uncoated rolled, pressed, and forged
shapes, plates, bars, and strip 0.0299 inch (0.76 mm) thick or thicker.
(K) Painting: All ferrous metal, except stainless steel and galvanized surfaces shall be properly
cleaned and given one shop coat of red lead or zinc chromate primer. Anchors that are
built into masonry shall be coated with asphalt paint, unless specified to be galvanized.
Metal work to be encased in concrete shall be left unpainted unless specified or shown; it
shall not be shop primed unless specifically required.

2.02 ROUGH HARDWARE AND FASTENERS

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(A) Rough Hardware: Furnish bent, or otherwise custom-fabricated, bolts, plates, anchors,
hangers, dowels, and other miscellaneous steel and iron shapes as required for framing
and supporting woodwork, and for anchoring or securing woodwork to concrete or other
structures. Fabricate items to sizes, shapes, and dimensions required. Furnish
malleable-iron washers for heads and nuts that bear on wood structural connections,
and furnish steel washers elsewhere.
(B) Fasteners - General: Provide plated fasteners complying with ASTM B633, Class Fe/Zn
25 for electro-deposited zinc coating, for exterior use or where built into exterior walls.
Select fasteners for the type, grade, and class required.
1. Bolts and Nuts: Regular hexagon-head bolts, ASTM A307, Grade A (ASTM F568,
Property Class 4.6), with hex nuts, ASTM A563 (ASTM A563M), and, where indicated,
flat washers.
2. Machine Screws: ANSI B18.6.3.
3. Lag Bolts: ANSI B18.2.1 (ANSI B18.2.3.8M).
4. Wood Screws: Flat head, carbon steel, ANSI B18.6.1.
5. Plain Washers: Round, carbon steel, ANSI B18.22.1 (ANSI B18.22M).
6. Lock Washers: Helical, spring type, carbon steel, ANSI B18.21.1.
7. Expansion Anchors: Anchor bolt and sleeve assembly of material indicated below with
capability to sustain, without failure, a load equal to 6 times the load imposed when
installed in unit masonry and equal to 4 times the load imposed when installed in
concrete as determined by testing per ASTM E488 conducted by a qualified independent
testing agency. Material: Group 1 alloy 304 or 316 stainless-steel bolts and nuts
complying with ASTM F593 (ASTM F 738M) and ASTM F594 (ASTM F836M).
8. Toggle Bolts: FS FF-B-588, tumble-wing type, class and style as required.
9. Cast in Place Anchors in Concrete: Anchors shall be 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 E488, conducted by a qualified independent
testing agency. Threaded or wedge type; galvanized ferrous castings, either ASTM A47
malleable iron or ASTM A27 cast steel. Provide bolts, washers, and shims as required,
hot-dip galvanized per ASTM A153

2.03 LOOSE BEARING AND LEVELING PLATES

(A) Provide loose bearing and leveling plates for steel items bearing on masonry or concrete
construction, made flat, free from warps or twists, and of the required thickness and
bearing area. Drill plates to receive anchor bolts and for grouting as required.
Galvanize after fabrication if indicated.

2.04 GROUT
(A) Nonshrink, Metallic Grout: Factory-packaged, ferrous-aggregate grout complying with
ASTM C1107, specifically recommended by manufacturer for heavy-duty loading
applications. Acceptable manufacturers include the following:
Supreme Plus; Cormix Construction Chemicals.
Hi Mod Grout; Euclid Chemical Co.
Embeco 885 and 636; Master Builders Technologies, Inc.
Ferrolith G Redi-Mix and G-NC; Sonneborn Building Products--ChemRex, Inc.
or approved substitution.
(B) Nonshrink, Nonmetallic Grout: Factory-packaged, nonstaining, noncorrosive,
nongaseous grout complying with ASTM C1107. Provide grout specifically

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recommended by manufacturer for interior and exterior applications. Acceptable

manufacturers include the following:
B-6 Construction Grout; W. R. Bonsal Co.
DiamoNd-Crete Grout; Concrete Service Materials Co.
Supreme; Cormix Construction Chemicals.
Sure-grip High Performance Grout; Dayton Superior Corp.
Euco N-S Grout; Euclid Chemical Co.
Five Star Grout; Five Star Products.
Vibropruf #11; Lambert Corp.
Crystex; L & M Construction Chemicals, Inc.
Masterflow 928 and 713; Master Builders Technologies, Inc.
Sealtight 588 Grout; W. R. Meadows, Inc.
Sonogrout 14; Sonneborn Building Products--ChemRex, Inc.
Kemset; The Spray-Cure Company
or approved substitution
(C) Concrete Fill: Comply with requirements of Division 3 Concrete for normal-weight,
air-entrained, ready-mix concrete with a minimum 28-day compressive strength of 3000
psi, unless higher strengths are indicated.

2.05 LOOSE STEEL LINTELS

(A) Provide steel lintels of angle or other shapes and light steel framing not included in
required to support openings in masonry.
(B) 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.
(C) Weld adjoining members together to form a single unit where indicated.
(D) Size loose lintels for equal bearing of 1 inch per foot of clear span but not less than 8
inches (200 mm) bearing at each side of openings, unless otherwise indicated.
(E) Galvanize loose steel lintels located in exterior walls.

2.06 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 wherever possible.
(B) Provide cutouts, fittings, and anchorages as required to coordinate assembly and
installation with other work. Provide anchors, welded to trim, for embedding in concrete
or masonry construction, spaced not more than 6 inches (150 mm) from each end, 6
inches (150 mm) from corners, and 24 inches (600 mm) o.c., unless otherwise indicated.
(C) Galvanize miscellaneous steel trim in the following locations:
1. Exterior locations.
2. Interior locations where indicated.

PART 3 EXECUTION

3.01 WORKMANSHIP
(A) Metal surfaces shall be clean and free from mill scale, flake rust and rust bitting;
well-formed and finished to shape and size with sharp lines and angles and smooth
surfaces. Shearing and punching shall leave clean true lines and surfaces. Weld or rivet
permanent connections. Welds and flush rivets shall be finished flush smooth on surfaces

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that will be exposed after installation. Do not use screws or bolts where they can be
avoided; where used, heads shall be countersunk, screwed up tight and threads nicked to
prevent loosening.
(B) Castings shall be of uniform quality, free from blowholes, porosity, hard spots, shrinkage
distortion or other defects. Castings shall conform to the dimensions indicated with a
tolerance of +/- 1/8", except in the dimensions of covers and the openings to receive them
shall be limited +/- 1/16". Castings shall be smooth and well cleaned by shop blastings or
other approved method. Covers subject to street or foot traffic shall have machined
bearing or contact surfaces for other joints where indicated or required.
(C) Fastenings shall be concealed where practicable. Thickness of metal and details of
assembly and supports shall give ample strength and stiffness. Joints exposed to weather
shall be formed to exclude water. Provide holes and connection into adjoining
construction.

3.02 INSTALLATION - GENERAL

(A) Coordinate and furnish anchorages, setting drawings, diagrams, templates, instructions,
and directions for installing anchorages, including concrete inserts, sleeves, anchor
bolts, and miscellaneous items having integral anchors that are to be embedded in
concrete or masonry construction. Coordinate delivery of such items to Project site.
(B) Set sleeves in concrete with tops flush with finish surface elevations. Protect sleeves
from water and concrete entry.
(C) Fastening to In-Place Construction: Provide anchorage devices and fasteners where
necessary for securing miscellaneous 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 as required.
(D) Cutting, Fitting, and Placement: Perform cutting, drilling, and fitting required for installing
miscellaneous metal fabrications. Set metal fabrication accurately in location, alignment,
and elevation; with edges and surfaces level, plumb, true, and free of rack; and
measured from established lines and levels.
(E) 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 the surfaces of exterior units that have been
hot-dip galvanized after fabrication and are intended for bolted or screwed field
connections.

3.03 FIELD WELDING

(A) 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 that
no roughness shows after finishing, and contour of welded surface matches those
adjacent.
5. Where field welding galvanized material; grind weld smooth and touch up welded area
with galvanizing repair paint.

3.04 SETTING LOOSE PLATES

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(A) Clean concrete and masonry bearing surfaces of bond-reducing materials, and roughen
to improve bond to surfaces. Clean 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. Use nonshrink, metallic grout in concealed locations where not exposed to
moisture; use nonshrink, nonmetallic grout in exposed locations, unless otherwise
indicated.

3.05 ADJUSTING AND CLEANING

(A) Wash thoroughly using clean water and soap; rinse with clean water.
(B) Do not use acid solution, steel wool or other harsh abrasive.
(C) If stain remains after washing, remove finish and restore in accordance with
recommendations of fabricator.
(D) Touchup Painting: Immediately after erection, clean field welds, bolted connections, and
abraded areas of shop paint, and paint exposed areas with same material as used for
shop painting to comply with SSPC-PA 1

3.06 REPAIR OF DEFECTIVE WORK

(A) Remove stained or otherwise defective work and replace with materials that meet
specifications requirements.

END OF SECTION

SECTION 05500
METAL FABRICATIONS