10/20/2023 DESIGN NO.

D021629

SECTION 05500
METAL FABRICATIONS

PART 1 - GENERAL

1.01 DESCRIPTION OF WORK

A. Provide metal fabrications and miscellaneous metals as

indicated on the Drawings and as specified herein,
including, but not limited to the following:

1. Steel ladders

2. Miscellaneous bolts, anchors and inserts to be

set in concrete

1.02 REFERENCES

A. References and industry standards listed in this

Section are applicable to the Work. Unless more
restrictive criteria or differing requirements are
explicitly stated in the Specifications, or mandated by
governing codes or regulations, the recommendations,
suggestions, and requirements described in the
referenced standards shall be deemed mandatory and
applicable to the Work.

B. ASTM International (ASTM), latest standards

C. American Welding Society (AWS).

D. American National Standards Institute (ANSI)

E. Society for Protective Coatings (SSPC)

F. Federal Specifications (FS)

G. National Association of Architectural Metals

Manufacturers (NAAMM)

H. Aluminum Association (AA)

I. The Building Code of the City of New York, latest

edition.

J. The American Galvanizers Association

1.03 DESIGN REQUIREMENTS

A. Not Required.

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1.04 SUBMITTALS

A. Product Data, for each item specified.

1. Submit product data sheets for products used in

metal fabrications, including anchoring devices.
Instructions for installation of anchorage devices
built into other work.

2. Submit product data sheets for painting materials.

3. Submit product data sheets for grouts and

sealants.

B. Shop Drawings, for each item specified.

1. Show all locations, markings, quantities,
materials, sizes and shapes.

2. Indicate all methods of connecting, anchoring,

fastening, bracing and attaching to work of other
trades.

C. Calculations

1. Where metal fabrications are required to comply

with certain design loadings, submit structural
design, structural calculations, materials
properties, and other information needed for
structural analysis, signed and sealed by the New
York State licensed Professional Engineer
responsible for their preparation.

D. Samples

Where specified, submit samples of fabricated items,

hardware, and finishes for selection.

E. Welder certificates signed by the Contractor certifying

that welders comply with requirements specified under
Article titled “Quality Assurance”.

F. Qualification data for firms and persons specified in

Article titled “Quality Assurance” to demonstrate
their capabilities and experience.

1. Provide proof of Zinc Metallizer’s qualifications

specified under “Quality Assurance”;
certification of qualifications meeting Military
Standard by one of the following:
a. A branch of the U.S. Dept. of Defense (DoD),
or

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b. A company certified by U.S. Dept. of

Defense; submit DoD certification for this
company, or

c. The Society for Protective Coatings (SSPC).

2. Hot Dip Galvanizer/Powder Coating Applicator:

Provide proof of Galvanizer/Applicator’s
qualifications by submittal of the following:

1) Galvanizer’s written Quality Control/Quality

Assurance manual for hot dip galvanizing and
factory applied coatings.

2) Certification from the American Galvanizers

Association that Galvanizer has completed
all course requirements and is a certified
Master Galvanizer.

G. Test Reports

Submit test reports for zinc metallizing or hot dip

galvanizing and coating system as specified herein,
paragraph titled “Galvanizing by the Zinc Metallizing
Process; or Hot Dip Galvanizing; with Finish Coating”.

H. Warranty

Warranty as specified herein.

1.05 QUALITY ASSURANCE

A. Items provided in this Section shall be manufactured

and fabricated by firms experienced in the type of
Work specified.

B. Installation shall be by installers experienced in the

type of Work specified for the respective item.
Installer shall be acceptable to the manufacturer.

C. Qualify welding processes and welding operators in

accordance with AWS D1.1 “Structural Welding Code –
Steel”, D1.3 “Structural Welding Code – Sheet Steel”,
and D1.2 “Structural Welding Code – Aluminum”.

1. Certify that each welder has satisfactorily

passed AWS qualification tests for welding
processes involved and, if pertinent, has
undergone recertification.
D. Engineer Qualifications: Professional engineer
licensed to practice in jurisdiction where project is
located and experienced in providing engineering

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services of the kind indicated that have resulted in

the successful installation of metal fabrications
similar in material, design, and extent to that
indicated for this project.

E. Zinc metallizer: The company or individual responsible

for application of zinc metallizing shall be certified
as qualified to perform this process by one of the
following:

1. Certification in accordance with Mil Std 1687 by

a branch of the U.S. Dept. of Defense, or by a
company that is certified by the Dept. of Defense
in accordance with this military standard.

2. Thermal Spray Certification by The Society for

Protective Coatings (SSPC).
The firm providing the zinc metallizing shall also
perform the painting of the members at the shop also
to provide a single source responsibility.

F. Hot-Dip Galvanizer/Powder Coating Applicator: The

company or individual responsible for application of
hot dip galvanizing with a powder coat finish shall be
certified as qualified to perform this process by the
following:

1. Certification from the American Galvanizers

Association that Galvanizer has completed all
course requirements and is a certified Master
Galvanizer.

2. Certification from the manufacturer of the powder

coatings that the galvanizer is an approved
applicator of said manufacturer’s material and
meets all application and performance criteria.

1.06 PRODUCT HANDLING

A. Before shipment to the job, all finishes shall be

adequately protected for transporting and erecting
periods.

B. Replace damaged items, with the approval of the

Project Architect, and at no additional cost to the
Authority.

1.07 PROJECT CONDITIONS

A. 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

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drawings. Coordinate fabrication schedule with

construction progress and work of other trades to
avoid delay of work.

1.08 WARRANTY

A. Warranty for metal fabrication items with galvanizing

by zinc metallizing or hot dip galvanizing, and finish
coated with epoxy paint system or powder coat system:
The coating applicator’s/Contractor’s warranty that
items shall not show signs of rust, and finish shall
be fully warranted against peeling, cracking, crazing,
blistering, chalking and fading for a period of 5
years from date of installation of products. If
rusting or failure of coating occurs, new items shall
be provided or coating shall be refurbished in the
shop. Warranty includes labor to remove and replace
the items.

PART 2 - PRODUCTS

2.01 MATERIALS

A. Metals
1. Metal Surfaces, General: For metal fabrications
exposed to view upon completion of the Work,
provide materials selected for their surface
flatness, smoothness, and freedom from surface
blemishes. Do not use materials whose exposed
surfaces exhibit pitting, seam marks, roller
marks, rolled trade names, roughness, and, for
steel sheet, variations in flatness exceeding
those permitted by reference standards for
stretcher-leveled sheet.
2. Ferrous Metals
a. Steel Plates, Shapes, and Bars: ASTM A36
b. Rolled Steel Floor Plates: ASTM A786
c. Steel Bars for Gratings: ASTM A1011 or
ASTM A36
d. Wire Rod for Grating Cross Bars: ASTM A510
e. Cold-Formed Steel Tubing: ASTM A500
f. Hot-formed Steel Tubing: ASTM A501
g. Hot-Rolled Steel Sheet: ASTM A1011
h. Cold-Rolled Steel Sheet: ASTM A1008
i. Galvanized Steel Sheet: ASTM A653
J. Steel Pipe: ASTM A53; finish, type, and
weight class as follows:

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a) Black finish, unless otherwise

indicated.
b) Galvanized finish for exterior
installations and where indicated.
c) Type S, Grade A, standard weight
(schedule 40), unless otherwise
indicated, or another grade or weight
or both required by structural loads.
k. Gray Iron Castings: ASTM A48, Class 30
l. Malleable Iron Castings: ASTM A47, Grade
32510
m. Brackets, Flanges and Anchors: Cast or
formed metal of the same type material and
finish as supported rails, unless otherwise
indicated.
n. Concrete Inserts: Threaded or wedge type;
galvanized ferrous castings, either
malleable iron, ASTM A47, or cast steel,
ASTM A27. Provide bolts, washers, and shims
as required, hot-dip galvanized per ASTM
A153.
1) “Peerless Wedge”, Manufactured by
“Peerless Hardware Manufacturing Co.,
Inc.
o. Welding Rods and Bare Electrodes: Select in
accordance with AWS specifications for the
metal alloy to be welded.
p. Stainless Steel bar: ASTM A276, Type 304
q. Stainless Steel plate: ASTM A240, Type 304.

B. Grout and Anchoring Cement

1. Nonshrink Metallic Grout: Premixed, factory-

packaged, ferrous aggregate grout complying with
Federal Specification CE CRD-C 621 specifically
recommended by manufacturer for heavy-duty
loading applications of type specified in this
section.

2. Nonshrink Nonmetalic Grout: Premixed, factory-

packaged, nonstaining, noncorrosive, non-gaseous
grout complying with Federal Specification CE
CRD-C 621. Provide grout specifically
recommended by manufacturer for interior and
exterior applications of type specified in this
section.

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3. Erosion-Resistant Anchoring Cement: Factory-

prepackaged, nonshrink, nonstaining, hydraulic
controlled expansion cement formulation for
mixing with water at project site to create
pourable anchoring, patching, and grouting
compound. Provide formulation that is resistant
to erosion from water exposure without need for
protection by a sealer or waterproof coating and
is recommended for exterior use by manufacturer.

4. Products: Subject to compliance with

requirements, provide one of the following:

a. Nonshrink Metallic Grouts:

“Hi Flow Grout”, Euclid Chemical Co.

“MasterFlow 885”, Master Builders
“Met-ox”, ChemMasters Specialty Construction
Products

b. Nonshrink Nonmetallic Grouts:

“Euco N-S Grout”, Euclid Chemical Co.

“Crystex”, L & M Construction Chemicals,
Inc.
“Masterflow 713”, Master Builders
“Five Star Grout”, Five Star.

c. Erosion-Resistant Anchoring Cement:

“Super Por-Rok”, CMP Specialty Products, A
division of CGM inc.
C. Fasteners

1. General: Provide galvanized or type 304/316 SS

fasteners for exterior use or where built into
exterior walls. Select fasteners for the type,
grade, and class required.

2. Bolts and Nuts: Regular hexagon head type, ASTM

A307, Grade A

3. Lag Bolts: Square head type, ANSI B18.2.1

4. Machine Screws: Cadmium plated steel, FS FF-S-92C

5. Drilled-In Expansion Anchors: Anchors installed

in concrete shall have current ICC-ES listing for
performance in cracked concrete as per Section
BC 1705.37.
6. Toggle Bolts: Tumble-wing type, type, class, and
style as required.

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7. Lock Washers: Helical spring type carbon steel,

FS FF-W-84A

8. Vandal resistant fasteners: Torx with pin, or as

otherwise indicated. Corrosion resistant.

D. Galvanizing by the Hot-dip Method – No Finish Coating

Items indicated to be painted shall not be hot—dip

galvanized except as specified herein.

1. Galvanize structural shapes in accordance with

ASTM A123.

2. Galvanize hardware in accordance with ASTM A153.

3. Galvanizing repair paint for regalvanizing welds

and damaged areas shall conform to ASTM A780 and
comply with Military Specification MIL-P-21035B,
such as ZRC Cold Galvanizing Compound.

2.02 FINISHES

A. General

1. Comply with NAAM “Metal Finishes Manual” for

recommendations relative to application and
designations of finishes.

2. Finish metal fabrications after assembly.

3. Refer to Articles 2.04 and 2.05 for painting and

galvanizing.

2.03 FABRICATIONS

A. General

1. 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 and support. Use
type of materials indicated or specified for
various components of each metal fabrication.

2. Form exposed work true to line and level with

accurate angles and surfaces and straight sharp
edges.

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3. 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): 180°F

4. Shear and punch metals cleanly and accurately.

Remove burrs.

5. Ease exposed edges to a radius of approximately

1/32 inch, unless otherwise indicated. Form
bent-metal corners to smallest radius possible
without causing grain separation or otherwise
impairing work.

6. Remove sharp or rough areas on exposed traffic

surfaces.

7. Weld corners and seams continuously to comply

with AWS recommendations and the following:

a. Use materials and methods that minimize

distortion and develop strength and
corrosion resistance of base metals.

b. Obtain fusion without undercut or overlap.

c. Remove welding flux immediately.

d. 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.

8. 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 flathead
(countersunk) screws or bolts. Locate joints
where least conspicuous.

9. Provide for anchorage of type indicated;

coordinate with supporting structure. Fabricate
and space anchoring devices to provide adequate
support for intended use.
10. Shop Assembly: Preassemble items in shop to
greatest extent possible to minimize field

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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.

11. Cut, reinforce, drill and tap miscellaneous metal

work as indicated to receive finish hardware,
screws, and similar items.

12. Fabricate joints that will be exposed to weather

in a manner to exclude water, or provide weep
holes where water may accumulate.

B. Support Inserts

1. Provide "Peerless Wedge" hot-dip galvanized

inserts for anchorage to concrete at locations
shown on the Drawings, or as required. Wedge
inserts shall be provided with a 3/4" bolt, nut,
and washers, all hot-dip galvanized. Install
3/4" diameter reinforcing bar X 1'-6" minimum
length through anchor loop to increase anchorage
in concrete. Space inserts 2'-6" on centers
(maximum) starting 6" from face of masonry
opening. Submit three (3) samples for approval.
Shims shall be square horseshoe shape, hot-dip
galvanized, as indicated on the Drawings.

Q. Steel Ladder

1. General: Fabricate ladders for the locations

shown, with dimensions, spacings, details and
anchorages as indicated. Comply with
requirements of ANSI A14.3.

2. Side Rails: Continuous steel flat bars, 3/8” inch

x 2½ inches, with eased edges, spaced 18 inches
apart.

3. Bar Rungs: Round steel bars, 3/4 inch diameter,

spaced 12 inches o.c.

4. Fit rungs in centerline of side rails, plug weld

and grind smooth on outer rail faces.

5. Support each ladder at top and bottom and at

intermediate points spaced not more than 5’-0”
o.c. by means of welded or bolted steel brackets.
a. Size brackets to support ladder securely and
to hold centerline of ladder rungs clear of

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the wall surface by not less than 7 inches.

b. Extend side rails 42 inches above top rung,

and return rails to wall or structure unless
other secure handholds are provided.

c. If the adjacent structure does not extend

above the top rung, goose-neck the extended
rails back to the structure to provide
secure ladder access.

6. Provide nonslip surface on 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 that is filled with
aluminum oxide grout.

7. Provide galvanized ladder, including fasteners

and brackets at exterior locations and as
indicated. At interior locations, provide shop
and finish paint.

R. Ladder Rungs

1. Where ladder rungs are indicated to be built into

masonry work, furnish to the mason 5/8" diameter
galvanized ladder rungs as detailed on the
Drawings. Provide finish paint.

2. Ladder rungs in concrete; 15" wide, built into

concrete every 14" in height projecting into
walls 4" on each side.

3. Ladder rungs in brickwork of chimney: 18" wide,

built into brickwork every five courses in
height, project 8" beyond face of wall and
continue 8" into wall with a 2" return. Start
first rung 10 feet above roof level at chimney.

2.04 PAINTING

A. All miscellaneous ferrous metal work, except those

members to be galvanized, shall be given one shop coat
of paint before leaving the shop. For those items to
be zinc metallized or hot dip galvanized and finish
painted, apply coatings in the shop as specified
herein.

B. Cleaning and Surface Preparation

1. Clean all steel first in accordance with SSPC-
SP1.

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2. Clean steelwork not to be painted (except steel

work to be galvanized) in accordance with SSPC-
SP2.

3. Clean steelwork to be painted within the same day

as it will be applied and in accordance with the
following methods, determined by location and
exposure:

a. Interior steel not exposed to view: SSPC-SP2.

b. Interior steel exposed to view: SSPC-SP3.

c. Cavity wall and exterior steel

exposed to weather: SSPC-SP6.
C. Shop Coat

1. Apply steel primer paint (general application) at

a rate to provide dry film thickness of 2.0 to
3.5 mils. Apply primer paint (cavity wall and
exterior application) at a rate to provide dry
film thickness of 4.0 to 6.0 mils. Provide full
coverage of joints, corners, edges, and exposed
surfaces.

2. Apply to dry surfaces only, when surface

temperatures are above dew-point, by brush,
spray, or roller, thoroughly and evenly, in
strict accord with manufacturer's instructions
for every detail of handling.

3. Apply second coat of the approved primer, in a

darker shade, to surfaces inaccessible to
painting after assembly or erection.

4. Protect machined surfaces with an approved rust-

inhibiting coating that is readily removable
prior to erection.

2.05 GALVANIZING AND FINISH COATING

A. General

Galvanize the following Work (items that are to be

finish painted shall be galvanized by the zinc
metallizing process or hot dip galvanized, and finish
coated as specified herein):

1. All angles and other steel items located in

exterior wall or roof construction

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2. All angles supporting exterior masonry or exposed

to the weather.

3. All steel members and fabrications exposed to the

exterior.

4. All other steel members and fabrications indicated

as galvanized on the Drawings and Specifications.

B. Zinc Metallizing-Finish Coating Applicators:

1. Atlantic Coast Metallizing & Coatings Corp.,

Melville, NY

2. Avant Guards Manufacturing, Brooklyn, NY

3. East Coast Metallizing & Coating Systems Inc.,

Westbury, NY

4. Island Wide Sandblasting Inc., Wyandanch, NY

5. Reneuxit LLC, West Chester, PA

C. Hot Dip Galvanizing with Powder Coating Finish

1. Duncan Galvanizing Corp, Everett, MA

D. Powder Coating Materials

1. Tiger Drylac, Ontario, California; Series 38 Super

Durable Powder Coating.

2. PPG Industries, Pittsburgh, PA; Coraflon

Ultradurable Powder Coating.

3. The Sherwin-Williams Co., Cleveland, OH; Powdura

Super Durable Powder Coatings Series.

E. Cleaning and Surface Preparation

1. Hardware (bolts, nuts, etc.): Clean and leave

free of mill scale before galvanizing.

2. Clean all steel first in accordance with SSPC-SP1

if needed.

3. Steel members: Clean in accordance with SSPC-SP8

before hot-dip galvanizing.

4. Steel members: Clean in accordance with SSPC-

SP10 before zinc metallizing. Surface shall have
a 3-4 mil anchor pattern. Moisture cannot be
present on steel and temperature cannot be less

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than 5oF above the dew point. Thermal spray must

be applied within 4 hours of blasting.

F. Shop Coat - Hot-dip Galvanizing –as required for

galvanized items not indicated to receive finish paint
coat.

1. Galvanize hardware in accordance with ASTM A153.

2. Galvanize steel shapes in accordance with ASTM

A123. Apply zinc coating as per Thickness Grade
specified in ASTM A123.

PART 3 - EXECUTION

3.01 INSPECTION
A. Make all required measurements in the field to ensure
proper and adequate fit.

3.02 DISCREPANCIES

A. Immediately notify the Authority's Representative.

B. Do not proceed until fully corrected.

3.03 ERECTION/INSTALLATION

A. Provide anchorage devices and fasteners where

necessary for securing metal fabrications to in-place
construction; including, threaded fasteners for
concrete and masonry inserts, toggle bolts, through-
bolts, lag bolts, wood screws and other connectors as
required.

1. Provide inserts, setting plates, and other items

of concealed work required for attachment of
metal fabrications in a timely manner to
facilitate on-going construction.

B. Perform cutting, drilling, and fitting required for

installation of metal fabrications. Set work
accurately in location, alignment, and elevation,
plumb, level, true, and free of rack, measured from
established lines and levels. Do not weld, cut, or
abrade surfaces of metal fabrications that have been
coated or finished after fabrication and are intended
for field connection by mechanical means without
further cutting or fitting.

C. Fit exposed connections accurately together to form

tight, hairline or, where indicated, with uniform
reveals and spaces for sealants and joint fillers.

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D. Provide temporary bracing or anchors in formwork for

items that are to be built into concrete masonry or
similar construction.

E. Install concealed gaskets, joint fillers, insulation

and flashings as the work progresses, so as to make
work weathertight, sound proof or lightproof as
required.

F. Restore protective coverings that have been damaged

during shipment or installation of the work. Remove
protective coverings only when there is no possibility
of damage from other work yet to be performed at the
same location.

G. Field Welding: Comply with applicable AWS

specification for procedures of manual shielded metal-
arc welding, for appearance and quality of welds made,
and for methods used in correcting welding work. Weld
connections that are not to be left as exposed joints,
but cannot be shop welded because of shipping size
limitations. Grind exposed welded joints smooth and
restore finish to match finish of adjacent surfaces.

H. Corrosion Protection: Coat concealed surfaces of

aluminum and steel which will be in contact with
grout, concrete, masonry, wood, or dissimilar metals,
with a heavy coat of bituminous paint.

I. Adjust metal fabrications prior to anchoring to ensure

matching alignment at abutting joints.

J. Install items as detailed in the drawings; for

manufactured items, install as recommended by the
Manufacturer, unless indicated otherwise.

K. Coordinate with other trades involved.

L. Field Touch-Up

1. Painted Members: After erection, clean all

damaged areas in shop coat, exposed surfaces of
bolts, bolt heads, nuts and washers, abrasions,
and all field welds and unpainted areas adjacent
to field welds to the same standards as the shop
coat and paint with primer paint to same
thickness as the shop coat. Finish painting is
specified in Section 09900.

2. Galvanized Members: After erection, clean and

paint all damaged areas to the galvanizing,
welds, and areas adjacent to welds with the
galvanizing repair paint complying to ASTM A780.
For galvanized members to be painted, finish

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painting shall be the final two coats of the epoxy

coating system. For powder coating system follow
instructions of the powder coat manufacturer, to
match surrounding undamaged areas.

3.04 PROTECTION

A. Protect finishes of metal work from damage during

construction period by use of temporary protective
coverings approved by ornamental metal manufacturer.
Remove protective covering at time of Substantial
Completion.

B. Restore finishes damaged during installation and

construction period so that no evidence remains of
correction work. Return items which cannot be
refinished in the field to the shop; make required
alterations and refinish entire unit, or provide new
units.

END OF SECTION

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LIST OF SUBMITTALS

SUBMITTAL DATE SUBMITTED DATE APPROVED

Product Data: ____

(for each item)

Shop Drawings: ____

(for each Item)

1. Materials, Locations, sizes,

shapes
2. Fastening, anchorage,
connections, bracing

Structural Design & Calculations: ______________ ______________

Samples: ____

Welder Certificates:

Qualification: ____

1. Fabricator
2. Installer
3. Professional Engineer
4. Hot Dip Galvanizer

Warranty: ______________ ______________

* * *

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