Qatar Embassy & Ambassador’s Residence in Jakarta – Indonesia

Section 9 ALUMINIUM METAL WORKS Page 1

SECTION 9

ALUMINIUM METAL WORKS

ARAB CONSULTING ENGINEERS

MOHARRAM – BAKHOUM
Qatar Embassy & Ambassador’s Residence in Jakarta – Indonesia

Section 9 ALUMINIUM METAL WORKS Page 2

INDEX

1.0 GENERAL..................................................................................................................... 3
2.0 CODES AND STANDARDS........................................................................................ 3
2.1 DEVIATIONS ........................................................................................................................... 4
2.2 RELATED WORK SPECIFIED ELSEWHERE ....................................................................... 4
3.0 SUBMITTALS .............................................................................................................. 4
3.2 DESIGN DATA......................................................................................................................... 4
4.0 DELIVERY, STORAGE AND HANDLING ............................................................... 5
5.0 MATERIALS AND GENERAL REQUIREMENTS ................................................... 5
5.1 MATERIALS............................................................................................................................. 5
5.2 GENERAL REQUIREMENTS ................................................................................................. 6
5.2.1 Windows...................................................................................................................... 6
5.2.1.1 General.........................................................................................................................6
5.2.1.2 Mullions, Sills and Trims.............................................................................................6
5.2.13 Anchors and Clips etc. .................................................................................................6
5.2.1.4 Finish ...........................................................................................................................7
5.2.2 Aluminium Flyscreens................................................................................................. 7
5.2.2.1 Fly-screens...................................................................................................................7
5.2.2 Aluminium flashings and Trims .................................................................................. 7
5.2.3 Architraves and Doorstops........................................................................................... 7
5.2.4 External Traffic Signs.................................................................................................. 7
5.2.5 Directional and Information Signs............................................................................... 8
5.2.7 Internal Warning/Prohibition/Information Signs ......................................................... 8
5.2.8 Protective Coating ....................................................................................................... 8
5.2.9 Protection from Dissimilar Materials........................................................................... 8
5.2.10 Aluminium Skylights................................................................................................... 9
6.0 INSTALLATION ........................................................................................................ 10
6.1 PRELIMINARY INSPECTION .............................................................................................. 10
7.0 CLEANING AND PROTECTION.............................................................................. 10

ARAB CONSULTING ENGINEERS

MOHARRAM – BAKHOUM
Qatar Embassy & Ambassador’s Residence in Jakarta – Indonesia

Section 9 ALUMINIUM METAL WORKS Page 3

1.0 GENERAL

The intent of this specification is to define the minimum requirement for the
furnishing and installation of all works necessary for or incidental to the
construction and completion of works as indicated on the drawings and as specified
herein.

The work includes, but is not necessarily limited only to the aluminium metalwork
listed below:

(a) Doors, Windows and Frames

(b) Louvers and flyscreens
(c) Flashings and Trims
(d) Architraves, Door Stops etc.
(e) External Traffic Signs
(f) Directional and Information Signs

2.0 CODES AND STANDARDS

Latest edition of the BS and, equivalent 'Indonesia Government Specifications and

Codes of Practice' of the issues listed below, but referred to thereafter by basic
designation only, form a part of this specification to the extent indicated by the
references thereto. In the event of conflicts or discrepancies between this
specification and the referenced codes, specifications or standards, the more
stringent applicable requirement shall be govern.

BS 1161 Specification for aluminium alloy sections for

structural purposes

BS 1473 Specification for wrought aluminium and aluminium

alloys for general engineering purposes. Rivet bolt
and screw stock

BS 1494:Part 1 Fixings for sheet, roof and wall coverings

BS 3987 Specification for anodic oxide coatings on wrought

aluminium for external architectural applications

BS 4873 Specification for aluminium alloy windows

BS 4842 Specification for liquid organic coating

BS 5286 Specification for aluminium framed sliding doors

BS 1245 Specification for metal door frames (steel)

BS 405 Specification for uncoated expanded metal carbon

steel sheets for general purposes

ARAB CONSULTING ENGINEERS

MOHARRAM – BAKHOUM
Qatar Embassy & Ambassador’s Residence in Jakarta – Indonesia

Section 9 ALUMINIUM METAL WORKS Page 4

2.1 DEVIATIONS

It is the intent of this specification to establish acceptable standards of quality.

Minor deviations in details due to manufacturer's standard shop process will be
considered for acceptance provided that, in the opinion of Engineer, the proposed
substitutions are equal in quality to those specified. Thinner gages and inferior
weather stripping will not be considered as minor deviations. All deviations shall be
called out in writing in the proposal, and shall be specifically indicated on the shop
drawings.

2.2 RELATED WORK SPECIFIED ELSEWHERE

The following categories of work are covered under other specifications and not
specified herein:

(a) Glass and glazing

(b) Caulking and sealing

3.0 SUBMITTALS

Shop drawings, catalogue cuts containing sufficient technical information and

samples indicating finish and construction shall be submitted and acceptance
obtained before beginning fabrication.

Material shall not be delivered to the job site before certified drawings are issued by
the Contractor. Shop drawings shall indicate the following information:

(a) Location and elevation of each type of item of work

(b) Details of construction and dimensions
(c) Hardware details
(d) Location and details of joints to accommodate movement due to expansion
and contraction
(e) Gauges of metal
(f) Type of finish
(g) Installation details

3.2 DESIGN DATA

(a) Design data shall be submitted to the Engineer

(b) Evidence that each aluminium door will reasonably withstand racking and
maintain square corners without sagging shall be submitted to the Engineer.

c) Design calculations to confirm that aluminium entranceway designs

submitted for review can safely withstand the maximum wind load velocity
for the geographical locality of the project, shall also be submitted to the
Engineer.

ARAB CONSULTING ENGINEERS

MOHARRAM – BAKHOUM
Qatar Embassy & Ambassador’s Residence in Jakarta – Indonesia

Section 9 ALUMINIUM METAL WORKS Page 5

4.0 DELIVERY, STORAGE AND HANDLING

All materials shall be delivered, stored, and handled in a manner to prevent damage
of any type. All packaged materials shall be delivered to the project in the
manufacturer's original unopened containers. All materials shall be stored under
cover in watertight enclosure, but affording proper air circulation.

Store door and windows upright on wood stripping to keep bottom of doors at least
25mm or more off the floor or ground, with at least 6mm between individual pieces.

Exposed finish surfaces of prefinished items shall be fully protected with non-
staining masking tape or other suitable covering.

Special storage and handling requirements of the manufacturer shall be followed.

Any unit, part or accessory damaged in any manner shall not be used in the work but
shall be replaced by a new undamaged unit, part or accessory of same quality and
design.

5.0 MATERIALS AND GENERAL REQUIREMENTS

5.1 MATERIALS

Extruded aluminium shall be of BS alloy HE 30; sheet aluminium shall be BS alloy

NS 3 or 4, and all other forms of aluminum shall be of alloys which possess such
properties that they will be durable in the climate that exists on Site.

Aluminium for angles and channels shall be BS alloy HE 30 and together with bolts,
screws etc., shall comply with the relevant requirements of BS 1161, BS 1473 & BS
1494 Part 1.

Materials for windows, screens and doors, form of construction finishes and
performance shall generally be in accordance with BS 4873.

Aluminium sheet or strip shall not be less than 0.9mm in thickness with a degree of
hardness corresponding to the recommendations in BS CP 143, Part 15, appropriate
to its thickness and composition. Fixing shall be with aluminium clips secured with
aluminium alloy screws.

Aluminium louvers and flyscreens shall be of accepted manufacturer. All

aluminium parts shall be finished in stoved polyester powder paint to BS 4842.

ARAB CONSULTING ENGINEERS

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Qatar Embassy & Ambassador’s Residence in Jakarta – Indonesia

Section 9 ALUMINIUM METAL WORKS Page 6

5.2 GENERAL REQUIREMENTS

5.2.1 Windows

5.2.1.1 General

Windows shall be of the types indicated. Each window shall consist of a unit
including frame, mullions where indicated or required, and anchors.

All frame sections shall be tubular extruded aluminium shapes and of alloy as per
applicable BS. Frame sections shall be not less than 50mm deep from front to back
and 60mm in height from top to bottom. The four corners of all window frames
shall be mitre-cut and electronic fusion welded throughout the entire section profile.
Welds shall be dressed smooth on exposed and contact surfaces. Mitre-cut
mechanical joints may also be used provided they are reviewed and accepted by the
Engineer prior to fabrication.

Windows shall be arranged for inside glazing with aluminium snap-in glazing beads
designed to accommodate insulating glass as specified. Snap-in glazing beads shall
securely interlock into the extruded window sections. Glazing rebate legs shall not
be less than 19mm in height.

5.2.1.2 Mullions, Sills and Trims

Mullions, sills, trim and other window sub-assemblies, indicated on the drawings or
as necessary to properly complete each aluminium window installation, shall be of
size and design to suit the window assembly, be compatible with the windows, and
conform with the requirements for these sub-assemblies as specified in relevant
British Standards.

5.2.13 Anchors and Clips etc.

Anchors, clips, bolts and screws necessary to secure windows and mullions shall be
provided and shall be, at manufacturer's option, with aluminium, non-magnetic
stainless steel, or zinc coated steel.

Hinges shall be of anodised extruded aluminium and of the quality as the windows.
Pivoting on stainless steel pins spaced by other stainless steel or nylon washers.

All windows shall be fitted with handles and limiting stays of a material compatible
with the window material and shall be of a simple but highly functional design
reviewed by the Engineer.

Side hung casements shall be friction stays as manufactured by or equal and

acceptable to the Engineer.

ARAB CONSULTING ENGINEERS

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Qatar Embassy & Ambassador’s Residence in Jakarta – Indonesia

Section 9 ALUMINIUM METAL WORKS Page 7

5.2.1.4 Finish

All windows furnished under this specification shall have aluminium surfaces
provided with a satin finish, followed by an anodic oxide coating. The coating shall
be similar to that specified for doors.

Weather stripping shall be of neoprene of woven pile as applicable and shall

continue around whole perimeter of casement and outer frame, wherever groove is
provided in extruded sections.

All windows shall be glazed using a water and dust protective gasket on rebates and
PVC pressure gasket snapped into extruded profiles of sections.

5.2.2 Aluminium Fly-screens

5.2.2.1 Fly-screens

Frames shall be of anodized extruded aluminium sections and be of the same quality
as the windows. Mesh shall be PVC coated glass fibre accepted by the Engineer and
shall be held secure by PVC rods inserted in a groove provided in the frame section.

5.2.2 Aluminium flashings and Trims

Aluminium sheet turned up against walls and upstands shall be welded to an

aluminium flashing or apron strip. Flashings and apron strips shall be folded and
tucked into blockwork joints to a minimum depth of 25mm, secured by folded
aluminium sheet wedges, pointed with sealant. Vertical joints in aprons and
flashings shall be welted.

Care shall be taken to avoid contact of aluminium with dissimilar metals, and
materials containing alkalis, etc.

5.2.3 Architraves and Doorstops

Architraves, doorstops, etc., shall be properly mitred at intersections.

5.2.4 External Traffic Signs

External traffic signs shall be manufactured to BS 873 from 11 swg aluminium

faced with reflective sheeting. Signs shall be Class 2 reflective faced with grey
backs. The signs shall generally be 900mm diameter in size and shall conform in
layout to the most recent edition of the "Qatar Highway Design and Traffic
Manuals". Signs shall be lettered in Arabic and English (where required); and shall
be supplied complete with fixing holes; radiused corners; and stainless steel clips (2
per sign) and stainless steel bolts and nuts for fixing to posts. Posts shall be
manufactured in 75mm diameter galvanized iron tube set in 0.5m x 0.5m x 0.7m
concrete foundations (concrete grade 20/20). Posts shall be painted with 300mm
vertical alternate bands of black and white paint.
ARAB CONSULTING ENGINEERS
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Qatar Embassy & Ambassador’s Residence in Jakarta – Indonesia

Section 9 ALUMINIUM METAL WORKS Page 8

5.2.5 Directional and Information Signs

External directional and information signs for post mounting shall be manufactured
to BS 873 from 11 swg aluminium class 2 reflective faced. The background
borders, logo and lettering of the signs shall be screen printed in accordance with the
requirements of the Client's corporate identity brochure and to the sizes given on the
Contract Drawings.
The signs shall be lettered in Arabic and English and shall be supplied complete
with radiused corners; fixing holes; stainless steel clips and stainless steel bolts and
nuts for fixing to posts.

Posts shall be manufactured in 75mm diameter galvanised iron tube set in 0.5m x
0.5m x 0.7m concrete foundations (concrete grade 20/20). Posts shall be painted
white.

External signs for wall mounting shall be manufactured in 22 swg aluminium Class
2 reflective faced, complete with radiused corners, fixing holes and stainless steel
slips for wall fixing.

All painting quality and colour shall match with Halul signposts.

5.2.7 Internal Warning/Prohibition/Information Signs

Internal warning, prohibition and/or information signs shall be manufactured in

1mm thick rigid plastic complete with fixing holes and radiused corners. Signs shall
be 300mm x 250mm in size and lettered in Arabic and English.

5.2.8 Protective Coating

Protective coating shall be applied by the manufacturer to exposed surface of all

aluminium components subject to staining from alkaline, mortar, plaster, abrasion
and other construction abuses, except surfaces which will receive caulking or
sealant.

Before application of the protective lacquer, manufacturer shall remove any

moisture, dirt and other foreign material from the finish surfaces to ensure adhesion
of the protective lacquer. Surface which will receive caulking shall be kept free of
the protective lacquer by covering same with tape before the lacquer is sprayed.
Insofar as is practical remove lacquer in field after construction is completed and
immediately prior to field cleaning.

5.2.9 Protection from Dissimilar Materials

Where aluminium is to be in contact with steel or other ferrous metal, concrete,

mortar, plaster or other dissimilar construction materials, the facing surfaces of the
aluminium shall be protected with non-absorbing tape or be painted before erection
with a heavy coat of coal-tar emulsion or alkali-resistant bituminous paint.
Protective tape, emulsion or paint shall not be applied to aluminium surfaces visible
in the finished work.

ARAB CONSULTING ENGINEERS

MOHARRAM – BAKHOUM
Qatar Embassy & Ambassador’s Residence in Jakarta – Indonesia

Section 9 ALUMINIUM METAL WORKS Page 9

5.2.10 Aluminium Sky lights

a. Profiles:
Aluminium profiles shall be from ‘R.C. Systems’ or equal and approved complying
to DIN 1725/1, DIN 1748 and the following:

Sizes:
Depth of aluminium skylight system: Depending on the application varying from 35
to 145mm Or as applicable to ENGINEER’S Approval.
Glazing Bead: >24mm
Groove for ironwork: vertically > 15mm
Type & Design:
Thermally insulated type : in accordance with DIN 4108 Class 2.2
Cover Profiles: Clamping & cover profiles of Open type
Glazing possibilities: Through cover and clamping profiles on inside & outside.
Assemblies: Through self-tapping screws in. stainless steel and/or aluminium
castings
Gaskets: To DIN 763 (EPDM)

b. Execution
i. Calculation: Prior to commencement of production, CONTRACTOR shall submit
calculation for approval for all skylight system components, drawn up by competent
engineer, and in accordance with standard methods for skylight system frame work
designed to comply to BS 5750 and BS CP 153: Part 1. Quality Assurance
Procedures to comply to BS 5750.

ii. Finish: Aluminium sections shall be powder coated finish with minimum thickness
of 60 micron. Aluminium sections shall match the colour and shade of the external
wall cladding.

iii. Profile: The basic structure of profiles shall be joined through self-drilling screws,
with provisions of EPDM installed in between profiles. Clips shall be installed using
self tapping stainless steel screws equipped with stainless steel joint ring & EPDM
and covered with the cover profile.

iv. Gaskets: The skylight system shall be provided with inside and outside glazing
gaskets, thickness to suit glass ranges. All the EPDM gaskets shall be glued and the
TPE gaskets shall be thermally welded. The joints between the structural work and
the skylight system shall be executed with cellular tape. The sealing gaskets shall
not be interrupted or cut short at the horizontal transoms.

vi. Shop drawings: The shop drawings shall fully illustrate the relationship of window
unit frames against the finishes.

vii. Mock-up: Mock-up shall be prepared in size to be agreed with ENGINEER and
tested for the following:
• Air infiltration
• Water penetration
• Structural performance
ARAB CONSULTING ENGINEERS
MOHARRAM – BAKHOUM
Qatar Embassy & Ambassador’s Residence in Jakarta – Indonesia

Section 9 ALUMINIUM METAL WORKS Page 10

The tests shall be witnessed by ENGINEER and approved prior to proceeding with
installation works.

6.0 INSTALLATION

6.1 PRELIMINARY INSPECTION

Conditions at each location where aluminium entranceways are to be installed shall

be examined. Field measurements shall be checked to ensure that work is ready to
receive the entranceway assemblies. All dimensions, fittings, anchors and other
items directly connected with the aluminium entranceway assemblies shall be
properly co-ordinated.

Aluminium entranceway assemblies shall be erected accurately, plumb, level,

square, true to line and in alignment with the work of other trades. Vertical and
horizontal frame members shall be fastened securely together with neat hairline
joints.

All hardware that are not installed in the factory, including cylinder locks specified
in Finish Hardware shall be installed. Each aluminium door shall be installed
complete with weather stripping and hardware, and adjusted for perfect operation.

Joints between all aluminium members, entranceway frames and surrounding

constructions shall be sealed by another trade as specified in Caulking and Sealing.

Doors and Windows shall be installed without forcing or distortion so that sills and
heads are level and jambs are plumb. Window frames shall be securely anchored
into the supporting construction. Joints between metal windows and metal members
including mullions shall be set in mastic of the type recommended by the window
manufacturer. Excess mastic shall be removed before hardening. Metal surfaces
shall be cleaned and any staining or discolouring of the finish shall be restored or
the unit replaced.

7.0 CLEANING AND PROTECTION

After completing the erection of the entranceway assemblies and the adjustment of
doors therein, each assembly shall be cleaned.

Remove protective materials and clean exposed aluminium surfaces with clear
water, or water with soap or household detergent rinsed with clear water. Glass
shall be washed with a stiff fiber brush, soap or household detergent and thoroughly
rinsed with clear water.

Stained or discoloured members shall be thoroughly cleaned or have the finish

restored in accordance with Architectural Aluminium Manufacturer's Association
Recommendations.

ARAB CONSULTING ENGINEERS

MOHARRAM – BAKHOUM
Qatar Embassy & Ambassador’s Residence in Jakarta – Indonesia

Section 9 ALUMINIUM METAL WORKS Page 11

After installation, the exposed portions of each entranceway assembly shall be

adequately and properly protected from any type of damage. Any damage must be
immediately and properly corrected.

ARAB CONSULTING ENGINEERS

MOHARRAM – BAKHOUM