A3-40 External Metalwork

A3-40 External Metalwork

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CONTENTS
Page

1.0 GENERAL 3
1.1 Scope 3
1.2 Related Sections 3
1.3 Standards 3
1.4 Trade Preamble 6

2.0 PERFORMANCE REQUIREMENTS 8

2.1 Contractor’s Brief 8

3.0 MATERIALS AND COMPONENTS 9

3.1 Types of Metalworks 9
3.2 Stainless Steel 9
3.3 Carbon Steel 10
3.4 Aluminium Alloy Components 11
3.5 Prefinished Metals 11
3.6 Fixing and Fasteners 12
3.7 Grout 12
3.8 Timber 12
3.9 Protective Coatings 12
3.10 Standard Elements 13

4.0 WORKMANSHIP 16
4.1 Fabrication 16
4.2 Grinding, Polishing and Finishing 16
4.3 Joints 16
4.4 Shims 16

5.0 VERIFICATION AND SUBMISSIONS 17

5.1 Submissions 17
5.2 Samples and Mock-ups 17

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1.0 GENERAL

Read with the General Requirements section, and all other contract documents.

1.1 Scope

This section covers the requirements for the fabrication and installation of external metalwork
which are generally meant for gates and fences, railings, fins etc. This section does not cover
metal fixtures and fittings and furniture such as lamp post, benches, bins etc. which shall be to
specialist suppliers’ specifications.

1.2 Related Sections

Read this work section in conjunction with the relevant requirements of the other work sections
as follows:

Al -80-3 External Painting and Coating

1.3 Standards

Unless otherwise agreed by the SO, ensure all of the Works comply with the relevant
requirements of the Standards and Codes listed below or referenced in the body of the
Specification. Alternative Standards and Codes may be submit to the SO, provided it can be
demonstrated that the alternative Standards and Codes comply with the requirements of the
standards specified. All Standards and Codes quoted are the current version, unless specific year
references are noted.

Singapore Standards

SS 470 Hot finished structural hollow sections of non-alloy and fine grain
structural steel

Other Standards

BS EN ISO 1461 Hot dip galvanized coatings on fabricated iron and steel articles -
specifications and test methods

BS EN ISO 3506-1 Mechanical properties of corrosion resistant stainless steel fasteners.

Bolts, screws and studs

BS EN ISO 3506-2 Mechanical properties of corrosion-resistant stainless-steel fasteners.

Nuts

BS EN 485 Aluminium and aluminium alloys

BS EN 499 Welding consumables – covered electrodes for manual metal arc welding
of non alloy and fine grain steels - classification

BS EN 895 Destructive tests on welds in metallic materials – transverse tensile test

BS EN 910 Destructive tests on welds in metallic materials – bend tensile test

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BS EN 1172 Sheet & strip for building purposes

BS EN 1321 Destructive tests on welds in metallic materials – macroscopic and

microscopic examination of welds

BS EN 1461 Galvanising

BS EN 1652 Plate, sheet, strip & circles for general purposes

BS EN 3506-1 Mechanical properties of corrosion resistant stainless steel

fasteners

BS EN 10048 Stainless Steel

BS EN 10055 Equal flange tees

BS EN 10056-1 & 2 Equal and unequal angles

BS EN 10088 Stainless Steels

BS EN 10088-01 Stainless steel-List of Stainless steel

BS EN 10088-02 Technically delivery conditions for semi finished products-sheet/plate

and
strip for general purposes

BS EN 10088-3 Technically delivery conditions for semi finished products-bars rods and
sections for general purposes

BS EN 10111 Low carbon steel sheet & strip for cold forming

BS EN 10130 Cold-rolled low carbon steel flat products for cold forming – technical
delivery conditions

BS EN 10131 Cold-rolled uncoated low carbon and high yield strength steel flats
products for cold forming – tolerances on dimensions and shape

BS EN 10137-1 to 3 Plates & wide flats. High yield strength steel

BS EN 10139 Uncoated mild steel narrow strip (1) for cold forming

BS EN 10140 Cold rolled narrow steel strip-tolerances on dimension and shape

BS EN 10142 Continuously hot dip zinc coated low carbon steels strip and sheet for
cold
forming – technical delivery conditions

BS EN 10143 Continuously hot dip metal coated steel sheet and strip – tolerances on
dimensions and shape

BS EN 10147 Continuously hot dip zinc coated structural steel sheet & strip
- technical delivery conditions

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BS EN 10149-1 to 3 Flat products. High yield strength for cold forming

BS EN 10152 Electrolytically zinc coated cold rolled steel flat products for cold forming
– Technical delivery conditions (AMD Corrigendum 14564)

BS EN 10169-1 Organic coated flat products

BS EN 10209 Low carbon steel flat products for vitreous enamelling

BS EN 10210-1 & 2 Non alloy & fine grain steels. Hot finished

BS EN 10214 Hot dip zinc-aluminium (za) coated sheet & strip

BS EN 10215 Hot dip aluminium-zinc (az) coated sheet & strip

BS EN 10218-2 Wire and wire products. General

BS EN 10258 Cold-rolled stainless steel and narrow strip and cut lengths - tolerances
on
dimensions and shape

BS EN 10259 Cold-rolled stainless steel wide strip and plate/sheet - tolerances on

dimensions and shape

BS EN 10268 Flat products. High yield strength micro-alloyed steels for cold forming

BS EN 12020 Aluminium and aluminium alloys

BS EN 12163 Rod for general purposes

BS EN 12166 Wire for general purposes

BS EN 12167 Profiles & rectangular bar for general purposes

BS EN 12449 Tube for general purposes

BS EN 12540 Corrosion protection of metals - Electrodeposited coatings

BS 499 Welding terms and symbols

BS 1052 Wire: Mild steel for general engineering purposes

BS 1449-1-1.15 Narrow strip (1). General engineering purposes

BS 1449-1-1.8& BS Narrow strip (1). Formable & general engineering purposes

1449-1 -1.14

BS 1453 Specification for filler materials for gas welding (AMD 5363)
(AMD 10840) (AMD Corrigendum 13107)

BS 1703 Refuse chutes and hoppers

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BS 2901 Fillers and rods for gas shielded arc welding

BS 2994 Steel sections

BS 3692 ISO metric precision hexagon bolts, screws and nuts

BS 3830 Vitreous enamelled steel building components

BS 3987 Specification for anodic oxide coatings on wrought aluminium for

external
architectural applications (AMD 10944)

BS 4190 ISO metric black hexagon bolts, screws and nuts

BS 4320 Metal washers for general engineering purposes

BS 4360 Specification for weldable structural steels

BS 4464 Spring washers for engineering work

BS 4604 The use of high strength friction grip bolts in structural steel work.
Metric series

BS 6323-1 to 7 Tubes. Seamless & welded

BS 6363 Specification for welded cold formed steel structural hollow sections

BS 7668 Weather resistant steels. Hot finished

AS 1231 Aluminium and aluminium alloys. Anodic oxidation coatings

AS 3715 Metal finishing: Thermoset powder coating

ASTM 2605.2 Organic coatings on aluminium extrusions

1.4 Trade Preambles

1.4.1 Contractor’s Submissions

The intended type and locations of the external metalworks are indicated in the drawings and
schedules. Based on the information supplied, engage qualified and experienced personnel to
carry out and submit the following items to the SO:

1.4.1.1 Develop all necessary details for the fabrication and installation of the work, and to
meet with the performance requirements as set out in clause 2.0 below; Details to
develop may include shape and sizing of components, accessories and connections to
the building.

1.4.1.2 Design for the appropriate structural support for the works including structural
connection to the building frames, and foundations, if not shown in the structural
engineering drawings. Where required as indicated in the PSD, engage a PE (civil) to
verify the design and endorse the submissions.

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1.4.1.3 Submit suitable methods of installation to the works.

1.4.1.4 Submit manufacturer and product for proprietary items when called for.

1.4.2 Shop Drawings

Prepare and submit shop drawings to enable the fabrication and installation of the works.

1.4.3 Co-ordination with Other Works

Co-ordinate the metalworks particularly the interfacing with the following trades:

a. Walls and parapets

b. Foundation for the metalworks

c. Hardscape

d. Softscape

e. All External services

1.4.4 Spare Material

The list and quantity of spare materials shall be advised by the SO.

1.4.5 Warranty

Provide warranty in accordance with contract conditions for the performance of the following
items:

a. A ten-year indemnity for all aluminum works and glazing.

1.4.6 Maintenance Manual

No item.

1.4.7 Quality Control Plan

No item.

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2.0 PERFORMANCE REQUIREMENTS

2.1 Contractor’s Brief

When carrying out the proposals as set out in clause 1.4.1, take account of the following
requirements:

2.1.1 Structural Criteria

2.1.1.1 Dead Loads

The self-weight and other associated dead loads of the metalworks shall be supported and
transferred to the main building structure.

2.1.1.2 Loading Capacity

All works shall sustain and withstand as a minimum, the gravity and lateral loadings as set out in
UBBL requirement, including crowd loads and impact loads.

2.1.1.3 Wind Loads

The whole of the Works shall be able to withstand repeatedly imposed wind pressures based on a
design wind speed of 33.5 m/s. (Ultimate design wind load of 1.25 kPa)

2.1.2 Structural Movement and Movement Between Works by Others

Take into account, that performance, appearance and proper functioning of the external
metalworks are not affected by any movements, settlement, deflection, expansion or contraction
which can be expected to occur in the site, building or the construction process.

Form the junction between the external metalworks systems and adjacent work by others to take
into account, possible structural deflections or movement in that adjacent element without
distortion to the Works, or disintegration of joints between the works.

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3.0 MATERIALS AND COMPONENTS

3.1 Types of Metalworks

Refer to the drawings for types and locations of external metalworks required for the project.

3.2 Stainless Steel

3.2.1 Sections

Stainless steel shall be to BS EN 10088-1. Stainless steel sections shall comply with BS EN 10088-3.

Unless otherwise indicated, stainless steel grade shall be 1.4401 (previously 316 external grade).

3.2.1.1 Finishes

a. 1GI2G (3A) Ground: Coarse, unidirectional texture; low reflectivity.

b. 1J/2J (3B or 4) Brushed or dull polished: Unidirectional texture; smoother than 1G/2G; low
reflectivity.

c. 1K/2K (5) Satin polished: Smoother than 1J/2J. Suitable for marine and external architectural
applications.

d. 1 P/2P (7 or 8) Bright buffed/polished: Nondirectional finish with high degree of reflectivity.

Achieved by mechanical polishing.

Note the references in brackets are the nearest equivalent finishes to the superseded
BS 1449-2.

The finish is achieved on the exposed surface only unless specified otherwise.

3.2.2 Plate, Sheet and Strip

3.2.2.1 Stainless steel in plate, sheet and strip to comply with, BS EN 10048, BS EN 10258, BS
EN 10259 and BS EN 10088 as appropriate.

3.2.2.2 Unless noted otherwise, grade 1.4401 (formerly 316) shall be used for visible
components, in all other circumstances grade 1.4301 (formerly 304) shall be used.

3.2.3 Welding of Stainless Steel

Comply with BS 1453 and BS 2901.

Use electrical fusion metal-arc method. Carbon-arc or gas welding will not permitted. Undertake
in a thorough manner, with edging rod of same composition as sheets or part welded.

Weld completed welds, strong and ductile, with excess metal ground off and joints finish smooth
to match adjoining surface. Welds shall be free of Mechanical imperfections such as gas holes,
pits, runs, crack etc. and shall have same colour as adjoining surfaces.

Continuously butt weld all sheets together with welds ground smooth and polished.

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Buff welds made by spot welding strips under beams and filling in the voids with solder and
finishing by grinding will not be acceptable

Wherever welds occur on surfaces not finished by grinding and polishing, such welds and the
accompanying discolouration shall be suitably coated in the factory by means of metallic base
paint to prevent the possibility of progressive corrosion to such joints.

3.2.4 Fixtures and Fastenings

Comply with BS EN ISO 3506-1 and BS EN ISO 3506-2.

Unless noted otherwise, use grade A4 for visible fasteners, in all other circumstances use grade
A2.

Submit suitable fastener property class to the SO, to meet the performance criteria specified.

3.3 Carbon Steel

3.3.1 Generally

Steel components to be hot dip galvanised after fabrication unless alternative corrosion
protection is approved.

Do not cut, drill or work galvanised members.

3.3.2 Metal Material

3.3.2.1 Steel Plates and Shapes

To B54360

3.3.2.2 Bolts, Nuts and Washers

To BS 3692: (Grade 8.8) / BS 4190: (Grade 4.6) High friction grip bolts shall comply with BS 4604:

a. Part 1: General grade

b. Part 2: (Parallel shank).

3.3.2.3 Cold Rolled Steel

To BS 1449: Section 1.3: matte finish.

3.3.2.4 Hot-dipped Galvanized Steel Sheets

To BS EN 10143:

3.3.2.5 Cold Formed Steel Hollow Section

To BS 6363:

3.3.2.6 Welding Materials

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To BS EN 499: and BS 6363:

3.3.2.7 Concrete Inserts

Cast steel or malleable bolts, washers, and shims, hot-dipped galvanized.

3.3.2.8 Fasteners & Washers

a. Fasteners – BS EN 3506-1:

b. Washers – BS 4320: and BS 4464:.

3.3.3 Welding of Steel

To BS 499: Part 1: & Part 2: and BS 135

3.4 Aluminium Alloy Components

3.4.1 Aluminium Alloy Plate, Sheets and Strip

To BS EN 485: acceptable 3003 – H14 and 5005 – H14 alloy and temper combinations for sheet
and plate subject to fabrications, finish and structural requirements. Provide 3.0 mm minimum
nominal thickness.

3.4.2 Aluminium Alloy Bars

Extruded tube sections and hollow sections: To BS EN 12020: acceptable alloy and temper
combinations for 6063-T5 and 6063-T6 for extrusion subject to fabrication, finish and structural
requirement. Nominal wall thickness of 3.0 mm or greater is required for structural extrusions.
Minimum nominal wall thickness for non-structural trim shall be 1.5 mm.

3.4.3 Aluminium Alloy Drawn Tubes

To BS EN 12020: acceptable alloy and temper combinations 6063-T5 and 6063-T6.

3.4.4 Welding of Aluminium

a) Weld aluminium in the factory and in conformance to BS EN 895, BS EN 910 and BS EN 1321.
Use inert gas process electric arc with a protective envelope of argon gas. Oxyacetylene
welding is not permitted as a substitute. Do not solder aluminium.

b) Weld aluminium only where specifically approved by the SO.

3.5 Prefinished Metals

Prefinished metals may be used if methods of fabrication do not damage or alter appearance of
finish.

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3.6 Fixing and Fasteners

3.6.1 Generally

Submit suitable fasteners to the SO.

3.6.1.1 Fasteners to be to the appropriate Singapore/European/British standards as agreed

with
the SO. And, unless stated otherwise, to be of the same metal as the component with
matching coating and finish.

3.6.1.2 Where a particular fixing or fastening is not shown or fully detailed, design the fixing in
order to fulfil the performance criteria.

3.6.2 Methods

Concealed fixings are to be adopted unless otherwise shown on drawings.

Locate face fixings in unobtrusive positions.

3.6.3 Strength

Allow minimum safety factor of 2.5 in addition to the anchorage design safety factor.

Where requested on drawings supply a torque setting for bolted or screwed fastenings.

Structural anchorage to be by two or more fixing devices.

3.7 Grout

Grout between base/face plates and concrete is to have a minimum compressive strength at 28
days of 40 N/m2

3.8 Timber

Timber accessories such as handrails etc shall be formed of species as noted in the drawings.
Timber handrails to be finished as set out in Section Al -80-3 “External Painting and Coating”
clause 3.1.

3.9 Protective Coatings

3.9.1 Generally

Apply coats after completion of fabrication and drilling of all fixing holes.
Remove all burrs and sharp arrises prior to coating.

3.9.2 Galvanizing

To BS EN ISO 1461.

Provide all necessary vent and drain holes in approved locations and seal to approval
after galvanizing.

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3.9.3 Electrolytically Zinc Coating

Electrolytically zinc coated cold rolled steel flat products to BS EN 10152.

3.9.4 CadmiumlZinc Plating

Cadmium/zinc plating of steel to BS 1703.

3.9.5 Chromium Plating

Chromium plating to comply with requirements of BS EN 12540.

3.9.6 Vitreous Enamelling

Vitreous enamelling to steel surfaces shall be to BS 3830.

3.9.7 Anodizing

Anodizing to aluminium surfaces shall be 25 micron thick to BS 3987

3.9.8 Externally Painted Steel

Refer to Section A1-80-3 “External Painting and Coating” clause 3.1.

3.9.9 Anodizing

Comply with A51231 thickness grade 25.

3.9.10 PVF2

Wet applied fluoropolymer to comply with ASTM 2605-2.

Resin content minimum of 70%, minimum coating 25 microns.

3.9.11 Polyester Powder Coating

Heavy duty external grade polyester powder coat that conforms to AS 3715 or Qualicoat Class 2
or AAMA 2604 grade.

Minimum thickness 70 microns. Submit suitable thickness to the SO.

3.10 Standard Elements

Unless otherwise indicated or specified, adopt the general requirement for standard elements as
below:

3.10.1 Chain Link Fence

Unless otherwise noted on drawings fence to be formed of:

a. 50mm square PVC coated galvanised mesh — 16 SWG including PVC

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b. 9SWG strong wire, PVC coated galvanised

c. 3mm thick, 75mm diameter galvanised steel hollow section top, bottom and bracing rails

d. 4mm thick 100mm square galvanised hollow section posts

e. Mesh attachment 20 x 10 x 3 galvanised U bolts.

Height above ground as indicated in the drawings.

Steel posts bedded in 450 square and 500 deep Grade 25 concrete set 100 below finished ground
level.

Align top and bottom rails with ground contour.

3.10.2 Steel Guard Rails, Handrails and Railings

Fabricate to dimensions shown on drawings.

Sand down all welded joints to provide a smooth finish.

Paint or finish as noted on drawings and in accordance with Section Al -80-3, clause 3.1.

3.10.3 Metal Gates

Fabricate as shown on drawings, refer to clause 3.1 for proprietary product including mechanised
movement control, and manufacturer if any.

3.10.4 Metal Stairs and Platforms

Fabricate to dimensions shown on drawings.

Available Manufacturers: Subject to compliance with requirements, available manufacturers

offering products that may be incorporated into the work include, but are not limited to:
i. Karisma Grating
ii. Other AE/Employer-approved manufacturer.

Metal Grating Floor

a. Indicative manufacturer: Karisma Grating

b. Indicative reference: TA325-2MSG
c. Performance:
i. Load Capacity: 5 kN/m² (general duty).
ii. Maximum deflection: l/200 of clear span (maximum 10mm).
d. Support structure: Secondary steel work to specialist’s details, and to include additional
structure as deemed necessary by fabricator.
e. Material: Mild Steel.
f. Finish: Hot Dip Galvanised.
g. Surface Finish: Rolled serrated
h. Other requirements
i. Full width anti-slip nosing/sight-bar to leading edge
i. To comply with BS 6180, BS EN 1991: Part 1 and PD6688, or equivalent local standard.
j. Edges: As the Design Drawings.

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k. All penetrations and cut-outs to be coordinated by the Contractor.
l. System to include all fixings, saddle clips, panel jointing clips, bracketry, support framing and
accessories to complete the installation.

Metal Grating Stair Treads

a. Indicative manufacturer: Karisma Grating

b. Indicative reference: Type T-6
c. Performance:
i. Load Capacity: 1.5 kN load over 100mm x 100mm area applied to the middle, front edge
of the tread.
ii. Maximum Deflection: l/300 (maximum 6mm).
d. Support structure: Secondary steel work to specialist’s details, and to include additional
structure as deemed necessary by fabricator.
e. Material: Mild Steel
f. Finish: Hot Dip Galvanized
g. To comply with BS 6180, BS EN 1991: Part 1 and PD6688, or equivalent local standard.
h. Tread width: 280mm
i. Surface Finish: Rolled serrated.
j. Thickness: Refer to structural engineer’s approval
k. Other requirements:
i. Full width nosing/sight-bar to leading edge
ii. Treads to be pre-drilled to enable installation to stair string.
m. System to include all fixings, saddle clips, panel jointing clips, bracketry, support framing and
accessories to complete the installation.

Metal Stair Railings

a. Loading Capacity: 0.74 kN/m² UDL.

b. Support posts:
i. Material: Mild steel
ii. Profile: Round.
iii. Finish: Hot Dip Galvanised.
c. Infill rods:
i. Material: Mild steel.
ii. Profile: Round.
iii. Protective coating: Hot dip Galvanised.
iv. Finish: Hot Dip Galvanised.
d) Handrail:
i. Material and finish: To match support posts, infill rods/ panel.
ii. Size: 50mm diameter.
iii. Height: 1000mm
iv. Corners and connections: Mitered and welded with matching end caps.
e) Other requirements:
i. Flat baseplate/ side palm as necessary to suit fabrication.
ii. 150mm x 6mm hot dip galvanized kickplate to be incorporated into the completed
assembly (for platform only)
iii. Modular 90° bends to corners, ramp bends, stair and platform returns to ends, openings
and abutments as necessary.
f) System to include all necessary fastenings, bracketing and accessories required to complete
the installation.

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4.0 WORKMANSHIP

4.1 Fabrication

Verify dimension and clearances on site prior to shop fabrication.

Fabricate items with joints tightly fitted and secured.

Fit and shop assemble in largest practical sections for delivery to site. Locate joints
only as indicated on the architectural drawings.

4.2 Grinding, Polishing and Finishing

Welded exposed joints are to be suitably ground flush with adjoining material. All ground
surfaces shall be smooth and consistent with good workmanship.

Exercise care in all grinding operations to avoid excessive heating of metal and metal
discoloration.
Remove grain of rough grinding by successive polishing operations. Texture of final polishing
operation shall be uniform and smooth.

4.3 Joints

Buff joints and contact joints, wherever they occur, shall be close fitting and shall not require
solder as filler.

Sheared edges are to be free of burrs, fins or irregular projection.

Neatly finish mitres or bull nose with under edges of material ground to uniform condition. Do
not overlap materials.

4.4 Shims

Separate all pairs of moving surfaces with friction reducing pads. Pads shall have/be:

a. minimum 3 mm thickness,

b. sufficiently reduce friction to permit movement,

c. resistant to wear,

d. positively retained in position (open ended slots are not acceptable).

e. not be subjected to heat damage from welding , cuffing or to excessive pressure from over
tightening of bolts.

Plastic shims are acceptable at static connections for which the shims transfer only compressive
forces.

Wood shims shall not be used.

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5.0 VERIFICATION AND SUBMISSION

5.1 Submission

5.1.1 Submissions

Include in construction program, event for submission of the following information:

a. Technical details for the manufactured items noted in clause 3.1.

b. Details of fabricators for items set out on drawings

c. Details of paint or coating applicator

5.1.2 Design Submissions

Prepare an installation strategy, containing the following information, prior to the preparation of
detailed shop drawings.

a. Sequence of construction

b. Method statements

c. Specimen of warranty

Do not proceed to Fabrication stage until the SO has approved Design drawings and installation
strategy.

5.1.3 Fabrication Submissions

5.1.3.1 Shop Drawings

Prepare shop drawings, which shall include:

a. Plan Layout and sections of all metalworks at a scale of 1:50.

b. Section showing all details of connections/interfacing.

Fabrication shall not commence until shop drawings have been reviewed and permission to
proceed has been obtained from the SO.

5.1.4 Certification of Materials

Provide the SO with certification from the manufacturer of all materials/components, certifying
that the respective material is of the correct grade, strength, size, finish, etc, and is in accordance
with the relevant codes and standards specified.

5.1.5 Maintenance Submissions

No item.

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5.1.6 Warranty

Submit the warranty upon completion of the works.

5.2 Samples and Mock-ups

As specified by SO.

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