BGS-AU-055 Rev B1

BOROUGE GENERAL SPECIFICATION
Borouge 2 Project Revision: B1

Thermal and Moisture Protection
Doc No: BGS-AU-055 Page: 2 of 19
CONTENTS
1.0 PURPOSE............................................................................................................................... 3
2.0 DEFINITIONS AND ABBREVIATIONS........................................................................... 3
2.1 DEFINITIONS..................................................................................................................................3
2.2 ABBREVIATIONS...........................................................................................................................3
3.0 CODES AND STANDARDS ................................................................................................ 3
4.0 REFERENCE DOCUMENTS.............................................................................................. 3
5.0 DOCUMENTATION REVIEW........................................................................................... 3
6.0 SPECIFICATION DEVIATION/CONCESSION CONTROL......................................... 3
7.0 QUALITY CONTROL ......................................................................................................... 3
8.0 DOCUMENTATION ............................................................................................................ 3
9.0 PACKING, SHIPPING AND STORAGE........................................................................... 3
10.0 DESIGN (ROOF AND METAL WALL PANEL SYSTEM) ............................................ 3
11.0 VAPOR BARRIER................................................................................................................ 3
11.1 MATERIAL BARRIER...................................................................................................................3
11.2 INSTALLATION .............................................................................................................................3
12.0 ROOFING SYSTEM............................................................................................................. 3
12.1 GENERAL ........................................................................................................................................3
12.2 MATERIALS....................................................................................................................................3
12.3 EXECUTION....................................................................................................................................3
13.0 BUILDING SEALANT ......................................................................................................... 3
13.1 VENDOR’S .......................................................................................................................................3
13.2 SEALANT MATERIALS ................................................................................................................3
13.3 BACKER ROD .................................................................................................................................3
13.4 MISCELLANEOUS MATERIALS ................................................................................................3
13.5 INSTALLATION .............................................................................................................................3
14.0 FIRE RETARDANT SEALANT.......................................................................................... 3
14.1 VENDORS.........................................................................................................................................3
14.2 MATERIALS....................................................................................................................................3
14.3 INSTALLATION .............................................................................................................................3
15.0 METAL PANEL SYSTEM................................................................................................... 3
15.1 VENDORS.........................................................................................................................................3
15.2 MATERIALS....................................................................................................................................3
15.3 TRIM MEMBERS AND COPING .................................................................................................3
DSN: 0076 BGS-AU-055 Rev B1 .doc

15.4 WINDOWS .......................................................................................................................................3

15.5 FABRICATION................................................................................................................................3
15.6 FINISHES .........................................................................................................................................3
15.7 PHYSICAL PROPERTIES OF MATERIALS .............................................................................3
15.8 INSPECTION ...................................................................................................................................3
15.9 INSTALLATION/ERECTION .......................................................................................................3
15.10 FIELD QUALITY CONTROL .......................................................................................................3
15.11 CLEANING AND PROTECTION .................................................................................................3
16.0 FLASHING AND SHEET METAL..................................................................................... 3
16.1 MATERIALS....................................................................................................................................3
16.2 EXECUTION....................................................................................................................................3

1.0 PURPOSE
The purpose of this document is to define the technical requirements for the materials,
procedures and criteria for design of the Thermal and Moisture Protection for the
buildings on the Borouge 2 Project. It is provided to the CONTRACTOR for the
specification and definition of the COMPANY’S minimum requirements for the
WORKS.
Any references to VENDOR define the requirements to be imposed on the VENDOR by
the CONTRACTOR.
2.0 DEFINITIONS AND ABBREVIATIONS
2.1 DEFINITIONS
For the purposes of this Specification, the following definitions shall apply:
COMPANY – means Abu Dhabi Polymers Company Limited (Borouge) and its
successors in interest.
CONCESSION REQUEST – refers to a technical or other deviation requested by the
CONTRACTOR or VENDOR to COMPANY. Its submission is often linked to an
authorization to modify the design, to use, repair, recondition, reclaim, or release
materials, components or equipment already in progress or completely manufactured but
which does not meet or comply with COMPANY requirements. A CONCESSION
REQUEST is subject to COMPANY approval.
CONTRACTOR – means a party contracted to COMPANY to carry out work or services
to the Project.
GOODS – means any and all things, including but not limited to materials and equipment
(including spare parts) required to be incorporated in the WORK.
PROJECT – means the Borouge 2 Project at Ruwais, Abu Dhabi, UAE.
VENDOR – means any and all persons, firms, partnerships, companies, bodies entities or
a combination thereof including sub-vendors and suppliers, who are providing GOODS,
and the successors and assigns of such persons, firms, partnerships, companies, bodies,
entities or a combination thereof.
Shall and Must – means a mandatory requirement.
In addition supplementary definitions are contained in Article 1 of the AGREEMENT.
Where definitions given here conflict with those given in Article 1 of the AGREEMENT,
ARTICLE 1 DEFINITIONS shall take precedence.
2.2 ABBREVIATIONS
EVT Equiviscous Temperature
FBT Finished Blowing Temperature
UAE United Arab Emirates
3.0 CODES AND STANDARDS

It shall be the CONTRACTOR’s responsibility to comply with the requirements of all
Codes and Standards which are applicable to meet the Specification.
The following Codes and Standards form a part of the Specification:

American Architectural Manufacturers Association (AAMA)

501.2 Field Check of Metal Curtainwalls for Water Leakage
American Society for Testing and Materials (ASTM)
ASTM A 653/A 653M Standard Specification for Steel Sheet, Zinc-Coated
(Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by
the Hot-Dip Process
ASTM A 924/A 924M Standard Specification for General Requirements for Steel
Sheet, Metallic-Coated by the Hot-Dip Process
ASTM C 272 Standard Test Method for Water Absorption of Core
Materials for Structural Sandwich Constructions
ASTM C 920 Standard Specification for Elastomeric Joint Sealants
ASTM D 41 Standard Specification for Asphalt Primer Used in Roofing,
Dampproofing, and Waterproofing-E-1
ASTM D 1621 Standard Test Method for Compressive Properties Of Rigid
Cellular Plastics
ASTM D1622 Standard Test Method for Apparent Density of Rigid Cellular
Plastics
ASTM D1623 Standard Test Method for Tensile and Tensile Adhesion
Properties of Rigid Cellular Plastics
ASTM E 72 Standard Test Methods of Conducting Strength Tests of
Panels for Building Construction
ASTM E 84 Standard Test Method for Surface Burning Characteristics of
Building Materials
ASTM E 119 Standard Test Methods for Fire Tests of Building
Construction and Materials
FM 4454 (Factory Mutual Engineering Corporation) Fire and
Windstorm Ratings (Lightweight Insulating Concrete Roof
Deck HOLD)
The edition or revision of the Codes and Standards shall be the edition current at the
EFFECTIVE DATE of the AGREEMENT.
CONTRACTOR shall advise COMPANY of any changes to Codes and Standards after
the EFFECTIVE DATE. CONTRACTOR shall comply with COMPANY instruction to
comply with any changed Codes and Standards.
CONTRACTOR shall advise of conflict among any referenced Codes and Standards and
any technical specification, and COMPANY will determine which shall govern.
4.0 REFERENCE DOCUMENTS

The following Reference Documents form a part of this Specification.
BGS-AU-034 Outline Building Specification
BGS-AU-057 Finishes
BGS-CU-001 Civil Engineering Design Criteria
BGS-CU-002 Structural Engineering Design Criteria

BGS-CU-010 Concrete Construction, Formwork and Coatings

BGS-CU-012 Fireproofing Requirements
BGS-CU-033 Design Basis for Buildings and Structures
BGS-MU-002 Preservation and Export Packing procedure
BGS-MU-013 Criticality Rating System
BGS-MU-014 Minimum Shop Inspection and Certification Requirements
BPM-GG-03-001 Document Numbering Procedure

BPM-GG-03-005 Document and Drawing Format Procedure
BPM-GG-03-008 Document Issuing Procedure CONTRACTOR’S
BPM-GG-03-009 Procedure for Concession Requests
BQP-GG-03-002 Quality Management Requirements for CONTRACTOR
BSS-GG-03-001 Basic Engineering Design Data
BDP-AA-03-001 Building Aesthetics Co-ordination Report
The edition or revision of the Reference Documents shall be the edition current at the
EFFECTIVE DATE of the AGREEMENT.
CONTRACTOR shall advise COMPANY of any changes to Reference Documents after
the EFFECTIVE DATE. CONTRACTOR shall comply with COMPANY instruction to
comply with any changed Referenced Documents.
CONTRACTOR shall advise of conflict among any Reference Documents and any
technical specification, and COMPANY will determine which shall govern.
5.0 DOCUMENTATION REVIEW

The CONTRACTOR shall notify the COMPANY of any apparent conflict between this
Specification, Codes and Standards, Referenced Documents and any other applicable
documentation (i.e. Datasheets, AGREEMENT).
The CONTRACTOR shall prepare a tabulated list of discrepancies between any of these
documents for review with the COMPANY. Resolution of any conflict shall be obtained
from COMPANY in writing before proceeding.
6.0 SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviations to this Specification shall be sought by the CONTRACTOR
only through the CONCESSION REQUEST procedure. Refer to BPM-GG-03-009 -
Procedure for Concession Requests.
COMPANY will review and consider all proposed CONCESSION REQUESTS.
Approval may be granted at COMPANY’S discretion. No proposed technical deviation
shall be implemented prior to approval being granted. Technical deviations implemented
prior to approval shall be subject to rejection.
7.0 QUALITY CONTROL

CONTRACTOR and VENDOR shall comply with the requirements of “Quality

Management Requirements for CONTRACTOR’S” BQP-GG-03-002.

The Criticality Rating (CR) System outlined in Project Specification BGS-MU-013 shall
be used by CONTRACTOR to develop the design checking levels and minimum
requirements for shop inspection, testing and material certification given in Project
Specification BGS-MU-014.
Regardless of the Criticality Rating CONTRACTOR shall review the VENDOR’S
documentation to ensure compliance with the requirements of the AGREEMENT.
CONTRACTOR shall develop a list of Criticality ratings for all equipment items.
8.0 DOCUMENTATION
CONTRACTOR and VENDOR shall comply with the requirements of the “Procedure
for Document and Drawing Format” BPM-GG-03-005, “Document Numbering
Procedure” BPM-GG-03-001 and “Document Issuing Procedure CONTRACTORS”
BPM-GG-03-008.
9.0 PACKING, SHIPPING AND STORAGE

As a minimum, the CONTRACTOR shall ensure that items are packed for shipment in
accordance with the requirements of “Preservation and Export Packing Procedure” BGS-
MU-002.
The CONTRACTOR shall ensure that detailed and specific instructions for the
preservation and maintenance of equipment while stored at the construction site, from
receipt at site to operational start-up, shall be delivered to construction site with the
equipment. Such instructions shall include as a minimum the preservation and
maintenance schedule, preservative materials, lubricants to be used etc.
10.0 DESIGN (ROOF AND METAL WALL PANEL SYSTEM)

The roofing system shall meet the requirements for a Factory Mutual Class 1 Fire Rated
and I-90 Windstorm Rating.
The Wind Load shall be that as listed in referenced Project General Specification
“Structural Engineering Design Criteria” BGS-CU-002.
11.0 VAPOR BARRIER
11.1 MATERIAL BARRIER

Provide under-slab moisture vapour barrier of 0.25 mm thick polyethylene film
conforming to ASTM D 3020 “Standard Specification for Polyethylene and Copolymer
Plastic Sheeting.”

11.2 INSTALLATION
11.2.1 Smooth sub-grade site to prevent protrusions that may cause damage or rupturing of
moisture vapour barrier.
11.2.2 Immediately under membrane vapour barrier, place sand to compacted depth of 100 mm.
Wet down not less than six (6) hours nor more than twenty (20) hours before placing
concrete. Remove free water before placing moisture vapour barrier and concrete as per
Project General Specification “Concrete” BGS-CU-010.
11.2.3 Install vapour barrier in accordance with VENDOR’S instruction rolling out to minimize
wrinkles and bubbles.
11.2.4 Where laps are required, lap moisture vapour barrier a minimum of 150 mm, with top lap
placed in direction of spreading concrete.
11.2.5 Carry vapour barrier to inside face of footings and up and around perimeter of the slab.
12.0 ROOFING SYSTEM
12.1 GENERAL
Buildings requiring heating, air conditioning or ventilation shall have properly insulated
roofs with the average thermal transmittance shall be U≤0.35 W/m2°C for the roof
assembly.
12.1.1 Warranty
The total roofing system shall be installed in such a manner that the VENDOR can and
will furnish to the COMPANY a ten (10) year warranty against a roofing system failure.
A copy of the warranty shall be submitted.
12.1.2 Submittals
Shop drawings are required for final inspection of the roof and shall include: outline of
roof and roof size, location and type of all penetrations, perimeter and penetration
flashing details, special details and equipment pads.
12.1.3 Inspection of Deck and Flashing Surfaces
The CONTRACTOR shall examine all surfaces designated to receive the system and
shall prepare or correct all surfaces as required to meet roofing VENDOR’S
requirements. Surfaces shall be free of sharp protrusions and swept clean of debris.
Flashing surfaces shall be free of contaminates such as, but not limited to, asphalt, oil,
grease, paint, scale, cement latencies, and similar materials.
12.1.4 Job and Weather Conditions
No application of the roofing membrane shall commence nor proceed during inclement
weather.
All surfaces to receive adhesive shall be thoroughly dry and free of dew.
All dirt and dust shall be removed from the surface either by vacuuming, sweeping,
blowing with compressed air or similar methods.
Surfaces not designated to receive the system shall be properly masked or otherwise
protected against accidental spillage or application of the material to those areas.

12.1.5 VENDORS
VENDOR’S shall be approved by the COMPANY.
12.2 MATERIALS
12.2.1 Base
Lightweight sand-cement screed laid to falls with a minimum average thickness.
12.2.2 Waterproof Covering
Inverted roof system combining impervious, cold applied flexible laminated sheet,
consisting of solar reflective multi-layer high density cross laminated polyethylene film
with a backing of self adhesive rubber bitumen compound and insulation boards.
12.2.3 Laying Waterproof Membrane Generally
• Start at lowest point of roof, discard siliconised release paper, and unroll
membrane up the slop with not less than 75 mm side and end laps. Well roll the
lap joints to ensure watertight continuity.
• At wall/upstand junctions use angle fillet bonded to the base membrane.
• Pre-measure the extent of the Solar-Shield flashing to accurately follow the
roof profile to the termination chase.
• Fix aluminium parapet flashing.
12.2.4 Primer
Primer to suit bitumen based waterproofing membrane.
Component 1: 4 mm thick torch applied modified bitumen based waterproofing
membrane.
Insulation: Expanded polystyrene insulation board, 75mm thick to a density of
32-35 kg/m3.
Component 2: Separating layer to be geotextile membrane of weight 100 g/m2.
Component 3: 500 x 500 x 50 mm pre-cast concrete paving slabs laid on plastic
spacer.
12.2.5 Accessories
Solar shield self-adhesive textured aluminium sheet for flashing to upstands. Parapet
metal flashing.
12.3 EXECUTION
12.3.1 General
Work shall be completed by a VENDOR’S approved applicator, in a manner conducive
to good workmanship and overall completion of the Specification.
All materials shall be mixed, thinned, modified, and applied only as per the VENDOR’S
instructions.
The CONTRACTOR shall protect the work and work areas as well as adjacent work and
materials by suitable covering, barricades, signs or other protective methods.
Any substrate joints, any substrate to-wall junctions, and other substrate to penetration
gaps which are greater than 6 mm shall be repaired with pourable sealer. Take necessary
measures to contain the pourable sealer.

Foreign materials shall be cleaned from the substrate prior to commencement of roofing.
12.3.2 Insulation Installation
Roof insulation shall be attached per roof insulation VENDOR’S Specifications.
12.3.3 Roof Membrane Installation
Apply roofing in accordance with roofing system VENDOR’S instructions and the
following requirements. Application of roofing shall immediately follow application of
base sheet and/or insulation as a continuous operation.
Make necessary preparations, utilise recommended application techniques, apply the
specified materials and exercise care in ensuring that the finished application is
acceptable to the COMPANY.
Prime metal flanges (all jacks, edge metal, lead drain flashing, etc.) and concrete and
masonry surfaces with a uniform coating of asphalt primer ASTM D 41.
Kettles and tankers shall be equipped with accurate, fully readable thermometers.
Asphalt shall not be heated to or above its flash point. Avoid heating at or above the
FBT, should conditions make this impractical, heating must be no more than 14ºC below
the EVT and no more than 14ºC above the equiviscous temperature (EVT).
If the EVT information is not provided, the following asphalt temperature shall be
observed. Maximum heating temperature shall be 274ºC. Minimum application
temperature shall be 205ºC.
Ensure that inter-ply moppings do not exceed a maximum of 11.3 kg per square (square
= 9.29 m2). Mopping shall be total in coverage, leaving no breaks or voids.
Cutting or alternations of bitumen, primer, and sealants will not be permitted.
12.3.4 Inspection
Upon completion of the installation, an inspection shall be made by a representative of
the membrane VENDOR to ascertain that the roofing system has been installed
according to the VENDOR’S published specifications and details. This method shall be
more than just a visual inspection. A seventy-two (72) hours water test to the whole roof
surface shall be performed. This test specification shall be co-ordinated with the
MANUFACTURER.
Warranty shall be issued upon approval of the installation. The CONTRACTOR shall be
responsible for all costs required to bring the roofing system into compliance with the
VENDOR’S published specifications and details. A water test, at least seventy-two (72)
hours, to the whole roof surface.
12.3.5 Clean Up
The CONTRACTOR shall remove all masking, protection, equipment, materials, and
debris from the work and storage areas and leave those areas in an undamaged and
acceptable condition.
13.0 BUILDING SEALANT
13.1 VENDOR’S
Dow Corning
GE Silicones
Fosroc, Inc

or equal and approved by the COMPANY.
13.2 SEALANT MATERIALS

13.2.1 Silicone (exterior)
1) ASTM C 920, Class 25, Type S, Grade NS, One-Part. "Dow Silicone Building
Sealant 790" or equal
2) ASTM C 920, Class 25, Type S, Grade NS, One-Part. "Dow Silicone Perimeter
Sealant 791" or equal (Adjacent to window or door frames)
13.2.2 Polysulfide (interior)
a. ASTM C 920, Class 25, Type S, Grade NS, One-Part, Nonsag
13.3 BACKER ROD

13.3.1 Compressible rod stock of neoprene foam, permanent, durable non-absorbent material 33
percent (33%) to 50 percent (50%) larger than joint as recommended for compatibility
with sealant VENDOR.
13.4 MISCELLANEOUS MATERIALS

13.4.1 Primers shall be as recommended by the sealant VENDOR to provide adhesion of the
sealant to, and to prevent staining of, adjacent surfaces for all conditions.
13.4.2 Bond breaker material shall be as recommended by the sealant VENDOR to prevent
bonding of the sealant to back surface of recess, for all conditions.
13.4.3 Cleaners for nonporous surfaces shall be non-staining chemical cleaner of a type
acceptable to the VENDOR of the sealant and sealant backing materials and are not
harmful to substrates and adjacent nonporous materials.
13.5 INSTALLATION
13.5.1 Joint Preparation
Prepare joints to receive compound and verify suitability. Failure of compound due to
claimed unsuitability of joint will not be valid. Installation of compound is considered as
evidence that joint is suitable to receive compound.
13.5.2 Joint Cleaning
a. Clean out joints immediately before installing joint sealers to comply with
recommendations of joint sealer VENDOR
b. Remove from joint substrates foreign material that could interfere with
adhesion of joint sealer. Such foreign material may include dust, paints, oil,
grease, waterproofing, water repellents, water, and surface dirt
c. Clean concrete, masonry, and unglazed surfaces of ceramic tile and similar
porous joint substrate surfaces by brushing, grinding, blast cleaning,
mechanical abrading, acid washing or a combination of these methods to
produce a clean, sound substrate capable of developing optimum bond with
joint sealers. Remove remaining loose particles by vacuuming or blowing out
joints with oil-free compressed air
d. Remove Latinate and form-release agents from concrete
e. Clean metal, glass, glazed surfaces of ceramic tile and other nonporous surfaces
by chemical cleaners or other means that are not harmful to substrates or leave
residues capable of interfering with adhesion of joint sealers

13.5.3 Joint Fillers and Backing Material

Install these materials at proper depth to provide support and correct joint width to joint
depth ratio as recommended by the VENDOR. Do not leave gaps between ends of joint
fillers. Do not stretch, twist, tear, or puncture joint filler or backing material. Remove
joint fillers which have become wet and replace with dry joint fillers before installing
sealant.
13.5.4 Sealants
Install Sealants using proven methods that allow sealant to directly contact and fully wet
joint substrate, to completely fill recesses provided for each joint configuration, and to
provide uniform cross-sectional shapes while maintaining proper joint width-to-joint
depth ratio.
14.0 FIRE RETARDANT SEALANT
14.1 VENDORS
Dow Corning
Rector Seal Corp.
Hilti Inc.l
GE Silicones
or equal and approved by the COMPANY.
14.2 MATERIALS
a. Cavity Filler: Two component, RTV silicone liquid foaming compound, UL
listed and meeting requirements of ASTM E 84 and ASTM E 119, General
Electric Company Pensil 200 foam or Dow Corning Fire Stop 2001 foam or
equal
b. Adhesive/Sealant: One component silicone, UL listed and meeting
requirements of ASTM E 84 and ASTM E 119, General Electric Company
Pensil 100 sealant or Dow Corning fire-stop sealant or equal
c. Damming Form Board: Fire-resistant rigid insulating fibreboard, UL listed,
minimum 25.4 mm thick, Johns-Manville “Cera Form.” Or equal
d. Packing: Loose or blanket type fire-resistant aluminium silica fibre, Johns-
Manville “Cerafibre” or equal
e. Primer: Liquid bond-enhancing agent, General Electric Company SS4155
Bonding Primer or equal. Do not use primer for Dow Corning products unless
sealing against aluminium or metal surface. Use Dow Corning 1200 prime coat
or equal when sealing against these surfaces
f. Fire-stopping materials shall be asbestos-free, emit no toxic or combustible
fumes, and be capable of maintaining an effective barrier against flame, smoke,
water and toxic gases in compliance with referenced standards in Sections 3.0
and 4.0
g. Fire-stopping materials/systems shall be flexible to allow for normal movement
of building structure and penetrating item(s) without affecting the adhesion or
integrity of the system
h. Cleaning Solvent: Hydrocarbon-based liquid solvent cleaning agent such as
naphtha, methylethyl-ketone or high-flash mineral spirit

i. Local Materials: Local materials of comparable quality and characteristics may

be submitted to the COMPANY for approval
14.3 INSTALLATION
14.3.1 Pre-inspection
Prior to work of this Specification, carefully inspect surfaces to receive sealants and
verify that such surfaces are complete to a point where this installation may properly
commence. Verify that sealants may be installed in accordance with VENDOR’S
recommendations.
14.3.2 Preparation
a. Clean receiving surfaces immediately before installation of sealant materials.
Remove dirt, insecure coatings, moisture and other substances which would
interfere with bond of sealant. Etch concrete and masonry surfaces as
recommended by sealant VENDOR.
b. Prime or seal receiving surfaces wherever recommended by sealant VENDOR.
Do not allow sealer to spill or migrate onto adjoining surfaces
c. Clean ferrous metals of rust, mill scale and coatings by wore brush, grinding, or
sandblasting. Remove oil, grease and protective coatings with solvent and clean
lint-less paper towels, and then wipe dry. Do not allow solvent to air dry
without wiping
14.3.3 Installation
a. General: Install fire retardant sealants, where indicated on Contract Drawings,
strictly according to VENDOR’S written instructions. Strictly adhere to
VENDOR’S limitations due to adverse weather conditions
b. Forming: Install damming materials to cover and seal penetration openings as
required by VENDOR’S recommendations. Cut damming materials to suit
opening and neatly perforate with holes in damming materials to allow
injection/venting of liquid foaming compound as recommended by the
manufacturer.
Secure damming materials firmly in place at penetration openings using
adhesive/sealant as required by VENDOR’S recommendations. Tightly fill all
gaps between penetrations and damming materials by stuffing with fibre
packing, followed by bead of adhesive/sealant. Apply sealant also to all edges
and joints of damming materials as recommended by the VENDOR
c. Sealing: Inject liquid foaming compound into openings enclosed by damming
materials in strict accordance with VENDOR’S written instructions, ensuring
that each entire cavity and all interstices between penetrations are completely
filled with foam, without gaps or air pockets. Do not allow compound to
overflow or spill onto adjoining surfaces. Clean adjoining surfaces, using
methods recommended by the manufacturer, to eliminate evidence of spillage
14.3.4 Curing and Protection
Cure sealant materials in accordance with VENDOR’S written instructions and
recommendations to obtain high early bond strength, internal cohesive strength and
surface durability. Protect sealed penetrations during construction period, to prevent
deterioration or damage other than normal wear and weathering.

15.0 METAL PANEL SYSTEM

All metal walls, both horizontal and vertical panels including the window system shall be
products of a single VENDOR to ensure a compatible weather tight system. The wall
system listed herein is Centria or equal in order to establish a level of quality.
15.1 VENDORS
Centria International
or equal and approved by the COMPANY
15.2 MATERIALS
System: Factory Insulated Metal Panel System shall be VERSAWALL. Panels shall be
factory assembled, 50 mm (2 inches) thickness, metal faced sandwich panels, with
poured in place rigid expanded polyisocyanurate insulating core. A 3 mm (1/8 inch)
nominal vertical side joint will be used.
The panel facings shall be steel conforming to ASTM A 653 Structural Quality Grade 33
(A 653M), with ASTM A 924 (A 924M) Class G 90 (Z 275) galvanizing. Face sheets
and interior sheets shall be 0.06 mm (24 gauge).
Both panel faces shall be embossed with a non-directional pattern.
Horizontal Side Joints: Shall be a double interlock, double sealed system, with factory
installed non curing sealant in both interior and exterior panel joints.
The double side lap design shall insure that both interior and exterior panel skins are
mechanically attached to the structural support system at both top and bottom of panel.
The panel attachment fasteners and anchor clip shall be concealed from view, as well as
protected from the elements.
The foam core and continuous metal edges shall be concealed and protected from
corrosive elements.
15.3 TRIM MEMBERS AND COPING

Extruded trim members shall be of aluminium to match the other extrusions in colour and
finish which are part of the factory insulated panel system. They shall have preformed
interior lap strips or splice plates to provide continuity and weather protection.
When sheet metal trim members are required, they are to be of same material and finish
as the exterior panel skins.
Thermal Break Construction: No through metal conductance will be permitted form the
exterior side to the interior side of the panel.
Vertical End Joints at Horizontally Applied Panels: Shall be a dry seal system with the
use of a specially designed rain screen gasket. Provide a vertical flashing member behind
each vertical panel joint.
Primary Seal at Horizontally Applied Panels: At the vertical panel joint shall be 10 mm
(3/8 inch) wide x 6 mm (1/4 inch) deep silicone seal capable of accommodating thermal
and structural movements of the foam panels. The joint depth shall be set with adhesive
backed silicone compatible foam tape applied to the panel. Blind seals compressed to a
thin film will not be acceptable as the vertical joint seal.
Fastening: Insulated metal panels shall be secured to the structural frame with Type 305
stainless steel self-tapping screws and galvanized steel clips so that no panel fasteners are

visible from the exterior face of the wall. Flashings and accessories shall be installed
with stainless steel Type 305 sheet metal screws or stainless steel pop-rivets as per
VENDOR’S standard practice.
15.4 WINDOWS
Provide TAF 6V fixed windows. All window framing members shall be specially
designed to integrate with the insulated metal panel systems provided.
The window head member shall provide the means of retaining the panel above it as well
as to incorporate drainage to the building exterior.
The sill and head members shall be of thermal break design with no through metal
conductance from the exterior to the interior face of the members.
If exposed mullion design is required, provide a pressure bar and snap-on cover members
attached to the vertical mullions.
Window framing members shall be fabricated from 6063-T5 Aluminium extrusions in
accordance with ASTM B 221.
15.5 FABRICATION
All parts of the curtain wall system shall be of the materials, design, sizes and thickness,
subject to commercial tolerances, shown or called for on the Architect/Engineer
approved drawings and herein specified. Methods of fabrication and assembly, unless
otherwise specifically stated, shall be at the discretion of the manufacturer.
All exposed work shall be carefully matched to produce continuity of line and design,
with all joints, unless otherwise shown or specified, being accurately fitted and rigidly
secured.
Protection against galvanic action shall be provided wherever dissimilar metals are in
contact, except in the case of aluminium in contact with galvanized steel, zinc, or
relatively small areas of stainless steel or nickel silver white bronze. This protection shall
be provided either by painting the contact surfaces with zinc chromate primer or by
application of an appropriate sealant or tape.
All shop welding shall be in accordance with recommendations of the American Welding
Society and shall be done with electrodes and by methods recommended by the suppliers
of the metals being welded.
Sealing materials shall be used in accordance with the recommendations of the
VENDOR of the material and joints to be sealed shall be in accordance with the designs
and tolerances shown on the approved shop drawings.
15.6 FINISHES
The exterior and interior of foam wall panels and flashings shall receive factory applied
coatings.
Interior side to be Polyester - 2 coats textured off white interior finish.
Exterior side to be Duragard Plus (Polyvinylidene Fluoride) -or Centrai International’s
Versacor TF or equal. Colour to be as selected by COMPANY from the VENDOR’S
standard colours.
Protective Coating, exterior face of panels and flashings shall receive a factory applied
plastic strippable coating.

15.7 PHYSICAL PROPERTIES OF MATERIALS

Core Material Cell Structure: Poured in place rigid expanded polyisocyanurate foam with
a minimum of 95 percent (95%) closed cell structure.
Shear Strength: 0.207 N/mm2 (30 pounds/square inch) minimum determined from actual
full length panels subjected to simulated wind loads by the chamber method determined
in accordance with the procedures specified in ASTM E 72.
Bond Strength: No metal corrosion at interface of primer or delamination of foam core
from metal shall occur after periodic checks at 7, 14, and 28 days at 48.9°C (120°F), 100
percent relative humidity.
Freeze and Heat Cycle: No delamination, surface blisters or large bubbles when
subjected to cyclic temperature extremes of 29°C to 82.2°C (20°F to 180°F).
Tensile Strength: 0.241 N/mm2 (35 pounds/square inch) minimum determined in
accordance with the procedures specified in ASTM D 1623.
Tensile Adhesive Strength: 0.290 N/mm2 (42 pounds/square inch) minimum determined
in accordance with the procedures specified in ASTM D 1623-78.
Compressive Strength: 0.297 N/mm2 (43 pounds/square inch) minimum determined in
accordance with the procedures specified in ASTM D 1621.
Density: 48 kg/m3 (3.0 pounds/cubic foot) minimum determined in accordance with the
procedures specified in ASTM D 1622.
Humid Age Exposure: There shall be no more than 6 percent (6%) increase in volume
when a sample of the insulated metal panel is subjected to a humid aging environment at
100 percent (100%) relative humidity and 48.9°C (120°F) for periodic volume checks at
7, 14, and 28 days.
Heat Exposure: There shall be no more than 5 percent (5%) increase in volume when a
sample of the insulated metal panel is subjected to an elevated temperature environment
at 82.2°C (180°F) for periodic volume checks at 7, 14, and 28 days.
Water Absorption of Foam Core: The relative weight increase due to water absorption,
when a sample of the insulated metal panel is immersed, shall be no greater than 4
percent (4%) when tested in accordance with the procedure specified in ASTM C 272.
Fatigue Test: Panels shall withstand a deflection cycling of 1.5 million cycles at 0.96 kPa
(20 pounds/square foot) simulated wind load with no de-lamination of failure of the foam
core.
15.8 INSPECTION
Examine supporting structure and conditions under which the work is to be erected, and
notify the CONTRACTOR in writing of conditions detrimental to proper and timely
completion of the work. Do not proceed with erection until unsatisfactory conditions
have been corrected.
15.9 INSTALLATION/ERECTION
15.9.1 General
Complete installation of all work under this Section shall be by the VENDOR, or by an
installer pre-approved by the VENDOR.
Do not cut, trim, weld, or braze component parts during erection, in a manner which
would damage finish, decrease strength, or result in a visual imperfection or a failure in

performance of wall panels. Return component parts which require alteration to the shop
for re-fabrication, if possible, or for replacement by new parts.
15.9.2 Metal separation
Apply a coat of bituminous paint, concealed on one or both surfaces wherever dissimilar
metals would otherwise be in contact. Use gasketed fasteners where needed to eliminate
the possibility of corrosive or electrolytic action between metals.
Anchor component parts of the metal wall securely in place, providing for necessary
thermal structural movement.
Sealing materials shall be used in strict accordance with the VENDOR’S written
instructions, and shall be applied only by installers specially trained or experienced in
their use. Before applying sealant, all mortar, dirt, dust, moisture and other foreign matter
shall be completely removed from surfaces it will contact. Adjoining surfaces shall be
masked when required to maintain a clean and neat appearance. Sealing compounds shall
be tooled to fill the joint and provide a smooth finished surface
15.9.3 Tolerances
Provide adjustment within curtain wall to accommodate variations of existing structure.
Deviation from established vertical, horizontal, or designed position must not exceed 6
mm (1/4 inch) per 305 mm (12 inches) of length of any member of 13 mm (1/2 inch) in
any total run in any line.
15.10 FIELD QUALITY CONTROL

15.10.1 Field Check for Water Leakage
Upon completion of the installation the wall shall be checked for water penetration in
accordance with AAMA Standard 501.2-83, Field Check of Metal Curtain walls for
Water Leakage. The CONTRACTOR will designate an area to be so checked.
15.11 Cleaning and Protection

Remove from site debris, excess materials and equipment at the completion of the work
and legally dispose of.
Make sure weep holes and drainage channels are unobstructed and free of dirt and
sealants.
16.0 FLASHING AND SHEET METAL
16.1 MATERIALS
Basic materials shall conform to the following standards and quality levels. Alternate
products will be considered upon submittal of full details to the COMPANY.
Galvanized steel: ASTM A366 or A6, zinc coated
Sheet aluminium: ASTM B209, alloy 3003-H14, mill finish
Stainless steel: 18-18 ASTM A 167, Type 302 or 304, AISI 2D finish
Lead: Fed Spec. QQ-L-201, Grade B
Solder: ASTM B 32, alloy grade Sb (5(95-5)

Soldering flux:
For stainless steel Zinc chloride type, Fed Spec. 0-F-506, Type II
For other metals Acid type, Fed Spec. 0-F-506. Type I, Form A
Fasteners: Same metal as sheet metal being fastened
Coal tar paint: Kop-Coat “Bitumastic Super Service Black”, Tnemec “450 Heavy
Tnemecol”.
Acrylic sealant: Pecora “Unicrylic”, Tremco “Mono”.
16.2 EXECUTION
16.2.1 Inspection
The sheet metal CONTRACTOR shall visit the site and inspect all surfaces which are to
receive sheet metal work.
Any defective or improperly installed surfaces shall be brought to the attention of the
CONTRACTOR and corrected before installation of the sheet metal work begins.
16.2.2 General
Sheet metal items, when possible, shall be shop fabricated.
All items shall be fabricated accurately forming to the required sizes, shapes, and
dimensions, with all angles and lines in true alignment. All work shall be straight, sharp
and erected plumb and level in proper place without bulges and waves. All workmanship
shall be equal to the best standards of practice in modern sheet metal work.
Items shall be fabricated in maximum lengths and all joints held to a minimum.
All dissimilar metals shall be isolated by back painting with a heavy coat of coal tar
paint.
16.2.3 Joints
Joints in sheet metal work shall be closed watertight unless slip joints are specifically
required. Watertight joints shall be mechanically interlocked and then thoroughly
soldered. All joints shall be wiped clean of flux after soldering. Acid flux shall be
neutralized by washing the joints with sodium bicarbonate.
16.2.4 Flashing
All exposed or contacting flashing shall be of the same materials.
Types and Materials:
Through wall flashing: Stainless steel, 0.34 mm (32 gauges) dead soft, fully
annealed: or Copper 284 g (10 ounce) or stainless steel, 0.34
mm (32 gauges), dead soft, fully annealed.
Cap flashing: Stainless steel, 0.55 mm (26 gauges).
Counter flashing: Stainless steel, 0.55 mm (26 gauge), with 100mm will flat
and hook dam for masonry wall installation or with snap lock
for reglet installation.
Reglets: Stainless steel, 0.55 mm (26 gauge), designed to retain
counter flashing by snap action or friction fit.
Through-wall flashings under copings shall be continuous. Flashings over lintels and

under sills shall extend 200 mm past each jamb and shall have ends turned up 6mm. Wall
flashings shall be formed with receivers for counter flashings where required. Joints in
wall flashings and receivers for counter flashings shall overlap and shall be interlocked.
Where multiple bends are required for through-wall installation, flashing may be
provided in single-bend sections with vertical legs over-lapped to drain to the outside
face of the wall.
Cap flashings shall be fabricated in sections not exceeding 3 meters in length; sections
shall overlap at least 75 mm and shall form a slip joint, but shall not be interlocked. All
corners and all joints other than slip joints shall be closed watertight as specified
hereinbefore. Cap flashings shall be installed after membrane base flashings have been
completed.
Reglets to be set in concrete to receive counter flashings shall be nailed into the forms in
accordance with the VENDOR’S recommendations, with care being taken to maintain
precise alignment of abutting sections. After the forms are stripped, the temporary form
filler strip shall be removed from the reglet and the form securing nails shall be clipped
flush.
Counter flashings shall be provided to overlap membrane base flashings and fit into
flashing reglets or receivers. Counter flashings shall be fabricated in sections not
exceeding 3 meters in length; sections shall overlap at least 75 mm and shall form a slip
joint, but shall not be interlocked. End joints between counter flashing sections shall be
offset form underlying joints between reglet or receiver sections. Corners in counter
flashings shall be closed watertight as specified hereinbefore. Counter flashings shall be
fitted into reglets or receivers and securely locked in place in accordance with the
VENDOR’S recommendations.
16.2.5 Flashing Pans
Flashing pans shall be provided for columns, equipment supports, and similar members
bearing on the roof. Flashing pans shall be fabricated of 0.70 mm (24 gauge) stainless
steel or 0.85 mm (22 gauge) galvanized steel, shall be of adequate size to accommodate
the enclosed member, shall have a 100 mm flanged base, and shall be at least 200 mm
high with hemmed top edge.
16.2.6 Hoods
Counter flashing hoods shall be provided for all pipes and conduits, except plumbing
vents, which pass through the roof and for columns, equipment supports, and similar
members bearing on the roof. Hoods shall be made from the same material as the pipe to
which they are fastened.
16.2.7 Clean Up
Upon completion of work, all surplus materials, debris, tools and equipment shall be
removed from the site.

BGS-AU-055 Rev B1

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BOROUGE GENERAL SPECIFICATION

Borouge 2 Project Revision: B1

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15.4 WINDOWS .......................................................................................................................................3

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2.0 DEFINITIONS AND ABBREVIATIONS

3.0 CODES AND STANDARDS

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American Architectural Manufacturers Association (AAMA)

4.0 REFERENCE DOCUMENTS

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BGS-CU-010 Concrete Construction, Formwork and Coatings

BPM-GG-03-001 Document Numbering Procedure

5.0 DOCUMENTATION REVIEW

6.0 SPECIFICATION DEVIATION/CONCESSION CONTROL

7.0 QUALITY CONTROL

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Management Requirements for CONTRACTOR’S” BQP-GG-03-002.

9.0 PACKING, SHIPPING AND STORAGE

10.0 DESIGN (ROOF AND METAL WALL PANEL SYSTEM)

11.0 VAPOR BARRIER

11.1 MATERIAL BARRIER

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12.0 ROOFING SYSTEM

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13.0 BUILDING SEALANT

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or equal and approved by the COMPANY.

13.2 SEALANT MATERIALS

13.3 BACKER ROD

13.4 MISCELLANEOUS MATERIALS

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13.5.3 Joint Fillers and Backing Material

14.0 FIRE RETARDANT SEALANT

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i. Local Materials: Local materials of comparable quality and characteristics may

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15.0 METAL PANEL SYSTEM

15.3 TRIM MEMBERS AND COPING

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15.7 PHYSICAL PROPERTIES OF MATERIALS

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15.10 FIELD QUALITY CONTROL

15.11 Cleaning and Protection

16.0 FLASHING AND SHEET METAL

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